EPA 10 - US, Canada, Mexico

N13 with SCR

ENGINE SERVICE MANUAL
ENGINE SERVICE MANUAL

N13 with SCR

0000003823

Navistar, Inc.
June 2015
Revision 2

2701 Navistar Drive, Lisle, IL 60532 USA

© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
 ENGINE SERVICE MANUAL I

TABLE OF CONTENTS
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Truck Repair Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273

Air Compressor and Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363

Oil Cooler, Filter Housing, and Crankcase Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .455

Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483

Air Intake Throttle Duct and Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .541

Front Cover, Fan Drive, Cooling System, and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .577

N13 Engine Brake by Jacobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .627

Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .653

Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .709

Oil Pan, Oil Pickup Tube, and Oil Fill Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .739

Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .769

Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .791

Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .827

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .849

II ENGINE SERVICE MANUAL

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .859

Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .871

Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .877

Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .895

Appendix D: Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .919

 ENGINE SERVICE MANUAL 1

Foreword
Navistar, Inc. is committed to continuous research and development to improve products and introduce
technological advances. Procedures, specifications, and parts defined in published technical service literature
may be altered.
This Engine Service Manual provides a general sequence of procedures for out-of-chassis engine overhaul
(removal, inspection, and installation). For in-chassis service of parts and assemblies, the sequence may vary.
NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in
a photo illustration may not be exact.
See vehicle manuals and Technical Service Information (TSI) bulletins for additional information.

N13 with SCR Engine Operation and Maintenance Manual

N13 with SCR Engine Service Manual (EPA 10)

N13 with SCR Engine Diagnostic Manual (EPA 10)

N13 with SCR Hard Start and No Start Diagnostics Form (EPA 10)
N13 with SCR Performance Diagnostics Form (EPA 10)
N13 with SCR Electronic Control System Diagnostics Form (EPA 10)

Technical Service Literature is revised periodically. If a technical publication is ordered, the latest revision will
be supplied.
NOTE: To order technical service literature, contact your International dealer.
All marks are trademarks of their respective owners.
2 ENGINE SERVICE MANUAL

Service Diagnosis
Service diagnosis is an investigative procedure that must be followed to find and correct an engine application
problem or an engine problem.
If the problem is engine application, see specific vehicle manuals for further diagnostic information.
If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges, diagnostic test equipment, and diagnostic software.
• Availability of current information for engine application and engine systems.
• Knowledge of the principles of operation for engine application and engine systems.
• Knowledge to understand and do procedures in diagnostic and service publications.
Technical Service Literature required for Effective Diagnosis
• Engine Service Manual
• Engine Diagnostic Manual
• Diagnostics Forms
• Electronic Control Systems Diagnostics Forms
• Service Bulletins
 ENGINE SERVICE MANUAL 3

Safety Information
This manual provides general and specific maintenance procedures essential for reliable engine operation and
your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible
safety conditions and hazards cannot be stated.
Read safety instructions before doing any service and test procedures for the engine or vehicle. See related
application manuals for more information.
Obey Safety Instructions, Warnings, Cautions, and Notes in this manual. Not following warnings, cautions, and
notes can lead to injury, death or damage to the engine or vehicle.

Safety Terminology
Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note
Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to
the engine or vehicle.
Note: A note describes actions necessary for correct, efficient engine operation.

Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Shift transmission to park or neutral, set parking brake, and block wheels before doing diagnostic or service
procedures.
4 ENGINE SERVICE MANUAL

• Clear the area before starting the engine.

Engine
• The engine should be operated or serviced only by qualified individuals.
• Provide necessary ventilation when operating engine in a closed area.
• Keep combustible material away from engine exhaust system and exhaust manifolds.
• Install all shields, guards, and access covers before operating engine.
• Do not run engine with unprotected air inlets or exhaust openings. If unavoidable for service reasons, put
protective screens over all openings before servicing engine.
• Shut engine off and relieve all pressure in the system before removing panels, housing covers, and caps.
• If an engine is not safe to operate, tag the engine and ignition key.
Fire Prevention
• Make sure charged fire extinguishers are in the work area.
NOTE: Check the classification of each fire extinguisher to ensure that the following fire types can be
extinguished.
1. Type A — Wood, paper, textiles, and rubbish
2. Type B — Flammable liquids
3. Type C — Electrical equipment
Batteries
• Always disconnect the main negative battery cable first.
• Always connect the main negative battery cable last.
• Avoid leaning over batteries.
• Protect your eyes.
• Do not expose batteries to flames or sparks.
• Do not smoke in workplace.
Compressed Air
• Use an OSHA approved blow gun rated at 207 kPa (30 psi).
• Limit air pressure to 207 kPa (30 psi).
• Wear safety glasses or goggles.
• Wear hearing protection.
• Use shielding to protect others in the work area.
• Do not direct compressed air at body or clothing.
Tools
• Make sure all tools are in good condition.
• Make sure all standard electrical tools are grounded.
 ENGINE SERVICE MANUAL 5

• Check for frayed or damaged power cords before using power tools.
Fluids Under Pressure
• Use extreme caution when working on systems under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after servicing the engine.
• Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is
done.
6 ENGINE SERVICE MANUAL
 ENGINE SYSTEMS 7

Table of Contents

Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Engine Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Accessory Labels and Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Heavy Duty On Board Diagnostics (HD-OBD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chassis Mounted Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Air Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Airflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Boost Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Low Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
High Pressure Charge Air Cooler (HPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Intake Manifold Pressure (IMP) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Intake Manifold Temperature (IMT) Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Turbocharger 2 Compressor Inlet Sensor (TC2IS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
Aftertreatment (AFT) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Decomposition Reactor Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Diesel Particulate Filter (DPF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Diesel Oxidation Catalyst (DOC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Selective Catalyst Reduction (SCR) Catalyst. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Aftertreatment (AFT) System Conditions and Responses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Diesel Exhaust Fluid (DEF) Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Aftertreatment Fuel Injection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Crankcase Oil Separator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

Fuel System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Fuel Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
Low Pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
High Pressure Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Intake Air Heater System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Intake Air Heater System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Oil Flow and Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Engine Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Cooling System Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52
Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
8 ENGINE SYSTEMS

Coolant Control Valve (CCV) assembly operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

Engine Brake System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Engine Brake Control System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Engine Brake System Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Engine Brake System Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Electronic Control System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Operation and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Reference Voltage (VREF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Signal Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Microprocessor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Diagnostic Trouble Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Microprocessor Memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Actuator Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Exhaust Back Pressure Valve (EBPV) Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Exhaust Gas Recirculation (EGR) Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Intake Air Heater Relay (IAHR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Intake Air Heater Fuel Solenoid (IAHFS) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Aftertreatment Fuel Shutoff (AFTFSO). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Aftertreatment Purge Air Valve (AFTPAV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Dosing Unit Heater (DEFDUH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Doser (DEFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Line Heater Relay (DEFLHR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Pressure Line Heater (DEFPLH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Return Line Heater (DEFRLH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Diesel Exhaust Fluid Valve (DEFRV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Diesel Exhaust Fluid Supply Line Heater (DEFSLH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Diesel Exhaust Fluid Supply Pump (DEFSP) and Temperature Sensor. . . . . . . . . . . . . . . . . . . .65
Diesel Exhaust Fluid Tank Heater (DEFTH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Diesel Exhaust Fluid Unit Heater Relay (DEFUHR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Engine and Vehicle Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Thermistor Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Variable Capacitance Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Magnetic Pickup Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Potentiometer Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Additional Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Ammonia (NH3) Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Humidity Sensor (HS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Nitrogen Oxides (NOx) IN Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Nitrogen Oxides (NOx) OUT Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
 ENGINE SYSTEMS 9

Engine Identification
Engine Serial Number

Figure 1 Engine serial number

1. Engine Serial Number (ESN) location
2. Engine emission label
3. Cylinder head
4. Flywheel housing
5. Crankcase

The Engine Serial Number (ESN) is located on the front of the crankcase (left side), below the cylinder head.

Engine Serial Number Examples

N13: 126HM2YXXXXXXX

Engine Serial Number Codes

126 – N13 with SCR engines
H – Diesel, turbocharged, Charge Air Cooler (CAC), and electronically controlled
M2 – Motor truck
Y – Huntsville, Alabama
7 digit suffix – Engine serial number sequence
10 ENGINE SYSTEMS

Engine Emission Label

Figure 2 2010 U.S. Environmental Protection Agency (EPA) exhaust emission label (example)

The U.S. Environmental Protection Agency (EPA) exhaust emission label is on top of the valve cover (front left
side). The EPA label typically includes the following:
• Model year
• Engine family, model, and displacement
• Advertised brake horsepower and torque rating
• Emission family and control systems
• Valve lash specifications
• Engine Serial Number (ESN)
• EPA, Onboard Diagnostics (OBD), EURO, and reserved fields for specific applications
 ENGINE SYSTEMS 11

Engine Accessory Labels and Identification Plates

The following engine accessories may have manufacturer's labels or identification plates:
• Aftertreatment Control Module (ACM)
• Aftertreatment Purge Air Valve (AFTPAV)
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Diesel Oxidation Catalyst (DOC)
• Diesel Particulate Filter (DPF)
• Engine Control Module (ECM)
• High Pressure (HP) fuel pump
• Power steering pump
• Selective Catalyst Reduction (SCR) catalyst
• Starter motor
• Turbochargers
12 ENGINE SYSTEMS

Engine Specifications

N13 Diesel Engine

Engine Configuration 4 stroke, inline six cylinder diesel
Advertised brake horsepower @ rpm
• N13 See EPA exhaust emission label
Peak torque @ rpm
• N13 See EPA exhaust emission label
Displacement
• N13 12.4 L (758 in³)
Compression ratio
• N13 17.0:1
Stroke
• N13 166 mm (6.54 in)
Bore (sleeve diameter)

• N13 126 mm (4.96 in)

Total engine weight (dry weight without trim or accessories)
• N13 1087 kgs (2392 lbs)
Firing order 1-5-3-6-2-4
Engine rotation direction (facing flywheel) Counterclockwise
Aspiration Dual turbocharged and charge air cooled
Combustion system Direct injection turbocharged
Fuel system High-pressure common rail
Lube system capacity (including filter) 40 L (42 qts)
• N13
Lube system capacity (overhaul only, with filter) 44 L (46 qts)
• N13
Engine oil pressure at operating temperature with SAE 15W-40 oil
• Low idle 69 kPa (10 psi) min.
• High idle 276 - 483 kPa (40 - 70 psi)
Idle speed (no load) 600 rpm, nominal

Thermostat operating temperature

• Primary 83°C - 95°C (181°F - 203°F)

• Secondary 87°C - 102°C (189°F - 216°F)
 ENGINE SYSTEMS 13

Heavy Duty On Board Diagnostics (HD-OBD)

The EPA has added new regulations for 2010 to reduce heavy duty vehicle emissions. The HD-OBD system
is designed specifically for electronically controlled heavy duty engines. The goal for HD-OBD regulation is to
keep engine emissions in specification for as long as a given vehicle is in use.
HD-OBD is legislated to be implemented in three phases:
• 2010: First engine for each Original Equipment Manufacture (OEM) becomes fully certified.
• The lead engine is determined by a legislated equation based on projected sales volume & useful life
of the engine.
• For Navistar®, this is the EPA 2010® N13 engine.
• 2013: One engine in each engine family becomes fully certified.
• This will be the largest step of the three phases.
• 2016: All engines must be fully HD-OBD certified.
The HD-OBD system continuously monitors for proper engine operation, and will alert the vehicle operator to
emission-related faults using the Malfunction Indicator Lamp (MIL).
The MIL is installed in the Electronic Instrument Cluster. When a detected emissions fault occurs, the MIL will
be illuminated. Diagnostic information is also stored in the Engine Control Module (ECM), and may be accessed
by the technician for diagnosis and repair of the malfunction. Diagnostic information is accessed by connecting
the Electronic Service Tool (EST) to the in-cab Diagnostic Connector.

Engine Description
The N13 diesel engine is designed for increased durability, reliability, and ease of maintenance.
The cylinder head has four valves per cylinder for increased airflow. The overhead valve train includes rocker
arms and valve bridges to operate the four valves. The fuel injector is centrally located between the four valves,
directing fuel over the piston for improved performance and reduced emissions.
The overhead camshaft is supported by seven bearings in the cylinder head. The camshaft gear is driven from
the rear of the engine. The overhead valve train includes roller rocker arms and dual valves that open, using a
valve bridge.
N13 engines use one-piece steel pistons. All pistons use an offset piston axis and centered combustion bowls.
Crown markings show correct piston orientation in the crankcase.
The one-piece crankcase uses replaceable wet cylinder liners that are sealed by dual crevice seals.
The crankshaft has seven main bearings with fore and aft thrust controlled at the sixth bearing. One fractured
cap connecting rod is attached at each crankshaft journal. The piston pin moves freely inside the connecting
rod and piston. Piston pin retaining rings secure the piston pin in the piston. The rear oil seal carrier is part of
the flywheel housing.
A gerotor lube oil pump is mounted behind the front cover and is driven by the crankshaft. Pressurized oil is
supplied to various engine components. All N13 engines also use an engine oil cooler and a cartridge-style
engine oil filter, which are installed in the engine lube oil module.
The low-pressure fuel pump draws fuel from the fuel tank(s) through a chassis mounted filter/water separator.
The low-pressure fuel pump provides fuel for the engine mounted fuel module. Conditioned low-pressure fuel is
supplied from the engine mounted fuel module to the high-pressure fuel pump, Intake Air Heater fuel solenoid,
and the AFT fuel doser module.
14 ENGINE SYSTEMS

The high-pressure fuel system is a direct fuel injected common-rail system. The common-rail includes a
high-pressure fuel pump, two fuel rail supply lines, fuel rail, six fuel injectors, and pressure relief valve.
The fuel injectors are installed in the cylinder head under the valve cover and are electronically actuated by the
ECM.
N13 engines use a dual stage, fixed geometry turbocharger assembly. Each stage includes a Charge Air Cooler
(CAC). The High Pressure (HP) turbocharger includes a pneumatically operated wastegate. The Low Pressure
Charge Air Cooler (LPCAC) is mounted on the lower right side of the engine, and uses the engine cooling system
to regulate charge air temperatures. The High Pressure Charge Air Cooler (HPCAC) is mounted in front of the
engine cooling package. The HPCAC is an air-to-air type cooler, and requires no connections to the engine's
cooling system.
The Exhaust Gas Recirculation (EGR) system circulates cooled exhaust into the air inlet duct. The dual stage
EGR cooler provides regulated cooling of the EGR gases before entering the air inlet duct. This cools the
combustion process, and reduces Nitrogen Oxides (NOX) emissions.
The open crankcase breather system uses a centrifugal Crankcase Oil Separator (CCOS) to return oil mist to
the crankcase, and vent the cleaned crankcase gasses to the atmosphere. The CCOS is part of the oil module.
The breather system has been redesigned, and uses no crankcase breather filter or external piping. Blowby
gases enter the CCOS through the side of the crankcase.
The Intake Air Heater system warms the incoming air supply during engine cranking and several minutes after
cold engine start up to help reduce emissions.
The Navistar® Engine Brake by Jacobs® is optional for N13 engine displacements. The engine brake is a
compression release system that provides additional vehicle braking performance. The operator can control
the engine brake for different operating conditions.

Optional Equipment
Optional cold climate features available are an oil pan heater and a coolant heater. Both heaters use an electric
element to warm engine fluids in cold weather.
The oil pan heater warms engine oil to ensure optimum oil flow to engine components.
The coolant heater warms the engine coolant surrounding the cylinders. Warmed engine coolant increases fuel
economy and aids start-up in cold weather.

Chassis Mounted Equipment

• The chassis mounted fuel filter/water separator removes a majority of the water and foreign particles that
may enter the fuel system from the supply tank(s). This filter works with the engine mounted fuel module to
eliminate foreign matter and moisture from the fuel before entering the fuel injection system.
• The Low Temperature Radiator (LTR) regulates the temperature of the LPCAC and the low-temperature
stage of the EGR cooler. The LTR is mounted in front of the radiator cooling package, and requires
connections to the engine cooling system.
• The HPCAC lowers temperature after the air is compressed by the turbochargers, and has no connections
to the engine cooling system. The HPCAC is an air-to-air cooler. The HPCAC is mounted in front of the
radiator cooling package.
 ENGINE SYSTEMS 15

• The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbons and carbon monoxide, provides heat for
exhaust system warm-up, aids in temperature management for the Diesel Particulate Filter (DPF), and
oxidizes NO into NO2 for passive DPF regeneration. The DOC is monitored by the Aftertreatment Control
Module (ACM) using one Diesel Oxidation Catalyst Intake Temperature (DPFIT) sensor positioned at the
DOC inlet, and one Diesel Particulate Filter Intake Temperature (DPFIT) sensor positioned at the DPF inlet.
• The DPF temporarily stores carbon-based particulates, oxidizes stored particulates, stores non-combustible
ash, and provides required exhaust back pressure for proper engine performance. The DPF is monitored by
the ACM using the DOC / DPF temperature sensor module installed on the DPF, and the Diesel Particulate
Filter Differential Pressure (DPFDP) / outlet pressure sensor installed on or near the DPF.
• The Selective Catalyst Reduction (SCR) catalyst oxidizes Nitrogen Oxides (NOx) into Nitrogen gas and
water. The SCR catalyst is monitored by the ACM using a NOx IN sensor module installed after the HP
turbocharger outlet pipe, and a NOx OUT sensor module installed after the outlet of the SCR catalyst. An
ammonia (NH3) sensor provides feedback to the ACM related to Diesel Exhaust Fluid (DEF) injection into
the SCR catalyst.
16 ENGINE SYSTEMS

Air Management System

Figure 3 Air Management System

1. Exhaust Gas Recirculation 6. Intake Manifold Temperature 11. Low Pressure (LP) turbocharger
Temperature (EGRT) sensor (IMT) sensor 12. Exhaust Back Pressure Valve
2. Intake Manifold Pressure (IMP) 7. EGR valve (EBPV)
sensor 8. Turbocharger 2 Compressor 13. Oxygen Sensor (O2S)
3. Engine Throttle Valve (ETV) Inlet Sensor (TC2IS) 14. High Pressure (HP) turbocharger
4. Charge Air Cooler Outlet 9. Air filter housing 15. HP turbocharger wastegate
Temperature (CACOT) Sensor 10. Humidity Sensor (HS) / Inlet Air 16. Exhaust manifold
5. EGR cooler Temperature (IAT) sensor 17. Cylinder head
 ENGINE SYSTEMS 17

Airflow
Air flows through the air filter assembly and enters the Low-Pressure (LP) turbocharger. The LP turbocharger
increases air pressure and temperature before entering the Low Pressure Charge Air Cooler (LPCAC). Cooled
and compressed air then flows from the LPCAC into the High Pressure (HP) turbocharger (compressor inlet). Hot
and highly compressed air flows from the HP turbocharger (compressor outlet) into the High Pressure Charge Air
Cooler (HPCAC) where it is cooled, and into the intake throttle duct, and continues through the Engine Throttle
Valve (ETV). The HP and LP turbochargers can increase pressures up to 345 kPa (50 psi).
If the Exhaust Gas Recirculation Valve (EGRV) is open, exhaust gases pass through the EGR cooler and into
the intake throttle duct where it is mixed with filtered air. This mixture flows into the intake manifold, and then
the cylinder head. The intake manifold is an integral part of the cylinder head casting.
During cold weather, the Intake Air Heater system activates the heater element, vaporizing and igniting small
quantities of fuel into the air inlet duct.
After combustion, exhaust gases exit through the cylinder head exhaust valves and ports. The exhaust gas is
forced through the exhaust manifold where, depending on EGRV position, it is split between the EGR system
and the exit path through the HP turbocharger, LP turbocharger, and Exhaust Back Pressure Valve (EBPV).
The EBPV is operated by the Air Control Valve (ACV), a pneumatic actuator. When the ACV is applied, the
EBPV restricts flow and increases exhaust back pressure. Operation of the EBPV is controlled by the ECM
using the ACV and the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor. When the EBPV is opened,
exhaust back pressure is released.
Exhaust gases exiting the engine flow through the EBPV, then through the vehicle Aftertreatment (AFT) system,
and out the exhaust tail pipe.
18 ENGINE SYSTEMS

Turbochargers

Figure 4 High and Low Pressure Turbocharger Components – Inner and Outer views
1. High Pressure (HP) turbocharger 6. Low Pressure (LP) turbocharger 11. HP turbocharger compressor
compressor inlet 7. Turbocharger oil supply tube outlet
2. HP turbocharger turbine inlet 8. LP turbocharger compressor
3. LP turbocharger turbine outlet outlet
4. HP turbocharger 9. Oil return tube
5. HP turbocharger wastegate 10. LP turbocharger compressor
actuator inlet

N13 engines are equipped with a pneumatically regulated two-stage turbocharger system. The High Pressure
(HP) and Low Pressure (LP) turbochargers are installed in parallel on the right side of the engine.
Intake air flow: Filtered air enters the LP compressor, where it is compressed and directed to the Low
Pressure Charge Air Cooler (LPCAC). Cooled compressed air then enters the HP compressor, where it is
further compressed and directed into the High Pressure Charge Air Cooler (HPCAC). Compressed air then
goes through the Engine Throttle Valve (ETV) and the intake throttle duct. This system provides high charge
air pressure to improve engine performance and to help reduce emissions.
Exhaust gas flow: The HP turbocharger is connected to the exhaust manifold through the HP turbine inlet.
Exhaust gases exit the HP turbine outlet and are directed to the LP turbine inlet. The HP turbocharger is
equipped with a wastegate, which is controlled by a pneumatic actuator. The HP turbocharger wastegate is
used to regulate boost by controlling the amount of exhaust gas that bypasses the turbine of the turbocharger.
 ENGINE SYSTEMS 19

When boost demand is low, the wastegate is opened, allowing part of the exhaust gas flow to bypass the HP
turbine.
Control system signals associated with the HP and LP turbochargers have been renamed for 2010.
All signals related to the LP turbocharger are designated as Turbocharger 1 (TC1) signals, and are identified
below:
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP)
All signals associated with the HP turbocharger are designated as Turbocharger 2 (TC2), and are identified
below:
• Turbocharger 2 Wastegate (TC2WG)
• Turbocharger 2 Compressor Inlet Sensor (TC2CIS)
20 ENGINE SYSTEMS

Air Control Valve (ACV)

Figure 5 Air Control Valve (ACV) Connections

1. Pigtail harness (to engine sensor harness connector)
2. Plug
3. Vehicle air supply port
4. Exhaust Back Pressure Valve (EBPV) control port
5. Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor port
6. High Pressure (HP) turbocharger wastegate control port

The ACV assembly contains the High Pressure (HP) turbocharger wastegate control port, the Exhaust Back
Pressure Valve (EBPV) control port, and the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) port. Although
these components are integral to the ACV, each circuit is controlled by the Engine Control Module (ECM). The
ACV controls compressed air for each control valve. The air supply port is connected to the vehicle's air system.
The ECM provides a Pulse Width Modulated (PWM) signal for operation of the wastegate control valve. With
no PWM signal, the control valve is closed, and vehicle no air is supplied to the wastegate actuator.
When an increase in the boost is required, the ECM supplies PWM voltage to close the control valve. This
reduces air pressure to the wastegate actuator causing the wastegate to close and vent air pressure, results in
increased boost. The limit values of the PWM signals are between approximately 9%, corresponding to a fully
opened air control valve, and 100% corresponding to a closed air control valve.
The TC1TOP sensor and EBPV control valve are in the ACV. The EBPV control valve is also operated by the
ECM using PWM, and the TC1TOP sensor is monitored by the ECM. The EBPV control valve operates the
EBPV actuator.
 ENGINE SYSTEMS 21

Boost Control
The wastegate control valve, in the ACV, provides for operation of a pneumatic wastegate actuator for the HP
turbocharger. Boost is controlled for HP turbocharger, by signals sent from the ECM to the ACV. In normal
operation the wastegate is actuated by the ACV using vehicle compressed air, regulated to 43 psi (296 kPa).
Positioning of the wastegate by the ACV is based on boost pressure and temperature signals monitored by the
ECM.
Because of the ability to generate very high charge air pressure levels and to avoid Charge Air Cooler (CAC)
overloading, the wastegate actuator for the HP turbocharger is also spring loaded. When boost levels increase
above specification, boost pressure alone will open the wastegate, and the exhaust gases will bypass the HP
turbocharger. Exhaust back pressure is constantly monitored by the ECM using TC1TOP. The TC1TOP sensor
is part of the ACV, and is connected to the exhaust system by a steel line.
22 ENGINE SYSTEMS

Low Pressure Charge Air Cooler (LPCAC)

The LPCAC is installed between the High Pressure (HP) and Low Pressure (LP) turbochargers, and is mounted
to the lower right side of the engine. The LPCAC air inlet is connected to the LP turbocharger compressor outlet,
and uses engine coolant to regulate the LP charge air temperature. The LPCAC air outlet is connected to the
compressor inlet of the HP turbocharger.
 ENGINE SYSTEMS 23

High Pressure Charge Air Cooler (HPCAC)

The HPCAC is installed between the HP turbocharger and the intake throttle duct. The HPCAC air inlet is
connected to the HP compressor outlet, and uses ambient airflow entering the front of the vehicle to reduce the
charge air temperature. The HPCAC air outlet is connected to the intake throttle duct.
24 ENGINE SYSTEMS

Intake Manifold Pressure (IMP) Sensor

Monitors charge air pressure entering the intake throttle duct and provides information used for boost and EGR
control.
The IMP provides an analog voltage output to the Engine Control Module (ECM) which is proportional to pressure
applied to an internal diaphragm in the sensor. The IMP sensor is connected to the ECM by the Reference
Voltage (VREF), signal, and ground wires. A transfer function in the ECM software converts the analog voltage
to a pressure value which is then used by software strategies.
 ENGINE SYSTEMS 25

Intake Manifold Temperature (IMT) Sensor

This sensor monitors charge air temperature entering the intake throttle duct. The temperature measured is
an input to the engine coolant control strategy. It also is used for evaluation of on-board diagnostics to ensure
proper functionality of the charge air cooling system.
This temperature sensor is a thermistor and has two connections to the Engine Control Module (ECM). A
thermistor varies resistance as temperature changes. When interfaced to the ECM circuitry, a change in sensor
resistance results in a voltage change internal to the ECM. A transfer function contained in the ECM software
translates the measured voltage to a temperature value.
The ECM continuously monitors the voltage resulting from the thermistor’s changing resistance. High and low
diagnostic voltage thresholds are evaluated to ensure that the output voltage is within a valid range.
26 ENGINE SYSTEMS

Turbocharger 2 Compressor Inlet Sensor (TC2IS)

This sensor is a dual function sensor that detects pressure and temperature of the charge air entering the High
Pressure (HP) compressor. It is installed in the piping between the Low Pressure (LP) compressor outlet and the
HP compressor inlet. This sensor is used for evaluation by on-board diagnostics to ensure proper functionality
of the charge air cooling system.
This sensor consists of a thermistor which varies resistance as temperature changes. When interfaced to the
Engine Control Module (ECM) circuitry, a change in sensor resistance results in a voltage change internal to
the ECM. An internal diaphragm which deflects due to pressure changes results in an analog voltage output to
the ECM which is proportional to the pressure. Transfer functions contained in the ECM software translate the
measured voltages into a temperature and a pressure value.
The ECM continuously monitors the voltages resulting from changes in both the temperature and pressure. High
and low diagnostic voltage thresholds are evaluated to ensure output voltage is within a valid range.
 ENGINE SYSTEMS 27

Exhaust Gas Recirculation (EGR) System

Figure 6 EGR system components

1. EGR cooler air bleed (to 6. EGR cooler outlet tube (2) 11. EGR cooler inlet tubes (gases)
deaeration tank) (gases) 12. EGRV
2. EGR cooler (low-temperature 7. Low temperature EGR cooler 13. EGR cooler inlet (coolant)
stage) inlet (coolant) 14. EGRGT sensor
3. EGRV coolant return line (to 8. Engine Coolant Temperature 2
deaeration tank) (ECT2) sensor
4. High temperature EGR cooler 9. Low temperature EGR cooler
5. Intake Manifold Temperature outlet (coolant)
(IMT) 10. EGRV coolant supply line
28 ENGINE SYSTEMS

EGR System Overview

The EGR system reduces NOX engine emissions by introducing inert cooled exhaust gas into the air inlet duct.
NOX forms during a reaction between nitrogen and oxygen at high-temperatures during combustion.
The Engine Control Module (ECM) monitors signals from the Charge Air Cooler Outlet Temperature (CACOT)
sensor, Oxygen sensor (O2S), Engine Coolant Temperature 1 (ECT1) sensor, EGRGT sensor to control the EGR
system.
EGR is switched Off (EGRV closed) if any of the following conditions are present:
• Engine coolant temperature less than 10°C (50°F) will close the EGR valve
• Intake manifold temperatures less than 7°C (45°F) will close the EGR valve
• During engine brake operation

EGR Flow
Hot exhaust gas from the exhaust manifold flows through the EGR inlet tubes to the Exhaust Gas Recirculation
Valve (EGRV). When EGR is commanded, the EGRV opens and allows exhaust gas to enter the EGR cooler.
Exhaust gas flows through the EGR cooler, is cooled and then flows through the EGR outlet tubes, and into the
intake throttle duct where it is mixed with filtered air.

EGR System Control

The EGR system consists of the EGRV, Engine Throttle Valve (ETV), and Oxygen Sensor (O2S). The EGRV
contains a Pulse Width Modulated (PWM) controlled valve and Exhaust Gas Recirculation Position (EGRP)
sensor.
The EGRV is installed at the rear of the EGR cooler, on the right side of engine valve cover. The EGRV limits
exhaust gas flow into the EGR cooler.
The ECM commands the EGRV to move and hold position. The EGRP sensor, installed inside the EGRV,
monitors and provides an EGRV position signal to the ECM.
The O2S is installed in the exhaust, in front of the aftertreatment fuel injector. The O2S has a heater element that
heats the sensor to its normal operating temperature of 780°C (1436°F). During initial engine warm-up, the O2S
heater element is activated only after engine coolant reaches 40°C (104°F) and the exhaust gas temperature
DOCIT sensor exceeds 100°C (212°F) for more than 30 seconds.
 ENGINE SYSTEMS 29

EGRV Control

Figure 7 EGRV position control

1. EGR position monitored by ECM
2. Engine Control Module (ECM)
3. ECM commands EGR to desired position
4. EGRV to desired position
5. EGRV
6. EGRV position matches ECM command
7. EGR position sent to ECM

The EGRV has an integrated position sensor, and provides feedback to the ECM indicating EGRV position.
30 ENGINE SYSTEMS

EGR – Open Loop

During engine warm-up and before the Oxygen Sensor (O2S) reaches normal operating temperature, the
Exhaust Gas Recirculation (EGR) system operates in open loop. In open loop, the EGR system is controlled by
the ECM based on the charge air temperature, engine coolant temperature, engine speed, and load conditions.

EGR – Closed Loop

After the O2S reaches operating temperature, the EGR system switches to closed loop operation. In closed loop,
the EGR system is controlled by the ECM based on coolant temperature and O2S readings.

EGR Flow Cooling

The EGR system includes a two-stage EGR cooler, and Coolant Control Valve (CCV) to allow the Engine
Control Module (ECM) to regulate EGR cooler temperatures. The ECM monitors intake manifold temperature
through the Exhaust Gas Recirculation Gas Temperature 1 (EGRGT1) sensor and the CCV regulates coolant
flow through the Low Temperature Radiator (LTR). Refer to Engine Cooling System (page 52) in this section
for more information.
 ENGINE SYSTEMS 31

Aftertreatment (AFT) System

Figure 8 Functional Diagram of AFT system

The AFT system, part of the larger exhaust system, processes engine exhaust to meet emission requirements.
The AFT system traps particulate matter (soot) and prevents it from leaving the tailpipe, and reduces Nitrogen
Oxides (NOx).
The AFT system performs the following functions:
• Monitors exhaust gas temperatures DOC In, DPF In, DPF Out, SCRIT, SCROT temperature, and Diesel
Particulate Filter (DPF) delta pressure. It controls engine operating parameters for emission control and
failure recognition.
• May cancel regeneration in the event of catalyst or sensor failure
• Monitors the level of soot accumulation in the DPF
• Initiates regeneration automatically when DPF is full with soot and controls engine operating parameters to
increase temperature to have successful regeneration
• Maintains vehicle and engine performance during regeneration
• Monitors NOx levels in the exhaust
32 ENGINE SYSTEMS

• Initiates Diesel Exhaust Fluid (DEF) dosing automatically when NOx levels are above a pre-calibrated
threshold
• Monitors and adjusts DEF dosing per Ammonia (NH3) sensor feedback
 ENGINE SYSTEMS 33

Decomposition Reactor Tube

The decomposition reactor tube does the following:
• Converts DEF to ammonia and CO2
• Uses an internal mixer to ensure even evaporation of DEF into the exhaust stream

Diesel Particulate Filter (DPF)

The DPF does the following:
• Captures and temporarily stores carbon-based particulates in a filter
• Allows for oxidation (regeneration) of stored particulates once loading gets to a particular level (restriction)
• Provides the required exhaust back pressure drop for engine performance
• Stores non-combustible ash

Diesel Oxidation Catalyst (DOC)

The DOC does the following:
• Oxidizes hydrocarbons and carbon monoxide (CO) in exhaust stream
• Provides heat for exhaust system warm-up
• Aids in system temperature management for the DPF

Selective Catalyst Reduction (SCR) Catalyst

The SCR catalyst does the following:
• Completes the breakdown of DEF into ammonia and CO2
• Converts ammonia and NOx to Nitrogen gas and water

Aftertreatment (AFT) System Conditions and Responses

The operator is alerted of system status either audibly or with instrument panel indicators. Automatic or manual
regeneration is required when levels of soot exceed acceptable limits. For additional information, see the
applicable vehicle Operator's Manual and the vehicle visor placard.
34 ENGINE SYSTEMS

Diesel Exhaust Fluid (DEF) Injection

Figure 9 Diesel Exhaust Fluid (DEF) Injection Components

1. Diesel Exhaust Fluid Doser 3. DEF supply module return line 5. DEF supply module
(DEFD) 4. DEF supply module pressure 6. DEF suction line
2. DEF tank line

Diesel Exhaust Fluid (DEF) injection is required when Nitrogen Oxides (NOx) levels exceed acceptable limits.
The Aftertreatment Control Module (ACM) determines when DEF injection is required by monitoring signals from
the Nitrogen Oxides (NOx) IN sensor module, NOx OUT sensor module, and Ammonia (NH3) sensor.
When NOx levels are too high, the ACM commands the DEF supply pump ON, allowing DEF to be drawn from
DEF tank, through the suction line, and to the DEF supply module. DEF then exits the supply module and travels
to the Diesel Exhaust Fluid Doser (DEFD) through the pressure line. The ACM then commands the DEFD ON
allowing DEF to be sprayed into the aftertreatment system.
 ENGINE SYSTEMS 35

Aftertreatment Fuel Injection

Figure 10 Aftertreatment Fuel Injection Components (Top View)

1. Fuel line retainers (rear and left 2. Aftertreatment Fuel Injector 3. AFTFI fuel pressure line
side of engine block) (AFTFI) 4. AFT fuel doser module

The AFT fuel doser module injects fuel into the exhaust system to increase temperature of the Diesel Oxidation
Catalyst (DOC), and is necessary for Diesel Particulate Filter (DPF) regeneration. AFT fuel doser module is
controlled by the Aftertreatment Control Module (ACM). The ACM receives signals from the Aftertreatment Fuel
Pressure (AFTFP) sensor (installed in the AFT fuel doser module), and control operation when aftertreatment fuel
injection (regeneration) is required. The ACM also controls the Aftertreatment Fuel Shutoff (AFTFSO) (installed
in the AFT fuel doser module) which controls the volume of fuel sent to the AFTFI.
36 ENGINE SYSTEMS

AFT Fuel Doser Module Injection

Figure 11 AFT Fuel Doser Module (Left Side View)

1. Fuel outlet port to Aftertreatment Fuel Injector (AFTFI)
2. Aftertreatment Fuel Pressure (AFTFP) sensor
3. Aftertreatment Fuel Shutoff (AFTFSO)
4. Fuel supply from fuel filter assembly

The AFT fuel doser module is connected to the clean side of the low-pressure fuel system, and provides
a metered amount of fuel to the Aftertreatment Fuel Injector (AFTFI). The AFT fuel doser module provides
pressurized fuel injection pulses to the AFTFI. The AFTFI is a solenoid type injector, and will only inject fuel
when commanded ON by the Aftertreatment Control Module (ACM). The AFT fuel doser module is installed on
the left side of the engine, to the rear of the fuel module.
The AFTFP sensor monitors fuel pressure in the AFT fuel doser module, and provides constant feedback to the
ACM.

Aftertreatment Fuel Injector (AFTFI)

The AFTFI is installed on the right side of the engine, in the exhaust pipe after the exhaust Oxygen Sensor (O2S).
Pressurized fuel is supplied to the AFTFI thru the AFT fuel doser module using the Aftertreatment Fuel Shutoff
(AFTFSO). When conditions required for regeneration are met, the ACM commands the AFTFSO ON, allowing
pressurized fuel to reach the AFTFI.
To protect the AFTFI internal components, continuous engine coolant flow through the AFTFI is maintained by
external coolant supply and return lines.
 ENGINE SYSTEMS 37

Crankcase Oil Separator

Figure 12 Oil Module with Crankcase Oil Separator

1. Coolant supply line 5. Oil filter access cap 9. CCOS ventilation tube heater
2. CCOS vent tube 6. Engine Oil Temperature (EOT)
3. Crankcase Oil Separator Speed sensor
(CCOSS) sensor 7. Engine Oil Pressure (EOP)
4. Crankcase Centrifuge Oil sensor
Separator (CCOS) 8. Coolant return line
38 ENGINE SYSTEMS

Crankcase ventilation is provided using the CCOS. Excess crankcase vapors are filtered by the CCOS, and are
then vented to the atmosphere.
A centrifugal oil separator, driven by engine oil pressure, separates and directs oil mist to the side of the CCOS
housing. The separated oil drains from the oil separator, through the crankcase, and into the oil pan. The oil
separator is an integral part of the oil module.
 ENGINE SYSTEMS 39

Fuel Management System

Fuel System Components

Figure 13 Fuel system

1. (Fuel) Injector (6) 7. Fuel supply to AFT fuel doser 12. Low Pressure (LP) fuel pump
2. Fuel Rail module 13. High Pressure (HP) fuel pump
3. Fuel rail pressure limiting valve 8. Fuel filter housing assembly 14. Fuel Rail Pressure (FRP) sensor
4. Fuel return from cylinder head 9. Fuel filter drain screw
5. Fuel return line 10. Fuel Delivery Pressure (FDP)
6. Engine fuel return connection (to sensor
chassis filter) 11. Fuel primer pump assembly

N13 engines are equipped with a high-pressure common rail fuel injection system which provides pressurized
fuel to the fuel injectors for optimal fuel atomization in the combustion chamber.
Excess fuel is returned to the chassis mounted filter separator, before returning to the fuel tank.
The fuel system is controlled by the Engine Control Module (ECM), various sensors, and the Fuel Pressure
Control Valve (FPCV) installed in the HP fuel pump.
40 ENGINE SYSTEMS

Fuel Flow

Figure 14 Fuel supply flow diagram

1. Fuel Return 6. Low Pressure (LP) fuel pump 11. Fuel rail
2. Fuel supply 7. Fuel filter housing assembly 12. Fuel injectors
3. Fuel tank (engine mounted) 13. Chassis mounted fuel filter/water
4. Chassis mounted fuel filter/water 8. AFT fuel doser module separator (bottom portion)
separator (Top portion) 9. High Pressure (HP) fuel pump
5. Fuel primer pump assembly with 10. Intake Air Heater Fuel Solenoid
fuel strainer element (IAHFS)

Fuel is pumped from the tank, through the chassis mounted fuel filter/water separator using the Low Pressure
(LP) fuel pump. Fuel is pumped from the LP fuel pump to the engine mounted fuel filter assembly, before being
supplied to the High Pressure (HP) fuel pump. The HP fuel pump supplies high-pressure fuel to the fuel rail,
which feeds the fuel injectors through individual tubes. The LP fuel pump and HP fuel pump are assembled as
one gear driven unit, and are serviced as an assembly.
 ENGINE SYSTEMS 41

Low Pressure Fuel System

Figure 15 Low Pressure (LP) fuel system

1. High Pressure (HP) fuel pump 9. Chassis mounted primary fuel 19. Fuel filter housing assembly
2. Fuel Pressure Control Valve filter access (engine mounted)
(FPCV) 10. Fuel supply to engine 20. Fuel filter drain screw
3. Fuel primer pump assembly w/ 11. Fuel return from engine 21. Intake Air Heater port
fuel strainer element 12. Fuel supply from tank 22. Fuel Delivery Pressure (FDP)
4. Fuel pressure test port 13. Chassis mounted fuel filter/water sensor
5. Engine fuel supply connection separator 23. LP fuel pump outlet
6. Engine mounted secondary fuel 14. Fuel Heater 24. LP fuel pump inlet
filter access 15. Water In Fuel (WIF) sensor 25. HP fuel pump inlet
7. Engine fuel return connection 16. Fuel return to tank 26. HP fuel pump return
8. Fuel supply to AFT fuel doser 17. Fuel return from engine
module 18. Fuel supply to engine

The LP fuel pump pumps fuel from the tank through the chassis mounted fuel filter/water separator, fuel strainer
element, and engine filter element, then to the high-pressure fuel system, Intake Air Heater system, and AFT
fuel doser module.
In addition to providing high-pressure fuel to the injectors, the fuel system provides filtered low-pressure fuel to
the downstream injection and Intake Air Heater systems.
42 ENGINE SYSTEMS

Chassis Mounted Filter/Water Separator

The chassis mounted filter/water separator removes debris and water from the fuel before it enters the fuel
primer pump and low-pressure fuel pump. The chassis mounted filter/water separator includes a Water In Fuel
(WIF) sensor and optional fuel heater.

Fuel Primer Pump Assembly

During fuel system priming, fuel is drawn from the tank through the chassis mounted filter/water separator by
the fuel primer pump assembly. The fuel primer pump assembly has an integrated fuel strainer element that
can be cleaned. The fuel primer pump assembly is manually operated, and is used to prime the low-pressure
fuel system anytime the fuel system has been emptied. The primer pump provides unrestricted fuel flow to the
low-pressure pump during normal engine operation.

Low Pressure (LP) Fuel Pump

The LP fuel pump and the High Pressure (HP) fuel pump are one assembly. Fuel is drawn through the fuel
primer pump assembly and into the LP fuel pump. The LP pump supplies fuel to the fuel filter housing assembly
at pressures varying between approximately 85 psi (586 kPa) at idle, and 120 psi (827 kPa) at rated speed. The
LP fuel pump has an internal pressure regulator that relieves the fuel pressure internally if the pressure exceeds
189 psi (1300 kPa).

Fuel Filter Assembly

The fuel filter assembly is installed on the left side of the engine and has a disposable filter element. A Fuel
Delivery Pressure (FDP) sensor is installed on the front side of the fuel filter assembly, which measures fuel
pressure between the LP fuel pump and the filter element. The fuel filter assembly also has a drain screw that
allows water and dirt to be drained periodically. Because water may accumulate inside the fuel filter assembly,
use the drain screw to drain water per maintenance schedule in the Engine Operation and Maintenance Manual.
An additional function of the fuel filter assembly is fuel system self-deaeration. The air separated from fuel is
pushed back into the fuel tanks through the return line. The fuel filter assembly also provides filtered fuel to
the AFT fuel doser module and Intake Air Heater system. An orifice regulator is integrated into the fuel filter
assembly, and regulates the fuel pressure for the Intake Air Heater system to approximately 10 psi (70 kPa).
 ENGINE SYSTEMS 43

High Pressure Fuel System

Figure 16 High Pressure (HP) fuel system

1. (Fuel) Injector (6) 4. Fuel Pressure Control Valve 6. Fuel return - HP fuel pump
2. Rail pressure limiting valve (FPCV) 7. HP fuel pump
3. Fuel rail 5. Fuel inlet - HP fuel pump 8. Fuel Rail Pressure (FRP) sensor

Pressurization and injection are separate in the common rail injection system. Optimal fuel injection pressure is
generated by the high-pressure pump at any engine speed. High-pressure fuel quantity from the high-pressure
pump is controlled by the FPCV. Injection timing and quantity are calculated in the Engine Control Module (ECM)
and implemented by solenoid valve controlled injectors. The use of solenoid valve controlled injectors allows
three injections per cycle.
The first injection is used to reduce combustion noise and emissions by introducing a small amount of fuel into
the cylinder, preventing a rapid rise in cylinder pressure when combustion begins. The second injection is the
main injection. This injection allows high-temperatures to be maintained during combustion, but not long enough
to allow generation of large soot amounts. The third injection is done during the power stroke to maximize
cylinder temperature and reduce engine soot generation.
The high-pressure fuel system consists of the high-pressure pump with integrated Fuel Pressure Control Valve
(FPCV), pressure pipe rail, high-pressure fuel lines, injectors, FRP sensor, and rail pressure limiting valve.
44 ENGINE SYSTEMS

High Pressure (HP) Pump

The HP pump supplies the necessary quantity of HP fuel for all operating engine modes. The HP pump is gear
driven and is fuel lubricated. Fuel from the LP fuel pump is forced through the fuel module assembly, and into
the HP pump. The flow of fuel to the suction chamber of the HP pump is controlled by the FPCV, in order to
control HP fuel output.

Fuel Pressure Control Valve (FPCV)

The FPCV is a variable position actuator installed on the suction side of the high-pressure pump and controls
the output fuel pressure. The Engine Control Module (ECM) sends a Pulse Width Modulated (PWM) signal to
control the FPCV. A 100% duty cycle PWM signal corresponds to minimum fuel pressure delivery, while a 0%
duty cycle PWM corresponds to maximum fuel pressure delivery.

Fuel Rail
The fuel rail is a HP fuel storage unit. The storage volume of the fuel rail is designed to reduce pressure pulses
caused by the HP pump and injectors, and to maintain constant fuel pressure even when large fuel quantities
are injected into the cylinders. Connection between the fuel rail and injectors are made through two individual
injection lines.

Fuel Rail Pressure (FRP) Sensor

The FRP sensor is a variable resistance sensor that monitors fuel pressure in the High Pressure (HP) fuel rail.
The FRP sensor is mounted in the front of the fuel rail, on the left side of the engine.

Rail Pressure Limiting Valve

The rail pressure limiting valve maintains fuel pressure inside the fuel rail below approximately 37,700 psi
(260,000 kPa). If HP fuel pump output exceeds specification the rail pressure limiting valve opens and fuel
flows into the fuel return line. With the pressure limiting valve open, fuel pressure in the high-pressure fuel rail
drops to approximately 15,950 psi (110,000 kPa).

Fuel Injectors
N13 engines are equipped with electronically controlled fuel injectors. During engine operation, injectors are
supplied with high-pressure fuel, and the injector solenoid valves open up to three times per combustion cycle.
The injectors are positioned vertically in the center of the cylinder head and are held in place by clamps. The
seal between the injectors and the combustion chamber consists of a copper washer on the tip of each injector.
 ENGINE SYSTEMS 45

Inlet Air Heater System

Intake Air Heater System Components

Figure 17 Intake Air Heater System

1. Intake Air Heater Fuel Igniter (IAHFI)
2. Intake Air Heater Fuel Solenoid (IAHFS) valve
3. Intake Air Heater Relay (IAHR)

Intake Air Heater Fuel Igniter (IAHFI)

The Intake Air Heater system rapidly activates the heater element, vaporizing and igniting small quantities of
fuel into the air inlet duct.
46 ENGINE SYSTEMS

Figure 18 Intake Air Heater Fuel Igniter (partial cut away view)
1. Electrical connection
2. Insulation
3. IAHFI fuel line connection
4. Metering device
5. Vaporizer filter
6. Vaporizer tube
7. Heater element
8. Protective sleeve

The IAHFI has an internal fuel metering device, vaporizer filter, vaporizer tube, heater element, and a protective
sleeve. The protective sleeve has holes that allow enough air to pass through the IAHFI to enable fuel
vaporization and combustion.
The IAHFI is installed on the left front side of the engine, in the intake throttle duct.

Intake Air Heater Relay (IAHR)

The IAHR is installed on the left side of the engine at the rear of the Engine Control Module (ECM). The IAHR
provides voltage to the IAHFI, and is controlled by the ECM.

Intake Air Heater Fuel Solenoid (IAHFS) Valve

The IAHFS valve is installed on the left side of the engine and is controlled by the ECM. The IAHFS valve is
supplied with low-pressure fuel regulated from the fuel filter assembly.
When the ECM provides battery voltage to the IAHFS valve, the solenoid opens and allows fuel to flow to the
IAHFI through the IAHFI fuel line.
 ENGINE SYSTEMS 47

Intake Air Heater System Operation

The Intake Air Heater system operates only in temperatures lower than 10°C (50°F).
When the truck operator turns the ignition switch to ON, the wait-to-start lamp in the instrument cluster illuminates.
Based on the temperature readings from the Engine Coolant Temperature (ECT) sensors, the ECM activates
the IAHR heater element. The IAHR then energizes the IAHFI for approximately 35 seconds.
Once the IAHFI is heated to approximately 1000°C (1832°F), the wait-to-start lamp starts to flash and the
operator can crank the engine. When the engine is rotating, the IAHFS valve opens and allows fuel to enter the
IAHFI. Inside the IAHFI, fuel passes through the vaporizer tube. The vaporized fuel then mixes with in coming
air and ignites in contact with the heater element.
With the engine running, the IAHFI remains energized and fuel continues to be injected, and the wait-to-start
lamp continues to flash for a maximum of four minutes. When the wait-to-start lamp stops flashing, the IAHFI
and the IAHFS valve are deactivated. If the operator accelerates while the wait-to-start lamp is flashing, the
Intake Air Heater system will shutdown.
48 ENGINE SYSTEMS

Oil Flow and Components

Figure 19 Oil flow

1. Oil filter element 7. Oil supply to air compressor 12. Oil supply to front cover
2. Oil return from cylinder head 8. Oil supply to crankshaft main 13. Oil pump output
3. Oil supply to exhaust valve bearings 14. Oil pressure relief valve
bridge 9. Oil supply to piston oil sprayer 15. Oil supply to oil module
4. Oil supply to rocker gear nozzles 16. Oil return shutoff valve
5. Oil supply to camshaft bearings 10. Oil supply to turbochargers 17. Oil cooler
6. Oil supply to intermediate gears 11. Oil supply to drive housing

Unfiltered oil is drawn from the oil pan through the pickup tube and front cover passage by the crankshaft driven
gerotor pump. Pressurized oil is moved through a vertical crankcase passage and into the oil module.
Inside the oil module, unfiltered oil flows through plates in the oil cooler heat exchanger. Engine coolant flows
around the plates to cool the surrounding oil. An oil return shutoff valve installed at the exit from the oil cooler
prevents oil from draining through the oil pump and back into the oil pan when the engine is stopped. If oil
pressure coming out of the oil pump is too high, a pressure relief valve allows excess oil to return through the
crankcase into the oil pan before entering the oil cooler.
 ENGINE SYSTEMS 49

Oil that exits the oil cooler flows through a return shutoff valve that prevents the oil from draining back into the
oil pan. From the return shutoff valve, oil enters the oil filter element and flows from the outside to the inside of
the filter element to remove debris. When the filter is restricted, an oil filter bypass valve opens and allows oil
to bypass the filter so engine lubrication is maintained. If oil pressure inside the oil filter element is too high, an
oil pressure relief valve, installed at the bottom of the oil filter element housing, allows the excess oil to return
to the oil pan.
After passing through the oil filter element, oil flow is directed to the cylinder head and crankcase.
Clean oil enters the cylinder head through an external flange elbow connected to the oil module. Inside the
cylinder head, oil flows through passages to lubricate the camshaft bearings, rocker arms, exhaust valve bridges,
and cylinder intermediate gear.
Clean oil enters the crankcase from the oil module to lubricate the crankshaft, high-pressure pump, air
compressor, intermediate gears, and turbochargers. The crankshaft has cross-drillings that direct oil to the
connecting rods.
Oil sprayer nozzles direct cooled oil to the bottom of the piston crowns.
The turbochargers are lubricated with filtered oil from an external supply tube that connects the main oil gallery
from the crankcase to the center housing of each turbocharger. Oil drains back to the oil pan through the low
and high-pressure turbocharger oil return pipes connected to the crankcase.
A service oil drain valve, installed at the bottom of the filter element cavity, opens automatically when the filter
element is lifted for replacement, and allows the oil from the oil filter element cavity to drain into the oil pan.
Oil is also supplied to the Navistar® Engine Brake housings (under valve cover) through specially designed rocker
mounting bolts.
50 ENGINE SYSTEMS

Crankcase Oil Separator

Figure 20 Oil module with crankcase oil separator assembly (inner and outer views)
1. Crankcase Oil Separator 6. Engine Oil Temperature (EOT) 12. Regulator
(CCOS) sensor 13. CCOS oil return
2. CCOS vent outlet 7. Oil return from cylinder head 14. Oil module pressure relief port
3. Crankcase Oil Separator Speed 8. Oil supply to cylinder head 15. Oil out to crankcase
(CCOSS) sensor 9. Crankcase gas inlet 16. Oil cooler outlet to crankcase
4. Filter cover 10. Oil cooler inlet 17. Engine Oil Pressure (EOP)
5. Oil filter assembly 11. Oil supply from oil pump sensor

The oil module contains a canister style filter, oil cooler, EOP and EOT sensors, a pressure relief valve, an oil
filter bypass valve, and an oil return shutoff valve. The oil module also collects, and directs crankcase emissions
to the CCOS. The oil that separates from the crankcase emissions, before it reaches the CCOS, is drained back
into the oil pan through the oil return port.
 ENGINE SYSTEMS 51

Remote Mounted Centrifugal Oil Filter (Optional)

The remote mounted centrifugal oil filter is used to remove particulates from engine oil, reducing wear and
extending engine oil change intervals. During operation, dirty oil enters the oil supply port to a regulator valve.
When engine oil pressure exceeds approximately 248 kPa (36 psi), the regulator valve opens, and oil enters the
centrifugal element through the center hollow spindle. Inside the element, centrifugal acceleration separates
contaminants from oil. Contaminants accumulate on the serviceable rotor surface as a solid cake. Clean oil
exits through opposing twin nozzles that power the centrifuge and returns to the crankcase from the oil level
control base. Oil level is managed by the oil float. When the oil float raises, compressed air enters the system
to force oil back to the crankcase. When the oil float drops, the air supply port is closed.

Figure 21 Remote Mounted Centrifugal Oil Filter

1. Serviceable rotor
2. Oil supply port (regulator valve)
3. Oil return port
4. Oil float
5. Air supply port (regulator valve)
52 ENGINE SYSTEMS

Engine Cooling System

Cooling System Flow

Figure 22 Cooling system flow

 ENGINE SYSTEMS 53

The water pump is installed on the water distribution housing and draws coolant from the radiator through the
coolant inlet.
N13 engines have no coolant passages between the crankcase and cylinder head through the cylinder head
gasket. This eliminates the possibility of coolant leaks at the cylinder head gasket. Coolant in and out of the
crankcase and cylinder head is directed through external passages. Coolant flows through the crankcase and
cylinder head from front to rear. This coolant flows around the cylinder liners and combustion chambers to
absorb heat from combustion.
Coolant exiting the crankcase and cylinder head at the rear of the engine is directed through an external coolant
pipe to the high-temperature stage of the Exhaust Gas Recirculation (EGR) cooler. Coolant passes between
the EGR cooler plates, travels parallel to the exhaust flow, through a transfer passage in the left side of the
low-temperature EGR cooler, into the EGR cooler return manifold, and into the thermostat housing. A deaeration
port on top of the high-temperature EGR cooler directs coolant and trapped air to the coolant deareation tank.
Coolant from the water pump also flows through the low-temperature EGR Cooler and then through the Low
Pressure Charge Air Cooler (LPCAC) to regulate charge air temperature. Flow through the low-temperature
EGR cooler/charge air cooler is controlled by the Coolant Mixer Valve (CMV) and Coolant Flow Valve (CFV).
Depending on the coolant flow, CMV sends coolant through the low-temperature EGR Cooler, or bypass
indirectly to the LPCAC, after going through the Low Temperature Radiator (LTR) installed in front of the main
coolant radiator. When charge air temperature is too low, CMV bypasses the LTR and directs all the coolant
through the Charge Air Cooler (CAC). When charge air temperature increases, the CMV directs a percentage
of coolant to the LTR before it enters the CAC to cool the charge air. If the engine coolant temperature is too
high, CMV sends all of the coolant flow through the LTR and through the LPCAC to help cool the engine faster.
Both CMV and CFV are controlled by the Engine Control Module (ECM) based on signals from the Engine
Coolant Temperature 1 (ECT1) sensor, ECT2 sensor, Intake Manifold Pressure (IMP), and Inlet Air Temperature
(IAT) sensors.
Coolant flow to the radiator is controlled by two thermostats. When the thermostats are closed, coolant flowing
out of the EGR cooler is directed through a bypass port inside the front cover into the water pump. When the
thermostats are open the bypass port is blocked, and coolant is directed from the engine into the radiator.
Coolant passes through the radiator and is cooled by air flowing through the radiator from ram air and operation
of the coolant fan. The coolant returns to the engine first through the transmission cooler, then through the
engine coolant inlet elbow.
The air compressor is cooled with coolant supplied by a hose from the left side of the crankcase. Coolant passes
through the air compressor cylinder head and returns through a coolant return line to the engine crankcase.
The oil module receives coolant from a passage in the crankcase. Coolant passes between the oil cooler plates
and returns back to the water pump suction passage.
The Diesel Exhaust Doser Valve (DEFD) and DEF Tank Heater (DEFTH) receive coolant from a supply line
running from the lower radiator hose. When DEF tank temperature is too low, the Aftertreatment Control Module
(ACM) commands the DEFTH ON allowing coolant to pass through the DEF tank heating coil. Coolant from the
DEF tank heating coil and DEFD then returns to the water pump inlet through a coolant return line.
54 ENGINE SYSTEMS

Thermostat Operation
N13 engines are fitted with two thermostats in a common housing to ensure sufficient coolant flow in all operating
conditions. The thermostat housing is installed on top of the water distribution housing.
The thermostat housing assembly has two outlets. One directs coolant to the radiator when the engine is at
operating temperature. The second outlet directs coolant to the water pump until the engine reaches operating
temperature. The thermostats begin to open at approximately 83°C (181°F) and are fully open at 91°C (196°F).
When engine coolant is below approximately 83°C (181°F), the thermostats are closed, blocking coolant flow to
the radiator.
When coolant temperature reaches opening temperature, the thermostats open allowing some coolant to flow to
the radiator. When coolant temperature exceeds approximately 91°C (196°F), the lower seat blocks the bypass
port directing full coolant flow to the radiator.
 ENGINE SYSTEMS 55

Coolant Control Valve (CCV) assembly operation

The CCV is installed on the upper right side of the water distribution housing and controls coolant flow to the
Charge Air Coolers (CAC)s.
The CCV has two separate solenoid actuated valves. The Coolant Mixer Valve (CMV) and the Coolant Flow
Valve (CFV) are part of the CCV assembly and cannot be serviced separately. The CMV and CFV solenoids
are controlled by two separate Pulse Width Modulated (PWM) signals from the Engine Control Module (ECM).
The PWM signal duty cycles vary between 0% and 100% depending on coolant and charge air temperature.

Coolant Flow Valve (CFV)

The CFV is installed on the lower side of the CCV and controls coolant flow through the Low Pressure Charge
Air Cooler (LPCAC). The CFV will close to reduce coolant flow through the LPCAC when the engine is operating
at high speeds.

Coolant Mixer Valve (CMV)

The CMV is installed on the upper side of the CCV and controls coolant flow through the Low Temperature
Radiator (LTR). When charge air and coolant temperature coming out of the LPCAC is low, the CMV directs
coolant through a LTR bypass into the LPCAC. This helps the engine reach normal operating temperature faster.
If charge air and coolant temperature coming out of the LPCAC is high, the CMV directs coolant flow through
the LTR. This prevents overheating the LPCAC, which can result in LPCAC failure.
56 ENGINE SYSTEMS

Engine Brake System

Engine Brake Control System Components

Figure 23 Engine brake control system components

1. Upper valve cover 6. Master piston roller assembly (3 10. Valve cover base
2. Injector harness connector each housing) 11. Engine brake solenoid (1 each
3. Engine brake solenoid harness 7. Engine brake master piston housing)
connector lead (2) (within housing) 12. Engine brake housing assembly
4. Pass through harness 8. Exhaust valve bridge (2)
5. ECM E1 connector 9. Engine brake slave piston
 ENGINE SYSTEMS 57

Engine Brake System Description

The Navistar® Engine Brake by Jacobs® braking system is standard equipment on the ProStar® and
optional equipment on the TranStar® and WorkStar® for Navistar®N13 engines. The braking system is a
hydro-mechanical device that mounts under the engine’s valve cover. It turns your power-producing diesel
engine into a power-absorbing air compressor.
Here’s how: when the driver releases the accelerator pedal, the forward momentum of the truck continues to
turn the drivetrain and engine. The pistons continue to move up and down. Once activated, the engine brake
opens the exhaust valves near the peak of the compression stroke, releasing the highly compressed air through
the exhaust systems. Little energy is returned to the piston, and as the cycle repeats, the energy of the truck’s
forward motion is now directed toward motoring the diesel engine, thus reducing the forward motion causing the
truck to slow down.
58 ENGINE SYSTEMS

Engine Brake System Operation

The engine brake system consists of two hydraulic braking housings, activated using two Engine Control Module
(ECM) actuated brake solenoids, and an exhaust bridge (pin). The engine brake depends on engine oil for
operation; minimum oil temperature for retarder activation is approximately 40°C (104°F).
Engine brake operation is automatic after the operator turns it On using the On / Off switch. When the clutch is
engaged and the throttle is not depressed, the engine brake is automatically activated.
NOTE: The operator can select various engine brake retarding levels by pressing a HIGH/MEDIUM/LOW switch.
Activation occurs through the following steps:
1. Engine oil pressure fills the housing passages up to the solenoid.
2. Activation of the engine brake is communicated by the ECM using the J1939 Controller Area Network
(CAN) data link. When activated, the energized solenoid valve permits engine lube oil to flow under
pressure through the control valve to both the master piston and slave piston circuits.
3. Oil pressure causes the master piston roller assembly to move down, picking up the motion of the cam
(dedicated braking lobe) pushing the piston back into the housing creating high-pressure oil.
4. High-pressure oil flows back through the master piston, slave piston and control valve circuits.
5. The check ball in the control valve seats, trapping oil in the circuit creating a high-pressure link between
the slave piston and master piston.
6. Once the high-pressure link is created, the master piston follows the cam profile causing the slave piston
to move down, momentarily opening exhaust valve (single valve opening), while the engine piston is
near its top dead center position, releasing compressed cylinder air to the exhaust manifold.
7. Compressed air escapes to atmosphere completing compression braking cycle.
NOTE:
1. The Navistar® Engine Brake by Jacobs® will disengage during Anti-lock Brake System (ABS) braking.
2. Will interact with the vehicle cruise control for smooth operation during engine braking
3. Will interact with the Eaton UltraShift® Transmission for smooth up-shifts under fueling conditions
 ENGINE SYSTEMS 59

Electronic Control System

Electronic Control System Components
Navistar®N13 engines are equipped with two control modules, the Engine Control Module (ECM), and the
Aftertreatment Control Module (ACM).

Operation and Function

The ECM and ACM monitor and control engine and aftertreatment system operation to ensure maximum
performance and adherence to emissions standards. The ECM and ACM, perform the following functions:
• Provide reference voltage (VREF)
• Condition input signals
• Process and store control strategies
• Control actuators

Reference Voltage (VREF)

The ECM and ACM supply 5 volt VREF signals to various input sensors in the electronic control system. By
comparing the 5 volt VREF signal sent to the sensors with their respective returned signals, the ECM and ACM
determine pressures, positions, and other variables important to engine, aftertreatment, and vehicle functions.

Signal Conditioner
Signal conditioning circuitry in the ECM and ACM convert analog signals to digital signals, squares up sine wave
signals, and amplifies low intensity signals.

Microprocessor
The microprocessor, installed inside the ECM and ACM, process stored operating instructions (control strategies)
and value tables (calibration parameters). The microprocessor compares stored instructions and values with
conditioned input values to determine the correct strategy for all engine operations.
Diagnostic strategies are also programmed into the ECM and ACM. Some strategies monitor inputs continuously
and command the necessary outputs for correct performance of the engine and aftertreatment.

Diagnostic Trouble Codes

Diagnostic Trouble Codes (DTCs) are stored by the ECM if inputs or conditions do not comply with expected
values. Diagnostic fault codes are communicated using the Suspect Parameter Number (SPN) and Failure Mode
Indicator (FMI) identifiers, and are accessed using an electronic service tool with ServiceMaxx™ diagnostic
software or other J1939 and J1708 RP1210B compliant interface device.

Microprocessor Memory
The ECM and ACM microprocessors includes Read Only Memory (ROM) and Random Access Memory (RAM).
60 ENGINE SYSTEMS

Read Only Memory (ROM)

ROM stores permanent information for calibration tables and operating strategies. Permanently stored
information cannot be changed or lost when the ignition switch is turned to OFF or when power to the control
modules is interrupted. ROM includes the following:
• Vehicle configuration, modes of operation, and options
• Engine Family Rating Code (EFRC)
• Engine warning and protection modes

Random Access Memory (RAM)

RAM stores temporary information for current engine conditions. Temporary information in RAM is lost when
the ignition switch is turned to OFF or power to control module is interrupted. RAM information includes the
following:
• Engine temperature
• Engine rpm
• Accelerator pedal position
 ENGINE SYSTEMS 61

Actuator Control
The Engine Control Module (ECM) and Aftertreatment Control Module (ACM) control actuators by applying a low
level signal (low-side driver) or a high level signal (high-side driver). When switched on, both drivers complete
a ground or power circuit to an actuator.
Actuators are controlled in one of the following ways, depending upon type of actuator:
• Duty cycle (percent time On / Off)
• Pulse Width Modulated (PWM)
• Switched On or Off
62 ENGINE SYSTEMS

Actuators
The ECM controls engine operation with the following:
• Coolant Control Valve (CCV)
• Exhaust Back Pressure Valve (EBPV)
• Exhaust Gas Recirculation Valve (EGRV)
• Air Control Valve (ACV)
• Intake Air Heater Relay (IAHR)
• Intake Air Heater Fuel Solenoid (IAHFS) valve
• Engine Throttle Valve (ETV)
• Fuel Pressure Control Valve (FPCV)
• Intake Air Heater Fuel Ignitor (IAHFI) relay
The ACM controls aftertreatment system operation with the following:
• Aftertreatment Fuel Shutoff (AFTFSO)
• Aftertreatment Purge Air Valve (AFTPAV)
• Diesel Exhaust Fluid Dosing Unit Heater (DEFDUH)
• Diesel Exhaust Fluid Doser (DEFD)
• Diesel Exhaust Fluid Line Heater Relay (DEFLHR)
• Diesel Exhaust Fluid Pressure Line Heater (DEFPLH)
• Diesel Exhaust Fluid Return Line Heater (DEFRLH)
• Diesel Exhaust Fluid Valve (DEFRV)
• Diesel Exhaust Fluid Supply Line Heater (DEFSLH)
• Diesel Exhaust Fluid Supply Pump (DEFSP) and Temperature Sensor
• Diesel Exhaust Fluid Tank Heater (DEFTH)
• Diesel Exhaust Fluid Unit Heater Relay (DEFUHR)

Coolant Control Valve (CCV)

The Coolant Mixer Valve (CMV) and Coolant Flow Valve (CFV) are a combined solenoid assembly that regulates
coolant flow and temperature through the Low Pressure Charge Air Cooler (LPCAC) and the low-temp EGR
cooler. The CMV and CFV are housed in the CCV assembly.
The CFV controls the rate of coolant flow through the CAC, and the CMV regulates the temperature of the
coolant, by directing coolant either through the Low Temperature Radiator (LTR) or through an internal bypass.
Both valves are controlled by the Engine Control Module (ECM).
The CCV is installed on the water distribution housing.
 ENGINE SYSTEMS 63

Exhaust Back Pressure Valve (EBPV) Control

The EBPV is controlled using the Air Control Valve (ACV) assembly. The ACV assembly contains the EBPV
control valve, and the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor. Both are used by the ECM to
control EBPV operation.
The EBPV regulates air pressure applied to the EBPV pneumatic actuator. The pneumatic cylinder actuates the
valve (in the exhaust system) in response to commands by the ECM.
The EBPV actuator is mounted on the right side of the engine, after the turbocharger exhaust connection.

Exhaust Gas Recirculation (EGR) Valve

The EGRV is mounted on the rear of the EGR cooler, on top of the engine. The EGRV assembly receives the
desired valve position from the ECM. The EGRV regulates the flow of exhaust gases through the EGR system.

Air Control Valve (ACV)

The ACV contains solenoids used for control of the High Pressure (HP) turbocharger wastegate and EBPV. It
also contains the TC1TOP sensor.
ACV solenoids are controlled through pulse width modulated signals sent by the ECM.
The ACV is installed on the right side of the engine, near the center of the EGR cooler.

Intake Air Heater Relay (IAHR)

The Intake Air Heater system warms incoming air supply up to four minutes for cold engine emissions reduction.
The Engine Control Module (ECM) is programmed to energize the Intake Air Heater Fuel Igniter (IAHFI) heater
element through the Intake Air Heater Relay (IAHR) while monitoring engine coolant temperature, air inlet
temperature, engine oil temperature, and atmospheric pressure.
The IAHR delivers battery voltage to the heater element for a set time, depending on engine coolant temperature
and altitude. The ground circuit is supplied from the battery ground. The relay is controlled by switching on a
voltage source from the ECM, and is installed to the rear of the ECM.

Intake Air Heater Fuel Solenoid (IAHFS) Valve

The IAHFS valve controls fuel flow to the IAHFI during Intake Air Heater operation.
When Intake Air Heater is required, the ECM provides voltage to open the IAHFS valve.
The IAHFS valve is mounted on the intake throttle duct, on the top left side of the engine.

Engine Throttle Valve (ETV)

The ETV controls the flow of fresh air (boosted and cooled) into the engine's air intake path through the Charge
Air Cooler (CAC) to help heat the exhaust aftertreatment during regeneration, and to when heavy Exhaust Gas
Recirculation (EGR) is requested. The electronic portion of the ETV contains a microprocessor that monitors
valve position, electronic chamber temperature, controls the electric motor, and reports diagnostic faults to the
ECM. The ETV changes position in response to ECM signals.
The ETV is integrated into the intake throttle duct, on the top left side of the engine.
64 ENGINE SYSTEMS

Fuel Pressure Control Valve (FPCV)

The FPCV is a variable position actuator that controls fuel flow to the suction side of the high-pressure fuel pump.
The FPCV changes valve position through pulse width modulated signals from the ECM.
The FPCV is mounted on the upper side of the high-pressure pump. The FPCV and fuel pump are serviced as
an assembly.

Aftertreatment Fuel Shutoff (AFTFSO)

The AFTFSO is used to control fuel flow to the Aftertreatment Fuel Injector (AFTFI). The AFTFSO is controlled
through an On-Off signal sent by the Aftertreatment Control Module (ACM). The AFTFSO is installed in the AFT
fuel doser module, located to the rear of the fuel filter assembly, on the left side of the engine.

Aftertreatment Purge Air Valve (AFTPAV)

The AFTPAV is used to purge the AFTFI of fuel after active regeneration of the aftertreatment system. When
purging is needed, the Aftertreatment Control Module (ACM) commands the AFTPAV ON, and AFTFI open.
This allows pressurized air from the vehicle air tanks, to flow through the AFTPAV, AFT fuel doser module, and
out the AFTFI.
The AFTPAV is mounted on the left side of the engine, behind the AFT fuel doser module.

Diesel Exhaust Fluid Dosing Unit Heater (DEFDUH)

The DEFDUH is used to maintain proper DEF temperature in the DEF supply module.
The ACM is programmed to energize the DEFDUH through the Diesel Exhaust Fluid Unit Heater Relay
(DEFUHR) when DEF supply module temperature is too low.

Diesel Exhaust Fluid Doser (DEFD)

The DEFD is a solenoid assembly controlled by the Aftertreatment Control Module (ACM). When the ACM
commands DEF dosing, it opens the doser valve and allows DEF to be sprayed into the exhaust stream.

Diesel Exhaust Fluid Line Heater Relay (DEFLHR)

The DEF line heaters are used to maintain proper DEF temperature to avoid DEF freezing. When DEF
temperature is too low. The ACM commands the DEFLHR ON, sending power to the DEF line heaters.
The DEFLHR is installed in the Power Distribution Module (PDM), behind the DEF tank.

Diesel Exhaust Fluid Pressure Line Heater (DEFPLH)

The DEFPLH is used to maintain proper DEF temperature in the DEF supply module pressure line.
The DEFPLH is wrapped around the pressure line between the DEF supply module and DEFD.

Diesel Exhaust Fluid Return Line Heater (DEFRLH)

The DEFRLH is used to maintain proper DEF temperature in the DEF supply module return line.
The DEFRLH is wrapped around the return line between the DEF supply module and DEF tank.
 ENGINE SYSTEMS 65

Diesel Exhaust Fluid Valve (DEFRV)

The DEFRV is switched On or Off by the ACM.
The DEFRV regulates the flow of DEF exiting the DEF supply module. When purging is needed, the ACM will
turn the DEFRV ON, and returns DEF in the lines to the tank.
The DEFRV is part of the DEF supply module, and is not serviceable individually.

Diesel Exhaust Fluid Supply Line Heater (DEFSLH)

The DEFSLH is used to maintain proper DEF temperature in the DEF supply module suction line.
The DEFSLH is wrapped around the suction line between the DEF supply module and DEF tank.

Diesel Exhaust Fluid Supply Pump (DEFSP) and Temperature Sensor

The DEFSP is controlled using a Pulse Width Modulated (PWM) signal from the ACM.
The DEF supply module has an internal temperature sensor used to monitor DEFSP temperature.
The DEFSP is part of the DEF supply module, and is not serviceable individually.

Diesel Exhaust Fluid Tank Heater (DEFTH)

The DEFTH controls coolant flow to the DEF tank. When DEF temperature is low, the ACM commands the
DEFTH open, allowing coolant flow to warm the DEF tank.
The DEFTH is typically mounted to the vehicle frame.

Diesel Exhaust Fluid Unit Heater Relay (DEFUHR)

The DEFUHR aids in defrosting the DEF supply module. When DEF temperature is too low, the ACM energizes
the heater element inside the DEF supply module through the DEFUHR.
66 ENGINE SYSTEMS

Engine and Vehicle Sensors

Thermistor Sensors

Figure 24 Thermistor

A thermistor sensor changes electrical resistance with changes in temperature. As temperature changes at the
thermistor, voltage at the ECM or ACM will change accordingly. Thermistors work with the control module to
produce a voltage signal proportional to temperature values.
A thermistor sensor has two electrical connectors, signal return and ground. The output of a thermistor sensor
is a non-linear analog signal.
Thermistor type sensors include the following:
• Aftertreatment temperature sensors
• Engine coolant temp sensors
• Engine Oil Temperature (EOT) sensor
• Turbocharger 2 Compressor Inlet Sensor (TC2CIS)
• Charge Air Cooler Outlet Temperature (CACOT) sensor
• Intake Manifold Temperature (IMT) sensor
• EGR (cooler) Temperature (EGRGT) sensor
• Ambient Air Temperature (AAT) sensor

Aftertreatment Temperature Sensors

Temperature sensors used in the Aftertreatment System include the following:
• Diesel Exhaust Fluid Tank Level and Temperature (DEFTLT) sensor
• DOC / DPF temperature sensor module
• Diesel Oxidation Catalyst Intake Temperature (DPFIT) sensor
• Diesel Particulate Filter Intake Temperature (DPFIT) sensor
• Diesel Particulate Filter Outlet Temperature (DPFOT) sensor
 ENGINE SYSTEMS 67

• SCR temperature sensor module

• Selective Catalyst Reduction Intake Temperature (SCRIT) sensor
• Selective Catalyst Reduction Outlet Temperature (SCROT) sensor

Diesel Exhaust Fluid Tank Level and Temperature (DEFTLT) Sensor Module
The DEFTLT sensor module is a combination sensor that monitors DEF tank level and temperature, and
communicates to the Aftertreatment Control Module (ACM) through J1939 Controller Area Network (CAN)
communication.
The DEFTLT sensor module is installed inside the DEF tank.

Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF) Temperature Sensor Module
The DOC / DPF temperature sensor module monitors aftertreatment DPF and DOC temperature. The DOC
/ DPF temperature sensor module monitors signals from the DOC Intake Temperaturee (DPFIT), DPF Intake
Temperature (DPFIT), and DPF Outlet Temperature (DPFOT) sensors, and communicates these signals to the
Aftertreatment Control Module (ACM) through J1939 Controller Area Network (CAN) communication.
The DOCIT, DPFIT, and DPFOT sensors are not serviceable individually, and are part of the DOC / DPF
temperature sensor module.

Selective Catalyst Reduction (SCR) Temperature Sensor Module

The SCR temperature sensor module monitors aftertreatment SCR catalyst temperature. The SCR temperature
sensor module monitors signals from the SCR Intake Temperature (SCRIT) sensor, and SCR Outlet Temperature
(SCROT) sensor, and communicates these signals to the ACM through J1939 Controller Area Network (CAN)
communication.
The SCRIT sensor and SCROT sensor are not serviceable individually, and are part of the SCR temperature
sensor module.

Engine Coolant Temperature (ECT) Sensors

The ECT1 and ECT2 sensors are thermistor-type sensors that detect engine coolant temperature.
The ECT1 signal is monitored by the ECM for operation of the instrument panel temperature gauge, coolant
temperature compensation, charge air temperature control, EGR system control, optional Engine Warning
Protection System (EWPS), and the wait to start lamp. The ECM uses ECT1 sensor input as a backup, if EOT
sensor values are out of range.
The ECT1 sensor is installed in the underside of the EGR coolant crossover manifold, at the back of the engine.
The ECT2 sensor is installed in the low-temperature stage of the EGR cooler, on the right side of the engine.

Engine Oil Temperature (EOT) Sensor

The EOT sensor is a thermistor sensor that detects engine oil temperature. The EOT sensor is installed in the
side oil module flange, behind the oil filter cover, on the right side of the engine.

Turbocharger 2 Compressor Inlet Sensor (TC2CIS)

The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the High
Pressure (HP) turbocharger. This sensor also monitors boost pressure for the Low Pressure (LP) turbocharger.
The TC2CIS sensor is monitored by the Engine Control Module (ECM), and is used for calculating fuel delivery
and controlling turbocharger wastegate operation.
68 ENGINE SYSTEMS

The TC2CIS is installed in the piping between the LP compressor outlet and the HP compressor inlet.

Charge Air Cooler Outlet Temp (CACOT) Sensor

The CACOT sensor is a thermistor sensor that monitors the temperature of charge air entering the intake air
duct.
The CACOT signal is monitored by the ECM.
The CACOT sensor is installed on the intake air duct, before the Engine Throttle Valve (ETV).

Intake Manifold Temperature (IMT) Sensor

The IMT sensor is a thermistor sensor that monitors temperature.
The IMT sensor is installed in the intake side of the cylinder head, on the left side of the engine.

Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor

The EGRGT sensor is a thermistor sensor that detects the exhaust gas temperature entering the EGR cooler.
The EGRGT signal is monitored by the ECM.
The EGRGT sensor is installed in the front of the low temp EGR cooler on the left side.

Ambient Air Temperature (AAT) Sensor

The AAT sensor is a thermistor sensor that detects the temperature of ambient air.
The AAT signal is monitored by the ECM.
The AAT sensor is installed in various places depending on the vehicle.

Variable Capacitance Sensors

Figure 25 Variable capacitance sensor example

Variable capacitance sensors measure pressure. The pressure measured is applied to a ceramic material. The
pressure forces the ceramic material closer to a thin metal disk. This action changes the capacitance of the
sensor.
The sensor is connected to the control module through the VREF, signal, and signal ground wires.
 ENGINE SYSTEMS 69

The sensor receives the VREF and returns an analog signal voltage to the Engine Control Module (ECM) or
Aftertreatment Control Module (ACM). The ECM or ACM compares the voltage with pre-programmed values to
determine pressure.
Variable capacitance sensors include the following:
• Aftertreatment Fuel Pressure (AFTFP)
• Diesel Exhaust Fluid Line Pressure (DEFLP) sensor
• Diesel Particulate Filter Differential Pressure (DPFDP) / outlet pressure sensor
• Fuel Delivery Pressure (FDP) sensor
• Engine Oil Pressure (EOP) sensor
• Fuel Rail Pressure (FRP) sensor
• Intake Manifold Pressure (IMP) sensor
• Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor

Aftertreatment Fuel Pressure (AFTFP) Sensor

The AFTFP sensor is a variable capacitance sensor that the ACM uses to monitor fuel pressure into the
aftertreatment system.
The AFTFP sensor is installed in the AFT fuel doser module, to the rear of the fuel filter assembly.

Diesel Exhaust Fluid Line Pressure (DEFLP) Sensor

The DEFLP sensor is a variable capacitance sensor that measures DEF pressure from the DEF Supply Pump
(DEFSP).
The DEFLP sensor provides feedback to the ACM for the DEF dosing system.
The DEFLP sensor is not serviceable individually and is part of the DEF supply module.

Diesel Particulate Filter Differential Pressure (DPFDP ) / Outlet Pressure Sensor

The DPFDP / outlet pressure sensor provides a feedback signal to the ACM indicating the pressure difference
between the inlet and outlet of the DPF.
The DPFDP / outlet pressure sensor is a differential pressure sensor with two tap-offs installed at the DPF. A
tap-off is installed before and after the DPF.

Fuel Delivery Pressure (FDP) Sensor

The FDP sensor is a variable capacitance sensor that measures fuel supply pressure.
The FDP sensor provides feedback to the ECM for the low-pressure fuel system.
The FDP sensor is installed in the front of the fuel filter assembly on the left side of the engine.

Engine Oil Pressure (EOP) Sensor

The EOP sensor is a variable capacitance sensor that detects engine oil pressure.
The EOP signal is monitored by the ECM for operation of the instrument panel pressure gauge and optional
Engine Warning and Protection System (EWPS).
The EOP sensor is installed in the oil module, on the right side of the engine.
70 ENGINE SYSTEMS

Fuel Rail Pressure (FRP) Sensor

The FRP sensor is a variable capacitance sensor that monitors fuel pressure in the high-pressure fuel rail.
The FRP sensor measures fuel pressure just before injection.
The FRP sensor is mounted in the front of the fuel rail on the left side of the engine.

Intake Manifold Pressure (IMP) Sensor

The IMP sensor is a variable capacitance sensor that monitors the pressure of charge air entering the intake air
duct.
The IMP signal is monitored by the ECM for control of the EGR system and turbocharger wastegates.
The IMP sensor is installed in the intake air duct, after the Engine Throttle Valve (ETV).

Turbocharger 1 Turbine Outlet Pressure (TC1TOP)

The TC1TOP sensor is a variable capacitance sensor that monitors exhaust back pressure.
The sensor measures back pressure in the exhaust system. A tap for the TC1TOP is installed in the exhaust,
between the low-pressure turbocharger and Exhaust Back Pressure Valve (EBPV).
The TC1TOP sensor is installed in the Air Control Valve (ACV), on the right side of the engine.
 ENGINE SYSTEMS 71

Magnetic Pickup Sensors

Figure 26 Magnetic pickup sensor examples

A magnetic pickup sensor contains a permanent magnet core that is surrounded by a coil of wire. The sensor
generates a voltage signal through the collapse of a magnetic field created by a moving metal trigger. The
movement of the trigger then creates Alternate Current (AC) voltage in the sensor coil.
Magnetic pickup sensors used include the following:
• CKP sensor
• CMP sensor
• VSS
• CCOSS sensor

Crankshaft Position (CKP) Sensor

The CKP sensor is a magnetic pickup sensor that indicates crankshaft speed and position.
The CKP sensor sends a pulsed signal to the Engine Control Module (ECM) as the crankshaft turns. The CKP
sensor reacts to holes drilled into the flywheel adjacent to the ring gear. For crankshaft position reference, teeth
59 and 60 are missing. By comparing the CKP signal with the CMP signal, the ECM calculates engine rpm and
timing requirements.
The CKP sensor is installed in the top left of the flywheel housing.

Camshaft Position (CMP) Sensor

The CMP sensor is a magnetic pickup sensor that indicates camshaft speed and position.
The CMP sensor sends a pulsed signal to the ECM as a toothed wheel on the camshaft rotates past the CMP
sensor. The ECM calculates camshaft speed and position from CMP signal frequency.
The CMP sensor is installed in the left rear of the cylinder head.
72 ENGINE SYSTEMS

Vehicle Speed Sensor (VSS)

The VSS provides the ECM with transmission tail shaft speed by sensing the rotation of a 16-tooth gear on the
rear of the transmission. The detected sine wave signal (AC) received by the ECM, is used with tire size and axle
ratio to calculate vehicle speed. The VSS is installed on the left side of the transmission housing for automatic
transmissions, or at rear of the transmission housing for manual transmissions.

Crankcase Oil Separator Speed (CCOSS) sensor

The CCOSS sensor sends the ECM information about the speed of the crankcase oil separator internal
components. The detected sine wave signal (AC) received by the ECM is used to monitor operation of the
cyclonic oil separator, installed inside the breather assembly on the engine oil filter assembly.

Potentiometer Sensors

Figure 27 Potentiometer example

A potentiometer is a variable voltage divider that senses the position of a mechanical component. A reference
voltage is applied to one end of the potentiometer. Mechanical rotary or linear motion moves the wiper along
the resistance material, changing voltage at each point along the resistive material. Voltage is proportional to
the amount of mechanical movement.
The engine has two potentiometers, both contained in the Accelerator Pedal Position (APP) Sensor.
 ENGINE SYSTEMS 73

Accelerator Pedal Position (APP)

The APP provides the ECM with a dual feedback signal (dual linear analog voltages) that indicate the operator's
demand for power. The APP contains two potentiometers, and provides two individual signals (APP1 and APP2)
to the ECM. The APP is installed in the cab on the accelerator pedal assembly.

Switches

Figure 28 Switch example

Switch sensors indicate position, level, or status. They operate open or closed, regulating the flow of current. A
switch sensor can be a voltage input switch or a grounding switch. A voltage input switch supplies the control
module with a voltage when it is closed. A grounding switch grounds the circuit when closed, causing a zero
voltage signal. Grounding switches are usually installed in series with a current limiting resistor.
Switches include the following:
• Driveline Disengagement Switch (DDS)
• Engine Coolant Level (ECL)
• Oil Level Sensor (OLS)

Driveline Disengagement Switch (DDS)

The DDS determines if a vehicle is in gear. For manual transmissions, the clutch switch serves as the DDS. For
automatic transmissions, the neutral indicator switch functions as the DDS. The DDS signal is sent to the Body
Controller (BC) and transmitted on the J1939 Controller Area Network (CAN) datalink to the engine ECM.

Engine Coolant Level (ECL) Switch

The ECL switch is part of the Engine Warning and Protection System (EWPS). The ECL switch is installed on
the deaeration tank. When the magnetic switch is open, the tank is considered full of coolant.
If engine coolant is low, the switch closes and the red ENGINE lamp on the instrument panel is illuminated.
74 ENGINE SYSTEMS

Oil Level Sensor (OLS)

The OLS is part of the EWPS. The OLS is installed in the engine oil pan. The OLS measures the volume of oil
in the oil pan and broadcast the percentage volume over J1939 Controller Area Network (CAN).
If the level of engine lube oil is low, the red ENGINE lamp on the instrument panel is illuminated.
 ENGINE SYSTEMS 75

Additional Sensors
Ammonia (NH3) Sensor Module
The NH3 sensor module is used to control DEF dosing by monitoring ammonia levels at the Selective Catalyst
Reduction (SCR) catalyst.
The NH3 sensor module monitors the NH3 sensor signal, and communicates this signal to the Aftertreatment
Control Module (ACM).
The NH3 sensor is not serviceable individually, and is part of the NH3 sensor module.

Humidity Sensor (HS)

The HS measures the moisture content of filtered air entering the intake system.
Using HS input, the Engine Control Module (ECM) will make adjustments to prevent condensation of airborne
water particles (moisture). The HS also houses the IAT sensor, which is used by the ECM for calculating fuel
delivery.

Nitrogen Oxides (NOx) IN Sensor Module

The Nitrogen Oxides (NOx) IN sensor module is a smart device used to measure the NOx emissions at the intake
of the aftertreatment system. The NOx IN sensor module performs internal diagnostics and reports malfunctions
back to the ACM using the J1939 CAN data link.
The NOx IN sensor is not serviceable individually, and is part of the NOx IN sensor module.

Nitrogen Oxides (NOx) OUT Sensor Module

The Nitrogen Oxides (NOx) OUT sensor module is a smart device used to measure NOx emissions at the outlet
of the SCR catalyst. The NOx OUT sensor module performs internal diagnostics and reports malfunctions back
to the ACM using the J1939 CAN data link.
The NOx OUT sensor is permanently attached to the NOx control module. They are not serviceable
independently and it is a single component.

Oxygen Sensor (O2S)

The O2S monitors oxygen levels in the exhaust.
O2S input is used by the ECM to control EGR flow to a specified ratio by monitoring the level of unused oxygen
in the exhaust stream.
The O2S compares oxygen levels in the exhaust stream with oxygen levels in the outside air. The sensor
generates an analog voltage and is monitored by the ECM. The level of voltage generated by the O2S
corresponds to the oxygen levels in the exhaust stream.
The O2S is installed in the turbocharger exhaust pipe, after the Exhaust Back Pressure Valve (EBPV).
76 ENGINE SYSTEMS
 MOUNTING ENGINE ON STAND 77

Table of Contents

Mounting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79

Engine Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .88

78 MOUNTING ENGINE ON STAND
 MOUNTING ENGINE ON STAND 79

Mounting Engine

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, make sure the engine is supported before removing
mounting hardware.
Engine Cleaning
1. Using Disposable Air and Fuel Caps (page 117), cover all engine openings to prevent water, degreasing
agents or detergents from entering engine.
2. Cover exposed electrical connectors and the Engine Control Module (ECM) using plastic and duct tape.
3. Use an appropriate detergent mixed in the correct ratio as described on the detergent directions and apply
to engine using a hot pressure washer or similar cleaning equipment.
80 MOUNTING ENGINE ON STAND

Mounting Engine on Stand

NOTE: Before mounting engine on engine stand, do the following.
1. Drain any remaining coolant from individual components as necessary into a suitable container.
2. Remove oil drain plug and drain oil into a suitable container.
3. Inspect oil drain plug O-ring. Discard and replace if damaged.
4. After oil is drained, lubricate oil drain plug O-ring with clean engine oil and install oil drain plug.
5. Tighten oil drain plug to special torque (page 88).

Figure 29 Low-pressure Charge Air Cooler (LPCAC) and tubes

1. Open breather tube assembly
2. Heater hose return tube
3. HCI coolant return tube assembly
4. LPCAC

6. Remove HCI coolant return tube assembly. See HCI Coolant Return Tube Assembly (page 232).
7. Disconnect heater hose return tube from water distribution housing, tube clamp and open breather tube
assembly. See Oil Module Assembly (page 463).
8. Remove open breather tube assembly. See Oil Centrifuge (page 461).
9. Remove oil module assembly. See Oil Module Assembly (page 463).
10. Remove Low-Pressure Charge Air Cooler (LPCAC). See Low-Pressure Charge Air Cooler (LPCAC) (page
283).
11. Remove starter motor assembly.

WARNING: To prevent personal injury or death, use a chain hoist rated for the weight of the engine,
follow manufacturer's installation and safety instructions, and attach safety latch lifting hooks to lifting
eyes on the engine.
 MOUNTING ENGINE ON STAND 81

Figure 30 Lifting Chain Assembly Connected to Main Engine Lift Bracket

1. Engine lift
2. Lifting Chain Assembly 12-000-01-07
3. Rear Lifting Ring 12-000-01-05
4. Main Engine Lift Bracket 12-000-01-01

12. Connect Lifting Chain Assembly (Figure 30) (Item 2) on Main Engine Lift Bracket (Figure 30) (Item 4) to
engine lift (Figure 30) (Item 1) using chain link closest to lifting ring. Connect at Rear Lifting Ring (Figure
30) (Item 3) if lifting engine and transmission as single assembly.
82 MOUNTING ENGINE ON STAND

Figure 31 Main Engine Lift Bracket Secured to Front Engine Lifting Eyelet
1. Front engine lifting eyelet
2. Main Engine Lift Bracket 12-000-01-01
3. Lynch Pin 12-000-01-03

13. Slide Main Engine Lift Bracket (Figure 31) (Item 2) into front engine lifting eyelet. Secure lift bracket with
Lynch Pin (Figure 31) (Item 3).
 MOUNTING ENGINE ON STAND 83

Figure 32 Adapter Bracket Installed

1. Adapter Bracket 12-000-01-02
2. Bolt and nut (4)
3. Rear lifting eyelet (2)

14. Remove engine cover (dog house).

15. Install Adapter Bracket (Figure 32) (Item 1) to front side of rear lifting eyelets (Figure 32) (Item 3) on flywheel
housing and Main Engine Lift Bracket. Secure with four bolts and nuts (Figure 32) (Item 2). Install all bolts
loosely to allow for bracket movement.
84 MOUNTING ENGINE ON STAND

Figure 33 Cab Shim Assembly Installed

1. Cab Shim Assembly 12-000-01-06
2. Cab mount

NOTE: Installation of Cab Shim Assembly 12-000-01-06 is not required for all models, although it may provide
additional access for some models.
16. To install Cab Shim Assembly:
a. Remove steel strap securing cab mount (Figure 33) (Item 2) to cab bushing.
b. Safely raise passenger side of cab.
c. Install Cab Shim Assembly (Figure 33) (Item 1).
d. Lower cab mount (Figure 33) (Item 2) down on Cab Shim Assembly.
17. Raise and remove engine from vehicle using engine lift.
 MOUNTING ENGINE ON STAND 85

Figure 34 Engine front mount support (right side)

1. M14 x 50 bolt (4)
2. Engine front mount support

NOTE: For reinstallation of engine front mount support, tighten M14 x 50 bolts to special torque (page 88).
18. Remove four M14 x 50 bolts (Figure 34) (Item 1) and engine front mount support (right).

Figure 35 Engine Stand Adapter Plate (mounting bracket) 12-051-01

86 MOUNTING ENGINE ON STAND

WARNING: To prevent personal injury or death, use metric class 10.9 or SAE grade 8 bolts when
mounting Engine Stand Adapter Plate to engine and engine stand. See instructions included with engine
stand and Engine Stand Adapter Plate.
NOTE: See manufacturer's safety instructions included with engine stand and Engine Stand Adapter Plate.

Figure 36 Engine Stand Adapter Plate (mounting bracket) Mounted to Engine

1. Mounting bolts (6) 12-051–01-02
2. Engine Stand Adapter Plate (mounting bracket) 12-051-01
 MOUNTING ENGINE ON STAND 87

19. Position Engine Stand Adapter Plate (Figure 36) (Item 2) on right side of engine. Secure adapter plate with
six mounting bolts (Figure 36) (Item 1). Tighten bolts to standard torque (page 881).

Figure 37 Engine Stand Adapter Plate Attached to Engine Roll-Over Stand

1. Engine Roll-Over Stand OTC1750A
2. Engine Stand Adapter Plate 12-051-01

20. Attach Engine Stand Adapter Plate to Engine Roll-Over Stand (Figure 37) (item 1) using four 5/8 x 1.5 inch
grade 8 mounting bolts. Tighten bolts to standard torque (page 881).
88 MOUNTING ENGINE ON STAND

Special Torque

M14 x 50 engine front mount support bolts 225 N·m (166 lb·ft)
Oil drain plug 75 N·m (55 lb·ft)

Special Service Tools

Description Tool Number

Disposable Air and Fuel Caps ZTSE4891
Engine Lifting Bracket 12-000-01
Engine Roll-Over Stand OTC1750A
Engine Stand Adapter Plate 12-051-01
 TRUCK REPAIR PROCEDURES 89

Table of Contents

High-Pressure (HP) Turbocharger Center Section Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

High-Pressure (HP) Turbocharger Center Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91

EGR Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

EGR Core Replacement Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Oil Fill Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Oil Fill Tube Assembly Leak Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Oil Fill Tube Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Oil Fill Tube Adapter Mount Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Oil Fill Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117

90 TRUCK REPAIR PROCEDURES
 TRUCK REPAIR PROCEDURES 91

High-Pressure (HP) Turbocharger Center Section Replacement Procedure

Overview
This section provides instruction for removal of individual turbocharger components when not doing a complete
engine teardown. For turbocharger component removal during a complete engine teardown follow Removal
(Complete Engine Teardown) Section.

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
High-Pressure (HP) Turbocharger Center Section

Overview
This section provides instruction specifically for removal of the high-pressure turbocharger center section when
Not doing a complete engine teardown.
92 TRUCK REPAIR PROCEDURES

Figure 38 High-Pressure (HP) and Low-Pressure (HP) Turbochargers and Connections.

1. Intake Air Temperature (IAT) 5. High-Pressure Charge Air 9. Air inlet duct
sensor Cooler (HPCAC) 10. HP Turbocharger
2. Air inlet connecting hose 6. High-Pressure Charge Air 11. LP Turbocharger
3. Mass Air Flow (MAF) sensor Cooler (HPCAC) pipe
4. Turbocharger 2 Compressor 7. HP turbocharger air supply duct
Inlet Pressure (TC2CIP) sensor 8. HP compressor out duct
 TRUCK REPAIR PROCEDURES 93

1. Using Coolant Management Tool KL5007NAV (page 343), drain coolant. Place suitable coolant drain pan
under truck.
2. Remove air inlet connecting hose (Figure 38) (Item 2).
3. Remove HPCAC pipe (Figure 38) (Item 6) from HPCAC (Figure 38) (Item 5) and HP compressor out duct
(Figure 38) (Item 8).
4. Install cap (Disposable Air and Fuel Caps) ZTSE4891 (page 343) on HPCAC.
5. Disconnect engine harness connectors at IAT sensor, MAF sensor (if equipped), and TC2CIP sensor (Figure
38) (Items 1, 3, and 4), and EOP sensor (Figure 39) (Item 10) and secure engine harness out of the way.
6. Remove HP compressor out duct.
7. Remove air inlet duct (Figure 38) (Item 9) and install a clean cap on inlet to LP turbocharger (Figure 38)
(Item 11).
94 TRUCK REPAIR PROCEDURES

Figure 39 HP Turbocharger and Connections.

1. High-Pressure (HP) 7. Coolant tube (EGR cooler to 12. Coolant return hose
turbocharger assembly LPCAC) 13. M10 x 200 bolt
2. HP turbocharger air supply duct 8. Turbocharger 2 Compressor 14. Clamp (2)
3. Cab heater return tube assembly Inlet Pressure (TC2CIP) sensor 15. Coolant return hose
4. Air Control Valve (ACV) 9. M10 x 200 bolt
assembly 10. Engine Oil Pressure (EOP)
5. Air supply tube sensor
6. M8 x 20 bolt (2) 11. M6 x 20 bolt
 TRUCK REPAIR PROCEDURES 95

8. Disconnect air supply tube (Figure 39) (Item 5) from Air Control Valve (ACV) (Figure 39) (Item 4) and secure
out of the way.
9. Remove two bolts (Figure 39) (Item 6) securing cab heater return tube (Figure 39) (Item 3) and coolant tube
(EGR cooler to LPCAC) (Figure 39) (Item 7).
10. Remove bolt (Figure 39) (Item 11) and position cab heater return tube out of the way.
11. Remove two clamps (Figure 39) (Item 14) and coolant tube (EGR cooler to LPCAC).
12. Disconnect coolant return hoses (Figure 39) (Items 12 and 15) from HP turbocharger air supply duct (Figure
39) (Item 2).
NOTE: Do not remove HP turbocharger air supply duct from HP turbocharger (Figure 39) (Item 1) at this time.
13. Remove two mounting bolts (Figure 39) (Items 9 and 13) from HP turbocharger air supply duct.

Figure 40 High-Pressure (HP) Turbocharger.

1. V-band clamp (turbine housing)
2. Turbocharger oil supply tube assembly
3. V-band clamp (compressor housing)
4. Turbocharger oil return tube

CAUTION: To prevent engine damage, do not reuse turbocharger oil supply tube.
14. Remove oil supply and oil return tubes (Figure 40) (Items 2 and 4). Discard oil supply tube. See
Turbocharger Oil Return and Oil Supply Tubes (page 291).
If oil supply tube will not come out of high-pressure turbocharger due to seizure, cut oil supply tube into two
pieces and leave line in high-pressure turbocharger for ease of removal, then discard oil supply tube.
96 TRUCK REPAIR PROCEDURES

NOTE: Disconnect coolant hoses and pipes before removing HP turbocharger air supply duct.
15. Remove V-band clamp (turbine housing) (Figure 40) (Item 1). Discard V-band clamp.

Figure 41 HP Turbocharger Center Section Removal.

1. HP turbocharger turbine housing
2. HP turbocharger center section
3. HP turbocharger air supply duct

CAUTION: Be careful to avoid damage to turbine blades.

16. Using a soft-blow mallet, gently tap HP turbocharger center section (Figure 41) (Item 2) until loose.
17. Pull on HP turbocharger center section, maneuvering it straight out until free from turbine housing (Figure
41) (Item 1).
18. Remove HP turbocharger center section and HP turbocharger air supply duct (Figure 41) (Item 3) from
engine together as a unit.
19. Separate HP turbocharger center section and HP turbocharger air supply duct. Discard 72.2 x 60 (DMR)
tube seal.
 TRUCK REPAIR PROCEDURES 97

EGR Replacement Procedure

Overview
This section provides instruction specifically for removal of the Exhaust Gas Recirculation (EGR) when not doing
a complete engine teardown.

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
98 TRUCK REPAIR PROCEDURES

EGR Core Replacement Procedure

Overview
This section provides instruction specifically for removal of the Low Temperature (LT) Exhaust Gas Recirculation
(EGR) Core when not doing a complete engine teardown.

Equipment Condition
Before replacing LT EGR Core, disconnect, remove or reposition parts per following table.

TransStar ProStar WorkStar

Disconnect battery x x x
Drain the cooling system x x x
Remove the grille
x
assembly
Remove front bumper x
Remove four torsion bar
x
stop bracket bolts
Remove Low Temp
Radiator (LTR) hose and x x
Radiator hose
Remove HPCAC inlet
x x
pipe (driver side)
Remove HPCAC pipe x x x
Remove fender well
(driver and passenger x
side)
Remove dearation tank x x x
Remove A/C condenser x x
Remove power steering
reservoir bolts, and
position power steering x x
reservoir away from the
radiator
Tilt the cooling package
forward, allowing room x
for LT Core removal
Remove brackets
securing fan shroud x
ring
Remove upper fan
x
shroud from radiator
Remove fan x
 TRUCK REPAIR PROCEDURES 99

Removal

Figure 42 Low Temperature (LT) EGR Cooler

1. M8 x 85 bolt (9) 4. EGR outlet tube (2) 7. Harness support bracket
2. EGR outlet cover 5. M8 x 30 bolt (4) 8. M8 x 16-10.9 bolt (2)
3. LT cooler housing 6. Harness connector

1. Disconnect engine harness connector (Figure 42) (Item 6) from EGR Temperature (EGRT) sensor.
2. Remove four M8 x 30 bolts (Figure 42) (Item 5) securing EGR outlet tubes (Figure 42) (Item 4) to EGR outlet
cover (Figure 42) (Item 2). Discard gaskets.
3. Remove two M8 x 16-10.9 bolts (Figure 42) (Item 8).
4. Remove nine M8 x 85 bolts (Figure 42) (Item 1).
100 TRUCK REPAIR PROCEDURES

Figure 43 EGR Module Cover

1. EGR outlet cover 3. LT EGR cooler core
2. Outlet cover seal 4. LT cooler housing

5. Remove EGR outlet cover (Figure 43) (Item 1).

6. Remove outlet cover seal (Figure 43) (Item 2) from groove in EGR outlet cover and discard.
 TRUCK REPAIR PROCEDURES 101

Figure 44 Low Temperature (LT) Exhaust Gas Recirculation (EGR) Core Puller
1. Removal bolt 2. LT EGR Core Puller Tool 3. LT EGR cooler core housing
12–892–04 4. LT EGR cooler core

7. Scrape off soot build-up on the outlet (face) of the LT EGR cooler core (Figure 46) (Item 4). Core puller tool
plate must sit flat against the face.
8. Install LT EGR Core Puller Tool 12–892–04 (Figure 46) (Item 2) onto LT EGR cooler core housing (Figure
46) (Item 3). Follow directions in tool instructions for proper installation procedure.
9. Turn the removal bolt (Figure 46) (Item 1) until LT EGR cooler core (Figure 46) (Item 4) pulls loose, typically
3/4 in. from LT cooler housing.
10. Remove LT EGR Core Puller Tool and pull LT EGR cooler core from LT cooler housing.
102 TRUCK REPAIR PROCEDURES

Figure 45 Low Temperature (LT) EGR Cooler Core

1. Low Temperature (LT) EGR 3. Core O-ring (4) 5. Low Temp (LT) cooler housing
cooler core 4. Low Temp (LT) cooler housing seal groove
2. Housing seal 6. Inlet manifold port (4)

11. Remove housing seal (Figure 45) (Item 2) and discard.

12. Using care not to damage O-ring groove in LT cooler housing, use seal pick to remove four core O-rings
(Figure 45) (Item 3) from LT cooler housing (Figure 45) (Item 4) and discard.
 TRUCK REPAIR PROCEDURES 103

Cleaning and Inspection

1. Replace EGR module cover if any of the following conditions exist:
• Severe soot build up
• Sealing joint corrosion
• Phenolic coating (orange colored coating in cover) missing from an area larger than one square inch
2. Clean LT cooler housing core O-ring grooves of contaminants (soot). Coolant is not a concern and will act
as a lubricant.
3. Clean Low Temp (LT) cooler housing seal groove (Figure 45) (Item 5) on face of LT cooler housing.
104 TRUCK REPAIR PROCEDURES

Installation

Figure 46 Low Temperature (LT) EGR Cooler Core

1. Low Temperature (LT) EGR 3. Core O-ring (4) 5. Low Temp (LT) cooler housing
cooler core 4. Low Temp (LT) cooler housing seal groove
2. Housing seal 6. Inlet manifold port (4)

1. Install four new core O-rings (Figure 46) (Item 3) from LT core kit into the LT cooler housing (Figure 46) (Item
4).
2. Lubricate inlet manifold ports (Figure 46) (Item 6) and core O-rings with liberal amounts of P-80.
3. Install new housing seal (Figure 46) (Item 2) into the LT cooler housing.
4. Insert LT EGR cooler core (Figure 46) (Item 1) into LT cooler housing. Header plate must be less than 1/2”
from the LT cooler housing face (core must rest in O-rings) before driving core in.
 TRUCK REPAIR PROCEDURES 105

Figure 47 Low Temperature (LT) Exhaust Gas Recirculation (EGR) Core Puller
1. Removal bolt 2. LT EGR Core Puller Tool 3. LT EGR cooler core housing
12–892–04 4. LT EGR cooler core

5. Install LT EGR Core Puller Tool 12–892–04 (Figure 47) (Item 2) onto LT EGR cooler core housing (Figure
47) (Item 3) per directions in tool instructions.
6. Press the LT EGR cooler core (Figure 47) (Item 4) into the LT cooler housing until the LT EGR cooler core
header plate makes contact with the housing seal. Do not over-torque bolt (Item 1). LT EGR cooler core
will seat / seal when the EGR module cover is installed.
106 TRUCK REPAIR PROCEDURES

Figure 48 EGR Module Cover

1. EGR outlet cover
2. Outlet cover seal
3. LT EGR cooler core
4. LT cooler housing

7. Install new outlet cover seal (Figure 48) (Item 2) into EGR outlet cover (Figure 48) (Item 1).
8. Install EGR outlet cover onto LT cooler housing (Figure 48) (Item 4).
 TRUCK REPAIR PROCEDURES 107

Figure 49 Low Temperature (LT) EGR Cooler

1. M8 x 85 bolt (9) 4. EGR outlet tube (2) 7. Harness support bracket
2. EGR outlet cover 5. M8 x 30 bolt (4) 8. M8 x 16-10.9 bolt (2)
3. LT cooler housing 6. Harness connector

9. Install nine M8 x 85 bolts (Figure 49) (Item 1). Hand tighten, then torque in criss-cross pattern to to 18 lb·ft
(24 N·m).
10. Place harness support bracket (Figure 49) (Item 7) into position.
11. Install two M8 x 16-10.9 bolts (Figure 49) (Item 8) and tighten to 00 lb·ft (00 N·m).
12. Install four M8 x 30 bolts (Figure 49) (Item 5) to secure EGR outlet tubes (Figure 49) (Item 4), using new
gaskets from LT Core kit, and tighten to 00 lb·ft (00 N·m).
13. Connect harness connector (Figure 49) (Item 6) to EGRT sensor.
108 TRUCK REPAIR PROCEDURES

Oil Fill Tube Assembly

Oil Fill Tube Assembly Leak Inspection

Overview
Inspect Oil Fill Tube Assembly for leaks and / or cracks or damage.

Tools Required
None

Equipment Condition
Steam clean and insert dye into engine oil. Road test vehicle, bringing up to operating temperature.

Figure 50 Oil Fill Tube Assembly

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing

See Oil Fill Tube Assembly (Figure 50) to locate oil fill tube assembly components.
 TRUCK REPAIR PROCEDURES 109

Inspection Procedure

Figure 51 Oil Fill Tube Assembly Tube and Hose Inspection

A. Oil fill tube hose sealing surface B. Oil fill tube
(2) C. Oil fill hose

See Oil Fill Tube Assembly Tube and Hose Inspection (Figure 51) to perform steps 1 through 4.
1. Inspect for oil leaks, cracked or damaged components at following locations:
• Oil fill tube (B)
• Oil fill hose (C)
2. If no indications of oil leaks are present and oil fill hose (C) and oil fill tube (B) show no signs of cracks of
damage, inspection is complete.
3. If oil fill hose (C) and / or oil fill tube (B) show indications of oil leaks or signs of cracks of damage, remove
oil fill hose and oil fill tube. See Oil Fill Tube Assembly Removal (page 111). Discard and proceed to Step 5.
4. If indications of oil leaks are present but oil fill hose (C) and oil fill tube (B) show no signs of cracks of damage,
remove oil fill hose and oil fill tube. See Oil Fill Tube Assembly Removal (page 111). Then proceed to Step
5.
110 TRUCK REPAIR PROCEDURES

Figure 52 Oil Fill Tube Adapter Inspection

A. Oil fill tube adapter to accessory
drive housing sealing surface
B. Oil fill tube adapter

See Oil Fill Tube Adapter Inspection (Figure 52) to perform steps 5 through 7.
5. Inspect for oil leaks at oil fill tube adapter to accessory drive housing sealing surface (A).
6. Inspect for cracked or damaged oil fill tube adapter (B).
7. If oil leak is present at oil fill tube adapter to accessory drive housing sealing surface (A) and / or if oil fill
tube adapter (B) is cracked or damaged, replace oil fill tube adapter. See Oil Fill Tube Assembly Removal
(page 111).

Expected Outcome
Oil Fill Tube Assembly should be free of oil leaks and / or cracks or damaged components.
 TRUCK REPAIR PROCEDURES 111

Oil Fill Tube Assembly Removal

Overview
This section provides instruction for removal of the oil fill tube assembly when not doing a complete engine
tear-down.

Equipment Condition
None

Special Tools Required

None

Torque Specifications

Oil fill tube adapter 26 lb-ft (35 N·m)

Oil fill tube hose clamp 46 lb-in (5.1 N·m)
112 TRUCK REPAIR PROCEDURES

Procedure

Figure 53 Oil Fill Tube Assembly

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing

See Oil Fill Tube Assembly (Figure 53) to perform steps 1 and 2.
1. Remove oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support
bracket (3).
2. Loosen two oil fill tube hose clamps (5) securing oil fill tube hose (6) to oil fill tube (1) and oil fill tube adapter
(Figure 54) (Item 2).
 TRUCK REPAIR PROCEDURES 113

Figure 54 Oil Fill Tube Assembly Removal

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump

See Oil Fill Tube Assembly Removal (Figure 54) to perform steps 3 through 5.
3. Remove oil fill tube (4) from oil fill tube hose (5) and oil fill tube hose (5) from oil fill tube adapter (2).
4. Discard two oil fill tube hose clamps (3).
5. If replacement is determined necessary per Oil Fill Tube Assembly Leak Inspection (page 108), remove oil
fill tube adapter (2) from accessory drive housing (1). Discard oil fill tube adapter.
114 TRUCK REPAIR PROCEDURES

Oil Fill Tube Adapter Mount Cleaning and Inspection

Figure 55 Oil Fill Tube Adapter Thread Mount

1. Accessory drive housing
2. Oil fill tube adapter threaded
mount

See Oil Fill Tube Adapter Thread Mount to perform step 1.

1. Clean oil fill tube adapter threaded mount (2) in accessory drive housing (1) with a soft cloth.
 TRUCK REPAIR PROCEDURES 115

Oil Fill Tube Assembly Installation

Procedure

Figure 56 Oil Fill Tube Assembly Installation

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump

See Oil Fill Tube Assembly Installation (Figure 56) to perform steps 1 through 9.
If not replacing oil fill tube adapter (2), go directly to step 4.
1. Apply Loctite 545 full 360° on first three threads of oil fill tube adapter (2).
2. Install oil fill tube adapter (2) to accessory drive housing (1).
3. Tighten oil fill tube adapter. See Torque Specifications (page 111).
4. Install oil fill tube hose (5) to oil fill tube adapter (2).
5. Secure oil fill hose tube (5) to oil fill tube adapter (2) with oil fill tube hose clamp (3), observing proper
orientation of clamp.
116 TRUCK REPAIR PROCEDURES

6. Tighten oil fill tube hose clamp. See Torque Specifications (page 111).
7. Place second oil fill tube hose clamp over oil fill hose tube (5), observing proper orientation of clamp, then
install oil fill tube (2) to oil fill hose tube (5).
8. Position oil fill tube hose clamp (3) to secure oil fill tube (4) to oil fill hose tube (5).
9. Tighten oil fill tube hose clamp. See Torque Specifications (page 111).

Figure 57 Oil Fill Tube Assembly

1. Oil fill tube 3. Oil fill tube assembly support 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting bracket 6. Oil fill tube hose
bolt 4. High Pressure (HP) fuel pump 7. Accessory drive housing

See Oil Fill Tube Assembly (Figure 57) to perform steps 10 and 11.
10. Install oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support bracket
(3).
11. Tighten oil fill tube assembly mounting bolt (2) to standard torque.
 TRUCK REPAIR PROCEDURES 117

Special Torque

M8 x 16-10.9 00 lb·ft (00 N·m)

M8 x 30 bolt 00 lb·ft (00 N·m)
M8 x 85 bolt 18 lb·ft (24 N·m)

Special Service Tools

Description Tool Number

LT EGR Core Puller Tool 12–892–04
118 TRUCK REPAIR PROCEDURES
 ENGINE ELECTRICAL 119

Table of Contents

Description of Engine Sensors, Valves and Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Engine Coolant Temperature (ECT) Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Nitrogen Oxides (NOx) IN Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
Aftertreatment Fuel Pressure Sensor 1 (AFTFP1). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Aftertreatment Fuel Shutoff Valve (AFTFSV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Humidity / Inlet Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Charge Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Fuel Rail Pressure (FRP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Air Control Valve (ACV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Warnings and Cautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .137
Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Humidity / Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .144
Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Fuel Rail Pressure (FRP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Nitrogen Oxides (NOx) IN Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Nitrogen Oxides (NOx) In Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
120 ENGINE ELECTRICAL

Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154

Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Engine Injection and Engine Sensor Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Sensors and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Engine Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .176
Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181
Nitrogen Oxides (NOx) In Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Nitrogen Oxides (NOx) IN Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .183
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Fuel Rail Pressure (FRP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Humidity / Inlet Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .196
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

 ENGINE ELECTRICAL 121

Description of Engine Sensors, Valves and Actuators

NOTE: Refer to the following publications for information on diagnostics and troubleshooting:
• N13 Engine Diagnostic Form
• N13 Engine Diagnostic Form
• N13 Electronic Control System Diagnostic Form
Crankshaft Position (CKP) Sensor

Figure 58 CKP sensor

The CKP sensor is a magnetic pickup sensor that indicates crankshaft speed and position.
The CKP sensor sends a pulsed signal to the Engine Control Module (ECM) as the crankshaft turns. The CKP
sensor reacts to holes drilled into the flywheel adjacent to the ring gear. For crankshaft position reference,
teeth 59 and 60 are missing. By comparing the CKP signal with the Camshaft Position (CMP) signal, the ECM
calculates engine rpm and timing requirements.
The CKP sensor is installed in the top left of the flywheel housing.
122 ENGINE ELECTRICAL

Camshaft Position (CMP) Sensor

Figure 59 CMP sensor

The CMP sensor is a magnetic pickup sensor that indicates camshaft speed and position.
The CMP sensor sends a pulsed signal to the ECM as a toothed wheel on the camshaft rotates past the CMP
sensor. The ECM calculates camshaft speed and position from CMP signal frequency.
The CMP sensor is installed in the left rear of the cylinder head.

Engine Coolant Temperature (ECT) Sensors

Figure 60 ECT sensor

The ECT1 and ECT2 sensors are thermistor sensors that detect engine coolant temperature.
The ECT1 and ECT2 signals are monitored by the ECM for operation of the instrument panel temperature gauge,
coolant temperature compensation, charge air temperature control, Exhaust Gas Recirculation (EGR) system
control, optional Engine Warning Protection System (EWPS) and the wait to start lamp. The ECM uses ECT1
sensor input as a backup, if Engine Oil Temperature (EOT) sensor values are out of range.
 ENGINE ELECTRICAL 123

The ECT1 sensor is installed in the underside of the EGR coolant crossover manifold at the back of the engine.
The ECT2 sensor is installed in the low-temperature stage of the EGR cooler on the right side of the engine.

Engine Oil Temperature (EOT) Sensor

Figure 61 EOT sensor

The EOT sensor is a thermistor sensor that detects engine oil temperature, and is monitored by the ECM for
inlet air heater assist. The EOT sensor is installed in the oil module flange, behind the CCV on the right side of
the engine.

Engine Oil Pressure (EOP) Sensor

Figure 62 EOP sensor

The EOP sensor is a variable resistance sensor that detects engine oil pressure. The EOP signal is monitored by
the ECM for operation of the instrument panel pressure gauge and optional EWPS. The EOP sensor is installed
in the oil module, on the right side of the engine.
124 ENGINE ELECTRICAL

Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 63 CCOSS sensor

The CCOSS sensor sends the ECM information about the speed of the crankcase oil separator internal
components. The detected sine wave signal (AC) is used to monitor proper operation of the cyclonic oil
separator, located on the oil centrifuge on the oil module assembly.

Fuel Delivery Pressure (FDP) Sensor

Figure 64 FDP sensor

The FDP sensor is a variable resistance sensor that measures fuel supply pressure, and provides feedback
to the ECM for the low-pressure fuel system. The FDP sensor is installed in the front of the fuel filter housing
assembly on the left side of the engine.
 ENGINE ELECTRICAL 125

Fuel Pressure Control Valve (FPCV)

Figure 65 FPCV

The FPCV is a variable-position actuator that controls the flow of fuel to the suction side of the high-pressure
fuel pump.
The FPCV changes valve position through pulse-width modulated signals from the ECM.
The FPCV is mounted on the upper side of the high-pressure fuel pump. The FPCV and high-pressure fuel
pump are serviced as an assembly.

Nitrogen Oxides (NOx) IN Sensor Module

Figure 66 NOx In Sensor Module

The Nitrogen Oxides Inlet Sensor (NOx IN) monitors the amount of Oxides of nitrogen in the exhaust before
entering the Aftertreatment system. The Aftertreatment Control Module (ACM) uses this information, along with
the NOxOut sensor, to monitor NOx emissions, control the Aftertreatment system, and warn the operator should
126 ENGINE ELECTRICAL

the system fail. The NOx IN Sensor is located in the Low Pressure Turbocharger Outlet Pipe on the right side
of the engine.

Aftertreatment Fuel Pressure Sensor 1 (AFTFP1)

Figure 67 AFTFP1 Sensor

The Aftertreatment Fuel Pressure Sensor 1 (AFTFP1) is a variable resistance sensor that measures fuel
pressure available to the Aftertreatment Fuel Injector (AFTFI) and provides constant feedback to the
Aftertreatment Control Module (ACM) for proper operation of the Aftertreatment System. The AFTFP1 is the
top connector located on the Aftertreatment (AFT) Fuel Doser Module on the left side of the engine.

Aftertreatment Fuel Shutoff Valve (AFTFSV)

Figure 68 AFTFSV

The Aftertreatment Fuel Shutoff Valve (AFTFSV) is controlled by the Aftertreatment Control Module (ACM).
When conditions for a regeneration are met, the ACM commands the AFTFSV to open allowing clean,
pressurized fuel to flow through the Aftertreatment (AFT) fuel doser module to the Aftertreatment Fuel Injector
(AFTFI). The AFTFSV is the bottom connector installed in the lower port of the AFT Fuel Doser Module on the
left side of the engine.
 ENGINE ELECTRICAL 127

Humidity / Inlet Air Temperature (IAT) Sensor

Figure 69 HS / IAT sensor

The HS / IAT sensor measures the moisture content of filtered air entering the intake system.
The HS / IAT sensor is used by the ECM to prevent EGR system component degradation due to moisture
contamination. Using the sensor, the ECM will adjust EGR system flow to prevent condensation of airborne
water particles. The sensor also measures intake air temperature, which is used by the ECM for calculating fuel
delivery.
The HS / IAT sensor is mounted in the air inlet duct at the upper right side of the engine.

Charge Air Cooler Outlet Temperature (CACOT) Sensor

Figure 70 CACOT sensor

The CACOT sensor is a thermistor sensor that monitors the temperature of charge air entering the intake air
duct.
The CACOT signal is monitored by the ECM for control of the EGR system.
The CACOT sensor is installed on the air intake throttle duct, before the Engine Throttle Valve (ETV).
128 ENGINE ELECTRICAL

Intake Manifold Pressure (IMP) Sensor

Figure 71 IMP sensor

The IMP sensor is a variable capacitance sensor that monitors the pressure of charge air entering the air
intake throttle duct. The IMP signal is monitored by the ECM for control of the EGR system and turbocharger
wastegates.
The IMP sensor is installed on the air intake throttle duct after the ETV.

Fuel Rail Pressure (FRP) Sensor

Figure 72 FRP sensor

The FRP sensor is a variable capacitance sensor that monitors the fuel pressure in the high-pressure fuel rail.
The sensor measures the fuel pressure just before injection.
The FRP sensor is mounted in the front of the fuel rail on the left side of the engine.
 ENGINE ELECTRICAL 129

Intake Manifold Temperature (IMT) Sensor

Figure 73 IMT sensor

The IMT sensor is a thermistor sensor that monitors the temperature of the mixture of recirculated exhaust gas
and fresh intake air.
EGR system operation is shut down under certain temperature conditions, to prevent acids from condensing
under cold charge-air temperatures and to protect the engine from excessively hot intake air in the event of an
EGR fault.
The IMT sensor is installed in the intake channel of the cylinder head, on the left side of the engine.

Oxygen Sensor (O2S)

Figure 74 O2S

The O2S monitors oxygen levels in exhaust gases. It is used to tune engine operation by monitoring the level
of unused oxygen in the exhaust stream.
130 ENGINE ELECTRICAL

The O2S compares oxygen levels in the exhaust stream with oxygen levels in the outside air. The sensor
generates an analog voltage and is monitored by the ECM. The level of voltage generated by the O2S
corresponds to the oxygen levels in the exhaust stream.
The O2S is installed in the exhaust back pressure valve housing.
NOTE: The Oxygen sensor should only be replaced after a coolant and/or oil loss into the exhaust system has
been verified based on the Engine Symptoms Diagnostics in the Engine Diagnostic Manual.
Engine Throttle Valve (ETV)

Figure 75 ETV

The ETV controls the flow of filtered air (boosted and cooled) into the engine's air intake through the Charge
Air Cooler (CAC) to help heat the exhaust aftertreatment during regeneration, and to assist when heavy EGR is
requested. The electronic portion of the ETV contains a microprocessor that monitors valve position, electronic
chamber temperature, controls the electric motor and reports diagnostic faults to the ECM. The ETV changes
position in response to ECM signals.
The ETV is integrated into the air intake throttle duct at the front top left side of the engine.
 ENGINE ELECTRICAL 131

Coolant Control Valve (CCV)

Figure 76 CCV

The Coolant Mixer Valve (CMV) and Coolant Flow Valve (CFV) are a combined solenoid assembly that regulates
coolant flow and temperature through the Low-pressure Charge Air Cooler (LPCAC) and the low temperature
EGR cooler. The CMV and CFV are housed in the CCV assembly.
The CFV controls the rate of coolant flow through the CAC and the CMV regulates the temperature of the coolant
by directing the coolant either through the low temperature radiator or through an internal bypass. Both valves
are controlled by the ECM.
The CCV is mounted on the right side of the water distribution housing.

Air Control Valve (ACV) Assembly

NOTE: Various air control valves have been used on this engine. Early production air control valves use two
mounting bolts and later production valves use three mounting bolts. Late production valves may also utilize a
remote electrical connector attached to a pigtail harness.

Figure 77 Early production ACV with two mounting bolts

132 ENGINE ELECTRICAL

Figure 78 Late production ACV with pigtail

The ACV contains solenoids for the control of the high-pressure turbocharger wastegate and Exhaust Back
Pressure Valve (EBPV). It also contains the Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor. ACV
solenoids are controlled through pulse-width modulated signals sent by the ECM.
The ACV assembly is installed on the right side of the engine, mounted near the center of the EGR cooler.

Exhaust Gas Recirculation (EGR) Valve

Figure 79 EGR valve

The EGR valve regulates the flow of exhaust gases through the EGR system. The desired valve position is
controlled by commands from the ECM.
The EGR valve is mounted on the rear of the EGR cooler on top of the engine.
 ENGINE ELECTRICAL 133

Exhaust Gas Recirculation Temperature (EGRT) Sensor

Figure 80 EGRT sensor

The EGRT sensor is a thermistor sensor that detects the exhaust gas temperature exiting the EGR cooler. The
sensor signal is monitored by the ECM to control the Coolant Flow Valve (CFV) and Coolant Mixer Valve (CMV),
and check for proper EGR cooling.
The EGRT sensor is installed in the front of the low-temperature EGR cooler on the left side.

Turbocharger 2 Compressor Inlet Sensor (TC2CIS)

Figure 81 TC2CIS

The TC2CIS sensor includes a thermistor sensor that monitors the temperature of charge air entering the
high-pressure turbocharger. This sensor also monitors boost pressure for the low-pressure turbocharger.
The TC2CIS sensor is monitored by the ECM, and is used to check for proper thermostat operation and charge
air cooling.
The TC2CIS is installed in the piping between the low-pressure compressor outlet and the high-pressure
compressor inlet.
134 ENGINE ELECTRICAL

Removal
Warnings and Cautions

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and
free connectors or clips.
Disconnect ground cable (–) from the negative terminal of the battery.
 ENGINE ELECTRICAL 135

Crankshaft Position (CKP) Sensor

Figure 82 CKP sensor

1. M6 x 16 bolt
2. Locking tab
3. CKP sensor harness connector
4. Flywheel housing
5. O-ring
6. CKP sensor

1. Pull out locking tab (Figure 82) (Item 2) on CKP sensor harness connector (Figure 82) (Item 3).
2. Press release lever and disconnect harness connector from CKP sensor (Figure 82) (Item 6) installed in top
left of flywheel housing (Figure 82) (Item 4).
3. Remove M6 x 16 bolt (Figure 82) (Item 1) from CKP sensor.
4. Remove CKP sensor and discard O-ring (Figure 82) (Item 5).
136 ENGINE ELECTRICAL

Camshaft Position (CMP) Sensor

Figure 83 CMP sensor

1. O-ring
2. Cylinder head
3. CMP sensor
4. CMP sensor harness connector
5. Locking tab
6. M6 x 12 bolt

1. Pull out locking tab (Figure 83) (Item 5) on CMP sensor harness connector (Figure 83) (Item 4).
2. Press release lever and disconnect harness connector from CMP sensor (Figure 83) (Item 3) installed in
rear left of cylinder head (Figure 83) (Item 2).
3. Remove M6 x 12 bolt (Figure 83) (Item 6) from CMP sensor.
4. Remove CMP sensor and discard O-ring (Figure 83) (Item 1).
 ENGINE ELECTRICAL 137

Engine Coolant Temperature 1 (ECT1) Sensor

Figure 84 ECT1 sensor

1. Turn ECT1 sensor harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from ECT1 sensor installed in underside of Exhaust Gas Recirculation (EGR)
coolant manifold at rear of engine.
3. Remove ECT1 sensor and discard seal ring.
138 ENGINE ELECTRICAL

Engine Coolant Temperature 2 (ECT2) Sensor

Figure 85 ECT2 sensor connector

1. Turn ECT2 sensor harness connector locking ring 90°counterclockwise.

2. Disconnect harness connector from ECT2 sensor installed in EGR module low-temperature housing on
upper right side of engine.
3. Remove ECT2 sensor and discard seal ring.
 ENGINE ELECTRICAL 139

Engine Oil Temperature (EOT) Sensor

Figure 86 EOT sensor

1. EOT sensor
2. Oil module flange

1. Turn EOT harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from EOT sensor and remove sensor from oil module flange. Discard seal
ring.
140 ENGINE ELECTRICAL

Engine Oil Pressure (EOP) Sensor

Figure 87 EOP sensor

1. Oil module assembly
2. EOP sensor

1. Turn EOP harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from EOP sensor and remove sensor from oil module assembly. Discard
seal ring.
 ENGINE ELECTRICAL 141

Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 88 CCOSS sensor

1. CCOSS sensor
2. Oil centrifuge (part of oil module assembly)
3. M6 x 14 bolt and nut

1. Press release tab to disconnect wiring harness connector from CCOSS sensor.
2. Remove M6 x 14 bolt and nut and remove sensor from bracket on oil centrifuge.
142 ENGINE ELECTRICAL

Fuel Delivery Pressure (FDP) Sensor

Figure 89 FDP sensor

1. Turn FDP sensor harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from FDP sensor installed in fuel filter assembly.
3. Remove FDP sensor and discard seal ring.
 ENGINE ELECTRICAL 143

Fuel Pressure Control Valve (FPCV)

Figure 90 FPCV (on high-pressure fuel pump)

1. FPCV
2. Harness connector

1. Pull out yellow locking tab on FPCV harness connector.

2. Press release tab and disconnect harness connector from FPCV mounted at upper rear of high-pressure
fuel pump.
3. See High-pressure Fuel Pump (HPFP) and Drive Housing (page 390) for removal of high-pressure pump
with integral FPCV if the FPCV requires replacement.
144 ENGINE ELECTRICAL

Humidity / Intake Air Temperature (IAT) Sensor

Figure 91 HS / IAT sensor

1. M6 x 16 bolt (2)
2. Harness connector
3. IAT sensor

1. Pull out yellow locking tab on IAT harness connector (Figure 91) (Item 2).
2. Press release tab to disconnect harness connector from IAT sensor (Figure 91) (Item 3).
3. Remove two M6 x 16 bolts (Figure 91) (Item 1) and remove sensor from air inlet duct. Discard O-ring.
 ENGINE ELECTRICAL 145

Charger Air Cooler Outlet Temperature (CACOT) Sensor

Figure 92 CACOT sensor

1. CACOT sensor
2. Harness connector
3. Standoff tie strap

1. Press release tab to loosen tie strap and remove standoff bracket securing connector harness lead to
CACOT sensor.
2. Press release tab to disconnect harness from CACOT sensor.
3. Remove CACOT sensor from throttle valve housing. Discard O-ring.
146 ENGINE ELECTRICAL

Intake Manifold Pressure (IMP) Sensor

Figure 93 IMP sensor

1. IMP sensor
2. Standoff tie strap
3. Harness connector

1. Press release tab to loosen tie strap and remove standoff bracket securing harness connector lead to IMP
sensor.
2. Press release tab to disconnect harness from IMP sensor.
3. Remove IMP sensor from Engine Throttle Valve (ETV) housing. Discard O-ring.
 ENGINE ELECTRICAL 147

Fuel Rail Pressure (FRP) Sensor

Figure 94 FRP sensor (typical)

1. Pull out yellow locking tab on FRP sensor harness connector.

2. Press release lever and disconnect harness connector from FRP sensor installed in front of fuel rail on left
side of engine.
3. Remove FRP sensor from fuel rail.
4. Install plastic protective cap from Disposable Air and Fuel Caps (page 453), to prevent dirt from entering
fuel system
148 ENGINE ELECTRICAL

Intake Manifold Temperature (IMT) Sensor

Figure 95 IMT sensor

1. Turn IMT sensor harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from IMT sensor.
3. Remove IMT sensor from cylinder head and discard seal ring.
 ENGINE ELECTRICAL 149

Oxygen Sensor (O2S)

NOTE: The Oxygen sensor should only be replaced after a coolant and/or oil loss into the exhaust system has
been verified based on the Engine Symptoms Diagnostics in the Engine Diagnostic Manual.

Figure 96 O2S (valve actuator removed for clarity)

1. Clip (2)
2. O2S (with harness lead)
3. Exhaust back pressure valve housing
4. NOx IN Sensor (with harness lead)

1. Press release lever and disconnect O2S harness lead (Figure 96) (Item 2) from engine electrical harness
at left rear of engine.
2. Disconnect clips (Figure 96) (Item 1) securing O2S harness lead at right rear of engine to coolant tube and
to valve actuator bracket.
3. Only if required, remove O2S from exhaust back pressure valve housing (Figure 96) (Item 2).
150 ENGINE ELECTRICAL

Nitrogen Oxides (NOx) IN Sensor Module

Figure 97 NOx IN Sensor Module Connector

1. NOx IN sensor module
2. Tiedown strap
3. NOx IN sensor harness
4. NOx IN sensor module nut (2)
5. NOx IN sensor module connector

1. Disconnect NOx IN sensor module connector (Figure 97) (Item 5) from NOx IN sensor module (Figure 97)
(Item 1).
2. Cut tiedown straps (Figure 97) (Item 2).
3. Remove two NOx IN sensor module nuts (Figure 97) (Item 4) from NOx IN sensor module.
 ENGINE ELECTRICAL 151

Nitrogen Oxides (NOx) In Sensor

Figure 98 NOx In Sensor (valve actuator removed for clarity)

1. Clip (2)
2. O2S (with harness lead)
3. Exhaust back pressure valve housing
4. NOx IN sensor (with harness lead)

1. Press release lever and disconnect NOx IN sensor (Figure 98) (Item 4) harness lead from engine electrical
harness at left rear of engine.
2. Disconnect clips (Figure 98) (Item 1) securing NOx IN sensor harness lead at right rear of engine to coolant
tube and to valve actuator bracket.
3. Only if required, remove NOx IN sensor from exhaust back pressure valve housing (Figure 98) (Item 3).
152 ENGINE ELECTRICAL

Engine Throttle Valve (ETV)

Figure 99 ETV
1. Harness connector
2. CPA tab
3. ETV

1. Push RED Connector Position Assurance (CPA) tab (Figure 99) (Item 2) away from Engine Throttle Valve
(ETV) (Figure 99) (Item 3), and press release tab to disconnect harness connector (Figure 99) (Item 1) from
ETV.
2. See Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose (page 206) for removal
procedure of the fuel supply inlet air heater hose.
3. See Air Intake Throttle Duct (page 557) for removal procedure of duct.
 ENGINE ELECTRICAL 153

Coolant Control Valve (CCV)

Figure 100 CCV

1. Coolant Mixer Valve (CMV) terminal
2. Coolant Flow Valve (CFV) terminal

NOTE: The coolant mixer and coolant flow valves are not serviced separately. Both valves are an integral part
of the CCV assembly which is available as a unit.
1. Press release tab and disconnect harness connector from CMV, installed in the CCV assembly on the right
side of the water distribution housing.
2. Lift release tab and disconnect harness connector from CFV, also in the CCV assembly.
3. See Coolant Control Valve (CCV) Assembly (page 597) for removal procedure.
154 ENGINE ELECTRICAL

Exhaust Gas Recirculation (EGR) Valve

Figure 101 EGR valve harness connector

1. CPA tab
2. Harness connector
3. EGR valve

1. Push RED Connector Position Assurance (CPA) tab (Figure 101) (Item 1) away from Exhaust Gas
Recirculation (EGR) valve (Figure 101) (Item 3), and press release tab to disconnect harness connector
(Figure 101) (Item 2) from EGR valve.
2. Remove dual flap EGR valve. See EGR Dual Flap Valve (page 500).
 ENGINE ELECTRICAL 155

Exhaust Gas Recirculation Temperature (EGRT) Sensor

Figure 102 EGRT sensor harness connector

1. EGR module cover
2. EGRT sensor

1. Pull out red locking tab on EGRT sensor connector.

2. Press release tab to disconnect harness connector from EGRT sensor.
NOTE: The EGRT has a non-serviceable crush washer for sealing. If sensor is removed, the complete sensor
must be replaced.
3. Only if required, remove EGRT sensor from EGR module cover and discard.
156 ENGINE ELECTRICAL

Turbocharger 2 Compressor Inlet Sensor (TC2CIS)

Figure 103 TC2CIS

1. M6 x 16 bolt (2)
2. TC2CIS

1. Pull out yellow lock tab on TC2CIS harness connector.

2. Press release tab and disconnect harness lead from TC2CIS.
3. Remove two M6 x 16 bolts and sensor from high-pressure turbocharger air supply duct. Discard O-ring seal.
 ENGINE ELECTRICAL 157

Wiring Harness ECM Connections

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and
free connectors or clips.
1. If not done, disconnect ground (–) cable from the negative terminal of the battery.
2. Note location of wire ties for reinstallation. Cut wire ties securing engine injector, engine sensor and chassis
harness connector lock levers at ECM.

Figure 104 ECM harness connectors

1. ECM
2. Engine injector harness connector (to ECM 16-pin E2 terminal)
3. ECM 58-pin C2 chassis terminal
4. ECM 58-pin C1 chassis terminal
5. Engine sensor harness connector (to ECM 96-pin E1 terminal)

3. If not already done, disconnect chassis wiring harness connectors from ECM 58-pin C1 and C2 terminals.
4. Remove connector clip and lift lock lever to release engine injector harness connector. Pull straight out to
remove connector from ECM terminal E2.
5. Lift lock lever to release engine sensor harness connector. Pull straight out to remove connector from ECM
terminal E1.
158 ENGINE ELECTRICAL

Engine Injector (Wiring) Harness

Figure 105 Injector harness attachment points at ECM

1. Injector harness
2. M6 x 30 bolt (2)

1. Remove two M6 x 30 bolts and remove injector harness retainer clips from ECM.
2. Remove upper valve cover from valve cover base. See Upper Valve Cover and Base(page 668) .

Figure 106 Injector harness attachment points at cylinder head

1. Injector harness nut (12)
2. Tie strap (7)
3. M6 x 16 bolt (4)
 ENGINE ELECTRICAL 159

3. Loosen 12 harness nuts (two at each injector) and disconnect harness leads from injector terminals.
4. Cut tie straps at six locations securing injector harness to valve cover base.
5. Cut tie strap securing harness at center of cylinder head.
6. Remove four M6 x 16 bolts from injector harness mounting flange.
7. Carefully pull harness through valve cover base opening and remove harness from engine.
160 ENGINE ELECTRICAL

Engine Sensor (Wiring) Harness

Figure 107 Sensor harness attachment points at right front

1. Tie strap (5) 2. M8 x 12 bolt 3. M8 x 16 bolt (2)

1. Disconnect harness connectors at IAT, MAF (if equipped), TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and
EOT terminals.
2. Starting on right side at front, cut tie straps securing sensor harness at ACV, CCV and to air supply tube.
3. Remove M8 x 12 bolt attaching harness clip to EGR cooler low-temperature housing.
4. Remove two M8 x 16 bolts attaching harness clip to EGR module cover.
5. At left front, disconnect harness connectors at EGRT, CACOT, IMP, FRP, FDP and EOL sensors.
 ENGINE ELECTRICAL 161

Figure 108 Sensor harness attachment points at left front (air intake throttle duct removed for clarity)
1. Tie strap (3) 2. M6 x 16 bolt 3. Other attachments

6. Cut tie straps securing sensor harness to back of air intake throttle duct and at back and bottom of ECM
support.
7. Remove M6 x 16 bolt attaching harness clip to coolant outlet manifold.
8. Remove other attachments as necessary.
9. At left rear, disconnect harness connectors at CMP, CKP, ECT1 sensors and EGR valve.
162 ENGINE ELECTRICAL

Figure 109 Sensor harness attachment points at left rear

1. M8 x 16 bolt (2) 3. M8 stud 5. 21-way connector
2. Tie strap (3) 4. Harness clips

10. At left side and rear of engine, cut tie straps securing sensor harness to harness support and coolant
manifold.
11. Disconnect harness from M8 stud at coolant manifold.
12. At left center of engine, remove two M8 x 16 bolts attaching harness bracket to crankcase.
13. Remove sensor harness from engine using care to avoid damage to harness as it is removed from around
components.
14. Remove 21-way connector from harness bracket.
 ENGINE ELECTRICAL 163

Engine Control Module (ECM) and Support

Figure 110 ECM mounting bolts

1. ECM
2. M6 x 30 bolt (8)

1. Remove eight M6 x 30 bolts and remove ECM from support.

164 ENGINE ELECTRICAL

Figure 111 ECM support

1. Inlet Air Heater Fuel Solenoid (IAHFS)
2. ECM support
3. Inlet Air Heater Relay (IAHR)
4. M8 x 40 bolt (3) with EDC bracket insulators (6)

2. Remove IAHR from ECM support. See Relay Assembly (page 204).
3. Remove IAHFS (Figure 111) (Item 1) from ECM support (Figure 111) (Item 2). See Fuel Supply Solenoid
Hose (page 208).
4. Remove three M8 x 40 bolts, six EDC bracket insulators (Figure 111) (Item 4) (three on each side of support)
and ECM support from cylinder head.
 ENGINE ELECTRICAL 165

Cleaning and Inspection

Engine Injection and Engine Sensor Wiring Harnesses
1. Carefully inspect engine injection wiring harnesses for worn conduit, frayed insulation or heat damage to
wires. Repair or replace if necessary.
2. Inspect injector terminal ends and ECM terminal connector for cracked connector body, bent or loose pins,
chafing and damaged or missing terminal nuts. Replace connector or terminal ends if necessary.
3. Inspect each connector for the following conditions and replace, if necessary:
• Corroded connectors and green, gray or white deposits on metal terminals.
• Terminals incorrectly latched in connector body or pushed back relative to other terminals in same
connector.
• Make sure that each connector has its seals in place. During disassembly, a seal may pull off its
connector and remain in mating socket of a sensor or actuator. A connector assembled without the
correct seals can be contaminated with moisture and have corroded terminals, causing a poor electrical
connection.
4. Carefully inspect main engine sensors wiring harness for worn conduit, frayed insulation or heat damage to
wires. Repair or replace if necessary.
5. Inspect sensor, actuator and valve connectors for cracked connector bodies, bent or loose pins, chafing and
damaged or missing O-rings. Replace connectors if necessary.
6. Inspect each connector for the following conditions and replace, if necessary:
• Corroded connectors and green, gray or white deposits on metal terminals.
• Terminals incorrectly latched in connector body or pushed back relative to other terminals in same
connector.
• Make sure that each connector has its seals in place. During disassembly, a seal may pull off its
connector and remain in mating socket of a sensor or actuator. A connector assembled without the
correct seals can be contaminated with moisture and have corroded terminals, causing a poor electrical
connection.

Sensors and Valves

1. Check all connector pins on sensors and valves. If bent or corroded, replace damaged component.
2. Remove scale or carbon build up.
3. Check for body cracks and leakage.
4. If orifices or valves are plugged, replace sensors or valves.

Engine Control Module (ECM)

1. Inspect rubber seal on harness connector and in ECM pin recesses.
2. Check for bent pins in ECM connections.
166 ENGINE ELECTRICAL

Installation
Engine Control Module (ECM) and Support
CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and
free connectors or clips.

Figure 112 ECM support

1. Inlet Air Heater Fuel Solenoid (IAHFS)
2. ECM support
3. Inlet Air Heater Relay (IAHR)
4. M8 x 40 bolt (3) with EDC bracket insulator (6)

1. Place ECM support in position on engine and install six EDC bracket insulators and three M8 x 40 bolts.
Tighten bolts to special torque (page 199).
2. Install IAHFS on ECM support. See Fuel Supply Solenoid Hose (page 211).
3. Install IAHR on ECM support. See Relay Assembly (page 216).
 ENGINE ELECTRICAL 167

Figure 113 ECM mounting bolts

1. ECM
2. M6 x 30 bolt (8)

4. Place ECM in position on support and install eight M6 x 30 bolts hand tight.

Figure 114 ECM bolt tightening sequence

5. Tighten M6 x 30 bolts in sequence shown to special torque (page 199).

168 ENGINE ELECTRICAL

Engine Sensor (Wiring) Harness

1. Place sensor harness in position on engine using care to properly route it around and between components.

Figure 115 Sensor harness attachment points at left rear

1. M8 x 16 bolt (2) 3. M8 stud 5. 21-way connector
2. Tie strap (3) 4. Harness clips

2. Install two M8 x 16 bolts to attach harness bracket to crankcase. Tighten bolts to special torque (page 199).
3. Attach harness clip to M8 stud at coolant manifold.
4. Install three tie straps to secure sensor harness to harness support and coolant manifold.
5. Attach 21-way connector to harness bracket.
6. At left rear, connect harness connectors at CMP, CKP, ECT1 sensors and EGR valve.
 ENGINE ELECTRICAL 169

Figure 116 Sensor harness attachment points at left front (air intake throttle duct removed for clarity)
1. Tie strap (3) 2. M6 x 16 bolt 3. Other attachments

7. Install M6 x 16 bolt to attach harness clip to coolant outlet manifold. Tighten bolt to standard torque (page
881).
8. Install three tie straps to secure sensor harness to back of air intake throttle duct and back and bottom of
ECM support.
9. Install other attachments as necessary.
10. Connect harness connectors at EGRT, CACOT, IMP, FRP, FDP and EOL sensors.
170 ENGINE ELECTRICAL

Figure 117 Sensor harness attachment points at right front

1. Tie strap (5) 2. M8 x 12 bolt 3. M8 x 16 bolt (2)

11. Install two M8 x 16 bolts to attach harness clip to EGR module cover. Tighten bolts to special torque (page
199).
12. Install M8 x 12 bolt to attach harness clip to EGR cooler low-temperature housing. Tighten bolt to standard
torque (page 881).
13. Install tie straps to secure sensor harness at ACV, EGR cooler, CCV and to air supply tube.
14. Connect harness connectors at IAT, MAF (if equipped), TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and EOT
terminals.
 ENGINE ELECTRICAL 171

Engine Injector (Wiring) Harness

Figure 118 Engine injector (wiring) harness O-ring location

1. Engine injector (wiring) harness
2. Harness mounting flange
3. 32.92 x 3.53 O-ring
4. Harness flange collar

1. Check that 32.92 x 3.53 O-ring is in position on collar of harness mounting flange and in good condition.
Replace as necessary.
CAUTION: To prevent engine damage, verify injector harness wires are not pinched or rubbing against the
engine brake housing or rocker arm assembly.
2. Carefully route injector harness through valve cover base opening and along valve cover base to injectors.
172 ENGINE ELECTRICAL

Figure 119 Injector harness attachment points at cylinder head

1. Tie strap (7) 2. Injector harness nut (12) 3. M6 x 16 bolt (4)

3. Install four M6 x 16 bolts to attach injector harness mounting flange to valve cover base. Tighten bolts to
standard torque (page 881).
4. Install tie strap to secure injector at center of cylinder head.
5. Install tie straps at six locations to secure injector harness to valve cover base.
6. Install 12 harness nuts to connect harness leads to injector terminals.
 ENGINE ELECTRICAL 173

Figure 120 Injector harness attachment points at ECM

1. Injector harness
2. M6 x 30 bolt (2)

7. Install two M6 x 30 bolts to attach engine injector harness retainer clips to ECM. Tighten bolts to special
torque (page 199).
174 ENGINE ELECTRICAL

Wiring Harness ECM Connections

Figure 121 ECM harness connectors

1. ECM
2. Engine injector harness connector (to ECM 16-pin E2 terminal)
3. ECM 58-pin C2 chassis terminal
4. ECM 58-pin C1 chassis terminal
5. Engine sensor harness connector (to ECM 96-pin E1 terminal)

1. Check that ECM E1 and E2 terminal pins are straight and undamaged.
2. Align engine sensor harness connector with ECM E1 terminal and push connector straight in to engage pins.
Push down on lock lever to draw in and secure connector.

Figure 122 Injector harness connector

1. Lock lever
2. Connector clip
 ENGINE ELECTRICAL 175

3. Align engine injector harness connector with ECM E2 terminal and push connector straight in to engage
pins. Push down on lock lever to draw in and secure connector. Install connector clip.
4. Connect chassis harness connectors to ECM 58–pin C1 and C2 terminals. Lock connectors in place.
176 ENGINE ELECTRICAL

Turbocharger 2 Compressor Inlet Sensor (TC2CIS)

Figure 123 TC2CIS

1. M6 x 16 bolt (2)
2. TC2CIS

1. Place TC2CIS sensor in position on air supply duct and install two M6 x 16 bolts. Tighten bolts to special
torque (page 199).
2. Connect harness to TC2CIS terminal by pushing in on connector until a click is heard.
3. Push in yellow tab to lock connector.
 ENGINE ELECTRICAL 177

Exhaust Gas Recirculation Temperature (EGRT) Sensor

Figure 124 EGRT sensor

1. EGR module cover
2. EGRT sensor

1. Install EGRT sensor in module cover. Tighten sensor to special torque (page 199).
2. Connect harness to EGRT sensor terminal by pushing in on connector until a click is heard.
3. Push in red tab to lock connector.
178 ENGINE ELECTRICAL

Exhaust Gas Recirculation (EGR) Valve

1. Install Exhaust Gas Recirculation (EGR) dual flap valve. See EGR Dual Flap Valve (page 526).

Figure 125 EGR valve harness connector

1. CPA tab
2. Harness connector
3. EGR valve

2. Connect harness connector (Figure 125) (Item 2) to EGR valve (Figure 125) (Item 3) by pushing in on
harness connector until a click is heard.
3. Engage Connector Position Assurance (CPA) tab (Figure 125) (Item 1).
 ENGINE ELECTRICAL 179

Air Control Valve (ACV)

1. Install ACV. See Air Control Valve (ACV) (page 267).

Figure 126 ACV

1. Pigtail harness
2. ACV assembly

2. Connect pigtail harness (Figure 126) (Item 1) to ACV terminal by pushing in on connector until a click is
heard.
180 ENGINE ELECTRICAL

Coolant Control Valve (CCV)

NOTE: The coolant mixer and coolant flow valves are not serviced separately. Both valves are an integral part
of the CCV assembly which is available as a unit.
1. See Coolant Control Valve (CCV) (page 615) for installation.

Figure 127 CCV

1. Coolant Mixer Valve (CMV) connector
2. Coolant Flow Valve (CFV) connector

2. Connect harness CMV and CFV connectors by pushing in until a click is heard.
3. Engage release tab and secure CMV and CFV connectors to wiring harness.
 ENGINE ELECTRICAL 181

Engine Throttle Valve (ETV)

1. See Air Intake Throttle Duct (page 561) for installation of air intake throttle duct and Engine Throttle Valve
(ETV) as an assembly.

Figure 128 ETV

1. Harness connector
2. CPA tab
3. ETV

2. Connect harness connector (Figure 128) (Item 1) to ETV (Figure 128) (Item 3) by pushing in on harness
connector until a click is heard.
3. Engage Connector Position Assurance (CPA) tab (Figure 128) (Item 2).
4. See Intake Manifold Pressure (IMP) Sensor (page 187) and Charge Air Cooler Outlet Temperature (CACOT)
Sensor (page 188) for installation of ETV-mounted sensors.
182 ENGINE ELECTRICAL

Nitrogen Oxides (NOx) In Sensor

Figure 129 NOx In Sensor (valve actuator removed for clarity)

1. Clip (2)
2. O2S (with harness lead)
3. Exhaust back pressure valve housing
4. NOx IN sensor (with harness lead)

NOTE: The NOx IN sensor should be reused unless there is damage to the sealing ring and evidence of an
exhaust leak.
1. Install NOx In sensor (Figure 129) (Item 4) in exhaust back pressure valve housing (Figure 129) (Item 3).
2. Tighten NOx In sensor to 37 lb‐ft (50 N∙m).
 ENGINE ELECTRICAL 183

Nitrogen Oxides (NOx) IN Sensor Module

Figure 130 NOx IN Sensor Module Connector

1. NOx IN sensor module
2. Tiedown strap
3. NOx IN sensor harness
4. NOx IN sensor module nut
5. NOx IN sensor module connector
6. NOx IN sensor module nut

1. Secure NOx In sensor module (Figure 130) (Item 1) on vehicle with two NOx In sensor mo dule nuts (Figure
130) (Items 4 and 6).
2. Tighten NOx In sensor module nuts to 115 lb‐in (13 N∙m).
3. Secure NOx In sensor harness (Figure 130) (Item 3) with tiedown straps (Figure 130) (Item 2) as required.
4. Connect NOx In sensor module connector (Figure 130) (Item 5) to No In sensor module (Figure 130) (Item
1).
184 ENGINE ELECTRICAL

Oxygen Sensor (O2S)

Figure 131 O2S (valve actuator removed for clarity)

1. Clip (2)
2. O2S (with harness lead)
3. Exhaust back pressure valve housing
4. NOx IN Sensor (with harness lead)

NOTE: The O2S should be reused unless there is damage to the sealing ring and evidence of an exhaust leak.
1. If removed, install O2S (Figure 131) (Item 2). Tighten O2S to 37 lbf·ft (50 N·m).
2. Attach clips (Figure 131) (Item 1) to secure harness lead to coolant tube and valve actuator bracket and at
left rear of engine.
3. Connect harness to O2S terminal end by pushing in on connector until a click is heard.
4. Engage release lever.
NOTE: Any time the O2S is replaced, an Oxygen Sensor Calibration Procedure must be done. See N13 Engine
Diagnostic Manual for details.
 ENGINE ELECTRICAL 185

Intake Manifold Temperature (IMT) Sensor

Figure 132 IMT sensor

1. Install new 16.7 x 24 seal ring and IMT sensor. Tighten sensor to special torque (page 199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness connector to IMT sensor.
3. Turn IMT sensor harness connector locking ring 90° clockwise.
186 ENGINE ELECTRICAL

Fuel Rail Pressure (FRP) Sensor

Figure 133 FRP sensor (typical)

1. Apply a thin film of Lubricant FT1V27 or equivalent to the threads and seal ring of the FRP sensor.
2. Remove plastic protective cap from the FRP sensor port.
3. Install and hand tighten FRP sensor. Tighten FRP sensor to special torque (page 199).
4. Connect engine harness connector to FRP sensor terminal by pushing in on connector until a click is heard.
5. Push in yellow tab to lock engine harness connector.
 ENGINE ELECTRICAL 187

Intake Manifold Pressure (IMP) Sensor

Figure 134 IMP sensor

1. IMP sensor
2. Standoff tie strap
3. Harness connector

1. Install new O-ring and install IMP sensor in Engine Throttle Valve (ETV) housing. Tighten sensor to special
torque (page 199).
2. Connect harness to IMP sensor terminal by pushing in on connector until a click is heard.
3. Engage release tab.
4. Attach tie strap to secure harness standoff bracket to IMP sensor.
188 ENGINE ELECTRICAL

Charger Air Cooler Outlet Temperature (CACOT) Sensor

Figure 135 CACOT sensor

1. CACOT sensor
2. Harness connector
3. Standoff tie strap

1. Install new 2.2 x 9.3 ID O-ring and CACOT sensor in throttle valve housing. Tighten sensor to special torque
(page 199).
2. Connect harness to CACOT sensor terminal by pushing in on connector until a click is heard.
3. Engage release tab.
4. Attach tie strap to secure harness standoff bracket to CACOT sensor.
 ENGINE ELECTRICAL 189

Humidity / Inlet Air Temperature (IAT) Sensor

Figure 136 HS / IAT sensor

1. M6 x 16 bolt (2)
2. Harness connector
3. HS / IAT sensor

1. Insert new O-ring and placeHS / IAT sensor (Figure 136) (Item 3) in position on air inlet duct.
2. Install two M6 x 16 bolts (Figure 136) (Item 1). Tighten bolts to 80 lbf·in (9 N·m).
3. Connect harness to IAT terminal by pushing in on connector until a click is heard.
4. Push in yellow tab to lock sensor connector.
190 ENGINE ELECTRICAL

Fuel Pressure Control Valve (FPCV)

1. See High-pressure Fuel Pump (HPFP) and Drive Housing (page 414) for installation of high-pressure fuel
pump.

Figure 137 FPCV (on high-pressure fuel pump)

1. FPCV
2. Harness connector

2. Connect harness to FPCV terminal by pushing in on connector until a click is heard.

3. Push in yellow tab to lock sensor connector.
 ENGINE ELECTRICAL 191

Fuel Delivery Pressure (FDP) Sensor

Figure 138 FDP sensor

1. Install FDP sensor and new 18.7 x 26 seal ring. Tighten sensor to special torque (page 199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness to FDP sensor.
3. Turn sensor harness connector locking ring 90° clockwise.
192 ENGINE ELECTRICAL

Crankcase Oil Separator Speed (CCOSS) Sensor

Figure 139 CCOSS sensor

1. CCOSS sensor
2. Oil centrifuge (part of oil module assembly)
3. M6 x 14 bolt and nut

1. Place CCOSS sensor in position on bracket and install M6 x 14 bolt and nut.
2. Tighten bolt to special torque (page 199).
3. Connect harness to CCOSS sensor by pushing in on connector until a click is heard.
4. Push in yellow tab to lock connector in place.
 ENGINE ELECTRICAL 193

Engine Oil Pressure (EOP) Sensor

Figure 140 EOP sensor

1. Oil module assembly
2. EOP sensor

1. Install EOP sensor and new 18.7 x 26 seal ring in oil module assembly. Tighten sensor to special torque
(page 199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness to EOP sensor.
3. Turn sensor connector locking ring 90° clockwise.
194 ENGINE ELECTRICAL

Engine Oil Temperature (EOT) Sensor

Figure 141 EOT sensor

1. EOT sensor
2. Oil module flange

1. Install EOT sensor and new 16.7 x 24 seal ring in oil module flange. Tighten sensor to special torque (page
199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness to EOT sensor.
3. Turn sensor connector locking ring 90° clockwise.
 ENGINE ELECTRICAL 195

Engine Coolant Temperature 2 (ECT2) Sensor

Figure 142 ECT2 sensor

1. Install ECT2 sensor and new 16.7 x 24 seal ring in EGR module low-temperature housing. Tighten sensor
to special torque (page 199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness to ECT2 sensor.
3. Turn sensor connector locking ring 90° clockwise.
196 ENGINE ELECTRICAL

Engine Coolant Temperature 1 (ECT1) Sensor

Figure 143 ECT1 sensor

1. Install ECT1 sensor with new 16.7 x 24 seal ring in EGR coolant manifold at rear of engine. Tighten sensor
to special torque (page 199).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness connector to ECT1 sensor.
3. Turn sensor harness connector locking ring 90° clockwise.
 ENGINE ELECTRICAL 197

Camshaft Position (CMP) Sensor

Figure 144 CMP sensor

1. O-ring
2. Cylinder head
3. CMP sensor
4. CMP sensor harness connector
5. Locking tab
6. M6 x 12 bolt

1. Clean CMP sensor bore with a shop towel.

2. Lubricate new O-ring (Figure 144) (Item 1) with oil-based grease and install on CMP sensor (Figure 144)
(Item 3).
CAUTION: To prevent sensor damage, do not use chemical cleaners to clean CMP sensor.
3. Clean debris build-up on CMP sensor with a shop towel.
4. Insert CMP sensor in port at left rear of cylinder head (Figure 144) (Item 2).
5. Install M6 x 12 bolt (Figure 144) (Item 6) to attach CMP sensor to cylinder head. Tighten bolt to 71 lb·in (8
N·m).
6. Connect CMP sensor harness connector (Figure 144) (Item 4) to CMP sensor terminal by pushing in on
connector until a click is heard.
7. Push in locking tab (Figure 144) (Item 5) to lock sensor connector in place.
198 ENGINE ELECTRICAL

Crankshaft Position (CKP) Sensor

Figure 145 CKP sensor

1. M6 x 16 bolt
2. Locking tab
3. CKP sensor harness connector
4. Flywheel housing
5. O-ring
6. CKP sensor

1. Clean CKP sensor bore with a shop towel.

2. Lubricate new O-ring (Figure 145) (Item 5) with oil-based grease and install on CKP sensor (Figure 145)
(Item 6).
CAUTION: To prevent sensor damage, do not use chemical cleaners to clean CKP sensor.
3. Clean debris build-up on CKP sensor with a shop towel.
4. Insert CKP sensor in port at top left of flywheel housing (Figure 145) (Item 4).
5. Install M6 x 16 bolt (Figure 145) (Item 1) to CKP sensor. Tighten bolt to 71 lb·in (8 N·m).
6. Connect CKP sensor harness connector (Figure 145) (Item 3) to CKP sensor terminal by pushing in on
connector until a click is heard.
7. Push in locking tab (Figure 145) (Item 2) to lock connector in place.
 ENGINE ELECTRICAL 199

Special Torque

Camshaft Position (CMP) sensor, M6 x 12 bolt 8 N·m (71 lb·in)

Charger Air Cooler Outlet Temperature (CACOT)
11 N·m (97 lb·in)
sensor
Crankcase Oil Separator Speed (CCOSS) sensor,
10 N·m (89 lb·in)
M6 x 14 bolt
Crankshaft Position (CKP) sensor, M6 x 16 bolt 8 N·m (71 lb·in)
10 N·m (89 lb·in)
Engine Control Module (ECM), M6 x 30 bolt
See procedure for tightening sequence
Engine Control Module (ECM) support, M8 x 40 bolt 13 N·m (115 lb·in)
Engine Coolant Temperature 1 (ECT1) sensor 45 N·m (33 lb·ft)
Engine Coolant Temperature 2 (ECT2) sensor 45 N·m (33 lb·ft)
Engine injector harness retainer clip, M6 x 30 bolt 10 N·m (89 lb·in)
Engine Oil Pressure (EOP) sensor 45 N·m (33 lb·ft)
Engine Oil Temperature (EOT) sensor 45 N·m (33 lb·ft)
Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT)
37 N·m (27 lb·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lb·ft)
Humidity / Inlet Air Temperature (IAT) sensor, M6
9 N·m (80 lb·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lb·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lb·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lb·in)
Oxygen Sensor (O2S) 50 N·m (37 lb·ft)
NOx IN Sensor 50 N∙m (37 lb∙ft)
Fuel Rail Pressure (FRP) sensor 70 N·m (52 lb·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lb·in)
M6 x 16 bolt

Special Service Tools

Description Tool Number

Disposable Air and Fuel Caps ZTSE4891
200 ENGINE ELECTRICAL
 INLET AIR HEATER SYSTEM 201

Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

Inlet Air Heater Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose. . . . . . . . . . . . . . . . . . . . . . . .206
Fuel Solenoid Valve and Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Fuel Solenoid Valve and Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose. . . . . . . . . . . . . . . . . . . . . . . .214
Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

202 INLET AIR HEATER SYSTEM
 INLET AIR HEATER SYSTEM 203

Exploded View
Inlet Air Heater Components

Figure 146 Inlet Air Heater Components

1. Inlet Air Heater Fuel Igniter 5. M8 x 1 banjo bolt 10. Wiring DMR 11-13 x 6-6.5 clip
(IAHFI) 6. M6 x 20 bolt (4) 11. Fuel supply solenoid hose
2. Fuel supply inlet air heater hose 7. Relay assembly 12. Banjo 6 bolt (M10 x 1)
3. Solenoid valve 8. Banjo 8 bolt (M12 x 1.5) 13. Seal 10.7 x 16 ring (2)
4. Washer (seal ring) (2) 9. Seal 12.7 x 18 ring (2)
204 INLET AIR HEATER SYSTEM

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
Relay Assembly

Figure 147 Relay Assembly

1. Engine Control Module (ECM) support bracket
2. M6 x 20 bolt (2)
3. Relay assembly

1. Disconnect wiring harness connector from relay assembly (Figure 147) (Item 3), if not already done.
 INLET AIR HEATER SYSTEM 205

2. Remove two M6 x 20 bolts (Figure 147) (Item 2) and remove relay assembly from ECM support bracket
(Figure 147) (Item 1).
206 INLET AIR HEATER SYSTEM

Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose

Figure 148 IAHFI and Fuel Supply Inlet Air Heater Hose
1. Inlet Air Heater Fuel Igniter (IAHFI)
2. Fuel supply inlet air heater hose fitting nut
3. Fuel supply inlet air heater hose
4. M8 x 1 banjo bolt
5. Washer (seal ring) (2)
6. Solenoid valve

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container
designed for and clearly marked diesel fuel.

WARNING: To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
1. Place suitable container clearly marked DIESEL FUEL under fuel supply inlet air heater hose (Figure 148)
(Item 3).
2. Loosen hose fitting nut (Figure 148) (Item 2) that attaches to IAHFI (Figure 148) (Item 1) fitting. Drain fuel
into container.
3. Loosen and remove M8 x 1 banjo bolt (Figure 148) (Item 4) securing fuel supply inlet air heater hose to
solenoid valve (Figure 148) (Item 6).
4. Remove fuel supply inlet air heater hose and discard two washers (seal rings) (Figure 148) (Item 5).
 INLET AIR HEATER SYSTEM 207

Figure 149 Inlet Air Heater Fuel Igniter (IAHFI)

1. Wiring harness
2. Inlet Air Heater Fuel Igniter (IAHFI)
3. Fuel line port
4. IAHFI locking nut
5. Fuel supply inlet air heater hose
6. Air intake throttle duct
7. IAHFI wiring harness nut

5. If not already done, remove IAHFI wiring harness nut (Figure 149) (Item 7) and remove wiring harness
(Figure 149) (Item 1) from the IAHFI (Figure 149) (Item 2).
6. Loosen IAHFI locking nut (Figure 149) (Item 4).
7. Remove IAHFI from air intake throttle duct (Figure 149) (Item 6) by rotating counterclockwise.
208 INLET AIR HEATER SYSTEM

Fuel Solenoid Valve and Fuel Supply Solenoid Hose

Figure 150 Fuel Supply Solenoid Hose (at Fuel Filter Housing)
1. Fuel filter housing
2. Seal 12.7 x 18 ring (2)
3. Banjo 8 bolt (M12 x 1.5)
4. Fuel supply solenoid hose

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container
designed for and clearly marked diesel fuel.

WARNING: To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
1. Place suitable container clearly marked DIESEL FUEL under lower end of fuel supply solenoid hose (Figure
150) (Item 4).
2. Remove banjo 8 bolt (M12 x 1.5) (Figure 150) (Item 3) from fuel filter housing (Figure 150) (Item 1) and drain
fuel into container.
3. Remove and discard two seal 12.7 x 18 rings (Figure 150) (Item 2).
 INLET AIR HEATER SYSTEM 209

Figure 151 Fuel Supply Solenoid Hose (at Solenoid Valve)

1. Solenoid valve
2. Seal 10.7 x 16 ring (2)
3. M6 x 20 bolt (2)
4. ECM support bracket
5. Banjo 6 bolt (M10 x 1)
6. Fuel supply solenoid hose (tube)

4. Remove banjo 6 bolt (M10 x 1) (Figure 151) (Item 5) from solenoid valve (Figure 151) (Item 1).
5. Remove and discard two seal 10.7 x 16 rings (Figure 151) (Item 2).
6. Remove two M6 x 20 bolts (Figure 151) (Item 3) securing the solenoid valve to the ECM support bracket
(Figure 151) (Item 4). Remove valve.
210 INLET AIR HEATER SYSTEM

Figure 152 Fuel Supply Solenoid Hose Clips

1. Clips on electrical harness (2) 3. Fuel supply solenoid hose (tube)
2. Clip on fuel filter bracket 4. Clip on fuel drain hose

7. Remove fuel supply solenoid hose from clips on electrical harness (Figure 152) (Item 1), fuel filter bracket
(Figure 152) (Item 2), and fuel drain hose (Figure 152) (Item 4) and remove hose from engine.
 INLET AIR HEATER SYSTEM 211

Installation
Fuel Solenoid Valve and Fuel Supply Solenoid Hose

Figure 153 Fuel Supply Solenoid Hose (at Solenoid Valve)

1. Solenoid valve
2. Seal 10.7 x 16 ring (2)
3. M6 x 20 bolt (2)
4. ECM support bracket
5. Banjo 6 bolt (M10 x 1)
6. Fuel supply solenoid hose (tube)

1. Install solenoid valve (Figure 153) (Item 1) to ECM support bracket (Figure 153) (Item 4) using two M6 x 20
bolts (Figure 153) (Item 3). Finger-tighten bolts.
2. Tighten two M6 x 20 bolts to 53 lb·in (6 N·m).
212 INLET AIR HEATER SYSTEM

Figure 154 Fuel supply solenoid hose

1. Clips on electrical harness (2)
2. Clip on fuel filter bracket
3. Fuel supply solenoid hose (tube)
4. Clip on fuel drain hose

3. Position fuel supply solenoid hose (Figure 154) (Item 3) on engine.

4. Install two new seal 10.7 x 16 rings (Figure 153) (Item 2), and install banjo 6 bolt (M10 x 1) (Figure 153)
(Item 5) into solenoid valve finger tight.
 INLET AIR HEATER SYSTEM 213

Figure 155 Fuel Supply Solenoid Hose (at Fuel Filter Housing)
1. Fuel filter housing
2. Seal 12.7 x 18 ring (2)
3. Banjo 8 bolt (M12 x 1.5)
4. Fuel supply solenoid hose (tube)

5. Install two new seal 12.7 x 18 rings (Figure 155) (Item 2) and banjo 8 bolt (Figure 155) (Item 3) into fuel filter
housing finger tight.
6. Install fuel supply solenoid hose (Figure 154) (Item 3) to clips on electrical harness (Figure 154) (Item 1),
fuel filter bracket (Figure 154) (Item 2), and fuel drain hose (Figure 154) (Item 4).
7. Tighten banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts to 11 lb·ft (15 N·m).
214 INLET AIR HEATER SYSTEM

Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose

Figure 156 Inlet Air Heater Fuel Igniter (IAHFI)

1. Wiring harness
2. Inlet Air Heater Fuel Igniter (IAHFI)
3. Fuel line port
4. IAHFI locking nut
5. Fuel supply inlet air heater hose
6. Air intake throttle duct
7. IAHFI wiring harness nut

WARNING: To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
1. Rotate IAHFI locking nut (Figure 156) (Item 4) until nut tops out on the IAHFI body (Figure 156) (Item 2) at
the top of the threads.
2. Thread IAHFI all the way into the air intake throttle duct (Figure 156) (Item 6) until nut contacts the duct
housing.
3. Rotate IAHFI counterclockwise to properly orient fuel line port (Figure 156) (Item 3) with fuel supply inlet air
heater hose (Figure 156) (Item 5).
4. Finger-tighten IAHFI locking nut.
 INLET AIR HEATER SYSTEM 215

Figure 157 Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose
1. Inlet Air Heater Fuel Igniter (IAHFI)
2. Fuel supply inlet air heater hose fitting nut
3. Fuel supply inlet air heater hose
4. M8 x 1 banjo bolt
5. Washer (seal ring) (2)
6. Solenoid valve

5. Install fuel supply inlet air heater hose (Figure 157) (Item 3), two new washers (seal rings) (Figure 157) (Item
5) and M8 x 1 banjo bolt (Figure 157) (Item 4) finger tight.
6. Install fuel supply inlet air heater hose onto IAHFI fitting finger tight.
CAUTION: To prevent engine damage, orient the fuel supply inlet air heater hose so the hose is not under
any excess tension. The hose should bend in a smooth arc, is not twisted, and does not touch other engine
components.
7. Tighten hose fitting nut (Figure 157) (Item 2) to 132 lb·in (10 N·m).
8. Tighten banjo bolt to 71 lb·in (8 N·m).
9. Tighten IAHFI locking nut (Figure 156) (Item 3) to 17 lb·ft (23 N·m).
10. Install wiring harness (Figure 156) (Item 1) and IAHFI wiring harness nut (Figure 156) (Item 7).
11. Tighten IAHFI wiring harness nut to 35 lb·in (4 N·m).
216 INLET AIR HEATER SYSTEM

Relay Assembly

Figure 158 Relay Assembly

1. ECM support
2. Relay assembly M6 x 20 bolt (2)
3. Relay assembly

1. Position relay assembly (Figure 158) (Item 3) on mounting pad at rear of ECM support (Figure 158) (Item 1).
2. Install two relay assembly M6 x 20 bolts (Figure 158) (Item 2).
3. Tighten bolts to 89 lb·in (10 N·m).
 INLET AIR HEATER SYSTEM 217

Special Torque

Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts 15 N·m (132 lb·in)

Banjo M8 x 1 bolt 8 N·m (71 lb·in)
Fuel supply inlet air heater hose fitting nut 10 N·m (89 lb·in)
IAHFI locking nut 23 N·m (17 lb·ft)
IAHFI wiring harness nut 4 N·m (35 lb·in)
Relay assembly M6 x 20 bolts 10 N·m (89 lb·in)
Solenoid valve M6 x 20 bolts 6 N·m (53 lb·in)
218 INLET AIR HEATER SYSTEM
 AFTERTREATMENT SYSTEM 219

Table of Contents

Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Aftertreatment System Fuel Supply Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Supply Fuel After Filter Hose and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Aftertreatment Purge Air Valve (AFTPAV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Aftertreatment (AFT) Fuel Doser Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
AFTFI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
AFTFI Coolant Return Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
Aftertreatment Fuel Injector (AFTFI) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238

Aftertreatment Fuel Injector (AFTFI) Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Exhaust Back Pressure Valve Housing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Aftertreatment Fuel Injector (AFTFI) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
AFTFI Coolant Return Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
AFTFI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Aftertreatment (AFT) Fuel Doser Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Aftertreatment Purge Air Valve (AFTPAV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Supply Fuel After Filter Hose and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

220 AFTERTREATMENT SYSTEM
 AFTERTREATMENT SYSTEM 221

Illustrations
Aftertreatment System Fuel Supply Components

Figure 159 Aftertreatment system components

1. 1. Aftertreatment Fuel Injector 7. AFTI coolant supply tube 12. Tube clamp (2)
(AFTI) fuel 2 tube assembly assembly 13. AFTI coolant return tube
2. NOx in sensor module assembly 8. Bolt (2) 14. Pipe single cushioned clamp
3. P6 x 15 clamp (2) 9. Aftertreatment Fuel Injector 15. M8 x 16 bolt
4. M6 x 40 bolt (2) (AFTI) 16. Straight fitting
5. Spacer (2) 10. 90 degree adjustable fitting
6. 90 degree adjustable fitting 11. Hose clamp (spring type)
222 AFTERTREATMENT SYSTEM

Figure 160 Aftertreatment System Fuel Supply

1. AFT fuel doser module bracket 7. AFTPAV supply tube 14. Aftertreatment Purge Air Valve
2. Aftertreatment (AFT) fuel doser 8. Clamp (AFTPAV) assembly
module 9. M6 x 16 bolt 15. M8 x 60 hex flange bolt (2)
3. 8 x 60 stud bolt 10. AFTI fuel tube assembly 16. M8 x 16 bolt
4. Harness retainer 11. AFTPAV support bracket 17. M8 x 65 hex flange bolt
5. AFTPAV connector 12. Clamp 18. Harness support
6. M6 x 16 bolt 13. M8 nut 19. M6 x 16 bolt (4)
 AFTERTREATMENT SYSTEM 223

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
224 AFTERTREATMENT SYSTEM

Supply Fuel After Filter Hose and Tubes

Figure 161 Supply Fuel After Filter Hose Connection

1. Aftertreatment (AFT) fuel doser module
2. Fitting (quick-connect adapter)
3. Supply fuel after-filter hose

WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container
designed for and clearly marked DIESEL FUEL.
CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel
compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service.
1. Place suitable container clearly marked DIESEL FUEL under AFT doser module.
 AFTERTREATMENT SYSTEM 225

Figure 162 AFTFI Fuel 1 and 2 Tube Assemblies

1. AFTFI fuel 1 tube assembly nut
2. Aftertreatment (AFT) fuel doser module
3. AFTFI fuel 1 tube assembly nut
4. AFTFI fuel 2 tube assembly fitting (brazed to tube)
5. P-clamp (2)
6. M6 x 16 bolt (2)

2. Loosen AFTFI fuel 1 tube assembly nut (Figure 162) (Item 1) and disconnect tube from fitting assembly at
AFT fuel doser module (Figure 162) (Item 2).
3. Remove two M6 x 16 bolts (Figure 162) (Item 6) and two P-clamps (Figure 162) (Item 5) from AFT fuel 1
tube assembly.
226 AFTERTREATMENT SYSTEM

Figure 163 AFTFI Fuel 1 Tube Assembly Connection

1. AFTFI fuel 1 tube assembly
2. AFTFI fuel 2 tube assembly
3. AFTFI fuel 1 tube assembly nut
4. M6 x 16 bolt

4. Loosen AFTFI fuel 1 tube assembly nut and disconnect fuel tube from AFTFI fuel 2 tube assembly.
5. Remove M6 x 16 bolt, P-clamp and AFTFI fuel 1 tube assembly.
 AFTERTREATMENT SYSTEM 227

Figure 164 AFTFI Fuel 2 Tube Assembly

1. 6.6 x 15 x 23 spacer (2)
2. M6 x 40 bolt (2)
3. AFTFI fuel 2 tube assembly nut
4. P 6 x 15 clamp (2)
5. AFTFI fuel 2 tube assembly
6. Aftertreatment Fuel Injector (AFTFI) Assembly

6. Loosen AFTFI fuel 2 tube assembly nut and disconnect tube from hydrocarbon injector assembly.
7. Remove two M6 x 40 bolts, two 6.6 x 15 x 23 spacers and remove AFTFI assembly.
228 AFTERTREATMENT SYSTEM

Aftertreatment Purge Air Valve (AFTPAV) Assembly

Figure 165 Aftertreatment Purge Air Valve (AFTPAV) Assembly

1. Harness retainer
2. AFTPAV connector
3. Quick connect fitting
4. Aftertreatment Purge Air Valve (AFTPAV) assembly
5. M8 x 60 hex flange bolt (2)
6. AFTPAV Air supply line quick‐connect fitting
7. M8 x 60 Stud bolt

CAUTION: Ensure that air system has been drained before removing air supply line from AFTPAV quick‐connect
fitting.
1. Remove AFTPAV connector (Figure 165) (Item 2) together with harness retainer (Figure 165) (Item 1) from
M8 x 60 Stud bolt (Figure 165) (Item 7).
2. Remove formed air tube (0.25”) from quick connect fitting (Figure 165) (Item 3).
3. Remove two M8 x 60 hex flange bolts (Figure 165) (Item 5) and AFTPAV assembly (Figure 165) (Item 4).
 AFTERTREATMENT SYSTEM 229

Figure 166 AFTPAV support bracket

1. M10 x 16 bolt
2. AFTPAV support bracket
3. M8 nut
4. M8 x 16 bolt

4. If necessary, remove M10 x 16 bolt (Figure 166) (Item 1), M8 x 16 bolt (Figure 166) (Item 4), and M8 nut
(Figure 166) (Item 3).
5. Remove AFTPAV support bracket (Figure 166) (Item 2) from engine.
230 AFTERTREATMENT SYSTEM

Aftertreatment (AFT) Fuel Doser Module

Figure 167 AFT Fuel Doser Module

1. AFT fuel doser module
2. Aftertreatment Purge Air Valve (AFTPAV) supply tube connector
3. M8 x 60 stud bolt
4. Aftertreatment Purge Air Valve (AFTPAV) supply tube
5. M8 x 65 hex flange bolt
6. Harness support bracket
7. Aftertreatment Fuel Doser Module (AFTFSV) fuel shutoff valve connector
8. Aftertreatment Fuel Pressure Sensor 1 (AFTFP1) connector

CAUTION: To prevent component damage, keep AFT fuel doser module and related components clean and
protected from damage until ready to install. Do not let dirt or other debris, lubricants, or water get into fuel
passages. Do not blow compressed air into fuel passages. If protection caps are used, they should be new, or
ultrasonically cleaned before using.
CAUTION: To prevent component damage, do not drop AFT fuel doser module onto a hard surface. If this
happens, replace the valve.
1. If not already done, remove the harness connectors from AFTFP1 (Figure 167) (Item 8) and AFTFSV (Figure
167) (Item 7).
2. Push 90 degree connector locking tab to release AFTPAV supply tube (Figure 167) (Item 4) from AFT fuel
doser module (Figure 167) (Item 1) and cap off the end of tube.
3. Remove M8 x 60 stud bolt (Figure 167) (Item 3), M8 x 65 hex flange bolt (Figure 167) (Item 5), harness
support bracket (Figure 167) (Item 6), and AFT fuel doser module.
 AFTERTREATMENT SYSTEM 231

Figure 168 AFT Fuel Doser Module, AFTFP1, and AFTFSV1

1. Aftertreatment Fuel Pressure 1 (AFTFP1) sensor
2. O-ring
3. AFT doser module
4. O-ring
5. Aftertreatment Fuel Shutoff Valve (AFTFSV)

NOTE: Do steps 4 and 5 only if AFTFP1 or AFTFSV are leaking or if AFT sensor is being replaced.
CAUTION: To prevent engine damage, all fuel exposed O‐rings and O‐ring seals must be replaced with biodiesel
compatible O‐rings and O‐ring seals. The specific Navistar P/N must be used for service.
4. Loosen and remove AFTFP1 (Figure 168) (Item 1) from AFT doser module (Figure 168) (Item 3) and discard
O‐ring (Figure 168) (Item2).
5. Loosen and remove AFTFSV (Figure 168) (Item 5) and discard O‐ring (Figure 168) (Item 4).
232 AFTERTREATMENT SYSTEM

AFTFI Coolant Supply Tube Assembly

Figure 169 AFTFI Coolant Supply Tube Assembly

1. Coolant Manifold
2. 90 degree adjustable fitting
3. AFTFI coolant supply tube nut
4. AFTFI coolant supply tube assembly
5. 90 degree adjustable fitting
6. AFTFI coolant supply tube nut
7. Aftertreatment Fuel Injector (AFTFI) assembly

1. Loosen the AFTFI coolant supply tube nut (Figure 169) (Item 6) and disconnect AFTFI coolant supply tube
assembly (Figure 169) (Item 4) from tube 90 degree adjustable fitting (Figure 169) (Item 5).
2. Loosen AFTFI coolant supply tube nut (Figure 169) (Item 3) and disconnect AFTFI coolant supply tube
assembly from 90 degree adjustable fitting (Figure 169) (Item 2) at coolant manifold (Figure 169) (Item 1).
3. Remove AFTFI coolant supply tube assembly.
NOTE: Perform following steps only if 90 degree adjustable fittings are leaking.
4. Remove 90 degree adjustable fitting (Figure 169) (Item 6) from AFTFI assembly (Figure 169) (Item 7).
5. Remove 90 degree adjustable fitting(Figure 169) (Item 2) from coolant manifold (Figure 169) (Item 1).
 AFTERTREATMENT SYSTEM 233

AFTFI Coolant Return Tube Assembly

Figure 170 AFTFI Coolant Return Tube Assembly

1. Straight fitting 3. AFTFI coolant return tube 6. Hose clamp (spring type)
2. Aftertreatment Fuel Injector assembly 7. M8 x 16 bolt
(AFTFI) assembly 4. Tube clamp (2) 8. Pipe single cushion clamp
5. Open breather tube 9. AFTFI coolant return tube nut

1. Loosen AFTFI coolant return tube nut (Figure 170) (Item 9) and disconnect AFTFI coolant return tube
assembly (Figure 170) (Item 3) from straight fitting (Figure 170) (Item 1).
2. Remove M8 x 16 bolt (Figure 170) (Item 7) from pipe single cushion clamp (Figure 170) (Item 8). Separate
clamp from AFTFI coolant return tube assembly as necessary.
3. Release AFTFI coolant return tube assembly (Figure 170) (Item 3) from two tube clamps (Figure 170) (Item
4) at open breather tube (Figure 170) (Item 5).
234 AFTERTREATMENT SYSTEM

4. Loosen hose clamp (spring type) (Figure 170) (Item 6). Separate AFTFI coolant return tube assembly from
open breather tube. Remove from engine.
NOTE: Do step 5 only if straight fitting is leaking.
5. Remove straight fitting (Figure 170) (Item 1) from AFTFI assembly (Figure 170) (Item 2).
 AFTERTREATMENT SYSTEM 235

Aftertreatment Fuel Injector (AFTFI) Assembly

Figure 171 AFTFI Harness and Connections

1. Aftertreatment Fuel Injector (AFTFI) connector
2. AFTFI connector mounting bracket
3. AFTFI harness fasteners (3)

NOTE: This Engine Service Manual is written for complete engine teardown. If removing AFTFI only, do not
drain cooling system and do not remove engine cover (dog house). Access AFTFI from under vehicle.
1. Press release tab to disconnect wiring harness lead from AFTFI connector (Figure 171) (Item 1).
2. Disconnect AFTFI connector from AFTFI connector mounting bracket (Figure 171) (Item 2).
3. Disconnect three AFTFI harness fasteners (Figure 171) (Item 3).
236 AFTERTREATMENT SYSTEM

Figure 172 AFTFI Connections (Disconnected)

1. Fuel supply line
2. AFTFI M6 mounting bolts (2)
3. Aftertreatment Fuel Injector (AFTFI)
4. Coolant supply line
5. AFTFI Coolant Line Plugs (2)
6. Coolant return line

4. Disconnect fuel supply line (Figure 172) (Item 1), and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap
line. Discard O-rings.
5. Disconnect coolant supply line(Figure 172) (Item 4) and coolant return line (Figure 172) (Item 6). Discard
O-rings.
6. Install two AFTFI Coolant Line Plugs (Figure 172) (Item 5) onto coolant supply and return line.
7. Open the BLUE vent valve on the Vacuum Module.
CAUTION: To prevent component damage, keep AFTFI and related components clean and protected from
damage until ready to install. Protect the injector nozzle tip, sealing surfaces, and threaded surfaces. Do not let
dirt, debris, lubricants, or water get into fuel or coolant passages. Do not blow compressed air into injector fuel
passage. If protection caps are used, they should be new, or ultrasonically cleaned before using.
CAUTION: To prevent component damage, do not drop AFTFI (especially nozzle tip) onto a hard surface. If this
happens, replace the injector.
8. Remove two AFTFI M6 mounting bolts (Item 2).
9. Remove AFTFI as an assembly from turbocharger exhaust outlet pipe. Discard metal gasket and fibrous
insulator.
 AFTERTREATMENT SYSTEM 237

Figure 173 AFTFI Block Off Plate and Bolts

1. AFTFI block off plate bolt (2)
2. AFTFI block off plate

10. Install AFTFI Block Off Plate 12-559-01-05 (Figure 173) (Item 2) onto turbocharger exhaust outlet pipe using
two AFTFI Block Off Plate Bolts 12-55-01-04 (Figure 173) (Item 1).
238 AFTERTREATMENT SYSTEM

Cleaning and Inspection

Aftertreatment Fuel Injector (AFTFI) Cleaning

Figure 174 Aftertreatment Fuel Injector (AFTFI) Assembly

1. AFTFI assembly
2. Injector nozzle tip
3. AFTFI Gasket
4. Raised sealing lip

CAUTION: To prevent component damage, cleaning of the AFTFI assembly using cleaner or solvents is
NOT recommended. Do not blast the injector with compressed air. Do not pull or otherwise manipulate
the injector nozzle tip.
1. Inspect AFTFI assembly (Figure 174) (Item 1) and injector nozzle tip (Figure 174) (Item 2) for cracks and
other damage. If damage is present, replace AFTFI assembly.
2. Use Fuel Injector Tip Cleaning Brush ZTSE4301 to clean any carbon buildup that may be present on the
injector nozzle tip.
 AFTERTREATMENT SYSTEM 239

Exhaust Back Pressure Valve Housing Cleaning

Figure 175 Exhaust Back Pressure Valve Housing

1. AFTFIport
2. Exhaust back pressure valve housing

CAUTION: To prevent damage to the aftertreatment system or plugging of the PDOC / DOC / DPF, ensure
no carbon debris remains in AFTFI port upon completion of steps 1 and 2.
1. Carefully remove carbon from the AFTFI port (Figure 175) (Item 1) on the exhaust back pressure valve
housing (Figure 175) (Item 2) with a chisel or other appropriate tool. Remove debris with a shop vac.
240 AFTERTREATMENT SYSTEM

Installation
Aftertreatment Fuel Injector (AFTFI) Assembly

Figure 176 AFTFI Block Off Plate and Bolts

1. AFTFI Block Off Plate Bolt (2)
2. AFTFI Block Off Plate

NOTE: When installing the AFTFI gasket , the raised seal lip must face down toward the exhaust back pressure
valve housing.
1. Remove two AFTFI Block Off Plate Bolts (page 240) 12‐55‐01‐04 (Item 1) and AFTFI Block Off Plate ( (page
240) Item 2) from turbocharger exhaust outlet pipe.
 AFTERTREATMENT SYSTEM 241

Figure 177 AFTFI Connections (Disconnected)

1. Fuel supply line
2. AFTFI M6 mounting bolts (2)
3. Aftertreatment Fuel Injector (AFTFI)
4. Coolant supply line
5. AFTFI Coolant Line Plugs (2)
6. Coolant return line

2. Install AFTFI (Figure 177) (Item 3), metal gasket, and fibrous insulator as an assembly onto turbocharger
exhaust outlet pipe.
3. Install two AFTFI M6 mounting bolts (Figure 177) (Item 2).
4. Close BLUE vent valve on Vacuum Module.
5. Remove two AFTFI Coolant Line Plugs (Figure 177) (Item 5) onto coolant supply and return line.
6. Install new O‐ring on coolant supply line (Figure 177) (Item 4) and install coolant supply line onto AFTI.
7. Install new O‐ring on coolant return line (Figure 177) (Item 6) and install coolant return line onto AFTI.
8. Remove air and fuel cap from fuel supply line (Figure 177) (Item 1).
9. Install new O‐ring onto fuel supply line and connect onto AFTFI.
242 AFTERTREATMENT SYSTEM

Figure 178 AFTFI Harness and Connections

1. Aftertreatment Fuel Injector (AFTFI) connector
2. AFTFI connector mounting bracket
3. AFTFI harness fasteners (3)

10. Connect three AFTFI harness fasteners (Figure 178) (Item 3).
11. Connect AFTFI connector (Figure 178) (Item 1) to AFTFI connector mounting bracket (Figure 178)(Item 2).
12. Connect wiring harness lead from AFTFI connector (Figure 178) (Figure 50) (Item 1).
 AFTERTREATMENT SYSTEM 243

AFTFI Coolant Return Tube Assembly

Figure 179 AFTFI Coolant Return Tube Assembly

1. AFTFI coolant return tube nut 5. Hose clamp (spring type) 6. Open breather tube
2. Aftertreatment Fuel Injector 7. AFTFI coolant return tube
(AFTFI) assembly assembly
3. Straight fitting 8. Pipe single cushion clamp
4. Tube clamp (2) 9. M8 x 16 bolt

NOTE: Do steps 1 and 2 if straight fitting was removed. Otherwise, skip to step 3.
1. Install straight fitting (Figure 179) (Item 2) onto AFTFI (Figure 179) (Item 3) and tighten fitting to maintain
alignment and clearance for AFTFI coolant return tube assembly (Figure 179) (Item 7).
2. Tighten straight fitting to 11 lbf·ft (15 N·m).
3. Position AFTFI coolant return tube assembly onto open breather tube (Figure 179) (Item 6) nipple, two tube
clamps (Figure 179) (Item 4) on open breather tube and pipe single cushion clamp (Figure 179) (Item 8).
244 AFTERTREATMENT SYSTEM

4. Install M8 x 16 bolt (Figure 179) (Item 9) through pipe single cushion clamp (Figure 179) (Item 8) and tighten
to 23 lbf·ft (31 N·m).
5. Snap AFTFI coolant return tube assembly into two tube clamps (Figure 179) (Item 4) and install hose clamp
(spring type) (Figure 179) (Item 5) to secure tube to open breather tube.
6. Tighten AFTFI coolant return tube nut onto straight fitting. Align fitting as needed to reduce tube stress and
to not contact other components. Tighten tube nut and straight fitting each to 13 lbf·ft (17.5 N·m).
 AFTERTREATMENT SYSTEM 245

AFTFI Coolant Supply Tube Assembly

Figure 180 AFTFI Coolant Supply Tube Assembly

1. Coolant Manifold
2. 90 degree adjustable fitting
3. AFTFI coolant supply tube nut
4. AFTFI coolant supply tube assembly
5. 90 degree adjustable fitting
6. AFTFI coolant supply tube nut
7. Aftertreatment Fuel Injector (AFTFI) assembly

1. If previously removed, loosely install 90 degree adjustable fitting (Figure 180) (Item 2) into coolant manifold
(Figure 180) (Item 1).
2. Loosely install AFTFI coolant supply tube nut (Figure 180) (Item 3 onto 90 degree adjustable fitting at coolant
manifold.
NOTE: Do step 3 if tube M10 elbow fitting was removed. Otherwise, skip to step 5.
3. Loosely install 90 degree adjustable fitting (Figure 180) (Item 5) onto AFTFI assembly (Figure 180) (Item 7)
and adjust to maintain alignment and clearance for AFTFI coolant supply tube assembly.
4. Loosely install AFTFI coolant supply tube nut (Figure 180) (Item 6) onto 90 degree adjustable fitting (Figure
180) (Item 5) (align fitting as needed) on AFTFI assembly.
5. Tighten AFTFI coolant supply tube nut s and 90 degree adjustable fittings to 13 lb·ft (17.5 N·m).
246 AFTERTREATMENT SYSTEM

Aftertreatment (AFT) Fuel Doser Module

Figure 181 AFT Fuel Doser Module, AFTFP1, and AFTFSV1

1. Aftertreatment Fuel Pressure 1 (AFTFP1) sensor
2. O-ring
3. AFT fuel doser module
4. Aftertreatment Fuel Shutoff Valve (AFTFSV)
5. O-ring (# 011)
6. O-ring seal

NOTE: Do steps 1 through 4 only if AFTFP1 or AFTFSV are leaking or if AFT sensor is being replaced.
CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel
compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service.
1. Lubricate new O-ring (Figure 181) (Item 2) and install onto AFTFP1 (Figure 181) (Item 1).
2. Install and tighten AFTFP1 into AFT fuel doser module (Figure 181) (Item 3).
3. Lubricate new O-ring (Figure 181) (Item 4) and install onto AFTFSV (Figure 181) (Item 5).
4. Install and tighten AFTFSV (Item 5) into AFT fuel doser module.
 AFTERTREATMENT SYSTEM 247

Figure 182 AFT Fuel Doser Module

1. Aftertreatment (AFT) fuel doser module
2. Aftertreatment Purge Air Valve (AFTPAV) supply tube connector
3. 8 x 60 stud bolt
4. Aftertreatment Purge Air Valve (AFTPAV) supply tube
5. M8 x 65 bolt
6. Harness support bracket
7. Aftertreatment Fuel Doser Module (AFTFSV) fuel shutoff valve connector
8. Aftertreatment Fuel Pressure Sensor 1 (AFTFP1) connector

5. Install harness support bracket (Item 6) and AFT fuel doser module (Item 1) and secure with M8 x 60 stud
bolt (Item 3) and M8 x 65 hex flange bolt (Item 5).
6. Tighten bolts to 23 lbf•ft (31 N•m).
7. Connect AFTPAV supply tube (Item 4) to 90 degree connector (Item 2) on AFT fuel doser module.
8. Connect harness connectors to AFTFP1 (Item 8) and AFTFSV (Item 7).
248 AFTERTREATMENT SYSTEM

Aftertreatment Purge Air Valve (AFTPAV) Assembly

Figure 183 AFTPAV support bracket

1. M10 x 16 bolt
2. AFTPAV support bracket
3. M8 nut
4. M8 x 16 bolt

1. Install AFTPAV support bracket (Figure 183) (Item 2).

2. Install M10 x 16 bolt (Figure 183) (Item 1), M8 x 16 bolt (Figure 183) (Item 4), and M8 nut (Figure 183) (Item
3) and tighten to 23 lbf•ft (31 N•m).
 AFTERTREATMENT SYSTEM 249

Figure 184 AFTPAV Assembly

1. Harness retainer
2. AFTPAV connector
3. AFTPAV supply tube connector
4. Aftertreatment Purge Air Valve (AFTPAV) assembly
5. M8 x 60 hex flange bolt (2)
6. AFTPAV air supply line quick-connect fitting
7. M8 x 60 stud bolt

3. Install AFTPAV assembly (Item 4).

4. Install two M8 x 60 bolts (Item 5) and tighten to 23 lbf•ft (31 N•m).
5. Install formed air tube (0.25”) to quick connect fitting (Item 3).
6. Install AFTPAV connector (Item 2) together with harness retainer (Item 1) to M8 x 60 Stud bolt (Item 7).
250 AFTERTREATMENT SYSTEM

Supply Fuel After Filter Hose and Tubes

Figure 185 AFTFI Fuel 2 Tube Assembly

1. 6.6 x 15 x 23 spacer (2)
2. M6 x 40 bolt (2)
3. AFTFI fuel 2 tube assembly nut
4. P 6 x 15 clamp (2)
5. AFTFI fuel 2 tube assembly
6. Aftertreatment Fuel Injector (AFTFI) assembly

1. Position AFTFI fuel 2 tube assembly onto engine.

2. Connect AFTFI fuel 2 tube assembly onto hydrocarbon injector assembly.
3. Install two M6 x 40 bolts, 2 clamps and two 6.6 x 15 x 23 spacers. Tighten bolts to standard torque (page
881).
4. Using a wrench, hold the hydrocarbon injector assembly hex to keep it from rotating. Tighten AFTFI fuel 2
tube nut to special torque (page 253), while holding the injector body hex.
 AFTERTREATMENT SYSTEM 251

Figure 186 AFTFI fuel 1 and 2 tube assemblies

1. AFTFI fuel 1 tube assembly nut
2. Downstream Injection (DSI) unit
3. AFT fuel doser module
4. AFTFI fuel 1 tube assembly nut
5. AFTFI fuel 2 tube assembly fitting (brazed to tube)
6. P-clamp (2)
7. M6 x 16 bolt (2)

5. Position AFTFI fuel 1 tube assembly to engine. Loosely connect fuel 1 tube with fuel 2 tube and DSI unit.
6. Install two M6 x 16 bolts, one M10 x 16 bolt, two P 6 x 15 clamps and cushioned 1/4 inch diameter clamp.
Tighten bolts to standard torque (page 881).
252 AFTERTREATMENT SYSTEM

Figure 187 Fuel Supply Assembly Connection

1. AFTFI fuel 1 tube assembly
2. AFTFI fuel 2 tube assembly
3. AFTFI fuel 1 tube assembly nut
4. M6 x 16 bolt

7. Tighten AFTFI fuel 1 tube assembly nut at AFTFI fuel 2 tube nut (brazed) to special torque (page 253).
8. Tighten AFTFI fuel 1 tube assembly nut at AFTFI to special torque (page 253).
9. Connect clamp from fuel drain tube to AFTFI fuel 1 tube assembly.
 AFTERTREATMENT SYSTEM 253

Special Torque

Coolant supply (straight) fitting at coolant manifold 35 N·m (26 lb·ft)

Fitting (quick-connect adapter) at DSI unit 35 N·m (26 lb·ft)
Fitting (straight union orifice) at DSI unit 35 N·m (26 lb·ft)
AFTI coolant supply and return tube nut at tube M10 elbow 15 N·m (11 lb·ft)
fittings
AFTI coolant supply tube nut at coolant manifold 25 N·m (18 lb·ft)
AFTI fuel 1 tube assembly nut at AFTI fuel 2 tube fitting 25 N·m (18 lb·ft)
(brazed)
AFTI fuel 1 tube assembly nut at DSI unit 25 N·m (18 lb·ft)
AFTI fuel 2 tube assembly nut at hydrocarbon injector 18 N·m (13 lb·ft)
assembly
Hydrocarbon injector assembly M8 x 45 bolt See tightening steps in procedure.
Hydrocarbon injector assembly body to assembly 20 N·m (15 lb·ft)
PDOC V-band clamp 7 N·m (62 lb·in)
PDOC M10 x 50 bolts 36 N·m (27 lb·ft)
M10 x 25 bolts 31 N·m (23 lb·ft)
PDOC M10 x 50 bolts 36 N·m (27 lb·ft)
Tube M10 elbow fittings at hydrocarbon injector assembly 17.5 N·m (13 lb·ft)

Special Service Tools

Description Tool Number

Coolant Block Off Plug 12–559–02–01
Coolant Management Tool KL5007NAV
Disposable Air and Fuel Caps ZTSE4891
Fuel Line Disconnect Tool 11.8 mm ZTSE4773
P-80® rubber lubricant or equivalent Obtain locally
Fuel Injector Tip Cleaning Brush ZTSE4301
254 AFTERTREATMENT SYSTEM
 EXHAUST BACK PRESSURE CONTROL 255

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .261
Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .268

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272

256 EXHAUST BACK PRESSURE CONTROL
 EXHAUST BACK PRESSURE CONTROL 257

Exploded Views
Control System

Figure 188 Exhaust back pressure control system

1. Air control valve (ACV) [updated] 8. Tube bracket 14. Heat shield spacer
2. M8 x 85 bolt (2) 9. TC1 turbine outlet pressure 15. M8 x 16 bolt
3. M8 x 65 bolt (if equipped) (TC1TOP) sensor tube assembly 16. Heat shield
4. M6 x 40 bolt 10. Flare M10 x 1.5 (37 degree) 17. Flare M10 x M12 (24 degree)
5. Exhaust back pressure valve fitting fitting
tube bracket (2) 11. Exhaust back pressure valve
6. Spacer assembly
7. Exhaust back pressure valve 12. Spacer (5)
tube assembly 13. M8 x 45 bolt (7)
258 EXHAUST BACK PRESSURE CONTROL

Removal
Warnings

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section:
• Engine Electrical
• Aftertreatment System
 EXHAUST BACK PRESSURE CONTROL 259

Air Control Valve (ACV)

Figure 189 Early production ACV

1. 10-way electrical connector
2. Air Control Valve (ACV) housing

Figure 190 Updated ACV with pigtail harness

1. Pigtail harness
2. Air Control Valve (ACV)

NOTE: Various Air Control Valves (ACV) have been used on this engine. Early production ACVs have the 10-way
electrical connector (Figure 189) (Item 1) on the ACV housing (Figure 189) (Item 2) , and updated 3-bolt ACVs
(Figure 190) (Item 2) have a pigtail harness (Figure 190) (Item 1) that relocates the 10-way pigtail connector.
NOTE: If engine has an early production 2-bolt EGRV coolant supply tube (Figure 197), install a new 3-bolt
EGRV coolant supply tube (Figure 198).
260 EXHAUST BACK PRESSURE CONTROL

Figure 191 Early production 3-bolt Air Control Valve (ACV), bolts, and tube connections
1. ACV (early production)
2. M8 x 65 bolt (if equipped)
3. M8 x 85 bolt (2)
4. Air supply tube nut
5. Exhaust back pressure tube nut
6. Exhaust back pressure valve tube
7. TC1TOP sensor tube nut
8. TC1 turbine outlet pressure (TC1TOP) sensor tube
9. High-pressure wastegate actuator hose
10. Crimp clamp

CAUTION: Relieve system pressure before loosening air supply tube valve.
1. Loosen air supply tube nut (Figure 191) (Item 4) from ACV (Figure 191) (Item 1). Disconnect air supply tube.
2. Remove crimp clamps (Figure 191) (Item 10 that secures High-pressure (HP) and Low-pressure (LP) (if
equipped) wastegate actuator hoses (Figure 191) (Item 9). Discard crimp clamps and disconnect hoses
from the ACV.
3. Loosen TC1TOP sensor tube nut (Figure 191) (Item 7) and exhaust back pressure tube nut (Figure 191)
(Item 5). Disconnect tubes from ACV.
NOTE: The LP wastegate actuator is installed only on early production models, is not functional, and the hose
can be removed and left off.
4. If equipped, remove and discard the LP wastegate actuator hose.
5. Remove one M8 x 65 bolt (Figure 191) (Item 2) (if equipped), two M8 x 85 bolts (Figure 191) (Item 3), and
ACV.
 EXHAUST BACK PRESSURE CONTROL 261

Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes

Figure 192 Exhaust back pressure valve actuator and TC1 turbine outlet pressure (TC1TOP) sensor
tubes
1. Exhaust back pressure valve tube nut
2. Exhaust back pressure valve actuator
3. TC1TOP sensor tube nut
4. M10 x M12 flare fitting (24 degree)

1. Loosen exhaust back pressure valve tube nut from exhaust back pressure valve actuator and disconnect
tube.
2. Loosen TC1TOP sensor tube nut from low-pressure turbocharger housing flare M10 x M12 (24 degree)
fitting and disconnect tube.
3. If necessary, remove M10 x M12 flare fitting (24 degree).
262 EXHAUST BACK PRESSURE CONTROL

Figure 193 TC1TOP sensor tube and exhaust back pressure valve tube (typical)
1. TC1TOP sensor tube bracket
2. TC1TOP sensor tube
3. Exhaust back pressure valve tube
4. M6 x 40 bolt (2)
5. Exhaust back pressure valve tube bracket (2)

4. Remove two M6 x 40 bolts, exhaust back pressure valve tube and TC1TOP sensor tube.
 EXHAUST BACK PRESSURE CONTROL 263

Exhaust Back Pressure Valve Assembly

Figure 194 Exhaust back pressure valve Assembly

1. Heat shield
2. M8 x 16 bolt (2)
3. Heat shield spacer
4. M8 x 45 bolt (7)
5. Spacer (5)
6. Exhaust back pressure valve assembly

1. Remove two M8 x 16 bolts that secure the heat shield to the HP turbocharger and exhaust back pressure
valve assembly.
2. Remove heat shield.
3. Remove seven M8 x 45 bolts, the heat shield spacer, five spacers, and exhaust back pressure valve
assembly.
264 EXHAUST BACK PRESSURE CONTROL

Installation
Exhaust Back Pressure Valve Assembly

Figure 195 Exhaust back pressure valve Assembly

1. Heat shield
2. M8 x 16 bolt (2)
3. Heat shield spacer
4. M8 x 45 bolt (7)
5. Spacer (5)
6. Exhaust back pressure valve assembly

1. Position the exhaust back pressure valve assembly, install five spacers, the heat shield spacer, and seven
M8 x 45 bolts.
2. Tighten M8 x 45 bolts to standard torque (page 881).
3. Position heat shield, and install two M8 x 16 bolts. Tighten M8 x 16 bolts to standard torque (page 881).
 EXHAUST BACK PRESSURE CONTROL 265

Figure 196 Exhaust back pressure valve actuator lubrication points

4. Apply Superlub™ synthetic high heat lubricant (page 272) or equivalent to areas indicated.
266 EXHAUST BACK PRESSURE CONTROL

Air Control Valve (ACV)

NOTE: Early production 2-bolt Air Control Valves (ACVs) that have the 10-way electrical connector on the ACV
housing , should not be updated with 3-bolt ACVs that have a pigtail harness unless the valve has failed.

Figure 197 EGRV coolant supply tube and EGR cooler (2-bolt early production)
1. EGRV coolant supply tube assembly (Early production)
2. EGR cooler casting rib

Figure 198 EGRV coolant supply tube and EGR cooler (Updated 3-bolt version)
1. EGR cooler third ACV mounting bolt boss (if equipped)
2. EGRV coolant supply tube assembly (updated version)
 EXHAUST BACK PRESSURE CONTROL 267

1. Determine if the EGRV coolant supply tube assembly (Figure 197) (Item 1) is the early production 2-bolt
version (Figure 197)(Item 2) or the updated 3-bolt version (Figure 198) (Item 1).
• If engine has an early production 2-bolt EGRV coolant supply tube assembly, obtain EGRV Coolant
Supply Tube Kit and install a new updated 3-bolt EGRV coolant supply tube assembly.

Figure 199 Air control valve tubes and hoses

1. Air Control Valve (ACV)
2. M8 x 65 bolt
3. M8 x 85 bolt (2)

2. Position new ACV onto the EGR cooler and install two saved M8 x 85 bolts finger tight. Tighten bolts to 23
lb·ft (31 N·m).
• If EGR cooler has a third ACV mounting bolt boss, install new M8 x 65 bolt. Tighten bolt to 23 lb·ft (31
N·m).
• If EGR cooler does not have a third ACV mounting bolt boss, the M8 x 65 bolt is not used.
268 EXHAUST BACK PRESSURE CONTROL

Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes

Figure 200 Exhaust back pressure valve actuator and TC1 turbine outlet pressure (TC1TOP) sensor
tubes
1. Exhaust back pressure valve tube nut
2. Exhaust back pressure valve actuator
3. TC1TOP sensor tube nut
4. M10 x M12 flare fitting (24 degree)

1. Install exhaust back pressure valve tube nut (Figure 200) (Item 1) onto exhaust back pressure valve actuator
(Figure 200) (Item 2). Leave loose at this time.
2. If removed, install and tighten M10 x M12 flare fitting (24 degree) (Figure 200) (Item 4) to 13 lb·ft (17.5 N·m).
3. Position TC1TOP sensor tube nut (Figure 200) (Item 3) to low-pressure turbocharger housing M10 x M12
flare fitting (24 degree). Leave loose at this time.
 EXHAUST BACK PRESSURE CONTROL 269

Figure 201 TC1TOP sensor tube and exhaust back pressure valve tube (typical)
1. TC1TOP sensor tube bracket
2. TC1TOP sensor tube
3. Exhaust back pressure valve tube
4. M6 x 40 bolt (2)
5. Exhaust back pressure valve tube bracket (2)

4. Position exhaust back pressure valve tube (Figure 201) (Item 3) and TC1TOP sensor tube (Figure 201)
(Item 2) against EGR cooler. Using two M6 x 40 bolts (Figure 201) (Item 4) and two spacers, secure tubes
to EGR cooler. Tighten bolts to 115 lb·in (13 N·m).

Figure 202 Air control valve tubes and hoses

1. M8 x 65 bolt
2. M8 x 85 bolt (2)
3. Low-pressure wastegate actuator port (not used)
4. Air supply (from air tank)
5. Exhaust back pressure valve tube
6. High-pressure (HP) wastegate actuator
7. Pressure sensor tube assembly [Turbocharger 1 Turbine Outlet Pressure (TC1TOP)]
270 EXHAUST BACK PRESSURE CONTROL

5. Connect exhaust back pressure valve tube (Figure 202) (Item 5) and pressure sensor tube assembly
(TC1TOP) (Figure 202) (Item 7) to ACV. Tighten tube nuts to 133 lb·in (15 N·m).
6. Connect air supply (Figure 202) (Item 4) to ACV. Tighten air supply tube nut to 106 lb·in (12 N·m).
7. Slide a new crimp clamp onto HP wastegate actuator hose and connect hose to ACV. Secure hose with
crimp clamp using Clamp Pliers (LIS30800).
NOTE: The LP wastegate actuator is installed only on early production models, is not functional, and the hose
can be removed and left off.

Figure 203 ACV pigtail harness attachment locations

1. Exhaust back pressure valve tube
2. ACV boss
3. High temperature tie strap (2)
4. Turbocharger 1 Turbine Outlet Pressure (TC1TOP) port

8. Install fir tree connector into ACV boss (Figure 203) (Item 2).
9. Install high temperature tie strap (Figure 203) (Item 3) around TC1TOP port (Figure 203) (Item 4) and ACV
pigtail harness.
10. Install high temperature tie strap around exhaust back pressure valve tube (Figure 203) (Item 1) and ACV
pigtail harness.
 EXHAUST BACK PRESSURE CONTROL 271

Figure 204 ACV harness routing and tie strap locations

1. Tie straps (2) 4. M6-M8 zip-tie harness retainer 6. ACV harness 10–way connector
2. Engine harness 5. Engine harness 10–way
3. M8 x 50 stud connector

11. Push ACV harness 10-way connector (Figure 204) (Item 6) onto the engine harness 10-way connector
(Figure 204) (Item 5) until a click is heard, and pull gently to verify that the 10-way connector is securely
latched.
12. Install M6-M8 zip-tie harness retainer (Figure 204) (Item 4) to ACV harness 10-way connector.
13. Secure ACV harness and engine harness with two tie straps (Figure 204) (Item 1) as shown.
14. Attach M6-M8 zip-tie harness retainer to M8 x 50 stud (Figure 204) (Item 3).
15. Cut all tie straps flush to head.
272 EXHAUST BACK PRESSURE CONTROL

Special Torque

Air supply tube (at bulkhead fitting) 17.5 N·m (13 lb·ft)
Air supply tube nut (at air control valve) 12 N·m (106 lb·in)
Exhaust back pressure valve tube nut (at actuator) 15 N·m (11 lb·ft)
Exhaust back pressure valve tube nut (at air control valve) 15 N·m (11 lb·ft)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lb·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lb·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting 15 N·m (11 lb·ft)

Special Service Tools

Description Tool Number

Crimping pliers Obtain locally
Superlub™ synthetic high heat lubricant Obtain locally
 TURBOCHARGERS 273

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275

Turbochargers and Charge Air Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Coolant Tube, Coolant Hoses and Low-Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . .276
Turbocharger Oil Supply Tube and Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Turbocharger Oil Return Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Air Inlets, Wastegate High-Pressure Actuator, and Air Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280

Removal (Complete Engine Teardown). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281

High-Pressure (HP) Wastegate Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
Low-Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
High-Pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
High-Pressure (HP) Turbocharger Wastegate Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300

Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301

Turbochargers and Related Parts Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
High-Pressure (HP) Turbocharger Turbine Housing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Turbocharger Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Low-Pressure Charge Air Cooler (LPCAC) Pressure Test — correction. . . . . . . . . . . . . . . . . . . . . . . . . . .304
High-Pressure Charge Air Cooler (HPCAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
High-Pressure Charge Air Cooler (HPCAC) Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
High-Pressure (HP) Turbocharger Wastegate Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
High-Pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .334
High-Pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .335
Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .336
Low-Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
High-Pressure (HP) Wastegate Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343

274 TURBOCHARGERS
 TURBOCHARGERS 275

Exploded Views
Turbochargers and Charge Air Cooler Assembly

Figure 205 Turbochargers and charge air cooler assembly.

1. Rear exhaust manifold 8. Cab heater return tube assembly 14. Low-Pressure Charge Air Cooler
2. High-pressure turbocharger 9. M8 x 20 bolt (LPCAC)
assembly 10. M6 x 20 bolt 15. Low-Pressure (LP) turbocharger
3. High-pressure wastegate hose 11. Inlet (and outlet) high-pressure assembly
4. Air inlet duct compressor seal 16. High-pressure wastegate
5. High-Pressure (HP) 12. M10 x 20 x 40 stud bolt (2) actuator
turbocharger air supply duct 13. High-pressure (HP) compressor 17. Turbocharger oil supply tube
6. O-ring out duct assembly
7. M8 x 16 bolt
276 TURBOCHARGERS

Coolant Tube, Coolant Hoses and Low-Pressure Charge Air Cooler (LPCAC)

Figure 206 Coolant tube, coolant hoses and Low-Pressure Charge Air Cooler (LPCAC).
1. LPCAC air inlet 8. Coolant return hose (at EGR 16. 72.2 x 60 (DMR) tube seal
2. Intake O-ring (low-pressure cooler) (extension tube)
turbocharger to LPCAC) 9. Coolant tube (EGR cooler to 17. LPCAC air outlet (to HP
3. Low-Pressure Charge Air Cooler LPCAC) turbocharger air supply duct)
(LPCAC) 10. Tube support 18. Coolant hose (coolant tube to
4. Coolant return hose (CAC to 11. High-Pressure (HP) CAC water inlet)
coolant return duct) turbocharger air supply duct 19. M10 x 100 bolt
5. M24 x 1.5 threaded fitting (2) 12. M10 x 200 bolt (2) 20. Ground stud bolt (2)
6. Coolant return duct (integral with 13. M8 x 20 bolt 21. EGR cooler assembly
air supply duct) 14. Coolant return hose (to water
7. 3/4 inch constant torque hose distribution housing)
clamp (7) 15. Hose clamp (1 inch worm gear)
 TURBOCHARGERS 277

Turbocharger Oil Supply Tube and Support Bracket

Figure 207 Turbocharger oil supply tube and support bracket.

1. Low-pressure turbocharger oil 4. M6 X 16 bolt (2) 10. M8 X 40 Bolt
supply port 5. Oil supply tube 11. M8 X 16 bolt
2. High-pressure turbocharger oil 6. Oil supply tube bracket
supply port 7. Oil supply tube T-fitting flare nut
3. High-pressure turbocharger 8. Turbocharger supply seal (2)
assembly 9. 19 x 20 spacer (2)
278 TURBOCHARGERS

Turbocharger Oil Return Tubes

Figure 208 Turbocharger oil return tubes.

1. High-Pressure (HP) 4. Oil return high-pressure 7. Oil return low-pressure
turbocharger assembly turbocharger tube turbocharger tube
2. Turbocharger oil drain gasket (2) 5. Metric bonded seal washer 8. Low-Pressure (LP) turbocharger
3. M8 x 20 bolt (4) 6. 24.7 x 32 seal ring assembly
 TURBOCHARGERS 279

Air Inlets, Wastegate High-Pressure Actuator, and Air Control Valve

Figure 209 Air inlets, wastegate high-pressure actuator, and air control valve.
1. Air Control Valve (ACV) 6. Plug (if equipped) 12. Inlet low-pressure compressor
assembly 7. Air inlet duct seal
2. 12.3 x 7 crimp clamp (2) 8. High-Pressure (HP) 13. High-Pressure (HP)
3. High-pressure wastegate hose turbocharger air supply duct turbocharger wastegate actuator
4. Cable lock strap (3) 9. Seal ring (2)
5. Inlet high-pressure compressor 10. M24 threaded fitting (2)
seal 11. Tie strap
280 TURBOCHARGERS

Turbochargers

Figure 210 Turbochargers.

1. M8 x 16 bolt (3) 5. High-Pressure (HP) 10. High-Pressure (HP)
2. High-pressure turbocharger heat turbocharger turbine housing turbocharger wastegate actuator
shield 6. Dowel pin (2) 11. Turbocharger heat shield
3. 10.5 x 20 x 15 sleeve (2) 7. M10 x 45 stud 12. M8 x 16 bolt (2)
4. High-Pressure (HP) 8. M10 nut (3) 13. M10 x 55 bolt (5)
turbocharger center section 9. M8 x 14 bolt (6) 14. Low-Pressure (LP) turbocharger
assembly
 TURBOCHARGERS 281

Removal (Complete Engine Teardown)

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
282 TURBOCHARGERS

High-Pressure (HP) Wastegate Hose

Figure 211 High-Pressure (HP) wastegate Hose.

1. Tie strap
2. Cable lock strap (3)
3. High-Pressure (HP) wastegate hose
4. High-Pressure (HP) wastegate
5. 12.3 x 7 crimp clamp

1. Cut and remove crimp clamp on HP wastegate hose on HP wastegate actuator and discard crimp clamp.
2. Cut and discard three cable lock straps.
3. Note routing of HP wastegate hose for later reassembly. Remove HP wastegate hose.
4. Inspect HP wastegate hose for damage or deformation and replace if necessary.
 TURBOCHARGERS 283

Low-Pressure Charge Air Cooler (LPCAC)

Figure 212 LPCAC and coolant hose connections.

1. Coolant hose (supply)
2. M10 x 100 bolt
3. Low-Pressure Charge Air Cooler (LPCAC)
4. M10 stud bolt (2)
5. 3/4 inch constant torque hose clamp (2)
6. Coolant return hose

NOTE: See Oil Centrifuge (page 461) for removal of the open breather tube assembly and related components.
1. Loosen 3/4 inch hose clamp and disconnect coolant hose (supply) from LPCAC.
2. Loosen 3/4 inch hose clamp and disconnect coolant return hose from LPCAC.
3. Remove M10 x 100 bolt from LPCAC.
4. Remove two M10 stud bolts from LPCAC.
5. Pull down to separate LPCAC from LP turbocharger and air supply HP turbocharger duct.
284 TURBOCHARGERS

Figure 213 LPCAC connections.

1. O-ring seal
2. LPCAC air inlet
3. 72.2 x 60 (DMR) tube seal (extension tube)
4. LPCAC air outlet
5. LPCAC
6. Coolant return
7. Coolant supply

6. Remove LPCAC from engine.

CAUTION: To prevent engine damage, do not remove extension tube by grabbing sealing surface.
7. Remove 72.2 x 60 (DMR) tube seal (extension tube) from LPCAC. Do so by inserting pry bar handle (or
wooden dowel) into tube seal and carefully prying side-to-side to lift tube from LPCAC. Inspect sealing
surfaces of tube seal and LPCAC. Discard if damaged.
8. Remove O-ring seal from LPCAC and discard.
 TURBOCHARGERS 285

Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses

Figure 214 Coolant return hose.

1. 3/4 inch constant torque hose clamp (2)
2. Low temperature housing (EGR cooler)
3. Coolant return hose
4. Coolant tube

1. Loosen two 3/4 inch hose clamps.

2. Disconnect coolant return hose from low temperature housing and coolant tube.
286 TURBOCHARGERS

Figure 215 Coolant and cab heater tubes.

1. Cable lock strap (2)
2. Coolant tube
3. Tube support
4. M8 x 20 bolt
5. Cab heater return tube assembly
6. M6 x 20 bolt
7. 3/4 inch constant torque hose clamp

3. Cut two cable lock straps from coolant tube.

4. Remove M8 x 20 bolt to release coolant tube support and cab heater return tube assembly retainer.
5. Remove M8 x 16 bolt and tube support behind air inlet duct. Remove M6 x 20 bolt to release cab heater
return tube assembly and remove tube. Remove and discard O-ring.
6. Loosen 3/4 inch hose clamp and disconnect coolant tube from coolant hose. Remove coolant tube.
 TURBOCHARGERS 287

Figure 216 Coolant return hose (at HP turbocharger air supply duct).
1. 3/4 inch constant torque hose clamp
2. Coolant return hose
3. High-Pressure (HP) turbocharger air supply duct (coolant return integral with duct)

7. Loosen 3/4 inch hose clamp and disconnect coolant hose from HP turbocharger air supply duct.

Figure 217 Coolant return hose (air supply duct to water distribution housing).
1. High-Pressure (HP) turbocharger air supply duct (coolant return integral with duct)
2. 3/4 inch constant torque hose clamp
3. Water distribution housing
4. 1 inch worm gear hose clamp
5. Coolant return hose
288 TURBOCHARGERS

8. Loosen 3/4 inch hose clamp, 1 inch hose clamp and disconnect coolant return hose from air supply duct
and water distribution housing.
 TURBOCHARGERS 289

High-Pressure (HP) Compressor Out Duct and Air Inlet Duct

Figure 218 HP compressor out duct and air inlet duct.

1. Air inlet duct
2. M8 x 45 bolt
3. M10 x 20 x 40 stud bolt (2)
4. M10 x 140 bolt
5. HP compressor out duct

1. Remove two M10 x 20 x 40 stud bolts.

2. Disconnect HP compressor out duct from HP turbocharger compressor outlet. Remove from engine.
NOTE: The high-pressure compressor inlet seal is used in two places on the high-pressure compressor including
both compressor inlet and outlet.
3. Remove high-pressure compressor inlet seal from compressor out duct and discard.
4. Remove M8 x 45 bolt and M10 x 140 bolt. Remove air inlet duct from low-pressure turbocharger.
5. Remove LP compressor inlet seal from LP turbocharger compressor inlet and discard.
290 TURBOCHARGERS

High-Pressure Turbocharger Air Supply Duct

Figure 219 High-Pressure (HP) turbocharger air supply duct.

1. HP turbocharger air supply duct
2. M10 x 200 bolt (2)
3. High-pressure compressor inlet seal
4. M24 threaded fitting

1. Remove two M10 x 200 bolts and HP turbocharger air supply duct from HP turbocharger.
2. Remove HP compressor inlet seal and discard.
3. Only if required, remove M24 threaded fitting and discard seal ring.
 TURBOCHARGERS 291

Turbocharger Oil Return and Oil Supply Tubes

Overview
This section describes removal of turbocharger oil supply tubes after turbocharger oil supply tube retrofit. If
configuration does not match this section see TSI in Appendix D .
1. Remove air intake and pipe, if not already done.
2. Remove CAC pipe from high-pressure charge air cooler and high-pressure turbocharger outlet elbow, if not
already done.
3. Remove high-pressure turbocharger outlet elbow from high-pressure turbocharger, if not already done.
4. Remove air inlet duct from low-pressure turbocharger, if not already done.

Figure 220 Turbocharger oil return tubes.

1. High-Pressure (HP) turbocharger oil return tube
2. M8 x 20 bolt (4)
3. Oil return tube fittings (2)
4. Low-Pressure (LP) turbocharger oil return tube
5. 24.7 x 32 seal ring
6. Turbocharger oil drain gasket (2)

5. Loosen LP turbocharger oil return tube fitting nut from HP turbocharger oil return tube.
6. Remove four M8 x 20 bolts and disconnect HP oil return tube from HP and LP turbocharger and LP oil return
tube.
7. Remove and discard two turbocharger oil drain gaskets.
8. Remove and discard bonded seal washer between HP and LP turbocharger oil return tubes.
9. Remove LP turbocharger oil return tube from crankcase and discard 24.7 x 32 seal ring.
292 TURBOCHARGERS

Figure 221 Turbocharger Oil Supply Tube.

1. M6 X 16 bolt (2)
2. High-pressure turbocharger
3. Oil supply tube flange(s)

10. Remove two M6 X 16 bolts (Figure 221) (Item 1). Retain bolts for future use.
 TURBOCHARGERS 293

Figure 222 Heater and Cooler Line Bracket Stud Bolt.

1. M8 stud bolt

11. Remove M8 stud bolt (Figure 222) (Item 1) from heater and cooler line brackets (Figure 223) (Item 4).

Figure 223 Turbocharger Oil Supply Tube.

1. Turbocharger oil supply tube
2. Oil supply T-fitting
3. Turbocharger oil supply tube bracket
4. Heater and cooler line brackets
294 TURBOCHARGERS

CAUTION: To prevent engine damage, do not reuse turbocharger oil supply tube.
12. Remove turbocharger oil supply tube (Figure 223) (Item 1) from LP turbocharger, HP turbocharger, and oil
supply T-fitting (Figure 223) (Item 2) and discard oil supply tube.
If oil supply tube will not come out of the high-pressure turbocharger due to seizure, cut the oil supply tube
into two pieces and leave the line in high-pressure turbocharger for ease of removal, then discard oil supply
tube pieces.
 TURBOCHARGERS 295

Turbocharger Heat Shields

Figure 224 Turbocharger heat shields.

1. HP turbocharger heat shield
2. M8 x 16 bolt (4)
3. Turbocharger heat shield

1. Remove two M8 x 16 bolts and HP turbocharger heat shield.

2. Remove two M8 x 16 bolts and turbocharger heat shield.
296 TURBOCHARGERS

Turbocharger Support Bracket

Figure 225 Turbocharger support bracket.

1. Turbocharger support bracket
2. M8 x 16 bolt
3. M8 x 40 bolt
4. M8 x 40 x 15 stud bolt
5. 19 x 20 spacer (2)

1. Remove M8 x 16 bolt at bottom of LP turbocharger.

2. Remove M8 x 40 bolt, M8 x 40 x 15 stud bolt, two spacers and support bracket.
 TURBOCHARGERS 297

High-Pressure (HP) Turbocharger Wastegate Actuator

Figure 226 High-Pressure (HP) wastegate actuator.

1. M8 x 14 bolt (3)
2. HP wastegate actuator
3. C-clip

NOTE: It is not necessary to remove the HP wastegate actuator to remove the turbocharger. The turbocharger
and HP wastegate actuator can be removed as an assembly.
1. Remove C-clip from HP actuator wastegate linkage.
2. Remove three M8 x 14 bolts.
3. Remove HP wastegate actuator.
298 TURBOCHARGERS

Turbocharger Mounting

Figure 227 HP turbocharger mounting (lower nut).

1. HP turbocharger assembly
2. M10 nut
3. M10 x 45 stud

WARNING: To prevent personal injury or death, use suitable lifting equipment and get help to
remove or install the turbochargers.
1. Get help from an assistant to support turbochargers during removal. Remove M10 nut.
 TURBOCHARGERS 299

Figure 228 High-Pressure (HP) turbocharger mounting (upper nuts and sleeves).
1. M10 nut (2)
2. 10.5 x 20 x 15 sleeve (2)
3. HP turbocharger mounting flange

2. Remove two M10 nuts and two 10.5 x 20 x 15 sleeves.

3. Remove turbochargers from middle exhaust manifold.
300 TURBOCHARGERS

Disassembly
Turbochargers

Figure 229 High-Pressure (HP) and Low-Pressure (LP) turbocharger connection.

1. M10 x 55 bolt (5)
2. HP turbocharger assembly
3. LP turbocharger assembly

1. Remove five M10 x 55 bolts and separate HP turbocharger from LP turbocharger.

2. Inspect mating flanges and two dowel pins for damage. Replace if necessary.
 TURBOCHARGERS 301

Cleaning, Inspection, and Testing

Turbochargers and Related Parts Cleaning

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 30 psi (207 kPa).
NOTE: Do not use a caustic solution on turbochargers and related components.
1. Clean ducting between air inlet duct and air cleaner assembly with soap and then, steam clean. Dry all
ducting with filtered compressed air.
2. Clean Low-Pressure Charge Air Cooler (LPCAC), air inlet duct, and high-pressure turbocharger duct with
filtered compressed air.
NOTE: Do not reuse turbocharger oil supply tube. Install new.
3. Clean turbocharger oil return tube with a non-chlorinated solvent and a nylon brush. Dry tubes with filtered
compressed air. Replace any damaged tubes.
4. Clean all gasket and O-ring sealing surfaces.
302 TURBOCHARGERS

High-Pressure (HP) Turbocharger Turbine Housing Cleaning

Figure 230 HP Turbocharger Turbine Housing.

1. HP turbocharger turbine housing
2. HP turbocharger turbine housing exterior flange

1. Using suitable solvent and clean emery cloth, clean inside HP turbocharger turbine housing (Figure 230)
(Item 1) and HP turbocharger turbine housing exterior flange (Figure 230) (Item 2).
 TURBOCHARGERS 303

Turbocharger Inspection
CAUTION: To prevent engine damage, do not damage compressor impeller or turbine wheel. If either is
damaged, a new turbocharger must be installed.
1. Inspect turbochargers for cracks. Replace if necessary.
2. Inspect compressor impellers and turbine wheels for blade erosion, bends, breakage, or deposits. Replace
turbochargers if damaged.
NOTE: Replace turbochargers if blades are bent. Do not attempt to straighten bent impeller or turbine wheel
blades.
3. Turn shafts by hand and check for impeller and wheel rub in the housings.
304 TURBOCHARGERS

Low-Pressure Charge Air Cooler (LPCAC) Pressure Test — correction

Figure 231 Charge Air Cooler Test Kit ZTSE6042

1. Coolant Port Plug (with 1/4” NPT hole), ZTSE6042-1
2. Coolant Port Plug (solid), ZTSE6042-2
3. Air Inlet Plug (with 1/4” NPT hole), ZTSE6042-3
4. Air Outlet Disc Plug, ZTSE6042-4
5. Air Outlet Disc Plug Retaining Bracket, ZTSE6042-4A
6. empty — delete

1. Remove LPCAC from engine.

WARNING: To prevent personal injury or death, ensure Charge Air Cooler Test Kit components are
tightened properly; otherwise, they can explode while LPCAC is under pressure.

WARNING: To prevent personal injury or death, ensure LPCAC air inlet and outlet, O-rings are
removed and that no lubricant is on sealing surface. O-ring and lubricant can cause the LPCAC Pressure
Test Kit components to explode while LPCAC is under pressure.
 TURBOCHARGERS 305

Figure 232 Pressure test on air side of LPCAC

1. LPCAC air outlet
2. LPCAC coolant return port
3. LPCAC coolant supply port
4. LPCAC air inlet

2. Attach Charge Air Cooler Test Kit to LPCAC.

• Obtain 3-inch couplers and clamps locally.
3. Cover LPCAC air outlet (Figure 232) (Item 1) with Air Outlet Disc Plug ZTSE6042-4.
4. Install Air Outlet Disc Plug Retaining Bracket ZTSE6042-4A on top of ZTSE6042-4. Tighten clamping bolt
to seal LPCAC air outlet.
5. Attach Air Inlet Plug (with 1/4″ NPT hole) ZTSE6042-3 to LPCAC air inlet (Figure 232) (Item 4), and tighten
clamps.
6. Attach Coolant Port Plug (solid) ZTSE6042-2 to LPCAC coolant return port (Figure 232) (Item 2). Tighten
clamp.
7. Attach Coolant Port Plug (with 1/4″ NPT hole) ZTSE6042-1 to LPCAC coolant supply port (Figure 232) (Item
3). Tighten clamp.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 30 psi (207 kPa).
8. Connect locally obtained regulator with shop air source, and pressurize the air side of LPCAC to 30 psi (207
kPa).
9. Spray a soapy water solution on LPCAC. Look for leaks from hose connections, LPCAC, or test components.
10. If a leak is detected on LPCAC or test gauge pressure drops, replace LPCAC.
306 TURBOCHARGERS

Figure 233 Pressure test on coolant side of Low-Pressure Charge Air Cooler (LPCAC)
1. LPCAC air outlet
2. LPCAC coolant return port
3. LPCAC coolant supply port
4. LPCAC air inlet

11. Connect regulator with shop air source, and pressurize the coolant side of LPCAC to 30 psi (207 kPa).
12. Spray a soapy water solution on LPCAC. Look for leaks from hose connections, LPCAC, or test components.
13. If a leak is detected on LPCAC or test gauge pressure drops, replace LPCAC.
14. Remove Charge Air Cooler Test Kit from LPCAC.
 TURBOCHARGERS 307

High-Pressure Charge Air Cooler (HPCAC) Pressure Test

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 234 CAC Cleaning Adapter Kit (Off Chassis) 09-925-01 With CAC Pressure Test Kit ZTSE4341
Installed
1. CAC Pressure Test Kit ZTSE4341

NOTE: Optional Charge Air Cooler (CAC) Pressure Test Kit ZTSE4341 (Figure 234) (Item 1) shown installed
in the CAC Cleaning Adapter Kit 09-925-01 carrying case. CAC Pressure Test Kit is not part of CAC Cleaning
Adapter Kit , but allows for storage in the carrying case.
1. Remove High-Pressure Charge Air Cooler (HPCAC) from vehicle. See appropriate Radiator / Cooling
System Service Manual.
2. Place HPCAC on a flat surface.
3. Visually inspect HPCAC for cracks, holes, and other damage. If cracked or damaged, replace HPCAC.

WARNING: To prevent personal injury or death, clean all hoses and other pressure test
components of oil, grease, or other lubricants before connecting.
308 TURBOCHARGERS

Figure 235 CAC Pressure Test Kit Installed on HPCAC Outlet

1. Gauge / regulator assembly
2. Quick disconnect fitting
3. Gauge coupler
4. T-clamp (2)
5. Large hose
6. High-Pressure Charge Air Cooler (HPCAC) outlet
7. Safety cable

4. Install large hose (Figure 235) (item 5) and T-clamp onto HPCAC outlet (Figure 235) (item 6). Tighten
T-clamp (Figure 235) (item 4) securing large hose to HPCAC outlet to 55 lb·in (6.2 N·m).
5. Install gauge coupler (Figure 235) (item 3) and T-clamp onto large hose. Tighten T-clamp securing gauge
coupler to large hose to 55 lb·in (6.2 N·m).
6. Connect safety cable (Figure 235) (item 7) to a known good anchor point.
7. Attach gauge / regulator assembly (Figure 235) (item 1) onto quick disconnect fitting (Figure 235) (item 2).
 TURBOCHARGERS 309

Figure 236 Bleed-Off Coupler Installed On HPCAC Inlet

1. Safety cable
2. Bleed-off coupler
3. T-clamp (2)
4. Small hose
5. High-Pressure Charge Air Cooler (HPCAC) Inlet

8. Install small hose (Figure 236) (Item 4) and T-clamp (Figure 236) (Item 3) onto HPCAC inlet (Figure 236)
(Item 5). Tighten T-clamp (Figure 236) (Item 3) securing small hose to HPCAC inlet to 55 lb·in (6.2 N·m).
9. Install bleed-off coupler (Figure 236) (Item 2) and T-clamp onto small hose. Tighten T-clamp securing
bleed-off coupler to small hose to 55 lb·in (6.2 N·m).
10. Connect safety cable (Figure 236) (Item 1) to a known good anchor point.
310 TURBOCHARGERS

Figure 237 Gauge / Regulator Assembly Connections

1. Air valve
2. Air regulator knob
3. Gauge

WARNING: To prevent personal injury or death, attach safety cables to High-Pressure Charge Air
Cooler (HPCAC) or a known good anchor point.
CAUTION: Adjust air regulator valve to minimum setting before connecting shop air supply. Accidentally applying
high-pressure can damage tool components or the High-Pressure Charge Air Cooler (HPCAC).
11. Connect filtered shop air supply to air valve (Figure 237) (item 1) on gauge / regulator assembly.

WARNING: To prevent personal injury or death, increase air pressure slowly to prevent coupler
blowing-out during testing.
12. Open air valve slightly, and slowly increase air pressure until gauge (Figure 237) (Item 3) reads 30 psi (205
kPa). If needed, adjust air regulator knob (Figure 237) (Item 2) as follows until gauge reads 30 psi (205 kPa):
a. Pull air regulator knob outward to unlock.
b. Turn air regulator knob to adjust pressure to 30 psi (205 kPa).
c. Push air regulator knob inward back into locked position.
13. Close air valve and monitor gauge pressure for 15 seconds.
• If air pressure drops more than 5 psi (34 kPa), replace HPCAC.
• If air pressure drops 5 psi (34 kPa) or less, perform cleaning procedure. See High-Pressure Charge Air
Cooler (HPCAC) Cleaning (page 314)
14. Repeat steps 12 and 13 three times to verify results.
 TURBOCHARGERS 311

Figure 238 Bleed-Off Coupler Components

1. Bleed-off coupler
2. Bleed-off valve

WARNING: To prevent personal injury or death, relieve air pressure through bleed-off valve slowly
before removing test equipment.
15. Slowly turn bleed-off valve (Figure 238) (Item 2) on bleed-off coupler (Figure 238) (Item 1) counterclockwise,
and release air from system.
16. Disconnect filtered shop air supply from air valve on gauge / regulator assembly.
312 TURBOCHARGERS

Figure 239 Bleed-Off Coupler Installed On HPCAC Inlet

1. Safety cable
2. Bleed-off coupler
3. T-clamp (2)
4. Small hose
5. High-Pressure Charge Air Cooler (HPCAC) inlet

17. Disconnect safety cable (Figure 239) (Item 1) from anchor point.
18. Remove bleed-off coupler (Figure 239) (Item 2) and T-clamp (Figure 239) (Item 4) from small hose.
19. Remove small hose (Figure 239) (item 4) and T-clamp from HPCAC inlet (Figure 239) (item 5).
 TURBOCHARGERS 313

Figure 240 CAC Pressure Test Kit Installed on HPCAC Outlet

1. Gauge / regulator assembly
2. Quick disconnect fitting
3. Gauge coupler
4. T-clamp (2)
5. Large hose
6. High-Pressure Charge Air Cooler (HPCAC) outlet
7. Safety cable

20. Remove gauge / regulator assembly (Figure 240) (item 1) from quick disconnect fitting (Figure 240) (item 2).
21. Remove safety cable (Figure 240) (item 7) from anchor point.
22. Remove gauge coupler (Figure 240) (item 3) and T-clamp (Figure 240) (Item 4) from large hose (Figure 240)
(Item 5).
23. Remove large hose and T-clamp from HPCAC outlet (Figure 240) (item 6).
314 TURBOCHARGERS

High-Pressure Charge Air Cooler (HPCAC) Cleaning

Figure 241 Cleaning Management System 12-353-01 Components

1. Timer 12-353-01-01
2. Heater 12-353-01-8
3. FLOW FROM PUMP hose 12-353-01-02
4. Front EGR cooler cleaning adapter 12-353-01-04
5. Cam-lock cap 12-353-01-06
6. Rear EGR cooler cleaning adapter 12-353-01-05
7. FLOW RETURN hose 12-353-01-3
8. Air blower 12-353-01-7
9. Container 12-353-01-17
10. HEATER / PUMP Switch Assembly 12-353-01-9

1. Clean the Cleaning Management System container (Figure 241) (Item 9) before use.
 TURBOCHARGERS 315

Figure 242 CMS Filter and Components

1. Filter sock
2. Coupler
3. Flow return tube

2. Inspect and clean the filter sock (Figure 242) (Item 1). Replace as needed.
a. Loosen coupler (Figure 242) (Item 2) on flow return tube (Figure 242) (Item 3).
b. Remove filter from coupler.
c. Install filter in coupler.
d. Tighten coupler on flow return tube. Torque only needs to be hand tight.

Figure 243 Level Gauge

316 TURBOCHARGERS

3. Add 5 US gal (19L) of tap water to Cleaning Management System (CMS) reservoir first, followed by 5 US
gal (19L) of EGR cleaning fluid 2512460C1.
4. Turn On the heating element by positioning PUMP / HEATER switch (Figure 241) (Item 10) CMS to HEATER.
Allow temperature to reach approximately 130°F (54°C).
NOTE: If not already done, remove High-Pressure Charge Air Cooler (HPCAC) from vehicle and place on a flat
surface. See appropriate Radiator / Cooling System Service Manual.
 TURBOCHARGERS 317

Figure 244 CAC Cleaning Adapter Kit 09-925-01 Installed on HPCAC Outlet
1. CAC adapter 09-925-01-01
2. T-clamp (2)
3. Large hose
4. High-Pressure Charge Air Cooler (HPCAC) outlet

5. With High-Pressure Charge Air Cooler (HPCAC) on a flat surface, install large hose (Figure 244) (item 3)
and T-clamp (Figure 244) (item 2) onto HPCAC outlet (Figure 244) (item 4). Tighten T-clamp securing large
hose to HPCAC outlet to 55 lb·in (6.2 N·m).
6. Install CAC adapter (Figure 244) (item 1) and T-clamp onto large hose. Tighten T-clamp securing CAC
adapter to large hose to 55 lb·in (6.2 N·m).
318 TURBOCHARGERS

Figure 245 CAC Cleaning Adapter Kit 09-925-01 Installed on HPCAC Inlet
1. CAC adapter 09-925-01-01
2. Small hose
3. High-Pressure Charge Air Cooler (HPCAC) inlet
4. T-clamp (2)

7. Install small hose (Figure 245) (item 2) and T-clamp (Figure 245) (item 4) onto HPCAC inlet (Figure 245)
(item 3). Tighten T-clamp securing small hose to HPCAC inlet to 55 lb·in (6.2 N·m).
8. Install CAC adapter (Figure 245) (item 1) and T-clamp onto small hose. Tighten T-clamp securing CAC
adapter to small hose to 55 lb·in (6.2 N·m).
 TURBOCHARGERS 319

Figure 246 FLOW FROM PUMP Hose Connected

1. FLOW FROM PUMP hose
2. Lever (2)
3. CAC adapter

Back-Flush With Water and EGR Cleaning Fluid:

9. Slide FLOW FROM PUMP hose (Figure 246) (item 1) onto CAC adapter (Figure 246) (item 3) until it bottoms
out. Then push both levers (Figure 246) (item 2) on FLOW FROM PUMP hose inward to secure FLOW
FROM PUMP hose to CAC adapter. Pull outward on FLOW FROM PUMP hose to verify it is securely
attached.
320 TURBOCHARGERS

Figure 247 FLOW RETURN Hose Connected

1. CAC adapter
2. Pin (2)
3. Lever (2)
4. FLOW RETURN hose

10. Slide FLOW RETURN hose (Figure 247) (item 4) onto CAC adapter (Figure 247) (item 1) until it bottoms out.
Then push both levers (Figure 247) (item 3) on FLOW RETURN hose inward to secure FLOW RETURN
hose to CAC adapter. Pull outward on FLOW RETURN hose to verify it is securely attached.
11. Set and start timer (Figure 241) (Item 1) on CMS to 20 minutes, position PUMP / HEATER switch (Figure
241) (Item 10) to PUMP, and allow CMS to back-flush HPCAC.
12. After back-flush is complete, position PUMP / HEATER switch to OFF.
13. Press both pins (Figure 247) (item 2) inward on levers securing FLOW RETURN hose to CAC adapter, while
simultaneously pulling out on levers. Remove FLOW RETURN hose from CAC adapter.
14. Press both pins inward on levers securing FLOW FROM PUMP hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW FROM PUMP hose from CAC adapter.

Forward-Flush With Water and EGR Cleaning Fluid:

15. Slide FLOW RETURN hose onto CAC adapter until it bottoms out. Then push both levers on FLOW
RETURN hose inward to secure FLOW RETURN hose to CAC adapter. Pull outward on FLOW RETURN
hose to verify it is securely attached.
16. Slide FLOW FROM PUMP hose onto CAC adapter until it bottoms out. Then push both levers on FLOW
FROM PUMP hose inward to secure FLOW FROM PUMP hose to CAC adapter. Pull outward on FLOW
FROM PUMP hose to verify it is securely attached.
17. Set and start timer on CMS to 20 minutes, position PUMP / HEATER switch to PUMP, and allow CMS to
forward-flush HPCAC.
18. After forward-flush is complete, position PUMP / HEATER switch to OFF.
 TURBOCHARGERS 321

19. Press both pins inward on levers securing FLOW FROM PUMP hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW FROM PUMP hose from CAC adapter.
20. Press both pins inward on levers securing FLOW RETURN hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW RETURN hose from CAC adapter.
21. Drain and clean CMS.

Back-Flush With Water:

22. Add 10 US gal (38L) of tap water to Cleaning Management System (CMS) reservoir.
23. Slide FLOW FROM PUMP hose (Figure 246) (item 1) onto CAC adapter (Figure 246) (item 3) until it bottoms
out. Then push both levers (Figure 246) (item 2) on FLOW FROM PUMP hose inward to secure FLOW
FROM PUMP hose to CAC adapter. Pull outward on FLOW FROM PUMP hose to verify it is securely
attached.
24. Slide FLOW RETURN hose (Figure 247) (item 4) onto CAC adapter (Figure 247) (item 1) until it bottoms out.
Then push both levers (Figure 247) (item 3) on FLOW RETURN hose inward to secure FLOW RETURN
hose to CAC adapter. Pull outward on FLOW RETURN hose to verify it is securely attached.
25. Set and start timer on CMS to 10 minutes, position PUMP / HEATER switch to PUMP, and allow CMS to
back-flush HPCAC.
26. After back-flush is complete, position PUMP / HEATER switch to OFF.
27. Press both pins (Figure 247) (item 2) inward on levers securing FLOW RETURN hose to CAC adapter, while
simultaneously pulling out on levers. Remove FLOW RETURN hose from CAC adapter.
28. Press both pins inward on levers securing FLOW FROM PUMP hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW FROM PUMP hose from CAC adapter.
29. Tip HPCAC on it’s side, and drain remaining water into a suitable container.
30. Drain and clean CMS.

Forward-Flush With Water:

31. Slide FLOW RETURN hose onto CAC adapter until it bottoms out. Then push both levers on FLOW
RETURN hose inward to secure FLOW RETURN hose to CAC adapter. Pull outward on FLOW RETURN
hose to verify it is securely attached.
32. Slide FLOW FROM PUMP hose onto CAC adapter until it bottoms out. Then push both levers on FLOW
FROM PUMP hose inward to secure FLOW FROM PUMP hose to CAC adapter. Pull outward on FLOW
FROM PUMP hose to verify it is securely attached.
33. Set and start timer on CMS to 10 minutes, position PUMP / HEATER switch to PUMP, and allow CMS to
forward-flush HPCAC.
34. After forward-flush is complete, position PUMP / HEATER switch to OFF.
35. Press both pins inward on levers securing FLOW FROM PUMP hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW FROM PUMP hose from CAC adapter.
36. Press both pins inward on levers securing FLOW RETURN hose to CAC adapter, while simultaneously
pulling out on levers. Remove FLOW RETURN hose from CAC adapter.
37. Tip HPCAC on it’s side, and drain remaining water into a suitable container.
38. Drain and clean CMS.
322 TURBOCHARGERS

39. Dry HPCAC with filtered compressed air.

 TURBOCHARGERS 323

Installation
Turbocharger Mounting

WARNING: To prevent personal injury or death, use suitable lifting equipment and get help to
remove or install the turbochargers.

WARNING: To prevent personal injury or death, do not allow the turbochargers to hang by the
lower stud and nut alone. Support the assembly until the upper sleeves and nuts are installed.

Figure 248 Turbocharger alignment tool installation

1. Crankcase-to-cylinder head deck
2. Tab
3. Turbo Alignment Bracket (ZTSE6041)
4. Middle exhaust manifold
5. Hand screw (2)

1. Install Turbo Alignment Bracket ZTSE6041 (Figure 248) (Item 3) on engine with tabs (Figure 248) (Item 2)
seated on crankcase-to-cylinder head deck (Figure 248) (Item 1).
2. Thread tool hand screws (Figure 248) (Item 5) into crankcase boss and tighten to secure bracket in place.
324 TURBOCHARGERS

Figure 249 High-Pressure (HP) turbocharger mounting stud alignment (engine not shown)
1. M10 nut (2)
2. 10.5 x 20 x 15 sleeve (2)
3. Middle exhaust manifold
4. Upper mounting stud (2)
5. HP turbocharger
6. M10 nut
7. M10 x 45 stud

3. With help of an assistant, align three studs (Figure 249) (Items 4, 7) and position HP turbocharger (Figure
249) (Item 5) to middle exhaust manifold (Figure 249) (Item 3).
4. With turbocharger supported in place, install two 10.5 x 20 x 15 sleeves (Figure 249) (Item 2) and two new
M10 nuts (Figure 249) (Item 1) on upper mounting studs (Figure 249) (Item 4). Finger-tighten nuts.
5. Install new M10 nut (Figure 249) (Item 6) on M10 x 45 stud (Figure 249) (Item 7), finger tight.
 TURBOCHARGERS 325

Figure 250 High-Pressure (HP) turbocharger alignment check

1. Middle exhaust manifold
2. Turbo Alignment Bracket (ZTSE6041)
3. HP turbocharger
4. Turbine exhaust outlet flange

NOTE: When installing HP turbocharger, turbine exhaust outlet flange must be aligned square with turbo
alignment bracket to ensure proper installation of HP turbocharger air supply duct, HP compressor out duct,
LP turbocharger, and air inlet duct.
6. Align turbine exhaust outlet flange (Figure 250) (Item 4) square with turbo alignment bracket (Figure 250)
(Item 2).
7. With turbine exhaust outlet flange aligned square with Turbo Alignment Bracket, tighten three M10 nuts to
45 lb·ft (62 N·m).
8. Remove Turbo Alignment Bracket from engine.
326 TURBOCHARGERS

Figure 251 LP turbocharger installation

1. M10 x 55 bolt (5)
2. HP turbocharger turbine outlet flange
3. HP turbocharger assembly
4. Dowel pin (2)
5. LP turbocharger assembly

9. Align two dowel pins (Figure 251) (Item 4) and support LP turbocharger (Figure 251) (Item 5) in position on
HP turbocharger turbine outlet flange (Figure 251) (Item 2).
10. Install five new M10 x 55 bolts (Figure 251) (Item 1) and tighten to 35 lb·ft (47 N·m).
 TURBOCHARGERS 327

Turbocharger Support Bracket

Figure 252 Turbocharger support bracket.

1. Turbocharger support bracket
2. M8 x 16 bolt
3. M8 x 40 bolt
4. M8 x 40 x 15 stud bolt
5. 19 x 20 spacer (2)

CAUTION: The turbocharger support bracket must be installed; if the bracket is not installed, the
turbochargers or exhaust manifold could crack.
1. Position turbocharger support bracket and install two 19 x 20 spacers, M8 x 40 x 15 stud bolt and M8 x 40
bolt.
2. Install M8 x 16 bolt into bottom of turbocharger. Tighten three bolts to standard torque (page 881).
328 TURBOCHARGERS

High-Pressure (HP) Turbocharger Wastegate Actuator

NOTE: If HP wastegate actuator was removed from turbocharger, do the following:

WARNING: Failure to observe the following warning may cause property damage, personal injury,
or death. To prevent personal injury or death, wear safety glasses with side shields.
NOTE: Check linkage movement for the HP wastegate actuator, using a hand pump or shop air regulated to no
more than 345 kPa (50 psi).

Figure 253 High-pressure (HP) wastegate actuator.

1. M8 x 14 HP bolt (3)
2. HP wastegate actuator
3. C-clip

1. Position HP wastegate actuator with hose port facing up and install three M8 x 14 bolts.
2. Tighten three bolts to special torque (page 343).
3. Position wastegate HP actuator linkage on wastegate lever pin.
4. Install actuator linkage C-clip on wastegate lever pin.

WARNING: Failure to observe the following warning may cause property damage, personal injury,
or death. To prevent personal injury or death, wear safety glasses with side shields.
NOTE: Check linkage movement for the HP wastegate actuator, using a hand pump or shop air regulated to no
more than 345 kPa (50 psi).
5. Attach air source to HP wastegate actuator and operate actuator through full range and check for free
movement. There should be smooth operation without binding. If operation is not smooth, loosen pushrod
jam nut and retighten. Recheck movement.
 TURBOCHARGERS 329

Turbocharger Heat Shields

Figure 254 Turbocharger heat shields.

1. HP turbocharger heat shield
2. M8 x 16 bolt (4)
3. Turbocharger heat shield

1. Position turbocharger heat shield and install two M8 x 16 bolts. Tighten bolts to standard torque (page 881).
2. Install HP turbocharger heat shield and three M8 x 16 bolts. Tighten bolts to standard torque (page 881).
330 TURBOCHARGERS

Turbocharger Oil Return and Oil Supply Tubes

Overview
This section describes installation of turbocharger oil return and oil supply tubes after turbocharger oil supply
tube retrofit. If configuration does not match this section or was not completed during removal, finish installation
of TSI in Appendix D .

Figure 255 Turbocharger Oil Supply Tube.

1. Turbocharger oil supply tube
2. Oil supply T-fitting
3. Turbocharger oil supply tube bracket
4. Heater and cooler line brackets

CAUTION: To prevent engine damage, install new turbocharger oil supply tube assembly if turbocharger
oil supply tube assembly is removed.
NOTE: Do not tighten bolts or flare nuts at this time.
1. Align oil supply tube (Figure 255) (Item 1) with oil supply T-fitting (Figure 255) (Item 2) and turbocharger oil
supply openings.
2. Loosely install oil supply tube flare nut end on oil supply T-fitting.
3. Position oil supply tube bracket (Figure 255) (Item 3) between heater and cooler line brackets (Figure 255)
(Item 4).
 TURBOCHARGERS 331

Figure 256 Heater and Cooler Line Bracket Stud Bolt.

1. M8 stud bolt

4. Install M8 stud bolt (Figure 256) (Item 1) through oil supply tube bracket, heater and cooler line brackets,
and to high-pressure turbocharger air inlet duct. Torque stud bolt to 23 lb-ft (31 N·m).
332 TURBOCHARGERS

Figure 257 Turbocharger Oil Supply Tube.

1. M6 X 16 bolt (2)
2. High-pressure turbocharger
3. Oil supply tube flange(s)

5. Lubricate turbocharger oil supply tube O-rings with P-80® rubber lubricant or equivalent.
6. Press oil supply tube fittings with O-rings installed into openings on high-pressure turbocharger (Figure 257)
(Item 2) and low-pressure turbocharger.
7. Align oil supply tube flanges (Figure 257) (Item 3) and loosely install two M6 X 16 bolts (Figure 257) (Item
1). Torque bolts (2) to 10 lb·ft (13 N·m).
 TURBOCHARGERS 333

Figure 258 Oil Supply Tube T-fitting Flare Nut.

1. M8 nut
2. Engine Oil Pressure (EOP) sensor
3. Oil supply tube T-fitting flare nut

8. Install M8 nut (Figure 258) (Item 1) over supply tube bracket, heater and cooler line brackets and stud bolt
in high-pressure turbocharger air inlet duct. Torque nut to 23 lb·ft (31 N·m)
9. Install oil supply tube T-fitting flare nut (Figure 258) (Item 3) to T-fitting. Torque flare nut to 19 lb·ft (26 N·m)
10. Install LP turbocharger oil return tube with new 24.7 x 32 seal ring into crankcase. Snug fitting only until
final tightening.
11. Connect HP turbocharger oil return tube to LP turbocharger oil return tube with new bonded seal washer.
Snug fitting only until final tightening.
12. Position HP turbocharger oil return tube with new oil drain gaskets to oil return outlet flanges of LP
turbocharger and HP turbocharger.
13. Install four M8 x 20 bolts and tighten bolts to standard torque (page 881).
14. Final tighten LP turbocharger oil return tube fitting nut at crankcase fitting as follows:
a. Tighten fitting nut to 10 N·m (89 lb·in).
b. Turn fitting nut an additional 90°.
15. Final tighten HP turbocharger oil return tube fitting nut at LP turbocharger oil return tube as follows:
a. Tighten fitting nut to 10 N·m (89 lb·in).
b. Turn fitting nut an additional 90°.
334 TURBOCHARGERS

High-Pressure Turbocharger Air Supply Duct

Figure 259 High-pressure (HP) turbocharger air supply duct.

1. HP turbocharger air supply duct
2. M10 x 200 bolt (2)
3. High-pressure compressor inlet seal
4. M24 threaded fitting

1. Lubricate new high-pressure compressor inlet seal with P-80® rubber lubricant or equivalent (page 343)
and install over HP turbocharger compressor inlet groove.
2. Install HP turbocharger air supply duct along with two M10 x 200 bolts. Tighten bolts to standard torque
(page 881).
3. If previously removed, install new seal ring and M24 threaded fitting and tighten to special torque (page 343).
 TURBOCHARGERS 335

High-Pressure (HP) Compressor Out Duct and Air Inlet Duct

Figure 260 HP compressor out duct and air inlet duct.

1. Air inlet duct
2. M8 x 45 bolt
3. M10 x 20 x 40 stud bolt (2)
4. M10 x 140 bolt
5. HP compressor out duct

1. Lubricate a new LP compressor inlet seal with P-80® rubber lubricant or equivalent (page 343) and install
seal over LP turbocharger compressor inlet.
2. Install air inlet duct to LP turbocharger. Install M8 x 45 bolt and M10 x 140 bolt. Tighten bolts to standard
torque (page 881).
NOTE: The high-pressure compressor inlet seal is used in two places on the high-pressure turbocharger
compressor including both compressor inlet and outlet.
3. Lubricate new HP compressor inlet seal with P-80® rubber lubricant or equivalent (page 343) and install
into groove in compressor out duct.
4. Install HP compressor out duct into HP turbocharger air outlet, install two M10 x 20 x 40 stud bolts and
tighten to standard torque (page 881).
336 TURBOCHARGERS

Low-Pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses

Figure 261 Coolant return hose (air supply duct to water distribution housing).
1. High-pressure (HP) turbocharger air supply duct (coolant return integral with duct)
2. 3/4 inch worm gear hose clamp
3. Water distribution housing
4. 1 inch worm gear hose clamp
5. Coolant return hose

1. Install coolant return hose to water distribution housing and air supply duct. Install 3/4 inch hose clamp and
1 inch hose clamp. Tighten 3/4 inch and 1 inch hose clamps to special torque (page 343).
 TURBOCHARGERS 337

Figure 262 Coolant return hose (High-pressure turbocharger air supply duct).
1. 3/4 inch worm gear hose clamp
2. Coolant return hose
3. Air supply HP turbocharger duct (coolant return integral with duct)

2. Install coolant return hose to air supply HP turbocharger duct. Install 3/4 inch hose clamp and loosely tighten
at this time.
338 TURBOCHARGERS

Figure 263 Coolant and cab heater tubes.

1. Cable lock strap (2)
2. Coolant tube
3. Tube support
4. M8 x 20 bolt
5. Cab heater return tube assembly
6. M6 x 20 bolt
7. 3/4 inch constant torque hose clamp

3. Lubricate new cab heater return tube O-ring with P-80® rubber lubricant or equivalent (page 343).
4. Install a new O-ring onto cab heater return tube assembly.
5. Position cab heater return tube assembly and install M6 x 20 bolt and M8 x 20 bolt through tube support
behind air inlet duct. Tighten bolts to standard torque (page 881).
6. Install coolant hose onto lower end of coolant supply tube. Install 3/4 inch hose clamp onto hose and loosely
tighten at this time.
7. Position coolant tube support and cab heater return tube assembly retainer and install M8 x 20 bolt. Tighten
bolt to standard torque (page 881).
NOTE: Two cable lock straps are installed later after LP wastegate hose is installed to secure hose to coolant
tube.
 TURBOCHARGERS 339

Figure 264 Coolant return hose.

1. 3/4 inch worm gear hose clamp (2)
2. Low-temperature housing (EGR cooler)
3. Coolant return hose
4. Coolant tube

8. Install coolant hose and two 3/4 inch hose clamps between coolant tube and low-temperature housing (EGR
cooler).
9. Tighten clamps to special torque (page 343).
340 TURBOCHARGERS

Low-Pressure Charge Air Cooler (LPCAC)

Figure 265 LPCAC.

1. O-ring seal
2. LPCAC air inlet
3. 72.2 x 60 (DMR) tube seal (extension tube)
4. LPCAC air outlet
5. Low-Pressure Charge Air Cooler (LPCAC)
6. Coolant return
7. Coolant supply

1. Lubricate 72.2 x 60 (DMR) tube seal (extension tube) with P-80® rubber lubricant or equivalent (page 343)
and install into LPCAC using Extension Tube Installer (page 343).
2. Lubricate new O-ring seal with P-80® rubber lubricant or equivalent (page 343) and install O-ring at LPCAC
air inlet.
 TURBOCHARGERS 341

Figure 266 LPCAC and coolant hose connections.

1. Coolant hose (supply)
2. M10 x 100 bolt
3. LPCAC
4. Ground stud bolt (2)
5. 3/4 inch worm gear hose clamp (2)
6. Coolant return hose

3. Install LPCAC to engine until tube seal (extension tube) and O-ring are fully engaged with air duct and LP
turbocharger.
4. Install two M10 stud bolts and M10 x 100 bolt. Tighten bolts to standard torque (page 881).
5. Connect coolant return hose to LPCAC and install 3/4 inch hose clamp.
6. Tighten two coolant return hose clamps to special torque (page 343).
7. Connect coolant (supply) hose to LPCAC and install 3/4 inch hose clamp.
8. Tighten two coolant (supply) hose clamps to special torque (page 343).
342 TURBOCHARGERS

High-Pressure (HP) Wastegate Hose

Figure 267 High-pressure (HP) wastegate hose.

1. Tie strap
2. Cable lock strap (3)
3. High-pressure (HP) wastegate hose
4. High-pressure (HP) wastegate
5. 12.3 x 7 crimp clamp

NOTE: Replace HP wastegate hose if damaged or deformed.

1. Route HP hose onto engine as noted during removal.
2. Slip crimp clamp over hose and connect HP wastegate hose to HP wastegate actuator fitting.
3. Install three cable lock straps and tie strap to secure HP wastegate hose to turbocharger oil supply tube and
EGRV coolant supply tube.
4. Slip crimp clamp over hose and connect HP wastegate hose to air control valve. See "Exhaust Back
Pressure Control" for procedure.
5. Using crimping pliers (page 343), tighten the crimp clamps on each end of HP wastegate hose.
 TURBOCHARGERS 343

Special Torque

3/4 inch and 1 inch worm gear hose clamps 3.5 N·m (31 lb·in)
High-pressure-to-low-pressure turbine bolts, M10 x 55 47 N·m (35 lb·ft)
High-pressure wastegate actuator bolts, M8 x 14 16 N·m (12 lb·ft)
Male stud connector 70 N·m (52 lb·ft)
M10 Nut 62 N·m (45 lb·ft)
M24 threaded fitting 60 N·m (44 lb·ft)
See tightening steps in
Oil return low-pressure turbocharger tube (at crankcase)
procedure (page 330).
See tightening steps in
Oil return low-pressure turbocharger tube fitting nut
procedure (page 330).
Turbocharger oil supply tube assembly fitting nut to male stud connector 27 N·m (20 lb·ft)

Special Service Tools

Description Tool Number

3-inch couplers and clamps Obtain locally
Charge Air Cooler Test Kit ZTSE6042
Crimping pliers Obtain locally
Extension Tube Installer ZTSE6043
P-80® rubber lubricant or equivalent Obtain locally
Turbo Alignment Bracket ZTSE6041
Disposable Air and Fuel Caps ZTSE4891
Coolant Management Tool KL5007NAV
344 TURBOCHARGERS
 AIR COMPRESSOR AND POWER STEERING 345

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347

Power Steering and One-Cylinder Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
Power Steering and Two-Cylinder Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .354

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
All components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .362

346 AIR COMPRESSOR AND POWER STEERING
 AIR COMPRESSOR AND POWER STEERING 347

Exploded Views
Power Steering and One-Cylinder Air Compressor

Figure 268 One-cylinder air compressor and power steering system (typical)
1. Extension clip 7. Lock washer (10 mm) (2) 14. O-ring seal
2. M6 x 25 bolt 8. Return coolant tube assembly 15. 1/2” 90 degree tube elbow
3. Power steering (low-pressure) 9. Return coolant hose assembly 16. 1-1/16” 90 degree elbow
tube assembly 10. Air compressor 17. Power steering (high-pressure)
4. M6 x 1.0 nut (2) 11. M8 x 110 bolt (4) tube assembly
5. Power steering pump 12. M8 x 40 bolt (2) 18. Support bracket
6. M10 x 40 bolt (2) 13. Power steering pump adapter 19. M16 straight union (2)

Optional two-cylinder compressors are available. Although compressor housings are longer, compressor and
power steering line connections to crankcase and chassis are similar to one-cylinder compressors.
348 AIR COMPRESSOR AND POWER STEERING

Power Steering and Two-Cylinder Air Compressor

Figure 269 Optional two-cylinder air compressor and power steering system (typical)
1. Extension clip 9. O-ring seal (3) 17. M10 x 110 bolt
2. M6 x 25 bolt 10. M16 straight fitting (3) 18. Power steering pump adapter
3. Power steering (low-pressure) 11. 21 mm constant-tension clamp 19. O-ring seal
tube assembly (4) 20. 1/2” tube 90 degree elbow
4. M6 x 1.0 nut (2) 12. Coolant return hose 21. 1-1/16”-12ST 90 degree elbow
5. Power steering pump 13. M16 45 degree fitting 22. Power steering (high-pressure)
6. M10 x 40 bolt (2) 14. Coolant supply hose tube assembly
7. Lock washer (10 mm) (2) 15. M8 x 40 bolt (2) 23. Support bracket
8. Air compressor 16. M8 x 110 bolt (4)
 AIR COMPRESSOR AND POWER STEERING 349

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
Power Steering Pressure Tubes

Figure 270 Power steering pump and Pressure tubes

1. Power steering pump
2. High-pressure tube fitting nut
3. 1/2” 90 degree tube elbow
4. 1-1/6” 90 degree tube elbow
5. Low-pressure tube fitting nut

1. Place a drain pan under the power steering pump to catch any fluid.
2. Loosen high-pressure tube fitting nut and disconnect tube from 1/2” 90 degree tube elbow.
3. Loosen low-pressure tube fitting nut and disconnect tube from 1-1/16” 90 degree elbow.
350 AIR COMPRESSOR AND POWER STEERING

Figure 271 Pressure tubes support bracket

1. Power steering (low-pressure) tube assembly
2. Extension clip
3. M6 nut
4. M6 x 20 stud
5. Rear support bracket
6. Power steering (high-pressure) tube assembly

4. Remove rear support bracket M6 nut from extension clip stud at the oil pan.
5. If equipped, remove front support bracket M6 nut from support bracket.
6. Remove high-pressure and low-pressure tubes as an assembly.
NOTE: If replacing high-pressure and low-pressure tubes, do steps 7 and 8.
7. Remove the rear support brackets and rubber isolator from the high-pressure and low-pressure tubes.
8. If equipped, remove front support brackets and rubber isolator from the high-pressure and low-pressure
tubes.
 AIR COMPRESSOR AND POWER STEERING 351

Power Steering Elbows

NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows
are leaking.

Figure 272 Power steering pump and 90 degree elbows

1. Power steering pump
2. 1/2” 90 degree tube elbow
3. 1-1/16” 90 degree elbow

1. Loosen the lock nut and rotate the 1/2” 90 degree tube elbow counterclockwise to remove from power
steering pump.
2. Loosen the lock nut and rotate the 1-1/16” 90 degree elbow counterclockwise to remove from power steering
pump.
352 AIR COMPRESSOR AND POWER STEERING

Power Steering Pump

Figure 273 Power steering pump

1. Power steering pump
2. Air compressor
3. M10 x 40 bolt and lock washer (2)

1. Remove two M10 x 40 bolts, lock washers and power steering pump.
2. Check pump collar O-ring for damage and replace as necessary.

Figure 274 Power steering pump adapter

1. Power steering pump adapter
2. Air compressor

3. Remove power steering pump adapter from air compressor bore.

 AIR COMPRESSOR AND POWER STEERING 353

Air Compressor Coolant Hoses

Figure 275 Air compressor coolant hoses

1. Coolant return hose
2. Coolant return tube (one cylinder air compressor) or Coolant supply hose (two cylinder air compressor)
3. Air compressor

1. Place suitable container under air compressor to collect any residual coolant.

Figure 276 Air compressor coolant hose removal

1. Coolant Line Release Tool
2. Coolant hose

2. Insert Coolant Line Release Tool (page 362) into retaining clips of air compressor coolant hose and remove
from crankcase.
3. Using Coolant Line Release Tool, release and remove air compressor coolant tube from air compressor.
4. Recycle or dispose of any coolant according to applicable regulations.
354 AIR COMPRESSOR AND POWER STEERING

Air Compressor

Figure 277 Air compressor (typical)

1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)

WARNING: To prevent personal injury or death, get assistance to remove and install the air
compressor and power steering pump assembly.
NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the air compressor
mounting hole next to the power steering pump.
1. For one-cylinder air compressor, remove two M8 x 40 bolts and four M8 x 110 bolts.
2. For two-cylinder air compressor, remove two M8 x 40 bolts, four M8 x 110 bolts and M10 x 110 bolt.
3. Remove air compressor from alignment dowels.
 AIR COMPRESSOR AND POWER STEERING 355

Cleaning
All components
1. Cover coolant, fluid and air openings to ensure dirt does not enter air compressor and power steering pump.
2. Clean foreign material from sealing surfaces of air compressor. Use a scraper to clean sealing material from
the sealing surfaces.
3. Use only hot water to clean all hoses and tubes.
356 AIR COMPRESSOR AND POWER STEERING

Installation
Air Compressor

Figure 278 Air compressor (typical)

1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)

WARNING: To prevent personal injury or death, get assistance to remove and install the air
compressor and power steering pump assembly.
NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the mounting hole next
to the power steering pump.
1. Apply Loctite® 515 to crankcase and air compressor mating surface.
2. For one-cylinder air compressor, position air compressor and install two M8 x 40 bolts and four M8 x 110
bolts. Tighten bolts to special torque (page 362).
3. For two-cylinder air compressor, position air compressor and install two M8 x 40 bolts, four M8 x 110 bolts
and M10 x 110 bolt. Tighten bolts to special torque (page 362).
 AIR COMPRESSOR AND POWER STEERING 357

Air Compressor Coolant Hoses

Figure 279 Air compressor coolant hoses

1. Coolant return hose
2. Coolant return tube (one-cylinder air compressor) or Coolant supply hose (two-cylinder air compressor)
3. Air compressor

1. Depending on compressor model, straight and 45° coolant fittings are used. If loosened, tighten fittings as
follows:
One-cylinder compressors
• Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 362).
• If equipped, tighten M16 45° fitting (at crankcase) to special torque (page 362).
• If equipped, tighten M18 straight fittings (at air compressor) to special torque (page 362).
Two-cylinder compressors
• Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 362).
• If equipped, tighten M16 45° fitting (at crankcase or air compressor) to special torque (page 362).
2. Check air compressor coolant supply and return hose O-rings before installation. Replace O-rings as
needed.
3. Place coolant supply hose in position between crankcase and air compressor coolant fittings.
4. Press down on quick-connect fittings until a click is heard to install hose. Lightly pull on hose to make sure
it is locked.
5. Repeat steps 3 and 4 to install air compressor coolant return hose.
358 AIR COMPRESSOR AND POWER STEERING

Power Steering Pump

Figure 280 Power steering pump adapter

1. Power steering pump adapter
2. Air compressor

1. Install power steering pump adapter to air compressor bore.

Figure 281 Power steering pump (typical)

1. Power steering pump
2. Air compressor
3. M10 x 40 bolt (2)

2. If pump collar O-ring was removed or damaged, install a new O-ring. Lubricate the new O-ring with P80®
rubber lubricant (page 362) or equivalent.
3. Install power steering pump and two M10 x 40 bolts. Tighten bolts to special torque (page 362).
 AIR COMPRESSOR AND POWER STEERING 359

Power Steering Elbows

Figure 282 Power steering elbows

1. Power steering pump
2. 1/2” 90 degree tube elbow
3. 1-1/16” 90 degree elbow

NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows
were removed.
1. Check seals on elbow for damage. Replace as necessary.
2. Install 1/2” 90 degree tube elbow to power steering pump. Lock nuts should not be tightened until power
steering lines are installed for proper orientation.
3. Install 1-1/16” 90 degree elbow to power steering pump. Lock nuts should not be tightened until power
steering lines are installed for proper orientation.
360 AIR COMPRESSOR AND POWER STEERING

Power Steering Pressure Tubes

NOTE: If high-pressure and low-pressure tubes were replaced, do steps 1 and 2.
1. If equipped and removed, install front support brackets and rubber isolator onto the high- and low-pressure
tubes.
2. If removed, install rear support brackets and rubber isolator onto the high- and low-pressure tubes.

Figure 283 Pressure tubes support bracket

1. High- and low-pressure tube assembly
2. Extension clip
3. M6 x 1.0 nut
4. M6 x 20 bolt
5. Rear support bracket
6. Power steering (high-pressure) tube assembly

3. Position high-pressure and low-pressure tube as an assembly. Install M6 x 1.0 nut onto extension clip stud
to secure rear support bracket at the oil pan. Tighten nut to standard torque (page 881).
4. If equipped, install front support bracket to extension clip stud on front engine support and secure with M6
x 1.0 flange nut. Tighten nut to standard torque (page 881).
 AIR COMPRESSOR AND POWER STEERING 361

Figure 284 Pressure tubes

1. Power steering pump
2. High-pressure tube
3. 1/2” 90 degree tube elbow
4. 1-1/16” 90 degree elbow
5. Low-pressure tube

NOTE: Do the following steps if fittings were removed or if power steering pump was replaced.
5. Loosely install the high-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the
elbow, tighten 1/2" 90 degree tube elbow lock nut to special torque (page 362).
6. Loosely install the low-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the
elbow, tighten 1-1/16" 90 degree elbow lock nut to special torque (page 362).
7. Tighten the high-pressure and low-pressure tube fitting nuts to special torque (page 362).
362 AIR COMPRESSOR AND POWER STEERING

Special Torque

1-1/16" 90 degree elbow lock nut 55 N·m (40 lb·ft)

1/2" 90 degree tube elbow lock nut 45 N·m (33 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (one cylinder) 35 N·m (26 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (two cylinder) 31 N·m (23 lb·ft)
(Two cylinder) Air compressor M10 x 110 bolt 67 N·m (49 lb·ft)
High-pressure tube fitting nut 62 N·m (45 lb·ft)
M16 straight fitting 35 N·m (26 lb·ft)
M16 45° fitting 17.5 N·m (13 lb·ft)
M18 straight fitting 37.5 N·m (28 lb·ft)
Low-pressure tube fitting nut 164 N·m (120 lb·ft)
Power steering pump M10 x 40 bolt 67 N·m (49 lb·ft)

Special Service Tools

Description Tool Number

Coolant Line Release Tool ZTSE4778
Loctite® 515 Obtain locally
P80® rubber lubricant or equivalent Obtain locally
 FUEL SYSTEM 363

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365

High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .367
High-pressure Fuel Pump and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374
Fuel Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377
Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383
Fuel Filter Stand Pipe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388
Piston Overflow Valve (KUEV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403

Low-pressure and High-pressure Fuel System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
Fuel Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
High-Pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414
Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Piston Overflow Valve (KUEV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .423
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425
Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .427
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .428
Fuel Rail Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434
High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .435
Filter and Fuel Strainer Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441
Fuel System Priming Tool Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441
Hand Primer Pump Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452

364 FUEL SYSTEM

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453

 FUEL SYSTEM 365

Exploded Views
High-pressure Fuel Lines

Figure 285 High-pressure fuel lines

1. Thrust washer (6) 8. Pressure limiting valve (fuel rail) 13. High-pressure rail to injector
2. Injector hold-down clamp (6) 9. High-Pressure Fuel Pump tube assembly (6)
3. Rounded washer (6) (HPFP) to rail supply tube 14. High-pressure connector
4. M8 x 50 bolt (6) damper assembly retaining nut (6)
5. Injector (6) 10. M8 x 40 bolt (3) 15. 13.5 x 3 O-ring (6)
6. 3 x 20.9 ID O-ring (6) 11. Fuel rail 16. High-pressure connector body
7. Combustion washer (6) 12. Fuel rail pressure sensor (6)
366 FUEL SYSTEM

Fuel Supply and Drain (Return) Lines

Figure 286 Fuel supply and drain (return) lines

1. Fuel drain (return) hose 6. Fuel drain (return) tube assembly 11. After-filter fuel supply hose
assembly 7. Closed (P) clamp and 8 x 16 bolt (assembly)
2. C-clip 8. Wiring clip 12. Pre-pump fuel supply hose
3. Fuel filter bracket assembly with 9. 8 x 13 single retainer assembly
brace 10. Pre-filter fuel supply hose
4. M14 banjo bolt (3) (assembly)
5. Seal ring, 14.7 x 22 (6)
 FUEL SYSTEM 367

Fuel Filter Housing Assembly

Figure 287 Fuel filter housing assembly

1. Priming cup cap 9. Fuel filter cap 18. Fuel Delivery Pressure (FDP)
2. Priming element 10. Fuel filter cap O-ring sensor
3. Fuel primer pump assembly 11. Fuel filter element 19. Fuel supply adapter
4. M8 x 25 bolt (2) 12. Fuel filter housing assembly 20. Banjo fitting
5. M8 x 30 bolt (4) 13. Threaded union (3) 21. Check valve (quick connect)
6. 9 ID x 18 OD x 10.5 spacer (3) 14. Seal ring, 14.7 x 22 (12) 22. Dust cap
7. Fuel filter bracket assembly with 15. M14 x 1.5 hex socket plug 23. Fuel filter stand pipe
brace 16. Fuel filter drain plug
8. 9 ID x 17 OD x 6.5 spacer 17. M8 x 45 bolts (3)
368 FUEL SYSTEM

High-pressure Fuel Pump and Drive Housing

Figure 288 High-Pressure Fuel Pump (HPFP) and drive housing

1. M24 jam nut 11. Quick-connect M16 x 1.5 20. Sleeve
2. Washer, 25 x 44 x 4 connector (4) 21. High-pressure pump (drive belt)
3. HPFP gear 12. M14 x 30 bolt (2) pulley housing
4. Drive housing 13. High-pressure (fuel) pump 22. M10 x 40 bolt (4)
5. M12 x 90 bolt support 23. 55 x 70 x 8 radial shaft seal
6. 100 x 3.349 O-ring 14. M12 x 30 bolt (2) 24. High-pressure pump (drive belt)
7. High-pressure fuel pump 15. M10 x 40 bolt (4) pulley
8. Fuel Pressure Control Valve 16. M12 x 130 bolt (2) 25. M16 x 40 LH bolt (left-hand
(FPCV) 17. M12 x 40 bolt thread)
9. Piston Overflow Valve (KUEV) 18. Drive belt shaft
10. Seal ring, 16.7 x 24 (4) 19. 30.2 x 3 O-ring
 FUEL SYSTEM 369

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, remove ground cable from the negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, do not turn ignition key to ON if fuel system parts
are removed or disconnected. Activation of the fuel pump could spill fuel and create a fire.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Inlet Air Heater
• Aftertreatment System
• Turbochargers
370 FUEL SYSTEM

High-pressure Fuel Lines

WARNING: To prevent personal injury or death, engine must be stationary for at least 5 minutes
before doing any work on high-pressure fuel system to allow for system depressurization.

WARNING: To prevent personal injury or death, whenever any fuel line (tubing) in the high-pressure
fuel system is removed, it must be replaced with new.
CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.
1. If not already done, disconnect air supply line from harness 21-way connector bracket.

Figure 289 Harness connector bracket

1. Harness 21-way connector bracket
2. M8 x 16 bolt (3)

2. Remove three M8 x 16 bolts and harness 21-way connector bracket.

Figure 290 Crowfoot wrench (typical)

 FUEL SYSTEM 371

3. Obtain a crowfoot wrench (page 453) for removal of all high-pressure fuel lines.

Figure 291 HPFP to rail supply tube damper assembly

1. HPFP to rail supply tube damper assembly
2. Line fitting nut at fuel rail
3. Line fitting nut at HPFP (2)
4. Orientation band
372 FUEL SYSTEM

4. Loosen line fitting nuts at HPFP (Figure 291) (Item 3) and fuel rail (Figure 291) (Item 2) and remove HPFP
to rail supply tube damper assembly (Figure 291) (Item 1). Cap open fuel pump and fuel rail connections
with clean Disposable Air and Fuel Caps (page 453).

Figure 292 High-pressure rail to injector tube assembly

1. Cylinder 1 high-pressure connector body and retaining nut
2. Cylinder 1 high-pressure rail to injector tube assembly
3. Fuel rail

5. Loosen injector 1 high-pressure rail to injector tube assembly fitting nuts at cylinder head and fuel rail.

Figure 293 Fuel cap on high-pressure connector body (typical)

 FUEL SYSTEM 373

6. Remove and discard cylinder 1 high-pressure rail to injector tube assembly. Cap open high-pressure
connector body and fuel rail connections with clean Disposable Air and Fuel Caps (page 453).

Figure 294 Cylinders 2-6 high-pressure rail to injector tubes

7. Remove high-pressure rail to injector tube assemblies for cylinders 2 through 6. Cap open high-pressure
connector body and fuel rail connections.
374 FUEL SYSTEM

Injector and Fuel Drain (Return) Lines

NOTE: It is not necessary to disassemble the fuel drain lines unless individual components are leaking or
damaged.
CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.

Figure 295 Fuel drain (return) tube

1. Fuel rail
2. 14.7 x 22 seal ring (4)
3. M14 banjo bolt (2)
4. Fuel drain tube
5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee)

1. Remove M8 x 16 bolt and closed (P) clamp securing fuel drain tube to crankcase.
2. Loosen fuel drain line fitting nut at the fuel return hex manifold tee and disconnect tube from fuel return line.
3. Remove M14 banjo bolt and two 14.7 x 22 seal rings to disconnect fuel drain tube at fuel rail. Discard seal
rings.
4. Remove M14 banjo bolt and 14.7 x 22 seal rings connecting fuel drain tube at cylinder head. Remove fuel
drain tube and discard seal rings.
 FUEL SYSTEM 375

Fuel Rail Assembly

Figure 296 Fuel rail and pressure limiting valve

1. M8 x 40 bolt (3)
2. Fuel rail assembly
3. Pressure limiting valve

WARNING: To prevent personal injury or death, the engine must be stationary for at least 5 minutes
to allow for system depressurization, before doing work on the high-pressure fuel system.
NOTE: The pressure limiting valve should not be removed from the fuel rail assembly. Replace the entire fuel
rail assembly if the pressure limiting valve is defective. Use ServiceMaxx®to verify fuel pressure following the
procedure in the Engine Diagnostic Manual .
1. Support fuel rail to prevent it from falling during removal.
2. Remove three M8 x 40 bolts and remove fuel rail from cylinder head.
376 FUEL SYSTEM

Fuel Primer Pump Assembly

Figure 297 Fuel primer pump assembly

1. Check valve
2. Threaded union
3. 14.7 x 22 seal ring (3)
4. Fuel primer pump assembly
5. M8 x 25 bolt (2)
6. Fuel filter housing
7. Banjo fitting
8. Fuel supply adapter

1. If removed from fuel filter housing, install fuel primer pump assembly and two M8 x 25 bolts. Tighten bolts
to special torque (page 452).
NOTE: If fuel primer pump assembly was replaced or fittings were previously removed, continue with step 2.
2. Install banjo fitting with two new 14.7 x 22 seal rings and fuel supply adapter in fuel primer pump assembly
inlet port. Tighten adapter to special torque (page 452).
3. Install check valve on banjo fitting. Tighten check valve to special torque (page 452) and install dust cap.
4. Install threaded union and 14.7 x 22 seal ring in fuel primer pump assembly outlet port. Tighten threaded
union to special torque (page 452).
 FUEL SYSTEM 377

Fuel Supply and Drain (Return) Lines

Figure 298 Fuel Line Disconnect Tool ZTSE4773 11.8 mm (Typical)

1. Release button (2)
2. Fuel Line Disconnect Tool ZTSE4773 11.8 mm
3. Quick-connect 90° fitting

CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.
NOTE: Use Fuel Line Disconnect Tool 11.8 mm (page 453) to disconnect all Low-Pressure (LP) fuel line
quick-connect fittings.
1. Slide Fuel Line Disconnect Tool (Figure 298) (Item 2) over release buttons (Figure 298) (Item 1) on quick
connect 90° fitting (Figure 298) (Item 3).
2. Pull quick-connect 90° fitting to disconnect.
378 FUEL SYSTEM

Figure 299 After-Filter Fuel Supply Hose Connections

1. Quick‐connect 90° fitting (at 2. Quick‐connect 90° fitting (at 4. 14.7 x 22 mm seal rings (2)
high‐pressure fuel pump inlet) Aftertreatment (AFT) fuel doser 5. M14 banjo bolt
module) 6. C-clip (3)
3. After‐filter fuel supply hose

3. Disconnect after-filter fuel supply hose assembly quick-connect 90° fittings at high‐pressure fuel pump inlet
(Figure 299) (Item 1) and at AFT fuel doser module (Figure 299) (Item 2). .
4. Cap openings using clean Disposable Air and Fuel Caps ZTSE4891.
 FUEL SYSTEM 379

5. Remove c-clips (Figure 299) (Item 5) , M14 banjo bolt (Figure 299) (Item 5), 4.7 x 22 mm seal rings (Figure
299) (Item 4) and remove after-filter fuel supply hose assembly (Figure 299) (Item 3). Discard seal rings.

Figure 300 Pre-Pump Fuel Supply Hose Connections

1. Quick-connect 90° fitting (at HPFP)
2. Quick-connect 90° fitting (at primer pump)
3. C-clip (2)
4. Pre-pump fuel supply hose

6. Disconnect pre-pump fuel supply hose assembly quick-connect 90° fittings at HPFP (Figure 300) (Item 1)
and at fuel primer pump assembly (Figure 300) (Item 2). Remove c-clips (Figure 300) (Item 3) and hose
(Figure 300) (Item 4), and cap openings.
380 FUEL SYSTEM

Figure 301 Pre-Filter Fuel Supply Hose Connections

1. Quick-connect 90° fitting (at HPFP)
2. Quick-connect 90° fitting (at fuel filter housing)
3. Pre-filter fuel supply hose

7. Disconnect pre-filter fuel supply hose assembly quick-connect 90° fittings at HPFP (Figure 301) (Item 1) and
at fuel filter housing (Figure 301) (Item 2). Remove hose (Figure 301) (Item 3) and cap openings.
 FUEL SYSTEM 381

Figure 302 Fuel Drain Hose Connections

1. Quick‐connect 90° fitting (at 4. AFT fuel doser module bracket 7. 8 x 13 single retainer (2)
high‐pressure fuel pump return) 5. Fuel filter housing bracket 8. Fuel drain hose
2. M6 x 16 bolt 6. Quick‐connect 90° fitting (at fuel
3. Closed (P) clamp filter housing)

8. Remove M6 x 16 bolt (Figure 302) (Item 2) and closed (P) clamp (Figure 302) (Item 3).
9. Disconnect fuel drain hose assembly quick-connect 90° fittings at high‐pressure fuel pump return (Figure
302) (Item 1) and at fuel filter housing (Figure 302) (Item 6).
10. Cap openings using clean Disposable Air and Fuel Caps ZTSE4891.
11. Disconnect 8 x 13 single retainers (Figure 302) (Item 7) and remove fuel drain hose (Figure 302) (Item 8)
from engine.
382 FUEL SYSTEM

Fuel Primer Pump Assembly

Figure 303 Fuel primer pump assembly

1. Fuel primer pump assembly
2. M8 x 25 bolt (2)
3. Fuel filter housing

NOTE: The fuel primer pump assembly can be removed as an assembly along with the fuel filter housing. If the
fuel primer pump assembly is to be replaced, remove two M8 x 25 bolts and remove pump assembly from filter
housing.
1. Remove two M8 x 25 bolts.
2. Remove fuel primer pump assembly from fuel filter housing.
 FUEL SYSTEM 383

Fuel Filter Housing Assembly

Figure 304 AFT Fuel Doser Module bracket

1. M8 x 16 bolts (3)
2. AFT fuel doser module bracket

1. Remove four M8 x 20 bolts (Figure 304) (Item 1) and remove AFT fuel doser module bracket (Figure 304)
(Item 2).
384 FUEL SYSTEM

Figure 305 Fuel filter housing assembly

1. Fuel filter housing assembly
2. M8 x 45 bolt (3)

2. Remove three M8 x 45 bolts and remove fuel filter housing assembly.

Figure 306 Fuel filter bracket assembly

1. 9 ID x 18 OD x 10.5 spacer (3)
2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer

3. Remove four M8 x 30 bolts and spacers; remove fuel filter bracket from crankcase.
 FUEL SYSTEM 385

Fuel Filter Stand Pipe Replacement

If diagnostic testing indicated replacement of the fuel filter stand pipe, remove the stand pipe and replace with
new following this procedure.

Figure 307 Fuel Filter Stand Pipe

1. Stand pipe O-ring
2. Stand pipe
3. Fuel filter housing
4. Fuel filter cap
5. Fuel filter cap O-ring
6. Fuel filter element

1. Remove fuel filter cap and O-ring.

2. Using an appropriate wrench, loosen and remove stand pipe from housing.
3. Remove O-ring from center tube at bottom of stand pipe.
4. Apply P-80® rubber lubricant or equivalent (page 453) to new O-ring and install O-ring on center tube in
bore at bottom of stand pipe.
5. Insert stand pipe into housing assembly and carefully thread pipe into bore in bottom of housing.
6. Tighten the stand pipe to special torque (page 452).
7. Apply P-80® rubber lubricant or equivalent (page 453) to filter cap O-ring and place in position in housing
O-ring groove.
8. Insert new filter element in filter housing.
9. Install filter cap and tighten to special torque (page 452).
386 FUEL SYSTEM

Radial Shaft Seal

NOTE: Do not remove HPFP pulley if removing HPFP.

Figure 308 HPFP Pulley

1. HPFP pulley
2. M16 x 40 LH bolt (left-hand thread)

1. Remove M16 x 40 LH bolt (Figure 308) (Item 2). Clean any sealer off of bolt threads.
2. Remove HPFP pulley (Figure 308) (Item 1) from drive belt shaft assembly. Clean any sealer from shaft and
pulley.

Figure 309 HPFP Pulley Housing and Seal

1. HPFP pulley housing
2. M10 x 40 bolt (4)
3. 30.2 x 3 O-ring
4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft
 FUEL SYSTEM 387

3. With an awl and hammer, punch two holes 180° apart in radial shaft seal.
4. Thread a slide hammer (page 453) with correct size screw into one of the two holes.
5. Slide hammer until one side of seal begins to pull out of housing. Move slide hammer to other hole and
repeat until radial shaft seal is removed.
388 FUEL SYSTEM

Fuel Pressure Control Valve (FPCV)

Figure 310 FPCV

1. Screw (2)
2. Fuel Pressure Control Valve (FPCV)

1. Remove two screws (Figure 310) (Item 1) securing FPCV (Figure 310) (Item 2) to High-Pressure Fuel Pump
(HPFP).
2. Remove FPCV from HPFP housing.
 FUEL SYSTEM 389

Piston Overflow Valve (KUEV)

Figure 311 KUEV

1. Piston Overflow Valve (KUEV)

1. Remove KUEV (Figure 311) (Item 1) from High-Pressure Fuel Pump (HPFP) housing.
390 FUEL SYSTEM

High-pressure Fuel Pump (HPFP) and Drive Housing

NOTE: The High-Pressure Fuel Pump (HPFP) and drive housing can be removed as an assembly without
removing the fuel filter assembly or HPFP pulley.

Figure 312 HPFP Support Bracket

1. HPFP
2. M12 x 30 bolt (2)
3. Support bracket
4. M14 x 30 bolt (2)

1. Remove two M12 x 30 (Figure 312) (Item 2) and two M14 x 30 (Figure 312) (Item 4) bolts and remove
support bracket (Figure 312) (Item 3) from below HPFP (Figure 312) (Item 1).
 FUEL SYSTEM 391

Figure 313 HPFP and Drive Housing

1. Drive housing
2. M12 x 90 bolt
3. M12 x 130 bolt (2)
4. M12 x 40 bolt

2. Remove M12 x 40 (Figure 313) (Item 4), M12 x 90 (Figure 313) (Item 2), and two M12 x 130 bolts (Figure
313) (Item 3) and remove HPFP and drive housing assembly (Figure 313) (Item 1) from crankcase.

Figure 314 Dowel Pin and Sleeve

1. Dowel pin
2. Sleeve
392 FUEL SYSTEM

NOTE: A dowel pin (Figure 314) (Item 1) and sleeve (Figure 314) (Item 2) is used to ensure correct placement of
drive housing on the engine block. Holding Plate ZTSE6044 may be bolted to the drive housing with the dowel
pin and sleeve in place.

Figure 315 Drive Housing Secured to Holding Plate ZTSE6044

1. Drive housing
2. HPFP pulley housing
3. HPFP
4. Holding Plate ZTSE6044
5. M10 x 40 bolt (4)

3. Secure Holding Plate (Figure 315) (Item 4) in a vise.

4. Install drive housing (Figure 315) (Item 1) and HPFP (Figure 315) (Item 3) to Holding Plate with M12 x 40,
M12 x 90 and two M12 x 130 bolts. Tighten bolts to 77 lb·ft (105 N·m). Holding Plate will prevent the HPFP
gear from turning while loosening the M24 jam nut.
5. Remove four M10 x 40 bolts (Figure 315) (Item 5) and remove HPFP pulley housing (Figure 315) (Item 2)
from drive housing.
 FUEL SYSTEM 393

Figure 316 Drive Housing With HPFP Pulley Housing Removed

1. Holding Plate
2. M24 jam nut
3. 25 x 44 x 4 washer
4. Drive housing and HPFP

6. Remove the M24 jam nut (Figure 316) (Item 2) and 25 x 44 x 4 washer (Figure 316) (Item 3) securing HPFP
gear to pump shaft.

Figure 317 HPFP Guide Studs

1. M10 x 40 bolt (4)
2. Guide Stud 12–454–01–2 (2)

7. Remove four M10 x 40 bolts (Figure 317) (Item 2). Install two Guide Studs (Figure 317) (Item 2) on opposite
sides of the HPFP.
394 FUEL SYSTEM

Figure 318 HPFP Removal Tool 12–454–01 On Drive Housing

1. M10 x 40 bolt (4)
2. Forcing Screw Adapter (flush with Forcing Screw Adapter Holding Plate) 12–454–01–4
3. Socket Head Bolt 12–454–01–3 (2)
4. Forcing Screw Adapter Holding Plate 12–454–01–1

8. Install Forcing Screw Adapter Holding Plate (Figure 318) (Item 4) on drive housing with four M10 x 40 bolts
(Figure 318) (Item 1). Tighten M10 x 40 bolts to 46 lb·ft (62 N·m).
9. Place two Socket Head Bolts (Figure 318) (Item 3) through Forcing Screw Adapter (Figure 318) (Item 2) and
thread them into holes in HPFP gear. Tighten bolts only until Forcing Screw Adapter is flush with Forcing
Screw Adapter Holding Plate.
 FUEL SYSTEM 395

Figure 319 HPFP Removal

1. Forcing Screw Adapter Holding Plate
2. Forcing Screw Adapter
3. M10 x 40 bolt (4)
4. Socket Head Bolt (2)
5. Forcing Screw 12–454–01–5

10. Install Forcing Screw (Figure 319) (Item 5) by hand into Forcing Screw Adapter until it contacts HPFP shaft.
11. Turn Forcing Screw clockwise until HPFP is removed from drive housing.
12. Remove Socket Head Bolts, Forcing Screw Adapter, and Forcing Screw Adapter Holding Plate from drive
housing.
396 FUEL SYSTEM

Figure 320 Drive Housing Separated From HPFP

1. HPFP gear 4. HPFP 6. Quick-connect M16 x 1.5
2. Drive housing 5. Seal ring, 16.7 x 24 (4) connector (4)
3. 100 x 3.349 O-ring

13. Remove drive housing from Holding Plate and remove HPFP gear (Figure 320) (Item 1) from drive housing.
14. Remove and discard 100 x 3.349 O-ring (Figure 320) (Item 3) from HPFP.
15. If required, remove four M16 x 1.5 quick-connect connectors (Figure 320) (Item 6) and discard four 16.7 x
24 seal rings (Figure 320) (Item 5).
 FUEL SYSTEM 397

Fuel Injectors
CAUTION: To prevent engine damage, remove injectors before removing cylinder head.
CAUTION: To prevent engine damage, do not use power tools to remove or install fuel injector clamp bolts.
Threads will be damaged if a bolt or nut is rotated too quickly.
CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing
injector.

Figure 321 Fuel injector connections

1. Injector harness nuts (12)
2. Engine injector harness

NOTE: The injector harness nuts are part of the injector harness and cannot be separated.
1. Loosen 12 injector harness nuts and position injector harness aside.

Figure 322 High-pressure connector body (typical)

1. Retaining high-pressure connector nut (6)
2. High-pressure connector body (6)
398 FUEL SYSTEM

2. Remove six retaining high-pressure connector nuts.

3. Remove and discard six high-pressure connector bodies.
4. Cover cylinder head high-pressure connector body bores with appropriate size plugs from Disposable Air
and Fuel Caps (page 453).

Figure 323 Injector hold-down clamp

1. M8 x 50 bolt (6) and rounded washer (6)
2. Injector hold-down clamp (6)
3. Thrust washer (6)

5. Remove six M8 x 50 hold-down clamp bolts and rounded washers.

6. Remove six thrust washers.
 FUEL SYSTEM 399

Figure 324 Injector Puller

1. Clamping sleeve
2. Extractor plate
3. Extractor
4. Knurled nut
5. Extractor nut
6. Plate column (2)
7. Plate column nuts (2)

7. Use Injector Puller (page 453) to remove injectors.

Figure 325 Injector extractor (typical)

1. Extractor (part of Injector Puller)
2. Injector

8. Install extractor on injector.

400 FUEL SYSTEM

Figure 326 Clamping sleeve on extractor (typical)

1. Extractor
2. Clamping sleeve

9. Slide clamping sleeve over extractor.

Figure 327 Extractor plate and plate columns (typical)

1. Extractor plate
2. Plate column (2)

10. Position two plate columns on two opposite cylinder head bolts, and slide extractor plate over extractor and
plate columns.
11. Install and finger-tighten plate column nuts on plate columns.
 FUEL SYSTEM 401

Figure 328 Extractor nut (typical)

1. Knurled nut
2. Extractor nut

12. Install knurled nut and extractor nut with the extractor nut backed out.
13. Hold knurled nut and tighten extractor nut to remove injector, combustion washer and hold-down clamp.
NOTE: Make sure that no combustion washer remains in the injector bore after the injector is removed.
14. Cover cylinder head injector bore with appropriate size plugs from Disposable Air and Fuel Caps (page 453).

Figure 329 Injector seals (typical)

1. Injector assembly
2. 3 x 20.9 ID O-ring
3. Combustion washer

15. Using a small non-metallic hand tool, carefully remove and discard combustion washer and O-ring. Wipe
injector nozzle with a lint-free cloth.
CAUTION: To prevent engine damage, do not clean fuel injectors with parts solvent or other chemicals.
402 FUEL SYSTEM

16. Clean injector tip with Fuel Injector Tip Cleaning Brush (page 453).
17. Insert injector into Fuel Injector Cup (page 453), and place in Fuel Injector Rack Holder (page 453).
 FUEL SYSTEM 403

Cleaning and Inspection

Low-pressure and High-pressure Fuel System Components
1. Inspect low-pressure fuel lines for kinks, obstructions or other damage. Replace if necessary.
2. Inspect low-pressure fuel line quick-connect fitting O-ring seals for damage. Replace low-pressure fuel lines
if necessary.
3. Inspect fuel filter housing assembly and fuel primer pump assembly for damage. Replace if necessary.
4. Inspect high-pressure pump input shaft and driving sleeve splines for wear or damage. Replace if necessary.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
5. Clean outside surfaces of low-pressure fuel lines, fuel filter housing assembly and fuel primer pump
assembly with a suitable non-caustic solvent. Dry with filtered compressed air.
404 FUEL SYSTEM

Fuel Injector Bore

1. Use Injector Sleeve Brushes (page 453) in injector bore to remove deposits.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
2. Use filtered compressed air to clean out debris from injector bores.

Fuel Injector Harness

Inspect injector wiring harness for kinked wires or terminals. Replace harness if kinks are found. Kinked wires
can result in oil leaking in between the harness protective foam covering and the wires.
 FUEL SYSTEM 405

Installation
Fuel Injectors
CAUTION: To prevent engine damage, remove protective plugs and cups only before immediate installation of
components.
CAUTION: To prevent engine damage, do not use power tools to remove or install fuel injector clamp bolts.
Threads will be damaged if a bolt or nut is rotated too quickly.

Figure 330 Thrust washer

CAUTION: To prevent engine damage, verify all thrust washers are properly installed in cylinder head.
1. Install six thrust washers on cylinder head.

Figure 331 Injection Quantity Adjustment (IQA) code

406 FUEL SYSTEM

NOTE: The Injection Quantity Adjustment (IQA) code is printed in capital letters and numbers near the top of
the fuel injector.
2. Record the IQA code of each new fuel injector and its corresponding cylinder number so the new code can
be programed into the ECM, after fuel injectors are installed.

Figure 332 Injector seals (typical)

1. Injector assembly
2. 3 x 20.9 ID O-ring
3. Combustion washer

CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing
injector.
3. Install a new combustion washer onto injector tip.
4. Lubricate a new 3 x 20.9 ID O-ring with clean engine oil and install in recess at mid-point of injector.

Figure 333 Injector and injector hold-down clamp orientation (typical)

1. Injector hold-down clamp
2. Injector fuel inlet opening
 FUEL SYSTEM 407

5. Slide injector into hold-down clamp with injector fuel inlet opening on opposite side of hold-down clamp.

Figure 334 Injector and injector hold-down clamp installation (typical)

1. Injector hold-down clamp
2. Injector

CAUTION: To prevent engine damage, align injector and hold-down clamp correctly with cylinder head. Do not
twist injector when inserting injector into cylinder head.
NOTE: Make sure injector bore in cylinder head is clean and no old combustion washer remains inside the bore.
6. Install injector by lowering injector and hold-down clamp as one unit into injector bore.
7. Using Injector Installer (page 453), firmly press injector and hold-down clamp and make sure injector is fully
seated into cylinder head.
408 FUEL SYSTEM

CAUTION: To prevent engine damage, six new high-pressure connector bodies must be installed and aligned
before tightening M8 x 50 bolts for six fuel injectors.

Figure 335 Alignment of high-pressure connector body (typical)

1. Notch in cylinder head
2. Locating ball
3. High-pressure connector body

8. Align locating ball on each new high-pressure connector body with notch in cylinder head and install six new
high-pressure connector bodies.
 FUEL SYSTEM 409

Injector hold-down clamp (M8 x 50 bolts)

Figure 336 Injector hold-down clamp bolt

1. M8 x 50 bolt (6) and rounded washer (6)
2. Injector hold-down clamp (6)
3. Thrust washer (6)

9. Install six rounded washers and M8 x 50 bolts finger tight.

410 FUEL SYSTEM

High-pressure connector body (retaining nuts)

Figure 337 High-pressure connector body (typical)

1. High-pressure connector retaining nut (6)
2. High-pressure connector body (6)

10. Install six high-pressure connector retaining nuts and tighten nuts to 55 N·m (41 lb·ft).
11. Completely loosen six high-pressure retaining nuts; then, retighten nuts to 10 N·m (89 lb·in).
 FUEL SYSTEM 411

Injector hold-down clamp (Final torque of M8 x 50 bolts)

Figure 338 Injector hold-down clamp bolt

1. M8 x 50 bolt (6) and rounded washer (6)
2. Injector hold-down clamp (6)
3. Thrust washer (6)

12. Tighten six M8 x 50 injector hold-down clamp bolts to 25 N·m (18 lb·ft).
13. Tighten six M8 x 50 injector hold-down clamp bolts an additional 90°.
412 FUEL SYSTEM

High-pressure connector body (Final torque of retaining nuts)

Figure 339 High-pressure connector body (typical)

1. High-pressure connector retaining nut (6)
2. High-pressure connector body (6)

14. Tighten six high-pressure connector retaining nuts to 20 N·m (15 lb·ft).
15. Tighten six high-pressure connector retaining nuts an additional 32°.

Figure 340 Injector connections

1. Injector harness nuts (12)
2. Engine injector harness

CAUTION: To prevent engine damage, hold injector harness terminals to prevent twisting or turning while
tightening the injector harness nuts. Kinked harness terminals can result in an oil leak path between the
protective cover and the wire.
CAUTION: To prevent engine damage, use a torque wrench to tighten injector harness nuts to 1.8 N·m (16 lb·in).
 FUEL SYSTEM 413

CAUTION: To prevent engine damage, verify injector harness wires are not pinched or rubbing against the
engine brake housing or rocker arm assembly.
16. Connect injector harness to injectors. Make sure harness terminals are in straight alignment with harness.
Hold terminals stationary to avoid twisting and tighten nuts to special torque (page 452).
17. See N13 Engine Diagnostic Manual Performance Diagnostics section, for instructions on how to program
the Engine Control Module (ECM), using ServiceMaxx™, with Injection Quantity Adjustment (IQA) codes
for fuel injectors being replaced.
414 FUEL SYSTEM

High-Pressure Fuel Pump (HPFP) and Drive Housing

Figure 341 High-Pressure Fuel Pump (HPFP) and Drive Housing Assembly
1. HPFP 4. 25 x 44 x 4 washer 7. HPFP gear
2. Dowel pin 5. M24 jam nut 8. 100 x 3.349 O-ring
3. Drive housing 6. Sleeve 9. M10 x 40 bolts (4)

1. Install a new 100 x 3.349 O-ring (Figure 341) (Item 8) on fuel pump mounting flange collar.
 FUEL SYSTEM 415

Figure 342 HPFP Guide Studs

1. M10 x 40 bolt (4)
2. Guide Stud 12–454–01–2 (2)

2. Install two Guide Studs (Figure 342) (Item 2) on opposite sides of HPFP.
3. Place HPFP gear (Figure 341) (Item 7) into drive housing and position drive housing on pump.
4. Remove two Guide Studs from HPFP.
5. Install four M10 x 40 bolts (Figure 342) (Item 1) hand-tight.
6. Install 25 x 44 x 4 washer (Figure 341) (Item 4) and M24 jam nut (Figure 341) (Item 5), hand-tight to secure
gear on HPFP shaft.
416 FUEL SYSTEM

Figure 343 Drive Housing With HPFP Pulley Housing Removed

1. Holding Plate ZTSE6044
2. M24 jam nut
3. 25 x 44 x 4 washer
4. Drive housing and HPFP

7. Secure Holding Plate (Figure 343) (Item 1) in a vise.

8. Install drive housing and HPFP (Figure 343) (Item 4) to Holding Plate with M12 x 40, M12 x 90 and two M12
x 130 bolts. Tighten bolts to 77 lb·ft (105 N·m). Holding Plate will prevent the HPFP gear from turning while
tightening the M24 jam nut (Figure 343) (Item 2).
9. Tighten M24 jam nut to 210 lb·ft (285 N·m).
 FUEL SYSTEM 417

Figure 344 Drive Housing Secured to Holding Plate

1. Drive housing
2. HPFP pulley housing
3. HPFP
4. Holding Plate
5. M10 x 40 bolt (4)
418 FUEL SYSTEM

10. Tighten four M10 x 40 bolts (Figure 344) (Item 5) to 46 lb·ft (62 N·m) to secure HPFP pulley housing (Figure
344) (Item 2) to drive housing (Figure 344) (Item 1).
11. Remove drive housing and HPFP from Holding Plate (Figure 344) (Item 4).

Figure 345 Dowel Pin and Sleeve Placement

1. Dowel pin
2. Sleeve

12. Check that dowel pin (Figure 345) (Item 1) and sleeve (Figure 345) (Item 2) are properly seated in drive
housing or crankcase.
 FUEL SYSTEM 419

Figure 346 HPFP and Drive Housing

1. Drive housing
2. M12 x 90 bolt
3. M12 x 130 bolt (2)
4. 16.7 x 24 seal ring (4)
5. HPFP
6. Quick-connect M16 x 1.5 connector (4)
7. M12 x 40 bolt

13. If required, install four M16 x 1.5 quick-connect connectors (Figure 346) (Item 6) with new 16.7 x 24 seal
rings (Figure 346) (Item 4). Tighten connectors to 22 lb·ft (30 N·m).
14. Apply Loctite® 515 to mating surfaces of drive housing and crankcase.
15. Position HPFP (Figure 346) (Item 5) and drive housing assembly (Figure 346) (Item 1) on crankcase using
care to align pump drive gear with idler gear. Install M12 x 40 (Figure 346) (Item 7), M12 x 90 (Figure 346)
(Item 2), and two M12 x 130 bolts (Figure 346) (Item 3) and tighten bolts to 77 lb·ft 105 (N·m).
420 FUEL SYSTEM

Figure 347 HPFP and Support (Bracket)

1. HPFP
2. M12 x 30 bolt (2)
3. Support (bracket)
4. M14 x 30 bolt (2)

16. Place support bracket (Figure 347) (Item 3) in position below HPFP (Figure 347) (Item 1) and install two
M12 x 30 (Figure 347) (Item 2) and two M14 x 30 bolts (Figure 347) (Item 4).
17. Tighten two M12 x 30 bolts to 79 lb·ft (107 N·m).
18. Tighten two M14 x 30 bolts to 126 lb·ft (172 N·m).
CAUTION: To prevent damage to the High-Pressure Fuel Pump (HPFP), do not start the engine until the fuel
system is properly primed. The Fuel System Priming Tool should be used to prime the fuel system. If the Fuel
System Priming Tool is not available, prime the fuel system using the hand primer pump method. See Fuel
System Priming (page 441).
 FUEL SYSTEM 421

Radial Shaft Seal

Figure 348 HPFP Pulley Housing and Seal

1. HPFP pulley housing
2. M10 x 40 bolt (4)
3. 30.2 x 3 O-ring
4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft

NOTE: Apply Loctite® 515(page 453) to joining surfaces of HPFP pulley housing (Figure 348) (Item 1) and drive
housing if removed.
1. If removed, install four M10 x 40 bolts (Figure 348) (Item 2) and tighten to 46 lb·ft (62 N·m).
2. Using Fan Hub/High Pressure Drive Seal Installer ZTSE6066 (page 453), drive new 55 x 70 x 8 radial shaft
seal (Figure 348) (Item 4) into housing. Seal is fully installed when tool bottoms out on housing.
422 FUEL SYSTEM

Figure 349 HPFP Pulley

1. High-pressure pump pulley
2. M16 x 40 LH bolt (left-hand thread)

3. Install HPFP pulley (Figure 349) (Item 1) onto drive belt shaft.
4. Install M16 x 40 LH bolt (Figure 349) (Item 2). Tighten bolt to 207 lb·ft (280 N·m).
 FUEL SYSTEM 423

Piston Overflow Valve (KUEV)

Figure 350 KUEV

1. Piston Overflow Valve (KUEV)

1. Install KUEV into High-Pressure Fuel Pump (HPFP) housing. Tighten to 37 lb·ft (49 N·m).
424 FUEL SYSTEM

Fuel Pressure Control Valve (FPCV)

Figure 351 FPCV

1. Screw (2)
2. Fuel Pressure Control Valve (FPCV)

1. Install FPCV (Figure 351) (Item 2) into High-Pressure Fuel Pump (HPFP) housing.
2. Tighten two screws (Figure 351) (Item 1) to 71 lb·in (8 N·m).
 FUEL SYSTEM 425

Fuel Filter Housing Assembly

Figure 352 Fuel filter bracket assembly

1. 9 ID x 18 OD x 10.5 spacer (3)
2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer

1. If removed, position fuel filter bracket assembly with brace on crankcase and install four M8 x 30 bolts and
spacers. Tighten bolts to special torque (page 452).

Figure 353 Fuel filter housing assembly

1. Fuel filter housing assembly
2. M8 x 45 bolts (3)

2. Install fuel filter housing assembly and three M8 x 45 bolts. Tighten bolts to special torque (page 452).
426 FUEL SYSTEM

Figure 354 AFT Fuel Doser Module bracket (typical)

1. M8 x 16 bolts (3)
2. AFT Fuel Doser Module bracket

3. Position AFT Fuel Doser Module bracket (Figure 354) (Item 2) on filter housing and install four M8 x 16 bolts
(Figure 354) (Item 1). Tighten bolts to 23 lbf·ft (31 N·m).
 FUEL SYSTEM 427

Fuel Primer Pump Assembly

Figure 355 Fuel primer pump assembly

1. Check valve
2. Threaded union
3. 14.7 x 22 seal ring (3)
4. Fuel primer pump assembly
5. M8 x 25 bolt (2)
6. Fuel filter housing
7. Banjo fitting
8. Fuel supply adapter

1. If removed from fuel filter housing, install fuel primer pump assembly and two M8 x 25 bolts. Tighten bolts
to special torque (page 452).
NOTE: If fuel primer pump assembly was replaced or fittings were previously removed, continue with step 2.
2. Install banjo fitting with two new 14.7 x 22 seal rings and fuel supply adapter in fuel primer pump assembly
inlet port. Tighten adapter to special torque (page 452).
3. Install check valve on banjo fitting. Tighten check valve to special torque (page 452) and install dust cap.
4. Install threaded union and 14.7 x 22 seal ring in fuel primer pump assembly outlet port. Tighten threaded
union to special torque (page 452).
428 FUEL SYSTEM

Fuel Supply and Drain (Return) Lines

CAUTION: To avoid fuel system damage, verify all retainers and c-clips are installed in correct position as shown,
to prevent fuel line rubbing and leaks.

Figure 356 Fuel Drain Hose Retainers (Typical)

1. Quick‐connect 90° fitting (at 4. AFT fuel doser module bracket 7. 8 x 13 single retainer (2)
high‐pressure fuel pump return) 5. Fuel filter housing bracket 8. Fuel drain return hose
2. M6 x 16 bolt 6. Quick‐connect 90° fitting (at fuel
3. Closed (P) clamp filter housing)

1. Check that O-rings are in place in fuel drain quick-connect 90° fittings (Figure 356) (Items 1 and 4) and not
damaged. Replace as necessary.
2. Place fuel drain hose (Figure 356) (Item 8) in position at bottom of fuel filter housing bracket (Figure 356)
(Item 5) and attach to bracket with two 8 x 13 single retainers (Figure 356) (Item 7).
3. Connect fuel drain hose at high pressure fuel pump inlet by pushing on quick-connect 90° fitting (Figure
356)f4650009059 (Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated.
 FUEL SYSTEM 429

4. Connect fuel drain hose to fuel filter housing by pushing on quick-connect 90° fitting (Figure 356) (Item 6)
until an audible click is heard. Pull quick-connect fitting to make sure it is seated.
5. Install closed (P) clamp (Figure 356) (Item 3) and M6 x 16 bolt (Figure 356) (Item 2) to attach end fitting of
fuel drain hose from hex manifold tee to AFT fuel doser module bracket (Figure 356) (Item 4). Tighten bolt
to 115 lb·in (13 N·m).
6. Cap unconnected end of hex manifold tee using Disposable Air and Fuel Caps ZTSE4891 to prevent dirt
from entering fuel system until final connection with injector and fuel rail drain tube is made.

Figure 357 Pre-Filter Fuel Supply Hose Assembly

1. Quick-connect 90° fitting (at HPFP)
2. Quick-connect 90° fitting (at fuel filter housing)
3. Pre-filter fuel supply hose

7. Check that O-rings are in place in pre-filter fuel supply quick-connect 90° fittings and not damaged. Replace
as necessary.
8. Install pre-filter fuel supply hose (Figure 357) (Item 3). Push on quick-connect 90° fitting at HPFP (Figure
357) (Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the
procedure for the quick-connect 90° fitting at fuel filter housing (Figure 357) (Item 2).
430 FUEL SYSTEM

Figure 358 Pre-Pump Fuel Supply Hose Assembly

1. Quick-connect 90° fitting (at HPFP)
2. Quick-connect 90° fitting (at fuel primer pump)
3. C-clip (2)
4. Pre-pump fuel supply hose

9. Check that O-rings are in place in pre-pump fuel supply hose quick-connect 90° fittings and not damaged.
Replace as necessary.
10. Install pre-pump fuel supply hose (Figure 358) (Item 4). Push on quick-connect 90° fitting at HPFP (Figure
358) (Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the
procedure for the quick-connect 90° fitting at fuel primer pump assembly (Figure 358) (Item 2).
CAUTION: Install c-clips in location shown (Figure 358) to prevent damage to fuel lines.
11. Install c-clips (Figure 358) (Item 3) between pre-pump fuel supply hose and pre-filter fuel supply hose.
 FUEL SYSTEM 431

Figure 359 After-Filter Fuel Supply Hose Connections

1. Quick‐connect 90° fitting (at 2. Quick‐connect 90° fitting (at 4. 14.7 x 22 mm seal rings (2)
high‐pressure fuel pump inlet) Aftertreatment (AFT) fuel doser 5. M14 banjo bolt
module) 6. C-clip (2)
3. After‐filter fuel supply hose

12. Check that O-rings are in place in after-filter fuel supply hose quick-connect 90° fittings and not damaged.
Replace as necessary.
13. Install after-filter fuel supply hose (Figure 359) (Item 3). Position banjo fitting with two new 14.7 x 22 seal
rings (Figure 359) (Item 4) at filter housing and install M14 banjo bolt (Figure 359) (Item 5).
14. Tighten banjo bolt to 22lb·ft (30 N·m).
15. Push on quick-connect 90° fitting at high-pressure fuel pump inlet (Figure 359) (Item 1) until an audible click
is heard. Pull quick-connect fitting to make sure it is seated.
CAUTION: Install c-clips in location shown to prevent damage to fuel lines.
16. Install C-clips (Figure 359) (Item 6) between after filter fuel supply hose and fuel drain hose.
432 FUEL SYSTEM

17. Cap quick-connect 90° connector at AFT fuel doser module (Figure 359) (Item 2) to prevent dirt from entering
fuel system until final connection to metering valve can be made.
 FUEL SYSTEM 433

Fuel Rail Assembly

NOTE: The pressure limiting valve should not be removed from the fuel rail assembly. Replace the entire fuel
rail assembly if the pressure limiting valve is defective. Use ServiceMaxx® to verify fuel pressure following the
procedure in the Engine Diagnostic Manual.

Figure 360 Fuel rail and pressure limiting valve

1. M8 x 40 bolt (3)
2. Fuel rail assembly
3. Pressure limiting valve

1. Support fuel rail assembly in position against underside of cylinder head. Install and hand tighten three M8
x 40 bolts.
2. Tighten bolts to special torque (page 452).
434 FUEL SYSTEM

Injector and Fuel Drain (Return) Lines

Figure 361 Fuel drain tube connections

1. Fuel rail
2. 14.7 x 22 seal ring (4)
3. M14 banjo bolt (2)
4. Fuel drain tube
5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee)

1. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to cylinder head. Do not
tighten at this time.
2. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to fuel rail. Do not tighten
at this time.
NOTE: Use a backup wrench when tightening fitting nut on hex manifold tee.
3. Connect fuel drain tube to fuel return hex manifold tee at fuel filter bracket. Tighten drain line fitting nut to
special torque (page 452).
4. Tighten fuel drain tube M14 banjo bolts at fuel rail and cylinder head to special torque (page 452).
5. Install closed (P) clamp and M8 x 16 bolt to secure drain tube to crankcase. Tighten bolt to standard torque
(page 881).
 FUEL SYSTEM 435

High-pressure Fuel Lines

Figure 362 Crowfoot wrench (typical)

1. Obtain a crowfoot wrench (page 453) to connect all high-pressure fuel line fittings. When using a crowfoot
wrench to tighten fittings, calculate the torque compensation to match specific wrench configuration. See
Using a Torque Wrench Extension (Using a Torque Wrench Extension, page 882)

WARNING: To prevent personal injury or death, whenever any fuel line (tubing) in the high-pressure
fuel system is removed, it must be replaced with new.
436 FUEL SYSTEM

Figure 363 Cylinder 1 high-pressure rail to injector tube assembly

1. Cylinder 1 high-pressure connector body and retaining nut
2. Cylinder 1 high-pressure rail to injector tube assembly
3. Fuel rail
4. Orientation band

NOTE: Install high-pressure rail to injector tube assembly with band side of assembly connected to fuel rail.
2. Install new high-pressure rail to injector tube assembly (Figure 363) (Item 2) for cylinder 1 between fuel rail
and cylinder head, with band (Figure 363) (Item 4) side of assembly connected to fuel rail (Figure 363) (Item
3).
3. Hand tighten line fitting nut at fuel rail and high-pressure connector body.
 FUEL SYSTEM 437

Figure 364 Cylinders 2-6 high-pressure fuel tubes

4. Repeat step 2 to install new high-pressure rail to injector tube assemblies for cylinders 2 through 6.

Figure 365 Fuel rail assembly

1. M8 x 40 bolt (3)
2. Fuel rail

Fuel rail assembly (M8 x 40 bolts)

5. Tighten three M8 x 40 bolts to 35 N·m (26 lb·ft).
High-pressure rail to injector tube assemblies (fittings)
6. Tighten fittings (cylinders 1–6) to 23 N·m (17 lb·ft).
7. Tighten fittings, an additional 60°.
438 FUEL SYSTEM

Figure 366 HPFP to rail supply tube damper assembly

1. HPFP to rail supply tube damper assembly
2. Line fitting nut at fuel rail
3. Line fitting nut at HPFP (2)

CAUTION: To prevent engine damage, replace HPFP to rail supply tube damper assembly as an assembly.
8. Install new HPFP to rail supply tube damper assembly (Figure 366) (Item 1) between high-pressure fuel
pump and fuel rail.
9. Tighten line fitting nuts at HPFP (Figure 366) (Item 3) and fuel rail (Figure 366) (Item 2).
High-pressure pump to rail tube assemblies (fittings)
10. Tighten fittings to 23 N·m (17 lb·ft).
11. Tighten fittings, an additional 60°.
 FUEL SYSTEM 439

Figure 367 Harness 21-way connector bracket

1. Harness 21-way connector bracket
2. M8 x 16 bolt (3)

12. Install harness 21-way connector bracket and three M8 x 16 bolts. Tighten bolts to standard torque (page
881)
13. Connect air supply line to harness 21-way connector bracket.
440 FUEL SYSTEM

Filter and Fuel Strainer Element

Refer to N13 Engine Operation and Maintenance Manual for filter element and fuel strainer element service
procedures.
 FUEL SYSTEM 441

Fuel System Priming

Fuel System Priming Tool Method
CAUTION: To prevent damage to the high-pressure fuel pump, do not start the engine until the fuel system is
properly primed. The Fuel System Priming Tool should be used to prime the fuel system. If the Fuel System
Priming Tool is not available, prime the fuel system using the hand primer pump method.
1. Obtain Fuel System Priming Tool (page 453).
NOTE: Fuel System Priming Tool ball valves should be in the closed position, unless suction and pressure hoses
are connected to the vehicle fuel system.
442 FUEL SYSTEM

Figure 368 Fuel System Priming Tool

1. Pressure hose 3. Suction hose 5. Ball valve (2)
2. Pressure regulator selector lever 4. Sight glass 6. Filler cap (filter housing)
 FUEL SYSTEM 443

CAUTION: To prevent damage to fuel system components, make sure pressure regulator handle is in the 50
psi (345 kPa) position (as shown) when servicing N13 engines.
2. Fill Fuel System Priming Tool fuel filter housing with clean diesel fuel, the first time the tool is used and any
time there is no diesel fuel in the filter housing.
3. Put a fuel drain pan under the chassis mounted primary fuel filter / water separator.
4. If necessary, fill the chassis mounted fuel filter with clean diesel fuel. Fill the cartridge type filter from the top
or pump the hand primer button for the spin-on type filter.
NOTE: For different vehicles the chassis mounted primary fuel filter / water separator is mounted in different
locations than what is shown in (Figure 370) and (Figure 371).
NOTE: The Fuel System Priming Tool will work with either of the primary fuel filter / water separators shown in
(Figure 369) or (Figure 370).

Figure 369 Chassis mounted primary fuel filter / water separator (optional)
1. Fuel output to engine
2. Chassis mounted primary fuel filter / water separator
3. Fuel input from tank
444 FUEL SYSTEM

Figure 370 Chassis mounted primary fuel filter / water separator (typical)
1. Chassis mounted primary fuel filter / water separator
2. Fuel input from tank
3. Fuel output to engine

5. Disconnect fuel supply line to engine (fuel output to engine) by pushing red release tab and pulling line off
the primary fuel filter housing (Figure 371).

Figure 371 Chassis mounted primary fuel filter / water separator (typical)
1. Fuel supply line to engine
2. Red release tab
 FUEL SYSTEM 445

6. Connect Fuel System Priming Tool suction hose to the primary fuel filter output (Figure 372).

Figure 372 Fuel Priming Tool suction hose connected to primary fuel filter output
1. Fuel supply line to engine
2. Fuel System Priming Tool suction hose
3. Ball valve (closed)

7. Connect Fuel System Priming Tool pressure hose to the fuel supply line to engine (Figure 373).

Figure 373 Connecting Fuel System Priming Tool pressure hose to the fuel supply line to engine
1. Fuel supply line to engine
2. Fuel System Priming Tool pressure hose
446 FUEL SYSTEM

Figure 374 Ball valves closed

1. Pressure hose ball valve closed
2. Suction hose ball valve closed

8. Open pressure and suction hose ball valves (Figure 375) .

Figure 375 Ball valves open

1. Pressure hose ball valve open
2. Suction hose ball valve open
 FUEL SYSTEM 447

Figure 376 Pressure regulator selector lever

9. Set Fuel System Priming Tool pressure regulator selector lever to 50 psi (345 kPa) (Figure 376).

Figure 377 Fuel System Priming Tool connected to vehicle and electrical power

10. Connect electrical power and press the Fuel System Priming Tool power button (Figure 377).
11. Run Fuel System Priming Tool for a minimum of 2 minutes after no bubbles are visible in the sight glass
(Figure 378).
448 FUEL SYSTEM

Figure 378 Fuel System Priming Tool sight glass

1. Sight glass

12. Turn Fuel System Priming Tool off.

13. Close pressure and suction hose ball valves (Figure 374).

Figure 379 Ball valves closed

1. Pressure hose ball valve closed
2. Suction hose ball valve closed

14. Disconnect Fuel System Priming Tool pressure and suction hoses.
15. Connect fuel supply line to engine to the chassis mounted primary fuel filter / water separator (Figure 380).
 FUEL SYSTEM 449

Figure 380 Chassis mounted primary fuel filter / water separator

1. Fuel supply line to engine
2. Red release tab

16. Install left front fender assembly and bracket.

Hand Primer Pump Method

NOTE: Priming the fuel system by hand is not necessary if the Fuel System Priming Tool was used to prime the
fuel system.

Figure 381 Fuel primer pump

1. Fuel primer pump
2. Fuel filter cover
3. Fuel filter housing
4. Water drain valve (closed)
450 FUEL SYSTEM

1. Prime engine at hand primer pump:

A. Turn the fuel primer pump knob counterclockwise to unlock the pump stem.
B. Pump the fuel priming pump a minimum of 250 times (approximately 2 minutes). Continue pumping
even after higher pumping force is required. Make sure to raise and lower the knob completely on
each stroke.
C. After priming, depress the fuel primer pump knob fully and turn the fuel primer pump knob clockwise
until tight to secure the pump stem.
CAUTION: To prevent engine damage, if engine fails to start after 20 seconds of cranking, stop cranking engine
and wait two minutes to allow the starter motor to cool.
2. Start engine and check for fuel leaks. Let engine run for 2 minutes. If engine does not start after 20 seconds
of cranking, wait 2 minutes before trying to start the engine again. If the engine does not start, reprime the
low-pressure fuel system using the above procedure.
3. Install left front fender assembly and bracket.
4. Flip up and secure front bumper (if equipped).
5. Close and secure hood.
6. Remove wheel chocks.
 FUEL SYSTEM 451

Specifications

Fuel strainer filtration 300 microns

Fuel filter element filtration 3-5 microns
452 FUEL SYSTEM

Special Torque

Banjo bolt, M14 30 N·m (22 lb·ft)

Check valve 35 N·m (26 lb·ft)
Closed (P) clamp and M6 x 16 bolt 13 N·m (115 lb·in)
Forcing Screw Adapter Holding Plate M10 x 40 bolts 27 N·m (20 lb·ft)
Fuel drain line fitting nut 26 N·m (19 lb·ft)
Fuel filter bracket M8 x 30 bolt 35 N·m (26 lb·ft)
Fuel filter housing assembly M8 x 45 bolt 35 N·m (26 lb·ft)
Fuel filter cap 25 N·m (18 lb·ft)
Fuel filter stand pipe 12 N·m (106 lb·in)
Fuel Pressure Control Valve (FPCV) screws 8 N·m (71 lb·in)
Fuel primer pump assembly M8 x 25 bolt 30 N·m (22 lb·ft)
Fuel rail M8 x 40 bolt 35 N·m (26 lb·ft)
Fuel strainer cover 10 N·m (89 lb·in)
Fuel supply adapter 30 N·m (22 lb·ft)
High-pressure connector (body) retaining nut See tightening steps in procedure
Drive housing M12 x 40, M12 x 90, M12 x 130 bolt 105 N·m (77 lb·ft)
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lb·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lb·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lb·ft)
Holding plate M12 bolts 47 N·m (35 lb·ft)
Injector harness nut 1.8 N·m (16 lb·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Piston Overflow Valve (KUEV) 49 N·m (37 lb·ft)
Pressure limiting valve 110 N·m (81 lb·ft)
Quick-connect M16 x 1.5 connector 30 N·m (22 lb·ft)
Support bracket M12 x 30 bolts 107 N·m (79 lb·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lb·ft)
 FUEL SYSTEM 453

Special Service Tools

Description Tool Number

Crowfoot wrench Obtain locally
Disposable Air and Fuel Caps ZTSE4891
Fan Hub/High Pressure Drive Seal Installer ZTSE6066
Forcing Screw 12-454-01-05
Forcing Screw Adapter 12-454-01-04
Forcing Screw Adapter Holding Plate 12-454-01-01
Fuel Injector Cups ZTSE4892
Fuel Injector Rack Holder ZTSE4299B
Fuel Injector Tip Cleaning Brush ZTSE4301
Fuel Line Disconnect Tool 11.8 mm ZTSE4773
Fuel System Priming Tool 15-922-01
Guide Stud 12-454-01-02
High-Pressure Pump Removal Tool 12-454-01
Holding Plate ZTSE6044
Injector Installer ZTSE4777
Injector Puller ZTSE4770
Injector Sleeve Brushes ZTSE4751
Loctite® 515 Obtain locally
P80® Rubber Lubricant or equivalent Obtain locally
Socket Head Bolt 12-454-01-03
Slide hammer Obtain locally
454 FUEL SYSTEM
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 455

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457

Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457
Oil Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459
Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .461
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .463
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .467
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .469

Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470

Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .470
Oil Cooler Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Extension Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .472

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479
Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482

456 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 457

Exploded Views
Oil Module Assembly

Figure 382 Oil module assembly

1. Clamp (spring) 7. Extension tube 13. M6 x 16 bolt (2)
2. Oil centrifuge (DMR37 x DN29) 14. Tube clamp (2)
3. Filter cover 8. Seal (formed) 15. Open breather tube assembly
4. M8 x 45 bolt (3) 9. Oil module assembly
5. Oil module flange 10. Heater return tube assembly
6. Extension tube 11. Hose clamp (spring)
(DMR20 x DN14) 12. Tube clamp (2)
458 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Oil Module

Figure 383 Oil module

1. Oil centrifuge 8. Extension tube 15. M10 x 170 bolt
2. Open breather tube connection (DMR37 x DN29) 16. M10 x 200 bolt (2)
3. Filter cover 9. Oil module flange 17. M10 x 80 bolt (7)
4. O-ring seal 10. Seal (formed) 18. M8 x 90 bolt (2)
5. Oil filter 11. Oil module assembly 19. M10 x 110 bolt (3)
6. M8 x 45 bolt (3) 12. Oil module gasket 20. M10 x 140 bolt
7. Extension tube 13. Oil cooler 21. M8 x 45 bolt (2)
(DMR20 x DN14) 14. Oil cooler gasket (2) 22. M6 socket head bolt (4)
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 459

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the
parking brake, and block the wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, remove the ground cable from the negative
terminal of the main battery before disconnecting or connecting electrical components. Always
connect the ground cable last.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Turbochargers
• Fuel System
460 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Oil Filter Cover and Filter

Figure 384 Oil filter cover

1. Filter cover
2. O-ring seal
3. Oil filter
4. Oil module assembly

1. Place absorbent material under the engine and oil module assembly.
2. Unscrew oil filter cover from oil module using a 36 mm wrench.
3. Rotate oil filter element slightly and remove oil filter from filter cover.
4. Remove and discard O-ring seal from exterior of oil filter cover.
5. Dispose of oil filter according to local regulations.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 461

Oil Centrifuge

Figure 385 Open breather tube assembly

1. Open breather tube assembly
2. Clamp (spring)
3. Oil centrifuge outlet

1. Release spring clamp and disconnect open breather tube assembly from oil centrifuge outlet.

Figure 386 Oil centrifuge

1. Oil centrifuge
2. M6 socket head bolt (4)
462 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

2. Remove four M6 socket head bolts from oil centrifuge base and remove oil centrifuge and base as an
assembly.
3. Remove seal ring from oil centrifuge base. Discard ring if damaged or leaking.

Figure 387 Oil module assembly oil passageways

1. Oil module assembly

4. Inspect oil module assembly oil passageways. Clean any obstructions or dirt as necessary.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 463

Oil Module Assembly

Figure 388 Open breather tube and heater return tube

1. Open breather tube assembly
2. M6 x 16 bolt (3)
3. Tube clamp (2)
4. Tube clamp (2) (for hydrocarbon injector (HCI) coolant return tube assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
7. Pipe single cushioned clamp

1. Remove two tube clamp M6 x 16 bolts securing open breather tube to low-pressure charge air cooler
(LPCAC).
2. If not previously done, unclip two tube clamps securing HCI coolant return tube assembly to open breather
tube assembly.
CAUTION: To prevent engine damage, when manipulating the open breather tube assembly, do not create a
severe bend to the elbow hose that connects the tube to the oil module centrifuge outlet. The hose can crack.
3. If not previously done, release hose clamp (spring type) securing HCI coolant return tube assembly and
disconnect tube from open breather tube.
4. Remove hose clamp (spring type) securing heater return tube to open breather tube assembly. Remove
open breather tube assembly.
5. Remove M6 x 16 bolt and pipe single cushioned clamp securing heater return tube to LPCAC.
6. Loosen tube nut securing heater return tube to straight fitting on water distribution housing. Remove heater
return tube.
CAUTION: To prevent engine damage, drain all coolant from the engine through the radiator when removing
the oil module assembly. Coolant can enter the oil sump and contaminate the engine oil. Engine oil must be
drained and replaced after oil module removal and installation, before the engine is started.
7. Drain coolant from engine through radiator.
464 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Figure 389 Oil module assembly (non-servicable items)

1. Plug (with seal)
2. Bottom cover

CAUTION: To prevent engine damage, do not remove oil module assembly plugs, seals or bottom cover to drain
the coolant or oil. These parts are not serviceable.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 465

Figure 390 Oil module flange

1. Extension tube (DMR20 x DN14)
2. Extension tube (DMR37 x DN29)
3. Oil module flange
4. M8 x 45 bolt (3)
5. Engine oil temperature sensor

8. If not previously done, disconnect engine oil temperature sensor connector. Remove engine oil temperature
sensor from oil module flange if needed. See "ENGINE ELECTRICAL" for procedure.
9. Remove three M8 x 45 bolts then remove oil module flange by pulling away from cylinder head to disengage
extension tubes. Discard the oil module flange seal (formed).
CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surfaces.
10. Remove DMR20 x DN14 and DMR37 x DN29 extension tubes. Inspect for damage. Replace as necessary.
466 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Figure 391 Oil module assembly

1. M10 x 80 bolt (7)
2. M10 x 170 bolt
3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer

11. Remove seven M10 x 80 bolts, three M10 x 110 bolts, M10 x 170 bolt, M8 x 150 bolt (from water pump
into front side of oil module assembly) and 9 x 16 x 15 spacer (between oil module assembly and water
distribution housing).
12. Remove oil module assembly and gasket from engine. Discard oil module assembly gasket.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 467

Oil Cooler

Figure 392 Oil cooler bolts

1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2)
3. Oil module assembly

1. Remove two M8 x 45 and two M8 x 90 bolts.

Figure 393 Oil cooler

2. Remove oil cooler from oil module assembly.

468 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Figure 394 Oil cooler gaskets

3. Remove two oil cooler gaskets from oil module assembly. Discard gaskets.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 469

Oil Pressure Relief Valve

NOTE: Perform this procedure if replacing oil pressure relief valve for oil pressure-related issues.

Figure 395 Oil pressure relief valve

1. Remove oil pressure relief valve. Clean and inspect oil pressure relief valve. Replace if necessary.
470 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Cleaning, Inspection and Testing

Oil Cooler

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
CAUTION: To prevent engine damage, replace the oil cooler if an engine bearing fails. Bearing debris can not
be removed from the oil cooler.
1. The oil cooler can be cleaned in solvent and dried with filtered compressed air.
• Clean oil cooler in suitable solvent.
• Flush and drain oil cooler to remove any residue. Dry components with filtered compressed air.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 471

Oil Cooler Leak Test

Figure 396 Engine oil cooler pressure test

1. Air pressure regulator
2. Engine Oil Cooler Pressure Test Plate

1. Install Engine Oil Cooler Pressure Test Plate (page 482) onto oil cooler.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
2. Attach an air pressure regulator (page 482) to Engine Oil Cooler Pressure Test Plate. Connect to
compressed air supply and adjust air pressure to approximately 172 to 207 kPa (25 to 30 psi).
3. Immerse oil cooler in large container of clean water.
4. Inspect oil cooler and test plate for leaks. If test plate fittings leak, tighten fittings and continue looking for
leaks. Air bubbles at any location from oil cooler indicate leaks. Replace oil cooler if leaking.
5. Dry oil cooler using filtered compressed air.
472 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Extension Tubes
1. Wipe extension tubes clean and inspect for tears, cuts or other damage to sealing surfaces. Replace as
necessary.

Oil Centrifuge
1. Clean the oil centrifuge and inspect for damage. Replace as necessary.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 473

Installation
Oil Pressure Relief Valve
NOTE: Perform this procedure if oil pressure relief valve is removed.

Figure 397 Oil pressure relief valve

1. Install oil pressure relief valve. Tighten valve to special torque (page 482).
474 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Oil Cooler

Figure 398 Oil cooler bolts

1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2)
3. Oil module assembly

1. Install two M8 x 45 and two M8 x 90 bolts through oil module assembly.

Figure 399 Oil cooler gaskets

2. Install new oil cooler gaskets over threads of installed bolts.

 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 475

Figure 400 Oil cooler installation

3. Install oil cooler over gaskets and into oil module. Hand-tighten bolts.
NOTE: Ensure gaskets remain in place during cooler installation.
Tighten two M8 x 45 and two M8 x 90 bolts to special torque (page 482).
476 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Oil Module Assembly

1. Position new gasket onto oil module assembly.

Figure 401 Oil module assembly

1. M10 x 80 bolt (7)
2. M10 x 170 bolt
3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer

CAUTION: To prevent engine damage, do not use any silicone or other sealant when installing oil module
assembly.
2. Position oil module assembly and install seven M10 x 80 bolts, M10 x 170 bolt and three M10 x 110 bolts.
3. Tighten oil module bolts to special torque (page 482).
4. Place 9 x 16 x 15 spacer between water distribution housing and oil module assembly.
5. Install M8 x 150 bolt through water pump assembly, water distribution housing, spacer and into front side of
oil module assembly. Tighten M8 x 150 bolt to special torque (page 482).
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 477

Figure 402 Oil module flange

1. Extension tube (DMR20 x DN14)
2. Extension tube (DMR37 x DN29)
3. Oil module flange
4. M8 x 45 bolt (3)
5. Engine oil temperature sensor

6. Lubricate sealing surfaces of DMR20 x DN14 and DMR37 x DN29 extension tubes with P-80® rubber
lubricant or equivalent (page 482) and insert into oil module flange.
7. Install extension tubes into oil module flange using Extension Tube Installer Large and Extension Tube
Installer Small (page 482).
8. Position oil module with new formed seal onto oil module while gently pushing extension tubes into cylinder
head. Install three M8 x 45 bolts. Tighten bolts to special torque (page 482).
9. If not previously done, install engine oil temperature sensor into oil module flange if needed. See "ENGINE
ELECTRICAL" for procedure. Connect temperature sensor electrical connector.
478 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Figure 403 Open breather tube and heater return tube

1. Open breather tube assembly
2. M6 x 16 bolt (3)
3. Tube clamp (2)
4. Tube clamp (2) (for HCI coolant return tube assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
7. Pipe single cushioned clamp

10. Install two tube clamps onto open breather tube. Position open breather tube assembly to LPCAC and install
two M6 x 16 bolts. Tighten bolts to special torque (page 482).
11. If not previously done, snap two tube clamps over open breather tube assembly and HCI coolant return tube
assembly.
12. If not previously done, install HCI coolant return tube onto open breather tube assembly and install hose
clamp (spring type). See HCI Coolant Return Tube (page 243).
13. Position heater return tube assembly to straight fitting on water distribution housing and loosely tighten tube
nut.
14. Install pipe single cushioned clamp onto heater return tube assembly and install M6 x 16 bolt into LPCAC
and tighten to special torque (page 482).
15. Install heater return tube assembly hose onto open breather tube and install hose clamp (spring type).
16. Tighten heater return tube assembly tube nut to special torque (page 482).
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 479

Oil Centrifuge

Figure 404 Oil centrifuge

1. Oil centrifuge
2. M6 socket head bolt (4)

1. Install centrifuge with base and new formed seal. Lubricate new formed seal with clean engine oil.
2. Install four M6 socket head bolts. Tighten bolts to standard torque (page 881).

Figure 405 Open breather tube assembly

1. Open breather tube assembly
2. Clamp (spring)
3. Oil centrifuge outlet
480 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

3. Slide spring clamp over open breather tube assembly.

4. Connect open breather tube assembly to centrifuge outlet.
5. Install spring clamp and tighten.
 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION 481

Oil Filter Cover and Filter

1. Lubricate new O-ring with clean engine oil and install onto exterior of oil filter cover.
2. Install oil filter into oil filter cover.

Figure 406 Oil filter cover

1. Filter cover
2. O-ring seal
3. Oil filter
4. Oil module assembly

3. Install oil filter, O-ring seal and oil filter cover as an assembly into oil module. Tighten 36mm cover hex to
special torque (page 482).

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
CAUTION: To prevent engine damage, do not start or allow engine to run until first changing engine oil.
4. Drain and replace engine oil with recommended type and amount. See Engine Operation and Maintenance
Manual for oil type, capacity and fill procedure.
5. Replace engine coolant with recommended type and amount. See Engine Operation and Maintenance
Manual for coolant type, capacity and fill procedure.
NOTE: Three additional bolts secure the oil module assembly. These bolts are installed along with the HP turbo
air supply duct (two M10 x 200 bolts) and the air inlet duct for the LP turbocharger (one M10 x 140 bolt). See
"TURBOCHARGERS" for procedures.
482 OIL COOLER, FILTER HOUSING, AND CRANKCASE VENTILATION

Special Torque

Heater return tube assembly bolt, M6 x 16 13 N·m (115 lb·in)

Heater return tube assembly tube nut 11 N·m (97 lb·in)
Oil cooler bolts, M8 x 45 and M8 x 90 25 N·m (18 lb·ft)
Oil filter cover 40 N·m (30 lb·ft)
Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110 65 N·m (48 lb·ft)
Oil module flange bolts, M8 x 45 24 N·m (18 lb·ft)
Oil pressure relief valve 40 N·m (30 lb·ft)
Open breather tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Water pump bolt, M8 x 150 (front side of oil module) 35 N·m (26 lb·ft)

Special Service Tools

Description Tool Number

Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
P-80® rubber lubricant or equivalent Obtain locally
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 483

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

EGR Coolant Manifold and Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .490
Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .491
Coolant Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .492
EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .493
EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
EGR Module Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .495
Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .496
EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497
Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499
EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .503

Disassembly and Assembly of EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .504

EGR Cooler High-Temperature or Low-Temperature Side Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . .504

Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511

EGR System Components Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .511
EGR Cooler Assembly Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .512
EGR Cooler Assembly Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .524

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525
EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .525
EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .526
Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .530
EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .531
Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
EGR Module Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .535
EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .536
Coolant Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .537
Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .538

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .539

484 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 485

Exploded Views
EGR Coolant Manifold and Elbow

Figure 407 EGR coolant manifold and elbow

1. Extension tube (DMR62 x 51) (2) 6. Engine Coolant Temperature 11. Hydrocarbon injector fuel supply
2. Coolant manifold (ECT1) sensor (tube) bracket
3. M18 O-ring boss plug 7. M8 x 45 bolt (2) 12. M8 x 25 bolt (3)
4. Seal 8. M8 x 50 x 16 stud bolt 13. 60 x 3 O-ring
5. Coolant supply fitting (to 9. Extension tube (DMR44 x 35) 14. M8 x 18 bolt
hydrocarbon injector) 10. Coolant elbow 15. M8 x 25 heat-resistant bolt
486 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 408 EGR outlet tubes (cylinders 1-3 and cylinders 4-6)
1. EGR outlet gasket (4) 4. EGR outlet (cylinders 4-6) tube 6. EGR module cover
2. M8 x 30 bolt (8) 5. Air intake throttle duct
3. EGR outlet (cylinders 1-3) tube (horizontal)
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 487

Figure 409 EGR module cover

1. M8 x 85 bolt (9) 3. EGR cover outlet seal
2. EGR module cover 4. M8 x 90 stud bolt
488 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 410 EGR inlet tube heat protection shield

1. M8 x 25 heat-resistant bolt (2) 2. Heat protection (cylinders 4-6) 3. 8.4 x 16 x 1.6 washer (3)
shield 4. M8 x 12 bolt (3)
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 489

Figure 411 EGR system components

1. EGR dual flap valve 7. M8 x 25 heat-resistant bolt (2) 14. M8 x 65 heat-resistant bolt (2)
2. EGR valve coolant return tube 8. EGR cooler bracket 15. M8 x 12 bolt (3)
assembly 9. M8 x 25 heat-resistant bolt (2) 16. Tube EGR gasket (4)
3. M8 x 30 heat-resistant bolt (9) 10. Spacer 17. Inlet EGR (cylinders 1-3) tube
4. EGR cooler assembly 11. Low-temperature EGR hose 18. Heat protection EGR shield
5. EGR valve coolant supply tube assembly 19. Inlet EGR (cylinders 4-6) tube
assembly 12. M10 x 45 bolt (6) 20. M8 x 25 heat-resistant bolt (6)
6. M10 x 170 bolt 13. EGR dual flap valve gasket
490 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Front Cover, Fan Drive, Cooling System and Related Components
• Turbochargers
• Oil Cooler, Filter Housing and Crankcase Ventilation
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 491

Coolant Manifold

Figure 412 Coolant manifold

1. Extension tube (DMR44 x 35)
2. M8 x 45 bolt (2)
3. M8 x 12 bolt
4. Extension tube (DMR62 x 51)
5. M8 x 25 heat-resistant bolt
6. M8 x 50 x 16 stud bolt
7. Extension tube (DMR62 x 51)

1. Remove M8 x 12 bolt securing heat protection EGR shield to coolant manifold.

2. Remove heat protection (cylinders 4-6) shield M8 x 25 heat-resistant bolt.
3. Remove two M8 x 45 bolts, one M8 x 50 x 16 stud bolt and coolant manifold.
CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface.
4. Remove two DMR62 x 51 and one DMR44 x 35 extension tubes. Pry the tubes out using a wood or plastic
hammer handle or similar tool. Inspect extension tube sealing surfaces for damage. Replace as needed.
492 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Coolant Elbow

Figure 413 Coolant elbow

1. M8 x 25 bolt (3)
2. Coolant elbow
3. Extension tube (DMR62 x 51)
4. Hydrocarbon injector fuel supply (tube) bracket

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface.
1. Remove DMR62 x 51 extension tube from coolant elbow. Pry the tubes out using a wood or plastic hammer
handle or similar tool. Inspect extension tube sealing surfaces for damage. Replace as needed.
2. Remove two lower M8 x 25 bolts and hydrocarbon injector fuel supply (tube) bracket.
3. Remove upper M8 x 25 bolt and coolant elbow. Remove and discard 60 x 3 O-ring.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 493

EGR Cooler Bracket

Figure 414 EGR cooler bracket

1. EGR cooler bracket
2. M8 x 25 heat-resistant bolt (2)
3. Spacer
4. Heat protection shield (at front exhaust manifold)

1. Remove and discard two M8 x 25 heat-resistant bolts that secure the EGR cooler bracket to front exhaust
manifold.
2. Remove spacer.
3. Leave cooler bracket attached to EGR cooler.
494 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Outlet Tubes

Figure 415 EGR outlet tubes

1. M8 x 30 bolt (8)
2. EGR outlet (cylinders 1-3) tube
3. EGR outlet (cylinders 4-6) tube

1. Remove four M8 x 30 bolts securing the EGR outlet (cylinders 4-6) tube.
2. Remove EGR outlet (cylinders 4-6) tube and discard tube gaskets.
3. Remove four M8 x 30 bolts securing the EGR outlet (cylinders 1-3) tube.
4. Remove EGR outlet (cylinders 1-3) tube and discard tube gaskets.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 495

EGR Module Cover

Figure 416 Front of EGR module

1. EGR module cover
2. M8 x 85 bolt (8)
3. M8 x 90 stud bolt

1. Remove eight M8 x 85 bolts and one M8 x 90 stud bolt. Remove EGR module cover.

Figure 417 EGR cover outlet seal

2. Remove EGR cover outlet seal from EGR module cover. Save seal for installation.
496 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Heat Protection (Cylinders 4-6) Shield

1. If not already done, remove Hydrocarbon Injector (HCI) coolant supply tube assembly. See HCI Coolant
Supply Tube Assembly (page 232).
2. If not already done, remove HCI coolant return tube assembly. See HCI Coolant Return Tube Assembly
(page 233).
3. If not already done, remove HCI / Aftertreatment Fuel Injector (AFI) assembly. See HCI / AFI Assembly
(page 235).

Figure 418 Heat protection (cylinders 4-6) shield

1. Heat protection (cylinders 4-6) shield
2. M8 x 25 heat-resistant bolt
3. M8 x 12 bolt (3)
4. 8.4 x 16 x 1.6 washer (3)

4. Remove three M8 x 12 bolts (Figure 418) (Item 3), and three 8.4 x 16 x 1.6 washers (Figure 418) (Item 4).
5. Remove M8 x 25 heat-resistant bolt (Figure 418) (Item 2), and remove heat protection shield (Figure 418)
(Item 1).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 497

EGR Inlet Tubes

Figure 419 EGR inlet (cylinders 1-3) tube

1. M8 x 25 heat-resistant bolt (4)
2. EGR inlet (cylinders 1-3) tube
3. Middle exhaust manifold

1. Remove four M8 x 25 heat-resistant bolts.

2. Remove EGR inlet tube (cylinders 1-3) and two gaskets. Discard gaskets.
CAUTION: To prevent engine damage, cover opening in the rear manifold to prevent dirt, debris, and objects
from entering rear manifold.
498 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 420 EGR inlet (cylinders 4-6) tube

1. M8 x 25 heat-resistant bolt (2)
2. EGR inlet (cylinders 4-6) tube
3. Rear exhaust manifold
4. M8 x 65 heat-resistant bolt (2)

3. Remove two M8 x 25 heat-resistant bolts.

4. Remove two M8 x 65 heat-resistant bolts.
5. Remove EGR inlet (cylinders 4-6) tube and two tube gaskets. Discard gaskets.
CAUTION: To prevent engine damage, cover opening in the rear manifold to prevent dirt, debris, and objects
from entering rear manifold.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 499

Heat Protection EGR Shield

Figure 421 Heat protection EGR shield

1. Heat protection EGR shield
2. M8 x 12 bolt (2)

1. Remove two M8 x 12 bolts at rear exhaust manifold.

2. Remove heat protection EGR shield.
500 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Dual Flap Valve

NOTE: If removing complete EGR cooler assembly for disassembly of engine, removal of EGR dual flap valve
is not required.
NOTE: The EGR dual flap valve can be removed as an in-vehicle service.

Figure 422 EGR valve coolant return tube assembly and EGR dual flap valve
1. EGR valve coolant return tube assembly
2. Spring clamp
3. EGR dual flap valve
4. M6 x 45 x 15 stud (2)
5. 6 x 15 x 23 spacer (2)

NOTE: Drain coolant from EGR cooler assembly before removal.

1. Remove two M6 x 45 x 15 stud bolts and two 6 x 15 x 23 spacers.
2. Disconnect coolant return tube spring clamp and EGR valve coolant return tube assembly from EGR dual
flap valve.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 501

Figure 423 EGR dual flap valve and rear mounting bolts
1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (2)

3. Remove and discard two M8 x 30 heat-resistant bolts.

502 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 424 EGR dual flap valve, front mounting bolts, and EGR valve coolant supply tube assembly
1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (7)
3. EGR valve coolant supply tube nut
4. EGR valve coolant supply tube assembly

4. Loosen tube nut and disconnect EGR dual flap valve coolant supply tube from bottom of EGR dual flap
valve.
5. Remove and discard seven M8 x 30 heat-resistant bolts.
6. Remove EGR dual flap valve.
7. Remove and discard EGR dual flap valve gasket.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 503

EGR Cooler Assembly

Figure 425 EGR cooler assembly

1. EGR cooler assembly
2. M10 x 45 bolt (6)
3. M10 x 170 bolt
4. Spring clamp
5. Low-temperature EGR hose assembly
6. Y-fitting (to deaeration port hoses)
7. EGR cooler bracket

1. Disconnect low-temperature EGR hose assembly spring clamp and hose from EGR cooler assembly.
2. Remove six M10 x 45 bolts, one M10 x 170 bolt and EGR cooler assembly.
504 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Disassembly and Assembly of EGR Cooler

EGR Cooler High-Temperature or Low-Temperature Side Replacement
1. Obtain EGR Cooler Alignment Tool (page 539) .

Figure 426 EGR cooler assembly

1. High-Temperature (HT) EGR 2. Low-Temperature (LT) EGR 3. Notch in tool
cooler mounting stud cooler mounting stud 4. EGR Cooler Alignment Tool

2. Install EGR Cooler Alignment Tool into a suitable bench vise

3. Install the EGR cooler assembly onto the EGR Cooler Alignment Tool with two shorter mounting studs
through High-Temperature (HT) EGR cooler and longer mounting stud through Low-Temperature (LT) EGR
cooler.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 505

Figure 427 EGR cooler assembly

1. 1. 7/16 SAE flat washer 4. 3/8 SAE flat washer 7. EGR Cooler Alignment Tool
2. 7/16-14 nut 5. 3/8-16 nut 8. HT EGR cooler
3. M8 x 50 hex socket screw (9) 6. LT EGR cooler

4. Install two 7/16 SAE flat washers and two 7/16-14 nuts onto two HT EGR cooler mounting studs of the EGR
Cooler Alignment Tool. Tighten nuts to special torque (page 539).
5. Install 3/8 SAE flat washer and 3/8-16 nut onto LT EGR mounting stud of the EGR Cooler Alignment Tool.
Tighten nuts to special torque (page 539).
6. Remove nine M8 x 50 hex socket screws. Discard screws.
506 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 428 EGR cooler assembly

1. HT EGR cooler mounting stud 4. 3/8 SAE flat washer 7. EGR Cooler Alignment Tool
2. HT EGR cooler 5. LT EGR cooler mounting stud
3. LT EGR cooler 6. Slider

NOTE: Do not remove the mid-plate from the HT EGR cooler. Disturbing the sealing surfaces could cause a
leak.

WARNING: To prevent personal injury or death, be sure bench vise is clamped sufficiently to keep
EGR Alignment Tool and EGR Cooler Assembly from falling.
7. Separate LT EGR cooler from mid-plate along the slider of EGR Cooler Alignment Tool.
8. Remove the two 7/16-14 nuts, and two 7/16 SAE flat washers, or the 3/8-16 nut and 3/8 SAE flat washer
(Figure 427) from mounting stud(s) through the cooler half to be replaced.
9. Loosen but do not remove fasteners on mounding stud(s) on the other cooler half.
10. Remove the cooler half to be replaced from EGR Cooler Alignment Tool. If replacing LT EGR cooler, skip
to step 14.(page 508)
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 507

Figure 429 HT EGR cooler and mid-plate

1. HT EGR cooler
2. Mid-plate

11. Inspect bolt holes for misalignment between HT EGR cooler housing and mid-plate.
12. Insert two punches into bolt holes on opposite sides of mid-plate and HT EGR cooler housing\.
508 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 430 HT EGR cooler alignment

13. Use punches to align mid-plate to HT EGR cooler housing.

14. Clean mating surfaces on HT EGR Cooler and LT EGR Cooler of any debris and contaminants.
15. Install replacement cooler half over the appropriate mounting stud(s) of EGR Cooler Alignment Tool.
16. Install the two 7/16-14 nuts and two 7/16 SAE flat washers, or the 3/8-16 nut and 3/8 SAE flat washer (Figure
427) to mounting studs (Figure 428). Tighten nut(s) finger tight.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 509

Figure 431 Center of EGR cooler assembly

1. 1. M8 x 50 hex cap screw (9) 2. Mid-plate 3. LT EGR cooler

17. Slide the LT EGR cooler along the EGR Cooler Alignment Tool slider (Figure 428) until the LT EGR cooler
seal contacts flush with the mid-plate surface.
NOTE: Be sure any EGR cooler assembly brackets are installed during assembly of HT EGR cooler and LT
EGR cooler.
18. Install EGR cooler assembly bracket(s) and nine new M8 x 50 hex socket screws. Tighten screws finger
tight.
19. Tighten two 7/16-14 nuts (Figure 427) on HT EGR cooler mounting studs to special torque (page 539).
20. Tighten 3/8-16 nut (Figure 427) on LT EGR cooler mounting stud to special torque (page 539).
510 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 432 Hex socket screw torque sequence

21. Tighten nine M8 x 50 hex socket screws using the following two step torque sequence:
A. Tighten M8 x 50 hex socket screws in sequence 1 through 9 to 20 N·m (15 lb·ft).
B. Tighten M8 x 50 hex socket screws in sequence 1 through 9 to 31 N·m (23 lb·ft).
22. Remove two 7/16-14 nuts, two 7/16 SAE flat washers, 3/8-16 nut, and 3/8 SAE flat washer (Figure 427)
from mounting studs of EGR Cooler Alignment Tool. Save fasteners.
23. Remove the EGR cooler assembly from the EGR Cooler Alignment Tool.
24. Remove EGR Cooler Alignment Tool from bench vise.
25. Store fasteners with EGR Cooler Alignment Tool for reuse.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 511

Cleaning, Inspection and Testing

EGR System Components Cleaning
1. Using steam, clean all carbon from ends of EGR dual flap valve, coolant manifold and coolant elbow at rear.
CAUTION: To prevent engine damage, do not use steam to clean EGR cooler assembly heat exchanger cores.
2. Using steam, clean EGR cooler coolant return manifold at front. Clean all EGR cooler assembly coolant
ports.
3. Inspect EGR system components for cracks and damage. Replace worn or damaged parts.
512 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Cooler Assembly Cleaning

Figure 433 Cleaning Management System 12-353-01 components

1. Timer 12–353–01–1
2. Heater 12–353–01–8
3. FLOW FROM PUMP hose 12–353–01–2
4. Front EGR cooler cleaning adapter 12–353–01–4
5. Cam-lock cap 12–353–01–6
6. Rear EGR cooler cleaning adapter 12–353–01–5
7. FLOW RETURN hose 12–353–01–3
8. Air blower 12–353–01–7
9. Container 12–353–01–17
10. HEATER / PUMP Switch Assembly 12–353–01–9

1. Make sure container is clean.

2. Inspect and clean the filter sock. Replace as needed.
a. Loosen coupler on flow return tube
b. Remove filter from coupler
c. Install filter in coupler
d. Tighten coupler on flow return tube. Torque only needs to be hand tight
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 513

Figure 434 Level gauge

3. Add 5 US gal (19 L) of EGR Cooler Cleaning Solution and 5 US gal (19 L) of tap water to the container.

Figure 435 PUMP / HEATER switch

4. Turn on the heating element by simultaneously pulling the HEATER / PUMP Switch Assembly outward and
moving to heater position.
NOTE: The heating element has a thermostat that will regulate the temperature. When the amber light on the
switch housing goes out, the fluid is up to temperature.
5. Disassemble the truck to gain access to the front and rear of the EGR cooler assembly.
6. Allow engine to cool and use the Coolant Management Tool (page 539) to drain engine coolant to a level
below the EGR cooler assembly.
7. Remove coolant manifold from EGR cooler assembly and thermostat housing. See Coolant Manifold (page
491).
8. Remove heat protection (cyclinders 4-6) shield. See Heat Protection (cyclinders 4-6) Shield (page 496)
9. Remove EGR inlet tubes. See EGR Inlet Tubes (page 497)
10. Remove EGR dual flap valve from EGR cooler assembly. See EGR Dual Flap Valve (page 500).
514 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

11. Remove EGR outlet (cylinders 4-6) tube, and EGR outlet (cylinders 1-3) tube from EGR cooler assembly
and intake throttle duct assembly. See EGR Outlet (cylinders 4-6) Tube, and EGR Outlet (cylinders 1-3)
Tube (page 494)
12. Disconnect EGRT sensor electrical connector.
13. Remove EGR module cover from EGR cooler assembly. See EGR Module Cover (page 495).
14. Inspect the O-rings on the front and rear EGR cooler cleaning adapters to be sure there is no damage that
would cause a leak.

Figure 436 Front EGR cooler cleaning adapter

15. Install the front EGR cooler cleaning adapter. Tighten bolts to special torque (page 539).

Figure 437 Rear EGR cooler cleaning adapter

1. Rear EGR cooler cleaning adapter
2. Drain valve

16. Install the rear EGR cooler cleaning adapter. Tighten bolts to special torque (page 539).
17. Be sure the drain valve is in the closed position.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 515

Figure 438 Front of EGR cooler

1. FLOW RETURN hose
2. Front cooler cleaning adapter
3. Air injection fitting
4. FLOW FROM PUMP hose

18. Connect one end of the FLOW FROM PUMP hose to the respective hose connection of the container and
the opposite hose end to the front EGR cooler cleaning adapter hose connection.
19. Connect one end of the FLOW RETURN hose to the respective hose connection of the container and the
opposite hose end to the remaining front EGR cooler cleaning adapter hose connection.
20. Connect air line to air injection fitting.

Figure 439 Timer and HEATER/PUMP switch

21. Set the timer for 20 minutes, start timer and turn on pump by moving the HEATER / PUMP switch to PUMP.
516 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 440 Front of EGR cooler

1. FLOW RETURN hose
2. Front EGR cooler cleaning adapter
3. Air injection button valve

NOTE: Be sure to push only the air injection button valve that corresponds with the FLOW FROM PUMP hose.
22. At the 5, 10, and 15 minute mark, press the air injection button valve on the front EGR cooler cleaning
adaptor to introduce bursts of air at a one second on, two seconds off interval. Be sure to push the air
injection button valve that corresponds with the FLOW FROM PUMP hose.
23. After 20 minutes has expired, turn off the pump by moving the PUMP / HEATER switch to the middle position.

Figure 441 Air injection button valves

24. Press the air injection button valves on both sides independently to purge some of the EGR Cooler Cleaning
Solution from the hoses. This will minimize spills when disconnecting the hoses.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 517

Figure 442 Front of EGR cooler

1. FLOW FROM PUMP hose
2. Air injection button valve
3. FLOW RETURN hose

25. Disconnect and reverse the hose connections at the front EGR cooler cleaning adaptor and repeat steps
21 through 24.
26. Verify pump and heater are switched off. PUMP / HEATER switch should be in the middle position.
518 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Flushing Procedure

Figure 443 Draining used EGR Cooler Cleaning Solution

27. Remove the FLOW RETURN hose from the container and place hose end into a suitable drain or disposal
container.

WARNING: The hose running to the drain will be under pressure. Be sure it is secure before
proceeding.
28. Turn on pump by moving the HEATER / PUMP switch to PUMP to remove as much of the used EGR Cooler
Cleaning Solution as possible.
29. Turn off pump by moving the HEATER / PUMP switch to the middle position.
30. Remove the FLOW FROM PUMP hose from the container.
31. Using the attached caps, cap each hose connection on the Cleaning Management System.
32. Clean the container by spraying it with clean tap water while the unit is tipped onto its front face. Be sure all
the EGR Cooler Cleaning Solution is out of the reservoir.

Figure 444 Cleaning Management System volume gauge

 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 519

33. Fill the container with clean tap water to the 20 gallon mark on the volume gauge.
34. Reconnect the FLOW FROM PUMP hose to the container with the FLOW RETURN hose still in a suitable
drain or disposal container.

WARNING: The hose running to the drain will be under pressure. Be sure it is secure before
proceeding.
35. Turn on pump by simultaneously pulling the HEATER / PUMP Switch Assembly outward and moving to
PUMP position until all of the clean water has been flushed through the EGR cooler.
36. Turn off pump by moving the HEATER / PUMP switch to the middle position.

Figure 445 Front of EGR cooler

1. FLOW RETURN hose
2. Front cooler cleaning adapter
3. Air injection fitting
4. FLOW FROM PUMP hose

37. Reverse the FLOW FROM PUMP and FLOW RETURN hoses on the front EGR cooler cleaning adapter
38. Repeat steps 32 through 36.
39. Disconnect the FLOW RETURN hose from the front EGR cooler cleaning adapter.
40. Disconnect the FLOW FROM PUMP hose from the container.
Purging Fluids / Equipment Removal Instructions
520 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 446 Front of EGR cooler

1. FLOW FROM PUMP hose
2. Cam-lock cap

NOTE: Be sure the cam-lock cap is installed properly to prevent discharge of fluid.
41. Install a cam-lock cap on the open port of the front EGR cooler cleaning adapter.

Figure 447 Air blower connection

1. Air blower
2. Cam-lock cap

42. Attach the air blower to the FLOW FROM PUMP hose.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 521

Figure 448 Rear of EGR cooler

1. Rear EGR cooler cleaning adaptor
2. Drain valve

43. Open the drain valve on the rear EGR cooler cleaning adaptor.

Figure 449 Blower connected

44. Run the blower on maximum power until the water coming out of the drain valve of rear EGR cooler cleaning
adapter is at a dripping state.
522 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 450 Cam-lock cap and air blower

1. Air blower
2. Cam-lock cap

45. Reverse the cam-lock cap and the FLOW FROM PUMP hose and repeat step 44.

Figure 451 Rear of EGR cooler

NOTE: Protect the inside of the truck from spray coming from the end of the EGR Cooler for the following steps.
46. Remove the rear EGR cooler cleaning adaptor.
47. Run the air blower on maximum power until there is no EGR Cooler Cleaning Solution coming from the rear
of the EGR cooler assembly.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 523

Figure 452 Cam-lock cap and air blower

1. Air blower
2. Cam-lock cap

48. Reverse the cam-lock cap and the FLOW FROM PUMP hose on the front EGR cooler cleaning adaptor
(Figure 452).
49. Run the air blower on maximum power until there is no EGR Cooler Cleaning Solution coming from the rear
of the EGR cooler assembly.
50. The cleaning of the EGR cooler assembly is now complete. Remove the front EGR cooler cleaning adaptor.
51. Install EGR module cover on EGR cooler assembly. See EGR Module Cover (page 534).
52. Connect EGRT sensor electrical connector.
53. Install EGR outlet (cylinders 4-6) tube, and EGR outlet (cylinders 1-3) tube (page 535) to EGR cooler
assembly and intake throttle duct assembly.
54. Check EGR outlet tube hose clamps for looseness. Tighten tube hose clamps to special torque (page 539).
55. Install EGR dual flap valve on EGR cooler assembly. See EGR Dual Flap Valve (page 526).
56. Install EGR inlet tubes. See EGR Inlet Tubes (page 531).
57. Install heat protection (cyclinders 4-6) shield. See Heat Protection (cyclinders 4-6) Shield (page 533).
58. Install coolant manifold to EGR cooler assembly and thermostat housing. See Coolant Manifold (page 538).
524 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Cooler Assembly Leak Test

1. Obtain Exhaust Gas Recirculation (EGR) Cooler Leak Detection Tool (page 539).
2. Follow the directions included with the tool to determine if the EGR cooler assembly has any leaks.
3. If any leaks are found, replace the defective part of the EGR cooler assembly. See EGR Cooler
High-Temperature or Low-Temperature Side Replacement (page 504).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 525

Installation
EGR Cooler Assembly
NOTE: Install or connect exterior components to the EGR cooler as necessary. When installing a replacement
EGR cooler assembly, transfer necessary components from the cooler being replaced.

Figure 453 EGR cooler assembly

1. EGR cooler assembly
2. M10 x 45 bolt (6)
3. M10 x 170 bolt
4. Spring clamp
5. Low-temperature EGR hose assembly

1. Install EGR cooler assembly, six M10 x 45 bolts and M10 x 170 bolt. Tighten bolts to special torque (page
539).
2. Connect low-temperature EGR hose assembly to EGR cooler assembly. Position and install spring clamp
to secure hose.
526 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Dual Flap Valve

NOTE: Complete this procedure only if the EGR dual flap valve was removed from EGR cooler assembly.

Figure 454 EGR dual flap valve

1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (7)

1. Install a new gasket.

2. Position EGR dual flap valve and install seven new M8 x 30 heat-resistant bolts. Tighten bolts finger tight.

Figure 455 EGR dual flap valve and rear mounting bolts
1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (2)

3. Install two new M8 x 30 heat-resistant bolts. Tighten bolts finger tight.

 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 527

Figure 456 EGR dual flap valve bolt torque sequence (step 1)

4. Tighten the four new M8 x 30 heat resistant bolts in sequence to 5 N·m (45 lb·in).

Figure 457 EGR dual flap valve bolt torque sequence (step 2 and 3)

5. Install remaining five new M8 x 30 heat resistant bolts. Tighten nine new M8 x 30 heat resistant bolts in
sequence as follows:
• Tighten bolts to 16 N·m (12 lb·ft).
• Tighten bolts to 24 N·m (18 lb·ft).
528 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 458 EGR dual flap valve and EGR valve coolant supply tube assembly
1. EGR dual flap valve
2. EGR valve coolant supply tube nut
3. EGR valve coolant supply tube assembly

6. Attach EGR valve coolant supply tube nut to EGR valve and tighten to special torque (page 539).

Figure 459 EGR valve coolant return tube assembly and EGR dual flap valve
1. EGR valve coolant return tube assembly
2. Spring clamp
3. EGR dual flap valve
4. M6 x 45 x 15 stud (2)
5. 6 x 15 x 23 spacer (2)

7. Attach EGR valve coolant return tube to EGR valve and secure tube with spring clamp.
8. Install two 6 x 15 x 23 spacers and two M6 x 45 x 15 stud bolts.
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 529

9. Tighten M6 x 45 x 15 stud bolts to standard torque (page 881).

530 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Heat Protection EGR Shield

Figure 460 Heat protection EGR shield

1. Heat protection EGR shield
2. M8 x 12 bolt (2)

1. Install heat protection EGR shield and two M8 x 12 bolts at rear exhaust manifold. Tighten bolts to standard
torque (page 881).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 531

EGR Inlet Tubes

Figure 461 EGR inlet (cylinders 4-6) tube

1. M8 x 25 heat-resistant bolt (2)
2. EGR inlet (cylinders 4-6) tube
3. Rear exhaust manifold
4. M8 x 65 heat-resistant bolt (2)

1. Position two new EGR inlet (cylinders 4-6) tube gaskets, one to EGR valve and one to rear exhaust manifold.
2. Install EGR inlet (cylinders 4-6) tube, two M8 x 25 and two M8 x 65 heat-resistant bolts. Tighten bolts to 16
N·m (12 lb·ft).
532 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Figure 462 EGR inlet (cylinders 1-3) tube

1. M8 x 25 heat-resistant bolt (4)
2. EGR inlet (cylinders 1-3) tube
3. Middle exhaust manifold

3. Position two new EGR inlet (cylinders 1-3) tube gaskets, one to EGR valve and one to middle exhaust
manifold.
4. Install EGR inlet (cylinders 1-3) tube and four M8 x 25 heat-resistant bolts. Tighten bolts to 16 N·m (12 lb·ft).
EGR Inlet (cylinders 4-6) Tube and EGR Inlet (cylinders 1-3) Tube
5. Tighten eight heat-resistant bolts to 24 N·m (18 lb·ft).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 533

Heat Protection (Cylinders 4-6) Shield

Figure 463 Heat protection (cylinders 4-6) shield

1. Heat protection (cylinders 4-6) shield
2. M8 x 25 heat-resistant bolt
3. M8 x 12 bolt (3)
4. 8.4 x 16 x 1.6 washer (3)

1. Install heat protection shield with three M8 x 12 bolts, and three 8.4 x 16 x 1.6 washers. Tighten bolts finger
tight.
2. Install M8 x 25 heat-resistant bolt finger tight.
3. Tighten M8 x 12 bolts, and M8 x 25 heat-resistant bolts to special torque (page 539).
534 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Module Cover

Figure 464 EGR cover outlet seal

1. Install EGR cover outlet seal into EGR module cover.

Figure 465 Front of EGR module

1. EGR module cover
2. M8 x 85 bolt (8)
3. M8 x 90 stud bolt

2. Install eight M8 x 85 bolts and one M8 x 90 stud bolt. Tighten bolts in a crisscross pattern to special torque
(page 539).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 535

EGR Outlet Tubes

Figure 466 EGR outlet tubes

1. M8 x 30 bolt (8)
2. EGR outlet (cylinders 1-3) tube
3. EGR outlet (cylinders 4-6) tube

1. Install EGR outlet (cylinders 4-6) tube, two new tube gaskets and four M8 x 30 bolts. Tighten bolts to
standard torque (page 881).
2. Install EGR outlet (cylinders 1-3) tube, two new tube gaskets and four M8 x 30 bolts. Tighten bolts to
standard torque (page 881).
3. Check EGR outlet tube hose clamps for looseness. Tighten tube hose clamps to special torque (page 539).
536 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

EGR Cooler Bracket

Figure 467 EGR cooler bracket

1. EGR cooler bracket
2. M8 x 25 heat-resistant bolt (2)
3. Spacer
4. Heat protection shield (at front exhaust manifold)

1. Install two EGR cooler bracket M8 x 25 lower heat-resistant bolts.

2. Tighten bolts to standard torque (page 881).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 537

Coolant Elbow

Figure 468 Coolant elbow

1. M8 x 25 bolt (3)
2. Coolant elbow
3. Extension tube (DMR62 x 51)
4. Hydrocarbon injector fuel supply (tube) bracket

1. Install new 60 x 3 O-ring. Install coolant elbow and loosely install upper M8 x 25 bolt.
2. Install HCI supply bracket and loosely install two lower M8 x 25 bolts.
3. Tighten three coolant elbow bolts to standard torque (page 881).
4. Lubricate sealing surfaces of extension tube (DMR62 x 51) with P-80® rubber lubricant or equivalent (page
539). Install extension tube (DMR62 x 51) to coolant elbow using Extension Tube Installer Large (page 539).
NOTE: Alternatively, install extension tube (DMR62 x 51) into coolant manifold.
538 EXHAUST GAS RECIRCULATION (EGR) SYSTEM

Coolant Manifold

Figure 469 Coolant manifold

1. Extension tube (DMR44 x 35)
2. M8 x 45 bolt (2)
3. M8 x 18 bolt
4. Extension tube (DMR62 x 51)
5. M8 x 25 heat-resistant bolt
6. M8 x 50 x 16 stud bolt
7. Extension tube (DMR62 x 51)

1. Lubricate two extension tubes (DMR62 x 51 and DMR44 x 35) sealing surfaces with P-80® rubber lubricant
or equivalent (page 539).
2. Install extension tube (DMR62 x 51) and extension tube (DMR44 x 35) into coolant manifold using Extension
Tube Installer Large and Extension Tube Installer Small (page 539).
3. Install coolant manifold using two M8 x 45 bolts, one M8 x 50 x 16 stud bolt and one M8 x 25 heat-resistant
bolt (at heat protection (cylinder 4-6) shield). Tighten M8 x 25 heat-resistant bolt to special torque (page
539). Tighten two M8 x 45 bolts and one M8 x 50 x 16 stud bolt to special torque (page 539).
4. Install one M8 x 18 bolt and tighten to special torque (page 539).
 EXHAUST GAS RECIRCULATION (EGR) SYSTEM 539

Special Torque

Coolant manifold, M8 x 18 bolt 22 N·m (16 lb·ft)

Coolant manifold, M8 x 25 heat–resistant bolt 24 N·m (18 lb·ft)
Coolant manifold, M8 x 45 bolt and M8 x 50 x 16 stud bolt 35 N·m (26 lb·ft)
EGR dual flap valve, M8 x 30 heat-resistant bolt See tightening steps in procedure.
EGR inlet (cylinders 1-3) tube, M8 x 25 heat-resistant bolt See tightening steps in procedure.
EGR inlet (cylinders 4-6) tube, M8 x 25 heat-resistant bolt See tightening steps in procedure.
EGR module cover, M8 x 85 bolts and M8 x 90 stud bolt 24 N·m (18 lb·ft)
EGR outlet tube hose clamps 5 N·m (45 lb·in)
EGR valve coolant supply tube nut 26 N·m (19 lb·ft)
Front EGR cooler cleaning adapter M8 bolts 24 N·m (18 lb·ft)
Heat protection (cylinders 4–6) shield, M8 x 25 heat–resistant bolts 24 N·m (18 lb·ft)
HT EGR cooler mounting studs 7/16 - 14 nuts 41 N·m (30 lb·ft)
Leak Detection Plate KL20060-4 M8 x 30 bolts 24 N·m (18 lb·ft)
Low-temperature and high-temperature EGR coolers, M8 x 55 hex See tightening steps in procedure.
socket screws
LT EGR cooler mounting studs 3/8 - 14 nuts 41 N·m (30 lb·ft)
Rear EGR cooler cleaning adapter M8 bolts 24 N·m (18 lb·ft)

Special Service Tools

Description Tool Number

Cleaning Management System 12-353-01
Coolant Management Tool KL5007NAV
EGR Cooler Alignment Tool 12-892-01A
Exhaust Gas Recirculation (EGR) Cooler Leak
KL 20060 NAV
Detection Tool
Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
P-80® rubber lubricant or equivalent Obtain locally
540 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 541

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543

Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
Air Intake Throttle Horizontal Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .544
Air Intake Throttle Vertical Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .545

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .546
Exhaust Manifold Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .548
Front Exhaust Manifold Cuff Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .549
Rear Exhaust Manifold Cuff Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .553
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556
Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .557

Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559

Air Intake Throttle Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .559
Manifold Warp Test for Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .560

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
Front Exhaust Manifold Cuff Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .566
Rear Exhaust Manifold Cuff Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .571
Exhaust Manifold Heat Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576

542 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 543

Exploded Views
Exhaust Manifold

Figure 470 Exhaust manifold

1. Cylinder head 7. Middle exhaust manifold 13. M10 x 57 Torx® bolt (18)
2. Exhaust manifold gasket (6) 8. Multipiece (FEY) ring (4) 14. Sleeve spacer (18)
3. M8 x 12 bolt 9. Seal packing (2) 15. Rear exhaust manifold
4. Heat protection shield 10. Ceramic mat wrap assembly (2) 16. Exhaust gas recirculation tube
5. Front exhaust manifold 11. Shield (4) gasket (2)
6. M10 x 45 stud 12. Ring seal clamp (4)
544 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Air Intake Throttle Horizontal Duct

Figure 471 Air intake throttle horizontal duct

1. Air intake throttle horizontal duct 4. Charge air cooler outlet 7. M8 x 100 bolt (2)
2. Sensor O-ring temperature sensor 8. M8 x 50 bolt
3. Intake manifold pressure sensor 5. O-ring 9. Inlet Air Heater Fuel Igniter
6. Intake throttle gasket (IAHFI)
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 545

Air Intake Throttle Vertical Duct

Figure 472 Air intake throttle vertical duct

1. Inlet Air Heater Fuel Igniter 4. Charge air cooler outlet 7. M8 x 100 bolt (2)
(IAHFI) temperature sensor 8. M8 x 50 bolt
2. Intake manifold pressure sensor 5. Sensor O-ring 9. Intake throttle gasket
3. O-ring 6. Air intake throttle vertical duct
546 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 547

NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Inlet Air Heater
• Aftertreatment System
• Exhaust Back Pressure Control
• Turbochargers
• Oil Cooler, Filter Housing, and Crankcase Ventilation
• Exhaust Gas Recirculating (EGR) System
• Front Cover, Fan Drive, Cooling System, and Related Components
548 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Exhaust Manifold Heat Shield

Figure 473 Heat protection shield

1. Heat protection shield (at front exhaust manifold)
2. M8 x 12 bolt

1. Remove M8 x 12 bolt (Figure 473) (Item 2) that secures the heat protection shield (Figure 473) (Item 1) to
the front exhaust manifold and remove heat protection shield.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 549

Front Exhaust Manifold Cuff Assembly

NOTE: If engine is not equipped with exhaust manifold cuff assembly, proceed to Exhaust Manifold (page 556).
NOTE: Early production front exhaust manifolds have one ring seal clamp, and updated front exhaust manifolds
have two ring seal clamps.

Figure 474 Updated Front Exhaust Manifold Cuff Assembly (two clamp version)
1. Ring seal clamp #2
2. Ring seal clamp #1

1. Remove and discard ring seal clamp(s) (Figure 474) (Items 1, 2) from front exhaust manifold.
550 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 475 Front Exhaust Manifold Shields

1. Exhaust manifold shield (2)
2. Manifold midpoint
3. Seal Packing
4. Beveled flange

2. Remove and discard two exhaust manifold shields (Figure 475) (Item 1).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 551

Figure 476 Front Exhaust Manifold Ceramic Mat Wrap Assembly

1. Ceramic mat wrap assembly
2. Front exhaust manifold
3. Manifold midpoint
4. Middle exhaust manifold

3. Remove and discard front exhaust manifold ceramic mat wrap assembly (Figure 476) (Item 1).
552 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 477 Front Exhaust Manifold Seal Packing

1. Seal packing
2. Front exhaust manifold
3. Middle exhaust manifold

4. Remove and discard exhaust manifold seal packing (Figure 477) (Item 1).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 553

Rear Exhaust Manifold Cuff Assembly

NOTE: If engine is not equipped with exhaust manifold cuff assembly, proceed to Exhaust Manifold (page 556).
NOTE: Early production front exhaust manifolds have one ring seal clamp, and updated front exhaust manifolds
have two ring seal clamps.

Figure 478 Updated Rear Exhaust Manifold Cuff Assembly (two clamp version)
1. Ring seal clamp #2
2. Ring seal clamp #1

1. Remove and discard ring seal clamp(s) (Figure 478) (Items 1, 2) from rear exhaust manifold.
554 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 479 Rear Exhaust Manifold Shields

1. Beveled flange
2. Exhaust manifold shield (2)
3. Seal packing
4. Manifold midpoint

2. Remove and discard two exhaust manifold shields (Figure 479) (Item 2).

Figure 480 Rear Exhaust Manifold Ceramic Mat Wrap Assembly

1. Ceramic mat wrap assembly
2. Ceramic mat wrap joint
3. Manifold midpoint
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 555

3. Remove and discard rear exhaust manifold ceramic mat wrap assembly (Figure 480) (Item 1).

Figure 481 Rear Exhaust Manifold Seal Packing

1. Seal packing

4. Remove and discard exhaust manifold seal packing (Figure 481) (Item 1).
556 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Exhaust Manifold
CAUTION: To prevent engine damage, do not reuse sleeve spacers or exhaust manifold bolts.

Figure 482 Exhaust manifold (typical)

1. Rear exhaust manifold
2. Middle exhaust manifold
3. M10 x 57 Torx® bolt and sleeve spacer (18)
4. Front exhaust manifold
5. Exhaust manifold gasket (6)
6. M8 x 12 bolt
7. Heat protection shield

1. Remove 18 M10 x 57 Torx® bolts and 18 sleeve spacers. Discard bolts and spacers after removal.
2. Remove exhaust manifold assembly and discard six exhaust manifold gaskets.

Figure 483 Exhaust manifolds

1. Rear exhaust manifold
2. Middle exhaust manifold
3. Multipiece (FEY) ring (4)
4. Front exhaust manifold

3. Separate front and rear exhaust manifold sections from middle exhaust manifold.
4. Remove and discard multipiece (FEY) rings from front and rear exhaust manifolds.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 557

Air Intake Throttle Duct

CAUTION: To prevent engine damage, make sure gasket debris and dirt do not enter cylinder head opening.
1. Remove glow plug from air intake throttle duct. See “INLET AIR HEATER SYSTEM” for procedure.
2. Remove temperature sensor and air pressure sensor from air intake throttle duct. See “ENGINE
ELECTRICAL” for procedures.

Figure 484 Air intake throttle horizontal duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle horizontal duct

Figure 485 Air intake throttle vertical duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle vertical duct
558 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

3. Remove M8 x 50 bolt and two M8 x 100 bolts. Depending on application, remove either air intake throttle
horizontal or vertical duct.
4. Remove and discard intake throttle gasket.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 559

Cleaning, Inspection and Testing

Air Intake Throttle Duct and Exhaust Manifolds
NOTE: Do not use air tools or abrasive pads to clean aluminum parts.
NOTE: Normal exhaust manifold sealing surface wear or minor leaks at the FEY ring joints do not require
manifold section replacement.
CAUTION: If engine is not equipped with exhaust manifold cuff assembly, install front and rear exhaust manifold
cuff assembly.
Air intake throttle duct and three exhaust manifold sections are castings and may be cleaned with steam or
suitable non-caustic solvents.
1. Clean cylinder head, air intake throttle duct and exhaust manifold gasket sealing surfaces.
2. Clean multipiece (FEY) ring grooves and sealing surfaces of the exhaust manifold sections.
560 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Manifold Warp Test for Exhaust Manifolds

Figure 486 Exhaust manifold section warp test

1. Left
2. Right
3. Diagonally

1. Use a straightedge and feeler gauge (page 576) to check seating surface flatness of three exhaust manifold
sections.
2. Check for flatness across left, right and diagonally of each exhaust manifold section individually. See
Specification (page 576).
3. If specification is not met, replace individual exhaust manifold section. Do not resurface.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 561

Installation
Air Intake Throttle Duct

Figure 487 Air intake throttle horizontal duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle horizontal duct

1. If equipped with horizontal air intake throttle duct, install intake throttle gasket (Figure 471) (item 6), horizontal
air intake throttle duct, M8 x 50 bolt and two M8 x 100 bolts. Tighten bolts to standard torque (page 881).

Figure 488 Air intake throttle vertical duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle vertical duct
562 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

2. If equipped with vertical air intake throttle duct, install intake throttle gasket (Figure 472) (item 9), vertical air
intake throttle duct, M8 x 50 bolt, and two M8 x 100 bolts. Tighten bolts to standard torque (page 881).
3. Install charge air cooler outlet temperature sensor and intake manifold pressure sensor to air intake throttle
duct. See Charge Air Cooler Outlet Temperature (CACOT) Sensor (page 188) and Intake Manifold Pressure
(IMP) Sensor (page 187).
4. Install Inlet Air Heater Fuel Igniter (IAHFI) to air intake throttle duct. See Inlet Air Heater Fuel Igniter (IAHFI)
and Fuel Supply Inlet Air Heater Hose (Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater
Hose, page 214).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 563

Exhaust Manifold
CAUTION: To prevent engine damage, hand torque all fasteners of the exhaust manifolds. The exhaust manifold
hardware has a special high-temperature coating which will be damaged by air tools.
CAUTION: To prevent engine damage, do not reuse sleeve spacers or exhaust manifold bolts.
NOTE: Do not apply anti-seize compound to threads.

Figure 489 Exhaust manifold

1. Rear exhaust manifold
2. Middle exhaust manifold
3. Multipiece (FEY) ring (4)
4. Front exhaust manifold

NOTE: Each multipiece (FEY) ring replacement comes as four individual rings. There are two multipiece rings
(two sets of four rings) for each front and rear exhaust manifold section. This results in four sets of four individual
rings or 16 total individual rings for a complete exhaust manifold assembly. Each set of four rings in an exhaust
manifold groove must have the ring gaps indexed 90 degrees apart (3, 6, 9 and 12 o'clock position), to ensure
the ring gaps are not aligned.
1. Install four new multipiece (FEY) rings, two to the front exhaust manifold and two to the rear exhaust manifold,
using FEY Rings Installation Tools (page 576). Refer to the tool kit installation instructions. Each multipiece
ring (four individual rings) must be positioned with the four individual ring gaps at 3, 6, 9 and 12 o'clock
position within each exhaust manifold ring groove.
2. Install the front and rear exhaust manifolds into the middle exhaust manifold.
564 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 490 Exhaust manifold

1. Rear exhaust manifold
2. Middle exhaust manifold
3. M10 x 57 Torx® bolt and sleeve spacers (18)
4. Front exhaust manifold
5. Manifold exhaust gasket (6)
6. M8 x 12 bolt
7. Heat protection shield

NOTE: Ensure that raised part of exhaust manifold gasket is facing out towards exhaust manifold.
3. Position six new exhaust manifold gaskets and install exhaust manifold assembly.

Figure 491 Exhaust manifold tightening sequence

4. Install 18 new M10 x 57 Torx® bolts and 18 new sleeve spacers.

a. Tighten all bolts to 40 N·m (30 lb·ft) using tightening sequence shown.
b. Turn all bolts an additional 90° using tightening sequence shown.
565 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
566 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Front Exhaust Manifold Cuff Assembly

Figure 492 Front Exhaust Manifold Seal Packing

1. Seal packing
2. Front exhaust manifold
3. Middle exhaust manifold

CAUTION: If engine was not originally equipped with front exhaust manifold cuff assembly, install new front
exhaust manifold cuff assembly.
1. Wrap seal packing (Figure 492) (Item 1) around manifold ring joint and align so that seal ends meet at top
of manifold.
2. Press seal packing tightly into joint with fingers.
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 567

Figure 493 Front Exhaust Manifold Ceramic Mat Wrap Assembly

1. Middle exhaust manifold
2. Ceramic mat wrap assembly
3. Front exhaust manifold
4. Manifold midpoint
5. Seal packing

CAUTION: To avoid engine damage, wrap thick end of ceramic mat wrap assembly over seal packing end.
3. Wrap joint between front exhaust manifold (Figure 493) (Item 3) and middle exhaust manifold (Figure 493)
(Item 1) and seal packing (Figure 493) (Item 5) with ceramic mat wrap assembly (Figure 493) (Item 2),
covering seal packing with thick end of ceramic mat wrap assembly.
568 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 494 Front Exhaust Manifold Ceramic Mat Wrap Assembly Alignment
1. Ceramic mat wrap assembly joint
2. Front exhaust manifold
3. Manifold midpoint
4. Middle exhaust manifold

4. Align ceramic mat wrap joint (Figure 494) (Item 1) with manifold midpoint (Figure 494) (Item 3).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 569

Figure 495 Front Exhaust Manifold Shields

1. Exhaust manifold shield (2)
2. Manifold midpoint
3. Sealing pack
4. Beveled flange

CAUTION: Install two shield halves with beveled flange on seal packing end side.
5. Install two shield halves (Figure 495) (Item 1) with beveled flange (Figure 495) (Item 4) on sealing pack
(Figure 495) (Item 3) end, and align joint with manifold midpoint (Figure 495) (Item 2).

Figure 496 Front Exhaust Manifold Cuff Assembly Cross Section

1. Middle exhaust manifold
2. Exhaust manifold shield
3. Seal packing
4. Ceramic mat wrap assembly
5. Beveled flange
6. Front exhaust manifold
570 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

6. Verify that exhaust manifold shield (Figure 496) (Item 2) completely covers ceramic mat wrap assembly
(Figure 496) (Item 4), and ceramic mat wrap assembly overlaps seal packing (Figure 496) (Item 3).

Figure 497 Front Exhaust Manifold Ring Seal Clamps

1. Ring seal clamp #2
2. Ring seal clamp #1

NOTE: If engine has an early production front exhaust manifold cuff assembly with one ring seal clamp, install
an updated front exhaust manifold cuff assembly with two ring seal clamps.
NOTE: Ring seal clamp alignment must match the clamp alignment as shown (Figure 497) to allow for proper
exhaust manifold heat shield installation.
7. Install ring seal clamp #1 (Figure 497) (Item 2) on seal packing end (right side) of shield.
8. Tighten ring seal clamp #1 to take up slack.
9. Install ring seal clamp #2 (Figure 497) (Item 1).
10. Alternately tighten each ring seal clamp until shield is snug, keeping shield aligned with manifold midpoint.
11. Tighten ring seal clamps to 70 lb·in (8 N·m).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 571

Rear Exhaust Manifold Cuff Assembly

Figure 498 Rear Exhaust Manifold Seal Packing

1. Seal packing

CAUTION: If engine was not originally equipped with rear exhaust manifold cuff assembly, install new rear
exhaust manifold cuff assembly.
1. Wrap seal packing (Figure 498) (Item 1) around manifold ring joint and align so that seal ends meet at top
of manifold.
2. Press seal packing tightly into joint with fingers.

Figure 499 Rear Exhaust Manifold Ceramic Mat Wrap Assembly

1. Ceramic mat wrap assembly
2. Ceramic mat wrap joint
3. Manifold midpoint
572 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

CAUTION: To avoid engine damage, wrap thick end of ceramic mat wrap assembly over seal packing end.
3. Wrap joint between rear exhaust manifold and middle exhaust manifold and seal packing with ceramic mat
wrap assembly (Figure 499) (Item 1), covering seal packing with thick end of ceramic mat wrap assembly.
4. Align ceramic mat wrap joint (Figure 499) (Item 2) with manifold midpoint (Figure 499) (Item 3).

Figure 500 Exhaust Manifold Shields

1. Beveled flange
2. Exhaust manifold shield (2)
3. Seal packing
4. Manifold midpoint

CAUTION: Install two shield halves with beveled flange on seal packing end side.
5. Install two exhaust manifold shields (Figure 500) (Item 2) with beveled flange (Figure 500) (Item 1) on seal
packing (Figure 500) (Item 3) end, and align joint with manifold midpoint (Figure 500) (Item 4).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 573

Figure 501 Exhaust Manifold Cuff Assembly Cross Section

1. Female manifold
2. Exhaust manifold shield
3. Seal packing
4. Ceramic mat wrap assembly
5. Beveled flange
6. Male manifold

6. Verify exhaust manifold shield (Figure 501) (Item 2) completely covers ceramic mat wrap assembly (Figure
501) (Item 4), and ceramic mat wrap assembly overlaps seal packing (Figure 501) (Item 3).
574 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Figure 502 Rear Exhaust Manifold Ring Seal Clamps

1. Ring seal clamp #1
2. Ring seal clamp #2

NOTE: If engine has an early production front exhaust manifold cuff assembly with one ring seal clamp, install
an updated front exhaust manifold cuff assembly with two ring seal clamps.
7. Install ring seal clamp #1 (Figure 502) (Item 1) on seal packing end (left side) of shield.
8. Tighten ring seal clamp #1 to take up slack.
9. Install ring seal clamp #2 (Figure 502) (Item 2).
10. Alternately tighten each ring seal clamp until shield is snug, keeping shield aligned with manifold midpoint.
11. Tighten ring seal clamps to 70 lb-in (8 N·m).
 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 575

Exhaust Manifold Heat Shield

Figure 503 Heat protection shield

1. Heat protection shield (at front exhaust manifold)
2. M8 x 12 bolt

1. Install heat protection shield (Figure 503) (Item 1) to exhaust manifold.

2. Install M8 x 12 bolt (Figure 503) (Item 2). Tighten bolt to 23 lb·ft (31 N·m).
576 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD

Specifications

Exhaust manifold maximum allowable warpage 0.1 mm (0.003 in)

Special Torque

Exhaust manifold Torx® bolts, M10 x 57 (Installation, page 561)

M8 x 12 bolt 31 N·m (23 lb·ft)

Special Service Tools

Description Tool Number

Feeler gauge Obtain locally
FEY Rings Installation Tools ZTSE6030
Straightedge Obtain locally
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 577
COMPONENTS

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .579

High Mount Fan Drive System and Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .579
Accessory Drive System (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580
Thermostat Assembly and Coolant Outlet Manifold (Low Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . .581
Thermostat Assembly and Coolant Outlet Manifold (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . .582
Water Pump Assembly, Coolant Control Valve (CCV), Water Distribution Housing, Thermostat
Housing and EGR Cooler Return Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .583
Front Belt-Driven Fan Cover (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
Front Gear-driven Fan Cover (Low Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .585
Fan Low Mount Drive (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .586

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587
Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .587
Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .589
High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .590
Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .591
Automatic Belt Tensioner and Idler Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .593
Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .594
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .595
Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .597
Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .601
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .603
Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .604
Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605

Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .606

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608
Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .608
Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .609
Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .610
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .611
Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .613
Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .615
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616
Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
Automatic Belt Tensioner and Idler Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619
Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .622
Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .625

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626

578 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626

 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 579
COMPONENTS

Exploded Views
High Mount Fan Drive System and Vibration Damper

Figure 504 High mount fan drive system and vibration damper
1. Fan drive clutch assembly 7. Fan drive pulley (high mount fan 13. Shoulder bolt
2. Tensioner bracket only) 14. Pulley assembly
3. M8 x 30 bolt (3) 8. M16 x 85 socket-head screw (8)
4. M10 x 35 bolt (9) 9. Fan drive tensioner assembly
5. Vibration damper 10. M10 x 70 countersunk screw
6. Damper hub (low mount fan 11. M10 x 150 bolt - 12.9 (5)
only) 12. M10 x 65 bolt
580 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Accessory Drive System (Typical)

Figure 505 Accessory drive system (typical)

1. Water pump pulley 4. High-pressure pump pulley 6. M10 x 70 countersunk screw
2. Idler pulley (2) (accessory belt drive) 7. M12 x 55 bolt (2)
3. Automatic belt tensioner 5. M16 x 40 bolt 8. M8 x 16 bolt (4)
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 581
COMPONENTS

Thermostat Assembly and Coolant Outlet Manifold (Low Mount Fan)

Figure 506 Thermostat assembly and coolant outlet manifold (low mount fan)
1. M8 x 70 bolt 3. Coolant outlet manifold 5. Bushing (2)
2. Fan coupling bracket assembly 4. Thermostat assembly (2) 6. M8 x 130 bolt (2)
582 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Thermostat Assembly and Coolant Outlet Manifold (High Mount Fan)

Figure 507 Thermostat assembly and coolant outlet manifold (high mount fan)
1. M8 x 70 bolt (3) 2. Coolant outlet manifold (to 3. Thermostat assembly (2)
radiator)
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 583
COMPONENTS

Water Pump Assembly, Coolant Control Valve (CCV), Water Distribution Housing, Thermostat Housing
and EGR Cooler Return Manifold

Figure 508 Water pump assembly, Coolant Control Valve (CCV), water distribution housing,
thermostat housing and EGR cooler return manifold
1. Extension tube (DMR40 / 10. Gasket 19. Engine water inlet
DN32F) (2) 11. Water distribution housing 20. CCV assembly
2. Extension tube (DMR62 / 51) 12. Dowel (2) 21. M8 x 60 stud bolt (2)
3. M8 x 30 bolt 13. Water pump assembly 22. Lock washer (2)
4. M8 x 75 bolt 14. M8 x 40 bolt (7) 23. Housing coolant distribution
5. EGR cooler return manifold 15. M8 x 130 bolt gasket
6. M8 x 145 bolt (4) 16. M8 x 150 bolt (2) 24. O-ring
7. Housing thermostat gasket 17. M8 x 150 bolt (tightens into oil
8. M8 x 60 bolt module assembly)
9. Thermostat housing 18. Water pump gasket
584 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Front Belt-Driven Fan Cover (High Mount Fan)

Figure 509 Front belt-driven fan cover (high mount fan)

1. Front belt driven fan cover 4. M12 x 75 bolt (3) 7. M8 x 40 bolt (2)
2. Front cover gasket 5. Radial shaft seal 8. M12 x 30 bolt (2)
3. Dowel pin (2) 6. M8 x 25 bolt (13)
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 585
COMPONENTS

Front Gear-driven Fan Cover (Low Mount Fan)

Figure 510 Front gear-driven fan cover (low mount fan)

1. Front gear driven fan cover 4. Dowel pin (2) 7. M8 x 25 bolt (13)
2. Front cover gasket 5. M12 x 75 bolt (3) 8. M8 x 40 bolt (2)
3. O-ring 108 x 3 6. Radial shaft seal 9. M12 x 30 bolt (2)
586 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Fan Low Mount Drive (Typical)

Figure 511 Fan low mount drive (typical)

1. M8 x 25 bolt (4) 3. O-ring 108 x 3 5. M8 x 40 bolt
2. Radial shaft seal 4. Fan low mount drive assembly
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 587
COMPONENTS

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Exhaust Gas Recirculation (EGR) System
Pulley (High Mount Fan)

Figure 512 Pulley assembly

1. Shoulder bolt
2. Pulley assembly
588 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

1. Remove shoulder bolt and pulley assembly.

 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 589
COMPONENTS

Tensioner Bracket (High Mount Fan)

Figure 513 Fan drive tensioner assembly (high mount)

1. Fan drive tensioner assembly
2. M10 x 70 countersunk screw

1. Remove M10 x 70 countersunk screw and fan drive tensioner.

Figure 514 Tensioner bracket

1. M8 x 30 bolt (3)
2. Tensioner bracket

2. Remove three M8 x 30 bolts and tensioner bracket.

590 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

High Mount Fan Drive

Figure 515 Fan drive clutch assembly (typical)

1. Fan drive clutch assembly
2. M10 x 150 - 12.9 bolt (5)
3. M10 x 65 bolt

1. Disconnect air line from back of fan drive clutch assembly.

2. Remove five M10 x 150 - 12.9 bolts and M10 x 65 bolt. Remove fan drive clutch.
3. Discard six M10 bolts.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 591
COMPONENTS

Coolant Outlet Manifold and Thermostat Assembly

Figure 516 Coolant outlet manifold (low mount fan)

1. M8 x 70 bolt
2. M8 x 130 bolt (2)
3. Fan coupling bracket
4. Coolant outlet manifold
5. Bushing (2)

Figure 517 Coolant outlet manifold (high mount fan)

1. M8 x 70 bolt (3)
2. Coolant outlet manifold

1. Remove coolant outlet manifold bolts as follows.

a. If equipped with low mount fan, remove M8 x 70 bolt, two M8 x 130 bolts, bracket and two bushings.
b. If equipped with high mount fan, remove three M8 x 70 bolts.
592 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

2. Remove coolant outlet manifold.

Figure 518 Thermostat assembly

1. Thermostat housing
2. Seals (part of thermostat assembly) (2)
3. Thermostat assembly (2)
4. Ball valves (part of thermostat assembly)

3. Remove two thermostat assemblies from thermostat housing.

 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 593
COMPONENTS

Automatic Belt Tensioner and Idler Pulleys

Figure 519 Automatic belt tensioner and idler pulleys (typical)

1. Idler pulley (2)
2. M12 x 55 bolt (2)
3. M10 x 70 countersunk screw
4. Automatic belt tensioner

1. Remove two M12 x 55 bolts and idler pulleys.

CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur,
resulting in improper alignment of the belt tensioner.
2. Remove M10 x 70 countersunk screw and automatic belt tensioner.
594 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Water Pump Assembly and Pulley

Figure 520 Water pump assembly and pulley

1. Water pump assembly
2. Water pump pulley
3. M8 x 16 bolt (4)
4. M8 x 130 bolt
5. M8 x 150 bolt
6. M8 x 40 bolt (7)

1. Remove four M8 x 16 bolts and water pump pulley.

NOTE: If the oil module is removed, the M8 x 150 bolt is also removed.
2. Remove M8 x 130, M8 x 150 and seven M8 x 40 bolts.
CAUTION: To prevent engine damage, do not drop water pump impeller or hit impeller with hard objects.
3. Remove water pump assembly and discard water pump gasket.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 595
COMPONENTS

Vibration Damper

Figure 521 Vibration damper (low mount fan with damper hub)
1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Damper hub
4. M10 x 35 bolt (9)

Figure 522 Vibration damper (high mount fan with fan drive pulley)
1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Fan drive pulley
4. M10 x 35 bolt (9)
596 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

WARNING: To prevent personal injury or death, support the vibration damper when removing bolts.
The damper can easily slide off the crankshaft.
NOTE: If equipped with high mount fan, remove fan drive pulley and vibration damper together. If equipped with
low mount fan, remove damper hub and vibration damper together.
1. Remove eight M16 x 85 socket-head cap screws.
2. Remove vibration damper with damper hub or fan drive pulley as an assembly.
3. For vibration damper replacement only, remove damper hub or fan drive pulley by removing nine M10 x 35
bolts.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 597
COMPONENTS

Coolant Control Valve (CCV) Assembly

Figure 523 CCV assembly

1. Low temperature hose assembly
2. Hose clamp (spring type)
3. Coolant Mixer Valve (CMV)
4. Coolant Flow Valve (CFV)
5. Lock washer (2)
6. M8 x 60 stud bolt (2)
7. CCV assembly

1. Release hose clamp (spring type) and remove low temperature hose assembly from CCV assembly.
2. Remove two M8 x 60 stud bolts, two lock washers, CCV assembly and O-ring. Discard O-ring.
598 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Thermostat Housing

Figure 524 EGR cooler return manifold

1. EGR cooler return manifold
2. M8 x 145 bolt (4)
3. M8 x 30 bolt
4. Extension tube (DMR62 / 51)

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface.
1. Remove extension tube (DMR62 / 51) from manifold. Inspect extension tube for damage, replace as needed.
2. Remove four M8 x 145 bolts and one M8 x 30 bolt.
3. Remove EGR cooler return manifold and discard gasket.

Figure 525 Thermostat housing

1. Thermostat housing
2. M8 x 75 bolt
3. M8 x 60 bolt
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 599
COMPONENTS

4. Remove M8 x 75 bolt and M8 x 60 bolt.

5. Remove thermostat housing and discard gasket.

Figure 526 Thermostat housing

1. Extension tube (DMR40 / DN32F) (2)
2. Thermostat housing

CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface with pliers
or other tools that can mar the surface.
600 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

6. Remove two extension tubes (DMR40 / DN32F) from thermostat housing using a wood-handled tool. Gently
pry the extension tubes out until removed. Inspect extension tubes for damage, replace as needed.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 601
COMPONENTS

Water Distribution Housing

Figure 527 Water distribution housing

1. Water distribution housing
2. M10 x 110 bolt with low mount fan drive or M10 x 150 - 12.9 bolt with high mount fan drive (5)
3. M8 x 150 bolt (2)
4. Engine water inlet (94°)
5. Coolant heater
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan)

1. Remove two M8 x 150 bolts.

• If equipped with low mount fan drive, five M10 x 110 bolts.
• If equipped with high mount fan drive, five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These bolts
are removed with high mount fan drive clutch assembly removal.)
2. Remove water distribution housing and discard gasket.
3. Remove two M10 x 30 bolts and separate engine water inlet from water distribution housing. Remove and
discard gasket.
4. Remove coolant heater from engine water inlet as needed.
602 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal

Figure 528 Radial shaft seal removal

1. Radial shaft seal
2. Slide hammer

WARNING: To prevent personal injury or death, wear safety glasses with side shields when doing
the following procedure.
1. With an awl and hammer, punch two holes 180° apart in front oil seal.
2. Thread a slide hammer (page 626) with correct size screw in one of the two holes.
3. Slide hammer until one side of seal begins to pull out of cover. Move slide hammer to other hole and repeat
until front oil seal is removed.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 603
COMPONENTS

Front Belt- or Gear-Driven Fan Cover

Figure 529 Front belt- or gear-driven fan cover bolts (high mount cover shown)
1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3)
3. M8 x 40 bolt (2)
4. M12 x 30 bolt (2)

WARNING: To prevent personal injury or death, use a suitable lifting device and get help when
removing, lowering and installing the front cover.
1. Remove two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts.
2. Remove front belt- or gear-driven fan cover and front cover gasket from crankcase dowels. Discard front
cover gasket.
604 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Radial Shaft Seal (Fan Low Mount Drive)

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
1. With an awl and hammer, punch two holes 180° apart in radial shaft seal.

Figure 530 Radial shaft seal removal

2. Thread a slide hammer (page 626) with correct size screw in one of the two holes.
3. Slide hammer until one side of seal begins to pull out of fan drive. Move slide hammer to other hole and
repeat until radial shaft seal is removed. Discard radial shaft seal.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 605
COMPONENTS

Fan Low Mount Drive Assembly

Figure 531 O-ring 108 x 3

1. Remove and discard O-ring 108 x 3.

Figure 532 Fan low mount drive assembly

1. M8 x 25 bolt (4)
2. Fan low mount drive assembly
3. M8 x 40 bolt

2. Remove four M8 x 25 bolts, one M8 x 40 bolt and fan low mount drive assembly.
606 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Cleaning, Inspection and Testing

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
1. Clean water distribution housing, water pump, coolant outlet manifold, thermostat housing and front belt- or
gear-driven fan cover with a suitable non-caustic solvent.
2. Blow parts dry using filtered compressed air.
3. Clean coolant and oil seal mating surfaces on the crankcase, cylinder head, water distribution housing,
water pump assembly, coolant outlet manifold, thermostat housing and front belt- or gear-driven fan cover.
4. Inspect water distribution housing, coolant outlet manifold, vibration damper and front belt- or gear-driven
fan cover for damage, contamination or excessive wear. Replace parts if required.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 607
COMPONENTS

5. Inspect belt automatic tensioners and pulleys to make sure tensioner arms and pulleys are properly in line
with the fan drive belt and accessory drive belt and not coming apart. Make sure tensioner arms are not
binding and pulley bearings are not loose. Replace belt tensioners if required.
6. Inspect idler pulleys to make sure pulleys are properly in line with the fan drive belt and accessory drive belt
and not coming apart. Replace idler pulleys if required.
7. Inspect thermostat assemblies. If thermostat assembly elements are stuck open, damaged, cracked or not
opening properly, replace thermostat assemblies.
8. Inspect water pump assembly. Wiggle water pump assembly hub and shaft. If water pump assembly
bearing has excess play, replace water pump assembly. Inspect water distribution housing and water pump
assembly for coolant leaks. Replace if leaking.
608 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Installation
Fan Low Mount Drive Assembly

Figure 533 Fan low mount drive assembly

1. M8 x 25 bolt (4)
2. Fan low mount drive assembly
3. M8 x 40 bolt

1. Install fan low mount drive, M8 x 40 bolt and four M8 x 25 bolts. Tighten bolts to standard torque (page 881).

Figure 534 O-ring 108 x 3

2. Lubricate new O-ring 108 x 3 with clean engine oil and install on fan low mount drive assembly.
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 609
COMPONENTS

Radial Shaft Seal (Fan Low Mount Drive)

1. Lubricate radial shaft seal with clean engine oil.

Figure 535 Radial shaft seal installation

1. Fan Seal Installer
2. Fan low mount drive assembly

2. Using Fan Seal Installer (page 626), install new radial shaft seal until fully seated.
610 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Front Belt- or Gear-Driven Fan Cover

Figure 536 Front belt- or gear-driven fan cover bolts (typical)

1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3)
3. M8 x 40 bolt (2)
4. M12 x 30 bolt (2)

WARNING: To prevent personal injury or death, use a suitable lifting device and get help when
removing, lowering and installing the front cover.
1. Position a new front cover gasket on crankcase dowels.
2. Install front cover on crankcase dowels.
3. Install two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts in locations shown.
Tighten M8 bolts to standard torque (page 881). Tighten M12 bolts to special torque (page 626).
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 611
COMPONENTS

Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal

Figure 537 Radial shaft seal installation (typical)

1. Front belt- or gear-driven fan cover
2. Front Crankshaft Seal Installer

CAUTION: To avoid damage to the radial shaft seal, do not touch inner seal lip, allow oil or grease on any part
of the seal during installation.
1. Using Front Crankshaft Seal Installer (page 626), install a new radial shaft seal into the front cover.
a. Install inner hub of tool to crankshaft flange. Use two bolts provided to secure tool.
b. Install radial shaft seal to inner hub of tool.
c. Install pressing hub and nut and tighten to install radial shaft seal. When tool bottoms out, seal is fully
installed.
612 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Water Distribution Housing

Figure 538 Water distribution housing

1. Water distribution housing
2. M10 x 110 bolt with low mount fan drive or M10 x 150 bolt - 12.9 with high mount fan drive (5)
3. M8 x 150 bolt (2)
4. Engine water inlet (94°)
5. Coolant heater
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan)

1. Install coolant heater into engine water inlet as needed. Tighten to special torque (page 626).
2. Install new gasket and install engine water inlet and two M10 x 30 bolts to water distribution housing. Tighten
bolts to special torque (page 626).
3. Lubricate a new water distribution housing gasket with clean coolant and install into water distribution
housing.
4. Install water distribution housing and secure as follows:
• If equipped with low mount fan drive, use five M10 x 110 bolts.
• If equipped with high mount fan drive, use five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These
bolts are installed with high mount fan drive clutch assembly installation.)
Tighten low mount fan drive bolts to special torque (page 626).
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 613
COMPONENTS

Thermostat Housing

Figure 539 Thermostat housing

1. Extension tube (DMR40 / DN32F) (2)
2. Thermostat housing

1. Lubricate sealing surfaces of two extension tubes (DMR40 / DN32F) with P-80® rubber lubricant or
equivalent (page 626) and install into thermostat housing using Extension Tube Installer Small (page 626).

Figure 540 Thermostat housing

1. Thermostat housing
2. M8 x 75 bolt
3. M8 x 60 bolt

2. Install new gasket and thermostat housing.

3. Install M8 x 75 bolt and M8 x 60 bolt. Do not tighten bolts until EGR cooler return manifold is installed.
614 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Figure 541 EGR cooler return manifold

1. EGR cooler return manifold
2. M8 x 145 bolt (4)
3. M8 x 30 bolt
4. Extension tube (DMR62 / 51)

4. Install new thermostat housing gasket and EGR cooler return manifold.
5. Install four M8 x 145 bolts and one M8 x 30 bolt. Tighten bolts to special torque (page 626).
6. Tighten M8 x 75 and M8 x 60 thermostat housing bolts to standard torque (page 881).
7. Lubricate sealing surfaces of extension tube (DMR62 / 51) with P-80® rubber lubricant or equivalent (page
626) and install into EGR cooler return manifold using Extension Tube Installer Large (page 626).
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 615
COMPONENTS

Coolant Control Valve (CCV) Assembly

Figure 542 CCV assembly

1. Low temperature EGR hose assembly
2. Hose clamp (spring type)
3. Coolant Mixer Valve (CMV)
4. Coolant Flow Valve (CFV)
5. Lock washer (2)
6. M8 x 60 stud bolt (2)
7. CCV assembly

1. Install a new O-ring on the CCV assembly.

2. Install CCV assembly, two lock washers and two M8 x 60 stud bolts. Tighten stud bolts to special torque
(page 626).
3. Install low temperature hose assembly and secure with hose clamp (spring type).
616 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Vibration Damper

Figure 543 Vibration damper (low mount fan with damper hub)
1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Damper hub
4. M10 x 35 bolt (9)

Figure 544 Vibration damper (high mount fan with fan drive pulley)
1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Fan drive pulley
4. M10 x 35 bolt (9)
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 617
COMPONENTS

NOTE: Install damper hub or fan drive pulley and vibration damper together as an assembly.
1. If previously disassembled, assemble damper hub or fan drive pulley to vibration damper with nine M10 x
35 bolts. Tighten bolts to special torque (page 626).
2. Install vibration damper assembly.
3. Install eight M16 x 85 socket-head cap screws. Using a crisscross pattern, tighten screws as follows.
a. Tighten socket-head cap screws to 150 N·m (111 lb·ft).
b. Angle-tighten socket-head cap screws an additional 90°.
618 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Water Pump Assembly and Pulley

Figure 545 Water pump assembly and pulley

1. Water pump assembly
2. Water pump pulley
3. M8 x 16 bolt (4)
4. M8 x 130 bolt
5. M8 x 150 bolt
6. M8 x 40 bolt (7)

NOTE: If the oil module is removed, the M8 x 150 bolt is installed along with oil module.
1. Lubricate a new water pump gasket with clean coolant and install onto water pump.
2. Install water pump and secure with one M8 x 130, one M8 x 150 and seven M8 x 40 bolts in location shown.
Tighten M8 bolts to special torque (page 626).
3. Install water pump pulley and four M8 x 16 bolts. Tighten bolts to special torque (page 626).
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 619
COMPONENTS

Automatic Belt Tensioner and Idler Pulley

Figure 546 Automatic belt tensioner and idler pulley (typical)

1. Idler pulley (2)
2. M12 x 55 bolt (2)
3. M10 x 70 countersunk screw
4. Automatic belt tensioner

CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur,
resulting in improper alignment of the belt tensioner.
1. Install automatic belt tensioner and M10 x 70 countersunk screw. Make sure locating pin is placed into
locating hole. Tighten countersunk screw to special torque (page 626).
2. Install two idler pulleys and two M12 x 55 bolts. Tighten bolts to special torque (page 626).
620 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Coolant Outlet Manifold and Thermostat Assembly

Figure 547 Thermostat assembly

1. Thermostat housing
2. Seals (part of thermostat assembly) (2)
3. Thermostat assembly (2)
4. Ball valves (part of thermostat assembly)

1. Install two thermostat assemblies into thermostat housing with ball valves at 12 o'clock position.

Figure 548 Coolant outlet manifold (low mount fan)

1. M8 x 70 bolt
2. M8 x 130 bolt (2)
3. Fan coupling bracket
4. Coolant outlet manifold
5. Bushing (2)
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 621
COMPONENTS

Figure 549 Coolant outlet manifold (high mount fan)

1. M8 x 70 bolt (3)
2. Coolant outlet manifold

2. Install coolant outlet manifold.

3. If equipped with low mount fan, install bracket and two bushings.
4. Install coolant outlet manifold bolts as follows.
a. If equipped with low mount fan, install one M8 x 70 bolt and two M8 x 130 bolts. Tighten bolts to special
torque (page 626).
b. If equipped with high mount fan, install three M8 x 70 bolts. Tighten bolts to special torque (page 626).
622 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

High Mount Fan Drive

Figure 550 Fan drive clutch assembly (typical)

1. Fan drive clutch assembly
2. M10 x 150 - 12.9 bolt (5)
3. M10 x 65 bolt

CAUTION: To prevent engine damage, clean and blow dry crankcase bolt holes with filtered compressed air.
Debris or fluids in bolt holes may cause binding and incorrect bolt torque.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
1. Using filtered compressed air, clean thread holes of fan drive clutch assembly.
2. Install fan drive clutch assembly and five new M10 x 150 - 12.9 and one new M10 x 65 bolt with engine oil
lightly applied to threads.

Figure 551 High mount fan drive bolt tightening sequence

 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 623
COMPONENTS

3. Tighten M10 bolts using sequence indicated above as follows.

a. Tighten six M10 bolts to 37 N·m (27 lb·ft).
b. Re-tighten six bolts to 37 N·m (27 lb·ft).
c. Angle-tighten five M10 x 150 - 12.9 bolts an additional 90° in sequence.
d. Tighten M10 x 65 bolt to 62 N·m (46 lb·ft).
4. Connect air line to back of fan drive clutch assembly.
624 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Tensioner Bracket (High Mount Fan)

Figure 552 Tensioner bracket

1. M8 x 30 bolt (3)
2. Tensioner bracket

1. Install tensioner bracket and three M8 x 30 bolts. Tighten bolts to standard torque (page 881).

Figure 553 Fan drive tensioner assembly (high mount)

1. Fan drive tensioner assembly
2. M10 x 70 countersunk screw

2. Install fan drive tensioner and M10 x 70 countersunk screw. Make sure locating pin is placed into locating
hole. Tighten countersunk screw to special torque (page 626).
 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED 625
COMPONENTS

Pulley (High Mount Fan)

Figure 554 Pulley assembly

1. Shoulder bolt
2. Pulley assembly

1. Install pulley assembly and shoulder bolt. Tighten shoulder bolt to special torque (page 626).
626 FRONT COVER, FAN DRIVE, COOLING SYSTEM, AND RELATED
COMPONENTS

Special Torque
Automatic belt tensioner countersunk screw,
47 N·m (35 lb·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lb·ft)
M8 x 60
Coolant heater 41 N·m (30 lb·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lb·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lb·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lb·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lb·ft)
Front belt- or gear-driven fan cover bolts,
• M12 x 75 115 N·m (85 lb·ft)
• M12 x 30 115 N·m (85 lb·ft)
High mount fan drive clutch assembly bolts,
See tightening steps in procedure
M10
High mount fan drive tensioner countersunk
47 N·m (35 lb·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lb·ft)

Idler pulley bolt, M12 x 55 60 N·m (44 lb·ft)

Low mount fan drive bolt, M10 x 110 37 N·m (27 lb·ft)
Vibration damper socket-head cap screws,
See tightening steps in procedure
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lb·ft)
Water pump assembly bolts, M8 35 N·m (26 lb·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lb·ft)

Special Service Tools

Description Tool Number

Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
Fan Seal Installer ZTSE6066
Front Crankshaft Seal Installer ZTSE4873
P-80® rubber lubricant or equivalent Obtain locally
Slide hammer Obtain locally
 N13 ENGINE BRAKE BY JACOBS 627

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .629

N13 Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .630
Engine Injector Wiring Harness With Engine Brake Solenoid Leads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .632
Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .632

Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .634
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .634
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635
Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636
Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640

Solenoid Assembly Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .640

Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .646
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .647

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649
Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .649
Engine Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .650

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651

628 N13 ENGINE BRAKE BY JACOBS
 N13 ENGINE BRAKE BY JACOBS 629

Exploded Views

Figure 555 N13 engine brake assembly installation

1. M10 x 90 bolt (6) 4. M12 x 60 (socket-head) screw 7. Valve bridge (exhaust) (6)
2. M12 x 100 (socket-head) screw (6)
(6) 5. Intake and exhaust rocker arm
3. Engine brake housing assembly assembly (6)
(2) 6. Valve bridge (intake) (6)
630 N13 ENGINE BRAKE BY JACOBS

N13 Engine Brake Housing Assembly

Figure 556 N13 engine brake housing assembly

1. Master piston roller assembly 8. Control valve retaining ring 15. Slave piston
2. Master piston roller spring 9. Control valve cover 16. Slave piston spring
3. Master piston spring guide 10. Outer spring 17. Slave piston washer
4. Solenoid assembly 11. Inner spring 18. Slave piston retaining ring
5. M6 x 10 socket-head cap screw 12. Control valve assembly 19. M6 x 30 master piston guide bolt
6. Solenoid cover 13. M10 (jam) nut 20. Master piston guide sleeve
7. Solenoid screen 14. Slave piston adjusting screw
 N13 ENGINE BRAKE BY JACOBS 631

Engine Injector Wiring Harness With Engine Brake Solenoid Leads

Figure 557 Engine injector wiring harness with engine brake solenoid leads
1. Solenoid assembly (2) 3. Engine brake assembly (2) 5. Engine injector harness
2. Solenoid connector nut (part of 4. Engine brake solenoid harness assembly
harness connector) (4) connector lead (2) 6. Tie strap (3)
632 N13 ENGINE BRAKE BY JACOBS

Removal
Engine Brake Housing Assembly

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure that the engine has cooled before
removing components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.

WARNING: To prevent personal injury or death, disconnect the main battery negative terminal
before disconnecting or connecting electrical components.

Figure 558 Engine brake assembly

1. M12 x 100 (socket-head) screw (6)
2. M10 x 90 bolt (6)
3. Solenoid connector nut (4)
4. Tie strap (3)

1. Remove upper valve cover. See Upper Valve Cover and Base (page 668).
 N13 ENGINE BRAKE BY JACOBS 633

2. Disconnect brake wiring harness connector leads from solenoid by disengaging two connector nuts on each
front and rear engine brake housing assemblies. The connector nuts are retained by the harness connectors.
3. Cut tie straps securing solenoid harness connector leads on front and rear brake housings. Position leads
out of the way.
4. Mark housings to indicate front and rear to insure they are reinstalled later in the correct locations.
5. Remove three M12 x 100 socket-head screws and three M10 x 90 bolts and remove front engine brake
housing assembly from cylinder head.
6. Repeat step 5 to remove rear brake housing assembly.
634 N13 ENGINE BRAKE BY JACOBS

Disassembly
NOTE: When disassembling the engine brake housing, keep all component parts together in sets and if reused,
reinstall each set back in its original location.
Solenoid

Figure 559 Solenoid

1. Solenoid assembly
2. M6 x 10 socket-head cap screw
3. Solenoid cover
4. Solenoid screen

1. If not already done, loosen connector nuts and disconnect harness connector leads from solenoid.
2. Remove M6 x 10 socket-head cap screw.
NOTE: Cover slides over solenoid and locks onto terminal ends. Cover is removed with solenoid as an assembly.
3. Remove solenoid and cover from brake housing.
4. Remove upper and lower seal rings from solenoid stem. Discard seal rings.
5. Remove and discard solenoid screen.
 N13 ENGINE BRAKE BY JACOBS 635

Control Valve

Figure 560 Control valve

1. Control valve retaining ring
2. Control valve cover
3. Outer spring
4. Inner spring
5. Control valve assembly

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
NOTE: Use same procedure to remove all control valves from engine.
1. Push down on control valve cover and hold to remove spring pressure from control valve retaining ring.
Using suitable snap-ring pliers, remove control valve retaining ring from housing control valve bore. Slowly
release control valve cover to relieve spring pressure.
2. Remove control valve cover from valve bore.
3. Using a pick, carefully remove inner and outer springs from bore.
4. Using a magnet or needle-nose pliers, remove control valve from housing bore.
636 N13 ENGINE BRAKE BY JACOBS

Master Piston

Figure 561 Master piston

1. Master piston spring guide
2. Master piston roller spring
3. Master piston roller assembly
4. M6 x 30 master piston guide bolt
5. Master piston guide sleeve

The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning
master piston, replace brake housing assembly.
 N13 ENGINE BRAKE BY JACOBS 637

Slave Piston

Figure 562 Slave piston

1. M10 (jam) nut
2. Slave piston adjusting screw
3. Slave piston
4. Slave piston spring
5. Slave piston washer
6. Slave piston retaining ring

WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove
or install slave piston. Slave piston springs are under heavy compression.

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
1. Remove M10 jam nut and back out slave piston adjusting screw until slave piston is fully retracted.
Use same procedure to remove all slave pistons from the engine.
638 N13 ENGINE BRAKE BY JACOBS

Figure 563 Slave Piston Removal Tool

1. Clamp screw collar
2. Slave Piston Removal Tool

2. Place Jacobs® Slave Piston Removal Tool in position with hole in tool clamp bracket over slave piston
adjusting screw and clamp screw collar over slave piston stem.
3. Slowly tighten clamp screw until collar contacts slave piston washer. Continue tightening clamp screw to
compress slave piston spring and relieve spring pressure against slave piston retaining ring.

Figure 564 Slave piston retaining ring

1. Slave piston retaining ring
2. Slave Piston Removal Tool
 N13 ENGINE BRAKE BY JACOBS 639

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
4. Using snap-ring pliers, remove slave piston retaining ring from piston bore.
5. Slowly loosen tool clamp screw to release slave piston spring pressure and remove tool.
6. Grasp piston stem and remove slave piston, spring and washer.
7. Remove slave piston adjusting screw.
640 N13 ENGINE BRAKE BY JACOBS

Cleaning and Inspection

Solenoid Assembly Check

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
1. Clean brake housings, control valve assemblies, master piston rollers, slave pistons and springs with a
suitable non-caustic solvent.
2. Blow parts dry using filtered compressed air.
3. Inspect brake housings for cracks. Replace as required.
4. Check for missing or loose pipe plugs at sides and ends of brake housings. If pipe plugs are missing or
loose, replace brake housing assembly.
5. Inspect master piston rollers and associated camshaft lobes for excessive wear, spalling and galling.
Replace complete brake housing assembly if any master piston roller is determined unacceptable to reuse.
If camshaft lobes for engine brake have excessive wear, spalling or galling, replace camshaft.
6. Inspect slave pistons, springs and control valve assembly for worn or damaged parts. Replace parts that
are broken or deformed.
7. Inspect slave piston bores in brake housing. Insert slave pistons in respective bores and check for free
movement without binding. If there is binding, replace brake housing assembly.
8. Inspect control valve assembly bores in brake housing. Insert control valve assemblies in respective bores
and check for free movement without binding. If there is binding, replace brake housing assembly.

Figure 565 Solenoid assembly check

1. Solenoid screen (removed for check)
2. Pin
3. Button of armature
 N13 ENGINE BRAKE BY JACOBS 641

9. Hold solenoid assembly upside down in hand so you can look into the end where the solenoid screen was
removed. Move button of armature with finger while looking into the open end to verify pin moves freely
within the solenoid assembly. If pin does not move freely, replace solenoid.
10. Using an ohmmeter, check solenoid assembly resistance per the following steps:
• Check resistance across the two terminals. If resistance is out of specification (page 651), replace
solenoid assembly.
• Check resistance from each terminal to the solenoid can. This should be an “open circuit.” If a resistance
is measured, replace solenoid assembly.
642 N13 ENGINE BRAKE BY JACOBS

Assembly
Slave Piston

Figure 566 Slave piston

1. M10 (jam) nut
2. Slave piston adjusting screw
3. Slave piston
4. Slave piston spring
5. Slave piston washer
6. Slave piston retaining ring

1. Check that housing slave piston bore is clean, free of any residue and debris.
2. Lubricate slave piston, spring and washer with clean engine oil.
3. Assemble slave piston spring, washer and retaining ring on slave piston stem.
4. Insert slave piston, spring and washer assembly into housing bore.
NOTE: Retaining ring with proper orientation must be placed on stem before using Jacobs® Slave Piston
Removal Tool to compress spring in housing bore.

WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove
or install slave piston. Slave piston springs are under heavy compression.
 N13 ENGINE BRAKE BY JACOBS 643

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 567 Slave Piston Removal Tool

1. Clamp screw collar
2. Slave Piston Removal Tool

5. Place slave piston retaining ring, oriented with sharp side up (away from washer), in position over slave
piston stem. Install Jacobs® Slave Piston Removal Tool with clamp screw collar on slave piston stem.
6. Slowly tighten clamp screw until screw collar contacts slave piston washer. Continue tightening clamp screw
to compress piston spring until washer is approximately 1/32 inch below retaining ring groove.
644 N13 ENGINE BRAKE BY JACOBS

Figure 568 Slave Piston Removal Tool

1. Slave piston retaining ring
2. Slave Piston Removal Tool

7. Using snap-ring pliers, install slave piston retaining ring in bore ring groove. Ensure retaining ring is oriented
with sharp side up (away from washer). Rotate retaining ring to ensure that it is properly seated in groove.
8. Slowly loosen tool clamp screw to release piston spring pressure and remove tool.
9. Install slave piston adjusting screw and jam nut. Do not tighten jam nut.
 N13 ENGINE BRAKE BY JACOBS 645

Master Piston

Figure 569 Master piston

1. Master piston spring guide
2. Master piston roller spring
3. Master piston roller assembly
4. M6 x 30 master piston guide bolt
5. Master piston guide sleeve

The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning
master piston, replace brake housing assembly.
646 N13 ENGINE BRAKE BY JACOBS

Control Valve

Figure 570 Control valve

1. Control valve retaining ring
2. Control valve cover
3. Outer spring
4. Inner spring
5. Control valve assembly

1. Check that housing control valve bore is clean, free of any residue and debris.
2. Lubricate control valve assembly and springs with clean engine oil.
3. With hex stud end up, insert control valve assembly into housing bore. Ensure control valve assembly
moves smoothly and freely down bore.
4. Insert inner and outer springs into bore. Make sure that springs are properly seated with inner spring on
control valve and outer spring on step of control valve bore.
5. Install control valve cover over springs.

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
6. Using snap-ring pliers, install control valve retaining ring in housing bore to contain control valve assembly.
Ensure retaining ring is installed with sharp side up (away from control valve cover). Rotate retaining ring
to insure that it is properly seated in groove.
 N13 ENGINE BRAKE BY JACOBS 647

Solenoid

Figure 571 Solenoid seal rings

1. Upper seal ring
2. Lower seal ring
3. Solenoid screen

1. Install new upper and lower seal rings in ring grooves on solenoid stem. Lubricate seal rings with clean
engine oil.
2. Clip solenoid screen on bottom of solenoid stem.
648 N13 ENGINE BRAKE BY JACOBS

Figure 572 Solenoid

1. Solenoid assembly
2. M6 x 10 socket-head cap screw
3. Solenoid cover
4. Solenoid screen

3. Place solenoid in position on brake housing. Using hand pressure, press solenoid into bore until it snaps
into place.
4. If removed, install solenoid cover on solenoid.
5. Install M6 x 10 socket-head cap screw. Tighten screw to special torque (page 651).
 N13 ENGINE BRAKE BY JACOBS 649

Installation
Engine Brake Housing Assembly

Figure 573 Engine brake assembly

1. M12 x 100 (socket-head) screw (6)
2. M10 x 90 bolt (6)
3. Solenoid connector nut (4)
4. Tie strap (3)

CAUTION: To prevent engine damage, verify injector harness wires are not pinched or rubbing against the
engine brake housing or rocker arm assembly.
1. Carefully place previously marked front engine brake housing assembly in front position over camshaft and
valve train.
2. Install three M12 x 100 socket-head screws and three M10 x 90 bolts. Tighten bolts to special torque (page
651).
3. Repeat steps 1 and 2 to install previously marked rear engine brake housing assembly in rear position over
camshaft and valve train.
CAUTION: To prevent engine damage, do not over torque nuts on wiring harness connector leads. Too much
torque will damage solenoid terminals.
4. Connect brake wiring harness connector leads to solenoid on front and rear engine brake housing
assemblies. Make sure harness terminal connectors are in straight alignment with harness. Hold terminal
connectors stationary to avoid twisting and tighten connector nuts to special torque (page 651).
5. Install two tie straps to secure solenoid harness connector lead on front brake housing and one tie strap to
secure harness connector lead on rear brake housing.
6. Adjust engine brake lash. See Engine Brake Lash Adjustment (page 650).
7. Install upper valve cover. See Upper Valve Cover and Base (page 703).
650 N13 ENGINE BRAKE BY JACOBS

Engine Brake Lash Adjustment

Figure 574 Engine brake lash adjustment

1. Slave piston adjusting screw
2. M10 (jam) nut
3. Actuator pin (in exhaust valve bridge)
4. Slave piston

See Valve Lash Adjustment (page 665) for procedure covering both valve lash and engine brake lash
adjustments on engines so equipped.
 N13 ENGINE BRAKE BY JACOBS 651

Specifications

Temperature Solenoid resistance

Cold — 25 ° C (77 ° F) 8.7–10 ohms
Hot — 121 ° C (250 ° F) 12–15.5 ohms

Special Torque

Brake housing M10 x 90 bolt 75 N·m (55 lb·ft)

Brake housing M12 x 100 (socket-head) screw 105 N·m (77 lb-ft)
Brake housing solenoid harness connector nut 3.5 N·m (31 lb·in)
Slave piston adjusting screw M10 (jam) nut 25 N·m (18 lb·ft)
Solenoid M6 x 10 socket-head cap screw 12.5 N·m (110 lb·in)

Special Service Tools

Description Tool Number

Jacobs® Slave Piston Removal Tool ZTSE6068

652 N13 ENGINE BRAKE BY JACOBS
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 653

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655

Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .655
Rocker Arm Assembly And Valve Bridges (Non-Brake). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .657
Camshaft and Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .658
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .659

Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660

Crankshaft Rotation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660
Cylinder No. 1 TDC Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .662
Valve Overlap Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .664
Valve Lash Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668
Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668
Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .672
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .678
Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681

Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .682

Cylinder Head and Crankcase Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .682
Camshaft Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .683
Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684
Valves Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .685

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688
Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .688
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695
Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .703

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .706

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .706

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .707

654 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 655

Exploded Views
Valve Cover and Base

Figure 575 Valve cover and base

1. Screw with damper (18) 3. M8 x 30 bolt (17) 5. Valve cover base
2. Upper valve (cover) gasket 4. Upper valve cover 6. Valve cover (base) gasket
656 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 657

Rocker Arm Assembly And Valve Bridges (Non-Brake)

Figure 576 Rocker arm assembly and valve bridges (non-brake)

1. Intake and exhaust rocker arm 2. M12 x 60 (socket-head) screw 4. Valve bridge (intake and
assembly (6) (12) exhaust) (12)
3. Rocker bearing block (6)

NOTE: Rocker arm assemblies and valve bridges shown and covered in this section represent the standard
non-brake engine configuration. For engines with optional engine brake, refer to N13 Engine Brake by Jacobs
section for procedures.
658 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Camshaft and Cylinder Head Idler Gear

Figure 577 Camshaft and cylinder head idler gear

1. M8 x 30 bolt (3) 5. M8 x 35 bolt (14) 10. Cylinder head idler gear
2. Camshaft timing disc (pulse 6. (Camshaft) bearing cap (7) 11. Small gear shaft
wheel) 7. 4H x 8 x 10 dowel pin (14) 12. M8 x 30 socket-head cap screw
3. Camshaft gear 8. Camshaft (3)
4. Timing (M6 x 20 dowel) pin 9. Bearing shell (14) 13. DMR 63.10 cup plug
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 659

Cylinder Head

Figure 578 Cylinder head

1. Front lifting eye 3. Cylinder head 5. Dowel pin (2)
2. M18 x 2 x 246 Torx® bolt (26) 4. Cylinder head gasket 6. M12 x 25 bolt (2)
660 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Periodic Service

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set
parking brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, remove the ground cable from the negative
terminal of the main battery before disconnecting or connecting electrical components. Always
connect the ground cable last.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
Crankshaft Rotation Procedure

Figure 579 High-pressure pump pulley

1. High-pressure pump pulley
2. M16 x 40 LH bolt (left-hand thread)

NOTE: The crankshaft can be rotated using the M16 x 40 LH bolt (left-hand thread) on the high-pressure pump
pulley. Care must be used to ensure the bolt is not loosened while the crankshaft is rotated.
1. Adjust a torque wrench to 162 N·m (120 lb-ft).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 661

2. Place a 19 mm socket on the torque wrench.

3. Slowly rotate the M16 x 40 LH bolt (left-hand thread) bolt clockwise. Stop pulling if the torque wrench clicks.
Torque in excess of 162 N·m (120 lb-ft) may cause the bolt to loosen. Continue rotating to desired position
when compression leaks down and less force is needed to rotate the crankshaft.
662 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Cylinder No. 1 TDC Procedure

1. Remove the upper valve cover and base. See Upper Valve Cover and Base (page 668).

Figure 580 Camshaft gear timing mark

1. Valve cover surface
2. Camshaft gear
3. Timing mark

2. Rotate crankshaft in direction of engine rotation until the camshaft timing gear mark aligns with the valve
cover surface on the intake side of the engine. See Crankshaft Rotation Procedure (page 660).

Figure 581 Flywheel housing timing index (typical)

1. Flywheel housing timing index
2. Flywheel timing mark

3. Remove timing hole cover from lower side of flywheel housing.

4. Rotate crankshaft in direction needed to align the flywheel timing mark with flywheel housing timing index.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 663

5. Recheck that the timing mark on camshaft gear is aligned with the valve cover gasket surface (on intake side
of cylinder head). If flywheel and camshaft gear marks are in agreement, the engine is at TDC for cylinder
1. Skip step 6 and proceed to Valve Overlap Procedure below.
CAUTION: To prevent engine damage, a new large idler gear must be installed, if the large idler gear has slipped.
6. If flywheel and camshaft gear marks are not in agreement, the large idler gear has slipped. See Rear Timing
Gears (page 783) for procedure to install a new large idler gear.
664 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Valve Overlap Procedure

NOTE: Valve lash adjustments are done in firing order sequence (1, 5, 3, 6, 2, 4), using the valve overlap
method. Valve overlap happens on the companion cylinder near the end of the exhaust stroke and the beginning
of the intake stroke, when both valves are open for a short period of time.
NOTE: Valve lash must be set with engine cold and cylinder head assembled to crankcase.
1. Starting with cylinder 1 at TDC compression, set valve lash for cylinder 1, according to Valve Lash Adjustment
Procedure below.
2. After valves for cylinder 1 have been adjusted, rotate crankshaft slowly and watch valves for cylinder 2;
watch the exhaust valve as it closes, and watch for intake valve to start opening. When cylinder 2 intake
and exhaust valves are open equally, adjust valves on cylinder 5 according to the Valve Lash Adjustment
Procedure below.
3. Repeat Valve Overlap Procedure, in order for remaining cylinders 3, 6, 2, and 4. See Table 29 (page 667).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 665

Valve Lash Adjustment Procedure

NOTE: Valve lash must be set with engine cold and cylinder head assembled to crankcase.

Figure 582 Valve Lash Adjustment (Typical)

1. Exhaust rocker arm
2. Intake rocker arm
3. Adjusting screw
4. Valve lash adjustment M10 nut
5. Valve bridge (intake/exhaust)

NOTE: Adjust engine valve lash and engine brake lash at 120,000 miles (190,000 km), 300,000 miles (480,000
km), then every 300,000 miles (480,000 km) thereafter.
1. Do Valve Overlap Procedure (page 664).
2. Loosen valve lash adjustment M10 nut (Figure 582) (Item 4) on intake rocker arm (Figure 582) (item 2).
3. Insert Lash Gauge ZTSE6076–5A 0.5 mm (0.020 in) between intake valve bridge (Figure 582) (Item 5) and
adjusting screw (Figure 582) (Item 3), and tighten adjusting screw until a slight drag on Lash Gauge 0.5 mm
(0.020 in) is felt.
4. Hold adjusting screw in position and tighten valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
NOTE: If equipped with N13 engine brake, go to step 6 to adjust exhaust valve lash and engine brake lash. If
no engine brake, continue to step 5.
5. For engines without brake, adjust exhaust valve lash as follows:
a. Loosen valve lash adjustment M10 nut on exhaust rocker arm (Figure 582) (item 1).
b. Insert Lash Gauge ZTSE6076–7A 0.8 mm (0.031 in) between exhaust valve bridge and adjusting screw
and tighten adjusting screw until a slight drag on Lash Gauge 0.8 mm (0.031 in) is felt.
c. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
d. Go to step 6.
666 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 583 Brake Lash Adjustment (Equipped with N13 Engine Brake)
1. Slave piston adjusting screw
2. Brake lash adjustment M10 (jam) nut
3. Engine brake housing assembly
4. Actuator pin (in exhaust valve bridge)
5. Slave piston

6. For engines with N13 engine brake, adjust exhaust valve lash and engine brake lash as follows:
a. Loosen brake lash adjustment M10 (jam) nut (Figure 583) (Item 2) on engine brake housing assembly
(Figure 583) (Item 3), and back out slave piston adjusting screw (Figure 583) (Item 1) so slave piston
no longer contacts valve bridge.
b. Loosen valve lash adjustment M10 nut on exhaust rocker arm (Figure 582) (item 1).
c. Insert Lash Gauge 0.8 mm (0.031 in) on exhaust rocker arm between exhaust valve bridge (Figure 582)
(Item 5) and adjusting screw, and tighten adjusting screw (Figure 582) (Item 4) until a slight drag on
Lash Gauge 0.8 mm (0.031 in) is felt.
d. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
e. Insert Lash Gauge 0.8 mm (0.031 in) on engine brake housing assembly between slave piston (Figure
583) (Item 5) and bridge actuator pin (Figure 583) (Item 4).
f. Turn adjusting screw in until slave piston contacts Lash Gauge 0.8 mm (0.031 in) and a slight drag on
Lash Gauge 0.8 mm (0.031 in) is felt.
g. Using a 5 mm Allen wrench, hold slave piston adjusting screw to prevent from turning and tighten jam
nut to 33 lb·ft (45 N·m).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 667

Table 1
Cylinder at TDC compression Companion cylinder in valve overlap
1 6
5 2
3 4
6 1
2 5
4 3

7. Turn crankshaft in direction of engine rotation to position next cylinder in firing order at TDC compression
(one at a time) and adjust lash for the respective cylinder. See (Crankshaft Rotation Procedure, page 660).
For each cylinder positioned at TDC compression, the companion cylinder will be in valve overlap as shown
in following table.
668 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Removal
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Turbochargers
• Air Compressor and Power Steering
• Fuel System
• Oil Cooler, Filter Housing and Crankcase Ventilation
• Exhaust Gas Recirculation (EGR) System
• Air Intake Throttle Duct and Exhaust Manifold
• Front Cover, Fan Drive, Cooling System and Related Components
Upper Valve Cover and Base

Figure 584 Upper Valve Cover and Base

1. Screw with damper (18)
2. M8 x 30 bolt (17)
3. Upper valve cover
4. Valve cover base

CAUTION: To prevent engine damage, do not use power tools to remove or install valve cover bolts. Threads
will be damaged if a bolt or nut is rotated too quickly.
NOTE: The upper valve cover can be removed separately or as an assembly with the valve cover base
depending on work being performed. If it is being removed as an assembly, start with step 2.
1. Remove 17 M8 x 30 bolts (Figure 584) (Item 2) and remove upper valve cover (Figure 584) (Item 3) from
base (Figure 584) (Item 4).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 669

NOTE: The valve cover base screws can only be removed from valve cover as assemblies with the dampers.
Screws and dampers should only be removed from cover if replacing the valve cover gasket.
2. Release 18 screws with dampers (Figure 584) (Item 1) from cylinder head. Do not completely remove
screws from valve cover at this time.
3. Remove valve cover base (or assembly) from cylinder head.
NOTE: Valve cover gaskets can be reused and do not require removal from valve cover base unless damaged.

Figure 585 Valve Cover Gaskets

1. Valve cover base
2. Screw with damper (18)
3. Upper valve cover gasket
4. (Lower) valve cover gasket

4. Inspect upper (Figure 585) (Item 3) and lower (Figure 585) (Item 4) valve cover gaskets for damage. If
damaged, replace as follows:
a. Upper gasket — remove from groove in upper surface of valve cover base (Figure 585) (Item 1) and
discard gasket.
b. Lower gasket — completely remove 18 screws with dampers (Figure 585) (Item 2) to release gasket
from bottom of valve cover base. Discard gasket.
670 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Rocker Arm Assembly (Non-Brake Engine)

CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their
orientation. Do not use paint or temporary markers.

Figure 586 Rocker Arm Assembly (Typical)

1. M12 x 60 (socket-head) screw (12)
2. Rocker arm assembly (6)

1. Mark rocker arm assemblies (Figure 586) (Item 2) 1 through 6 so each assembly can be installed in its
original cylinder location.
2. Remove 12 M12 x 60 socket-head screws (Figure 586) (Item 1).
3. Remove six rocker arm assemblies.

Figure 587 Rocker Bearing Block and Valve Bridges

1. Rocker bearing block (6)
2. Valve bridge (12)
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 671

4. Mark rocker bearing blocks (Figure 587) (Item 1) 1 through 6 so each block can be installed in its original
cylinder location.
5. Remove six rocker bearing blocks.
6. Mark valve bridges (Figure 587) (Item 2) so each bridge can be installed in its original location and orientation.
7. Remove 12 valve bridges.
672 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Camshaft
CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their
orientation. Do not use paint or temporary markers.

Figure 588 Camshaft end play check (typical)

1. Check camshaft end play as follows:

a. Mount dial indicator with magnetic base (page 707) on cylinder head with indicator tip on end of camshaft
as shown.
b. Move camshaft toward rear of engine and zero the dial indicator.
c. Move camshaft back and forth while reading dial indicator. Compare dial indicator reading with camshaft
end play specification (page 706).
d. If end play exceeds specified limits, install a new camshaft.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 673

Figure 589 Camshaft timing mark (typical)

1. Camshaft gear
2. Timing mark

2. Turn engine crankshaft in direction of engine rotation until timing mark on camshaft gear is aligned with
cylinder head surface.
674 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 590 Flywheel housing timing index (typical)

1. Flywheel housing timing index
2. Flywheel timing mark

3. Remove timing hole cover from lower side of flywheel housing and verify timing mark on flywheel is aligned
with flywheel housing timing index.
• If timing mark on flywheel is out of alignment, then the timing has slipped due to large idler gear slippage.
Install a new large idler gear. See Rear Timing Gears (page 783) section of this manual for procedures
to replace large idler gear.
• If timing mark on flywheel is aligned with flywheel housing timing index, continue to next step.

Figure 591 Camshaft bearing caps

1. Camshaft bearing cap (7)
2. M8 x 35 bolt (14)

4. Remove 14 M8 x 35 bolts.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 675

5. Remove seven camshaft bearing caps from the cylinder head. Mark each bearing cap with location number
and orientation.
676 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 592 Camshaft bearing cap and bearing shell (typical)

1. Camshaft bearing cap
2. 4H x 8 x 10 dowel pin (2)
3. Bearing shell

6. Remove seven bearing shells from camshaft bearing caps. Mark each bearing shell with camshaft bearing
cap number and orientation.
7. If damaged, remove 14 - 4H x 8 x 10 dowel pins from seven camshaft bearing caps.
8. Remove camshaft.
9. Remove seven lower bearing shells from cylinder head. Mark each bearing shell with camshaft bearing cap
number and orientation.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 677

Figure 593 Camshaft gear and camshaft timing disc (pulse wheel)
1. Timing (M6 x 20 dowel) pin
2. Camshaft gear
3. Camshaft timing disc (pulse wheel)
4. M8 x 30 bolt (3)

10. Remove three M8 x 30 bolts.

11. Remove camshaft timing disc and camshaft gear.
12. If damaged, remove timing pin from camshaft.
678 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Cylinder Head
CAUTION: To prevent engine damage, remove fuel injectors before removing cylinder head.
1. Remove six fuel injectors. See Fuel Injectors (page 397).

Figure 594 Cylinder Head Lifting Bracket

1. Cylinder Head Lifting Bracket
2. M8 x 20 class 10.9 bolt (4)

2. Position Cylinder Head Lifting Bracket (page 707) on rear end of cylinder head.
3. Install four M8 x 20 class 10.9 bolts (page 707). Tighten bolts to standard torque (page 881).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 679

Figure 595 Cylinder head bolts

4. Use Head Bolt Torx® Socket (page 707) and working in a circular pattern, loosen, remove, and discard 26
M18 x 246 Torx® bolts. Begin with the outer bolts and move inward.
680 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 596 Cylinder head removal

5. Lift cylinder head using a suitable lifting device.

WARNING: To prevent personal injury or death, use a hoist rated for the weight of the cylinder
head and follow the manufacturer's operative and safety instructions. Attach safety lifting hooks to the
cylinder head lifting bracket and lifting eye.
CAUTION: To prevent engine damage, do not scratch gasket surface of cylinder head.
CAUTION: To prevent engine damage, carefully set cylinder head on wooden blocks to protect the cylinder head
idler gear.
6. Place cylinder head on a clean, non-metallic surface.
7. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 707).
8. Remove and discard cylinder head gasket.

Figure 597 8 mm dowel pin (2)

9. If damaged, remove two 8 mm dowel pins.

 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 681

Cylinder Head Idler Gear

Figure 598 DMR 63.10 cup plug removal

1. Use a punch to knock in bottom of DMR 63.10 cup plug. Remove and discard cup plug.

Figure 599 Cylinder head idler gear

1. Small gear shaft
2. Cylinder head idler gear
3. M8 x 30 socket-head cap screw (3)

2. Remove three M8 x 30 socket-head cap screws, small gear shaft and cylinder head idler gear.
CAUTION: To prevent engine damage, check piston protrusion before installing cylinder head.
682 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Cleaning, Inspection, and Testing

Cylinder Head and Crankcase Components

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
CAUTION: Do not use chlorinated solvents on cylinder head bolts. If parts are not cleaned thoroughly, parts will
corrode over time. Be sure parts are clean, dry and free of chemicals other than engine oil.
CAUTION: To prevent engine damage, do not scratch gasket surface of cylinder head.
1. Use a scraper and wire brush to remove deposits and gasket material from valve heads and gasket surface.
2. Use a suitable solvent to remove dirt, grease and deposits from removed parts.
3. Clean all bolt holes. Make sure gasket surfaces are clean. Clean all surfaces and ports with steam, and
then dry with filtered compressed air.
4. Clean all bolts (except head bolts) with a suitable solvent and dry thoroughly. New head bolts must be
installed.
CAUTION: To prevent engine damage, clean and dry threads in crankcase bolt holes with filtered compressed
air. Dirt or oil in holes may cause binding and incorrect torque readings.

Figure 600 Head bolt bottoming tap (typical)

5. Clean cylinder head bolt holes in crankcase with Head Bolt Bottoming Tap (page 707).
6. Clean out debris with filtered compressed air.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 683

Camshaft Bearings
1. With camshaft removed, install previously marked bearings and camshaft bearing caps. Tighten M8 x 35
bolts to special torque (page 706).

Figure 601 Camshaft bearing check (typical)

2. Use a telescoping gauge set (page 707) and a 1 - 2 inch micrometer (page 707) to measure camshaft
bearing inside diameter. If inside diameter does not meet specification (page 706), install new camshaft
bearings.
684 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Fuel Injector Bore

1. Use Injector Sleeve Brushes (page 707) in injector bore to remove deposits.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
2. Use filtered compressed air to clean out debris from injector bores.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 685

Valves Leak Test

NOTE: Position wooden blocks so the view of all the intake and exhaust valve heads and valve seat areas is
not restricted.
1. Position cylinder head on wooden blocks with cylinder head gasket surface facing down.

Figure 602 Air intake throttle duct (typical)

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle duct

2. Apply Loctite® 5900 sealant or equivalent (page 707) to joining surfaces of air intake throttle duct and
cylinder head.
3. Install air intake throttle duct.
686 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

4. Install M8 x 50 bolt and two M8 x 100 bolts. Tighten bolts to standard torque (page 881).
5. Spray mineral spirits into exhaust ports.
6. Pour mineral spirits into air intake throttle duct until intake manifold inside cylinder head is filled.

Figure 603 Leak inspection

1. Inspection mirror
2. Reflection of valve
3. Flashlight

NOTE: Valve seats must not leak. If valve seats leak, install a new cylinder head. Cylinder head replacement
is not required if the cylinder head passes the valves leak test using mineral spirits.
7. Wait five minutes. Use an inspection mirror to inspect valve seat area for leakage of mineral spirits. If there
is no leakage of mineral spirits through the intake or exhaust valves, the cylinder head is acceptable for
reinstallation.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 687

Figure 604 Air intake throttle duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
3. Air intake throttle duct

8. Position a suitable container under air intake throttle duct to catch mineral spirits. M8 x 50 bolt and two M8
x 100 bolts.
9. Remove air intake throttle duct.
10. Lift rear end of cylinder head to drain all remaining mineral spirits out of the intake manifold.
688 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Installation
Cylinder Head Idler Gear

Figure 605 Cylinder head idler gear

1. Small gear shaft
2. Cylinder head idler gear
3. M8 x 30 socket-head cap screw (3)

1. Install small gear shaft and cylinder head idler gear.

2. Install three M8 x 30 socket-head cap screws. Tighten screws to special torque (page 706).
3. Clean cylinder head mating surfaces for cylinder head idler gear DMR 63.10 cup plug.
4. Apply Loctite® 262™ Threadlocker (page 707) to the outside edge of new cylinder head idler gear cup plug.

Figure 606 DMR 63.10 cup plug installation

5. Drive new cup plug into the hole using a Bearing Installer (page 707) approximately 6 mm (0.25 in) smaller
in diameter than the cup plug.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 689

6. Recess cup plug 2.3 mm (0.9 in) below the machined surface.
690 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Cylinder Head

Figure 607 8 mm dowel pin (2)

1. If previously removed, install two 8 mm dowel pins in crankcase.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
CAUTION: Do not use chlorinated solvents on cylinder head bolts. If parts are not cleaned thoroughly, parts will
corrode over time. Be sure parts are clean, dry and free of chemicals other than engine oil.
CAUTION: To prevent engine damage, clean and blow dry threads in the crankcase bolt holes with filtered
compressed air. Dirt or oil in holes may cause binding or an incorrect torque reading.
CAUTION: To prevent engine damage, remove debris and contaminants from cylinder head gasket mating
surfaces. If debris is not removed, a faulty seal between the cylinder head, gasket and crankcase will cause oil,
coolant and compression leaks. Do not apply sealant to head gasket surfaces.
CAUTION: To prevent engine damage, install a new cylinder head gasket with part number facing up.
CAUTION: To prevent engine damage, check piston protrusion before installing cylinder head.
2. Check piston protrusion. See Preliminary Checks (page 796).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 691

Figure 608 Cylinder head gasket

1. N13 cylinder head gasket 2. MaxxForce® 11 cylinder head 3. Right rear corner
gasket 4. Notch at right rear corner

CAUTION: To prevent engine damage, install correct cylinder head gasket for application.
3. Verify correct cylinder head gasket isused for application. N13 cylinder head gaskets (Figure 608) (Item 1)
have a notch at the right rear corner (Figure 608) (Item 4).
4. Install a new cylinder head gasket on crankcase, over dowel pins.
692 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 609 Cylinder Head Lifting Bracket

1. Cylinder Head Lifting Bracket
2. M8 x 20 class 10.9 bolt (4)

5. Position Cylinder Head Lifting Bracket (page 707) on rear end of cylinder head.
6. Install four M8 x 20 class 10.9 bolts (page 707). Tighten bolts to standard torque (page 881).

Figure 610 Cylinder head installation

WARNING: To prevent personal injuries or death, use a hoist rated for the weight of the cylinder
head and follow the manufacturer's operation and safety instructions. Attach safety lifting hooks to the
cylinder head lifting bracket and lifting eye.
CAUTION: To prevent engine damage, do not drop or slide cylinder head on cylinder head gasket. This can
damage the cylinder head gasket, dowel pins and the cylinder head idler gear.
7. Attach an appropriate hoist and lifting hooks to cylinder head lifting bracket and lifting eye.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 693

8. Lower cylinder head onto crankcase and align cylinder head alignment dowels in the crankcase with dowel
holes in the cylinder head.

Figure 611 Cylinder head bolts

CAUTION: To prevent engine damage, install new cylinder head bolts when installing cylinder head. Apply a
light coat of clean engine oil to new bolt threads and under bolt head. Too much oil will cause hydrostatic lock
and give incorrect torque reading. Do not use anti-seize compound, grease, or any other lubricant on cylinder
head bolt threads.
9. Install 26 new lightly lubricated M18 x 246 Torx® bolts. Do not tighten bolts at this time.
10. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 707).
694 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 612 Cylinder head bolt tightening sequence

CAUTION: To prevent engine damage, use only permanent ink markers to identify bolt torque orientation.
CAUTION: To prevent engine damage, use a torque wrench to tighten cylinder head bolts; do not use an impact
wrench.
NOTE: For proper cylinder head surface seating and sealing, follow the correct tightening sequence.
11. Use Head Bolt Torx® Socket (page 707) to tighten the M18 x 246 Torx® bolts in sequence indicated above
as follows:
1. Hand-tighten Torx® bolts.
2. Tighten Torx® bolts numbered 1 through 26 to 10 N·m (89 lb·in) in numerical sequence as shown.
3. Tighten Torx® bolts numbered 1 through 26 to 150 N·m (111 lb·ft) in numerical sequence.
4. Tighten Torx® bolts numbered 1 through 26 to 300 N·m (221 lb·ft) in numerical sequence.
5. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical
sequence.
6. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical
sequence for second time.
7. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical
sequence for third time.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 695

Camshaft

Figure 613 Camshaft gear and camshaft timing disc (pulse wheel)
1. Timing (M6 x 20 dowel) pin
2. Camshaft gear
3. Camshaft timing disc (pulse wheel)
4. M8 x 30 bolt (3)

1. If previously removed, install timing (M6 x 20 dowel) pin into camshaft.

2. Align camshaft gear with timing pin and install on camshaft.
3. Align camshaft timing disc with timing pin and install on camshaft.
4. Install and finger-tighten three M8 x 30 bolts.

Figure 614 Camshaft lower bearing shell oil hole alignment (typical)

NOTE: If original camshaft bearings are installed, make sure to place them as previously marked in their original
location and orientation.
696 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

5. Install seven new or previously marked camshaft lower bearings on cylinder head. Make sure oil holes in
bearings are aligned with oil holes in cylinder head bearing support.
6. Rotate crankshaft so cylinder number 1 is positioned at TDC. See Crankshaft Rotation Procedure (page
660).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 697

Figure 615 Flywheel housing timing index (typical)

1. Flywheel housing timing index
2. Flywheel timing mark

7. Verify timing mark on flywheel is aligned with flywheel housing timing index at bottom of flywheel housing.

Figure 616 Camshaft timing mark (typical)

1. Camshaft gear
2. Timing mark

8. Lower camshaft on cylinder head and make sure timing mark on camshaft gear is aligned with cylinder head
surface.
698 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 617 Camshaft bearing cap and bearing shell

1. Camshaft bearing cap
2. 4H x 8 x 10 dowel pin (2)
3. Bearing shell

NOTE: Make sure that each bearing cap has the two dowel pins installed.
9. If previously removed, install 14 - 4H x 8 x 10 dowel pins into seven camshaft bearing caps.
NOTE: If original bearings are installed, make sure each is placed as previously marked in its original location
and orientation.
10. Install seven new or previously marked bearing shells on camshaft bearing caps.

Figure 618 Camshaft bearing caps

1. Camshaft bearing cap (7)
2. M8 x 35 bolt (14)
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 699

11. Install seven previously marked camshaft bearing caps with each placed in its original location and
orientation.
12. Install 14 M8 x 35 bolts. Tighten bolts to special torque (page 706).

Figure 619 Camshaft gear bolts tightening

1. Camshaft gear
2. M8 x 30 bolt (3)

13. Tighten three M8 x 30 bolts to 15 N·m (133 lb·in).

14. Tighten three M8 x 30 bolts an additional 90° (1/4 turn).
700 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Rocker Arm Assembly (Non-Brake Engine)

Figure 620 Rocker Bearing Block and Valve Bridges

1. Rocker bearing block (6)
2. Valve bridge (12)

NOTE: If original valve bridges are installed, make sure each is placed as previously marked in its original
location.
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 701

Figure 621 Valve Bridge Orientation (Typical)

1. Camshaft side
2. Exhaust manifold side

1. Place 12 new or previously marked valve bridges on intake and exhaust valves with milled end oriented
toward camshaft.
NOTE: If original rocker bearing blocks are installed, make sure each is placed as previously marked in its
original location.
2. Install six new, or previously marked rocker bearing blocks.

Figure 622 Rocker Arm Assembly (Typical)

1. M12 x 60 (socket-head) screw (12)
2. Rocker arm assembly (6)

NOTE: If original rocker arm assemblies are installed, make sure each is placed as previously marked in its
original location.
3. Install six new or previously marked rocker arm assemblies (Figure 622) (Item 2).
702 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

4. Install 12 M12 x 60 socket-head screws (Figure 622) (Item 1). Tighten screws to 77 lb·ft (105 N·m).
5. Adjust valve lash. See Cylinder No. 1 TDC Procedure (page 662).
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 703

Upper Valve Cover and Base

Figure 623 Valve Cover Gaskets

1. Valve cover base
2. Screw with damper (18)
3. Upper valve cover gasket
4. (Lower) valve cover gasket

1. Apply Loctite® 5127 sealant (page 707) at sharp corners and curved surfaces to joining surfaces of cylinder
head and lower valve cover gasket (Figure 623) (Item 4).
2. If necessary, install a new lower and/or upper valve cover gasket (Figure 623) (Item 3).
3. If previously removed, install 18 screws with dampers (Figure 623) (Item 2) in valve cover base (Figure 623)
(Item 1) and through lower valve cover gasket.
704 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Figure 624 Upper Valve Cover and Base

1. Screw with damper (18)
2. M8 x 30 bolt (17)
3. Upper valve cover
4. Valve cover base

CAUTION: To prevent engine damage, do not use power tools to remove or install valve cover bolts. Threads
will be damaged if a bolt or nut is rotated too quickly.
4. Install valve cover base (Figure 624) (Item 4) on cylinder head and finger tighten 18 screws with dampers
(Figure 624).

Figure 625 Valve Cover Base Tightening Sequence

 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 705

5. Tighten 18 screws with dampers (Figure 624) (Item 1) in sequence shown above (Figure 625). Tighten to
97 lb·in (11 N·m).
6. If removed, install upper valve cover (Figure 624) (Item 3) on valve cover base.
7. Install 17 M8 x 30 bolts (Figure 624) (Item 2) and tighten to 80 lb·in (9 N·m).
706 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN

Specifications

Camshaft
Camshaft bearing inside diameter 39.925 – 39.950 mm (1.57185 – 1.57283 in)
Camshaft end play 0.25 – 0.85 mm (0.0098 – 0.0334 in)
Valve Lash Adjustment
Exhaust valve clearance 0.8 mm (0.0315 in)
Intake valve clearance 0.5 mm (0.0197 in)
Cylinder Head Idler Gear Cup Plug
Cup plug, DMR 63.10 Recess 2.3 mm (0.9 in)

Special Torque

Camshaft gear M8 x 30 bolt See tightening steps in procedure

(Camshaft) bearing cap M8 x 35 bolt 25 N·m (18 lb·ft)
Cylinder head idler gear M8 x 30 socket-head cap screw 30 N·m (22 lb·ft)
Cylinder head M18 x 246 Torx® bolt See tightening steps in procedure
Rocker arm assembly M12 x 60 (socket-head) screw 105 N·m (77 lb·ft)
Upper valve cover M8 x 30 bolt 9 N·m (80 lb·in)
Valve cover base screw with damper 11 N·m (97 lb·in)
Valve lash adjustment M10 nut 45 N·m (33 lb·ft)
 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 707

Special Service Tools

Description Tool Number

1 - 2 inch micrometer Obtain locally
Bearing installer Obtain locally
Connecting Rod Bolt Torx® Socket ZTSE4835
Cylinder Head Lifting Bracket ZTSE4869
Dial indicator with magnetic base Obtain locally
Feeler gauge (Jacobs® 96-020949) Obtain from Jacobs
Head Bolt Bottoming Tap ZTSE4855
Head Bolt Torx® Socket ZTSE4787
Injector Sleeve Brushes ZTSE4751
Lash Gauge 0.5 mm (0.020 in) ZTSE6076-5A
Lash Gauge 0.8 mm (0.031 in) ZTSE6076-7A
™
Loctite® 262 Threadlocker Obtain locally
Loctite® 5127 sealant Obtain locally
Loctite® 5900 sealant or equivalent Obtain locally
M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally
708 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
 FLYWHEEL AND FLYWHEEL HOUSING 709

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711

Flywheel Housing and Flywheel (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711
Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .712
Rear Engine Mounts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .713

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Preliminary Checks and Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Pilot Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .716
Flywheel (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718
Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .719
Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .721

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .723

All Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .723
Flywheel and Flexplate Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .724

Recondition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727
Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .730
Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731
Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
Pilot Bearing (Flywheel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734

Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .737

710 FLYWHEEL AND FLYWHEEL HOUSING
 FLYWHEEL AND FLYWHEEL HOUSING 711

Exploded Views
Flywheel Housing and Flywheel (Manual Transmission)

Figure 626 Flywheel housing and flywheel (manual transmission)

1. Radial shaft ring seal 6. Dowel pin (2) 12. 12PT flange bolt (10)
2. M10 x 30 bolt (12) 7. Timing hole cover 13. M16 x 150 bolt (4)
3. M10 x 40 bolt (3) 8. Tapping screw (2) 14. Lifting eye (2)
4. Flywheel housing 9. Plug
5. 56/48 x 19 plug (converter bolt 10. Flywheel assembly
access) 11. Pilot bearing
712 FLYWHEEL AND FLYWHEEL HOUSING

Flywheel and Flexplate Assembly (Automatic Transmission)

Figure 627 Flywheel and flexplate assembly (automatic transmission)

1. 12PT flange bolt (10) 3. Flexplate assembly 5. 8 x 60-ST pin
2. Wear plate (reinforcement ring) 4. Flywheel assembly
 FLYWHEEL AND FLYWHEEL HOUSING 713

Rear Engine Mounts

Figure 628 Rear engine mounts

1. Left offset engine mounting 4. 3/4” x 2” bolt (12) 7. 3/4” washer (12)
support 5. Right offset engine mounting
2. Extension assembly support
3. PDO base bracket 6. Flywheel housing
714 FLYWHEEL AND FLYWHEEL HOUSING

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: Refer to the following service section for information on removal of components prior to this section:
• Aftertreatment System
Preliminary Checks and Measurements
Flywheel Assembly (Manual Transmission)
1. Inspect flywheel for cracks around webbing and bolt holes.
2. Inspect flywheel for heat cracks and extensive scoring.
3. Inspect all ring gear teeth for starter pinion damage.
4. Replace flywheel if necessary.

Flywheel Surface Runout

CAUTION: To prevent engine damage, check runout of flywheel surface for correct alignment of engine
to transmission. Failure to ensure correct bore concentricity and face runout may reduce life of clutch or
transmission.
 FLYWHEEL AND FLYWHEEL HOUSING 715

Figure 629 Flywheel surface runout

1. Dial indicator with magnetic base
2. Flywheel

1. Attach dial indicator with magnetic base (page 737) to surface of lifting eye. Place indicator tip against
flywheel.
NOTE: Keep crankshaft end play at zero and rotate in same direction for all measurements.
2. Push the flywheel inward to eliminate crankshaft end play, zero dial indicator.
3. While pushing inward on the flywheel to eliminate crankshaft end play, slowly rotate crankshaft one complete
revolution. See Crankshaft Rotation Procedure (page 660). Compare total dial indicator variation (highest
- lowest reading) to specification (page 737).
716 FLYWHEEL AND FLYWHEEL HOUSING

Pilot Bearing

Figure 630 Pilot bearing removal (typical)

1. Slide hammer and blind hole puller
2. Pilot bearing

1. Using a slide hammer (page 737), install blind hole puller (page 737), into pilot bearing.
2. Tap slide hammer and remove pilot bearing.
 FLYWHEEL AND FLYWHEEL HOUSING 717

Flywheel (Manual Transmission)

Figure 631 Flywheel removal

1. 12PT flange bolt (10)
2. Flywheel assembly

1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service
publications.)
2. Remove and discard two 12PT flange bolts at approximately 3 o'clock and 9 o'clock position.
3. Install two guide pins (make locally) into crankshaft flange.
4. Remove and discard remaining eight 12PT flange bolts.
5. Slide wear plate (reinforcement ring) and four flexplates off guide pins.
6. Slide flywheel assembly off guide pins and out of flywheel housing.
7. Remove guide pins from crankshaft flange.
718 FLYWHEEL AND FLYWHEEL HOUSING

Flywheel and Flexplate Assembly (Automatic Transmission)

Figure 632 Flywheel and flexplate assembly

1. Flexplate and flywheel assembly
2. 12PT flange bolt (10)
3. Guide pin (2)
4. Wear plate (reinforcement ring)

1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service
publications.)
2. Remove and discard two 12PT flange bolts, 180 degrees from each other (approximately 3 o’clock and 9
o’clock positions).
3. Install two guide pins (made locally) in place of two removed 12PT flange bolts.
4. Remove and discard the remaining eight 12PT flange bolts.
NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an
assembly.
5. Slide wear plate (reinforcement ring) and four flexplates off guide pins.
6. Slide flywheel assembly off guide pins and out of flywheel housing.
7. Remove guide pins from crankshaft flange.
 FLYWHEEL AND FLYWHEEL HOUSING 719

Radial Shaft Ring Seal

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 633 Radial shaft ring seal removal

1. Slide hammer
2. Radial shaft ring seal

1. With an awl and hammer, punch two holes 180° apart in radial shaft ring seal.
2. Thread a slide hammer (page 737) with correct size screw into one of the two holes.
3. Slide hammer until one side of seal begins to pull out of flywheel housing. Move slide hammer to other hole
and repeat until seal is completely removed.
720 FLYWHEEL AND FLYWHEEL HOUSING

Lifting Eyes

Figure 634 Lifting eye

1. M16 x 150 bolt (4)
2. Lifting eye (2)

1. Remove four M16 x 150 bolts.

2. Remove two lifting eyes.
 FLYWHEEL AND FLYWHEEL HOUSING 721

Flywheel Housing

WARNING: To prevent personal injury or death, support the flywheel housing before removing
bolts and breaking sealant bond between flywheel housing and crankcase.

WARNING: To prevent personal injury or death, get help when removing or installing the flywheel
housing.

Figure 635 Right offset engine mounting support assembly

1. Right offset engine mounting support
2. PDO base bracket
3. Flywheel housing
4. 3/4" x 2” bolt with 3/4” washer (6)

1. Remove six 3/4" x 2” bolts with washers, PDO base bracket and engine mounting support from right side of
flywheel housing.
2. Remove 3/4" x 2” bolts with washers, extension bracket and engine mounting support from the left side of
flywheel housing.
722 FLYWHEEL AND FLYWHEEL HOUSING

Figure 636 Flywheel housing (typical)

1. M10 x 30 bolt (12)
2. M10 x 40 bolt (3)
3. Flywheel housing

WARNING: To prevent personal injury or death, support the flywheel housing before removing
bolts and breaking sealant bond between housing and crankcase.
3. Remove 12 M10 x 30 and three M10 x 40 bolts from flywheel housing.
4. Use a thin gasket scraper to separate sealant between flywheel housing and crankcase.

WARNING: To prevent personal injury or death, get help when removing or installing the flywheel
housing.
5. Remove flywheel housing with aid of an assistant.
 FLYWHEEL AND FLYWHEEL HOUSING 723

Cleaning and Inspection

All Components

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
1. Clean foreign material from gasket surfaces of crankcase and flywheel housing. Use a scraper or wire brush
to remove sealant from gasket surfaces.
2. Gasket surfaces must be oil-free for good adhesion of liquid gasket during assembly. Use a commercially
available, non-caustic brake cleaner to clean gasket surfaces of crankcase and flywheel housing.
3. Wash flywheel, flexplate (if equipped) and flywheel housing. Dry all with filtered compressed air.
4. Wash crankshaft timing gear with a stiff brush and suitable solvent. Dry all with filtered compressed air.
724 FLYWHEEL AND FLYWHEEL HOUSING

Flywheel and Flexplate Assemblies

1. Inspect flywheel for cracks around webbing and bolt holes.
2. Inspect flywheel for extensive heat cracks and scoring.
3. If equipped, inspect flexplate for cracks, damage or warpage. Replace if required.
4. Inspect all ring gear teeth for starter pinion damage.
5. Replace flywheel if necessary.
 FLYWHEEL AND FLYWHEEL HOUSING 725

Recondition

Flywheel
NOTE: Flywheels used with manual transmissions may be resurfaced to correct minor wear and scoring. If
flywheel meets the following requirements it can be resurfaced.

WARNING: To prevent personal injury or death, do not machine flywheel beyond minimum
thickness specified for flywheel resurfacing.

Figure 637 Flywheel surface dimension (typical)

1. Flywheel thickness (dimension “A”)
2. Clutch disc mounting face
3. Crankshaft timing gear face

NOTE: Flywheel resurfacing information is provided for guidance only. Navistar, Inc. assumes no responsibility
either for the results of any work performed in accordance with this information or for the ability of service
personnel to detect cracks.
726 FLYWHEEL AND FLYWHEEL HOUSING

WARNING: To prevent personal injury or death, carefully examine flywheel for any cracks or heat
checks before and after resurfacing. Cracks in the flywheel can cause it to separate. If there are any
questions, do not reuse the flywheel.
1. Check flywheel for cracks and damage. Replace flywheel if required.
2. Using 1-2 inch micrometer (page 737), measure flywheel thickness and compare to minimum required
thickness specification (dimension “A”) (page 737). Discard flywheel if below minimum thickness
specification or if flywheel will be below minimum thickness after resurfacing.
3. Resurface flywheel. See Flywheel Resurfacing Machine operators manual for instructions on flywheel
resurfacing procedure.
4. Check flywheel for cracks and damage after resurfacing. Replace flywheel if required.
5. Measure flywheel thickness after resurfacing and compare to minimum required thickness specification.
Discard flywheel if below minimum thickness specification.
 FLYWHEEL AND FLYWHEEL HOUSING 727

Installation
Flywheel Housing
CAUTION: To prevent engine damage, apply Liquid Gasket and component within 5 minutes of application to
inhibit the formation of a skin and ensure a leak proof joint.

Figure 638 Flywheel housing to crankcase alignment dowel pins

1. Flywheel housing to crankcase mating surface
2. Flywheel housing to crankcase dowel pin (2)

1. Verify flywheel housing alignment dowels are installed into the crankcase and are not damaged. Replace
as necessary.
728 FLYWHEEL AND FLYWHEEL HOUSING

Figure 639 Flywheel housing sealant application

1. Apply sealant on mating surface
2. Front of flywheel housing

2. Apply Loctite 5900 or Wacker® A–442 RTV sealant (page 737) to mating surfaces of flywheel housing and
crankcase.

WARNING: To prevent personal injury or death, get help when removing or installing the flywheel
housing.
3. Install flywheel housing to crankcase with the aid of an assistant.

Figure 640 Flywheel housing (typical)

1. M10 x 30 bolt (12)
2. M10 x 40 bolt (3)
3. Flywheel housing
 FLYWHEEL AND FLYWHEEL HOUSING 729

4. Install 12 M10 x 30 and three M10 x 40 flywheel housing bolts. Tighten bolts to special torque (page 737).

Figure 641 Right offset engine mounting support assembly

1. Right offset engine mounting support
2. PDO base bracket
3. Flywheel housing
4. 3/4" x 2” bolt with 3/4” washer (6)

5. Install 3/4" x 2” bolts, washer, extension bracket and rear engine mount on left side of flywheel housing.
Tighten to standard torque (page 881).
6. Install 3/4" x 2” bolts, washer, PDO base bracket and engine mounting support on right side of flywheel
housing. Tighten to standard torque (page 881).
730 FLYWHEEL AND FLYWHEEL HOUSING

Lifting Eyes

Figure 642 Lifting eyes

1. M16 x 150 bolt (4)
2. Lifting eye (2)

1. Install two lifting eyes.

2. Install four M16 x 150 lifting eye bolts. Tighten bolts to special torque (page 737).
 FLYWHEEL AND FLYWHEEL HOUSING 731

Radial Shaft Ring Seal

Figure 643 Radial shaft ring seal installation (typical)

1. Rear Oil Seal Installer
2. Radial shaft ring seal

CAUTION: To avoid damage to the radial shaft ring seal, do not touch inner seal lip or allow oil or grease on any
part of the seal during installation.
1. Using Rear Oil Seal Installer (page 737), install ring radial shaft seal into flywheel housing.
a. Install inner hub of tool to crankshaft flange. Use two bolts provided with tool.
b. Install radial shaft seal to inner hub of tool.
c. Install pressing hub and nut and tighten to install seal. When tool bottoms out, seal is fully installed.
732 FLYWHEEL AND FLYWHEEL HOUSING

Flywheel Assembly (Manual Transmission)

1. Install two guide pins (made locally) into crankshaft flange at approximately 3 o'clock and 9 o'clock position.

Figure 644 Flywheel assembly and bolts

1. 12PT flange bolt (10)
2. Flywheel assembly
3. 8 x 60-ST pin

2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft timing gear pin and slide flywheel
onto guide pins.
CAUTION: To prevent engine damage, always install new flywheel mounting bolts.
CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate
mounting bolts.
3. Loosely install eight new 12PT flange bolts to secure flywheel assembly to crankshaft.
4. Remove both guide pins and loosely install two remaining new 12PT flange bolts.
 FLYWHEEL AND FLYWHEEL HOUSING 733

Figure 645 Flywheel bolt tightening sequence

NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from
turning.
5. Tighten 12PT flange bolts using sequence indicated above as follows:
a. Tighten bolts to 110 N·m (81 lb·ft).
b. Angle tighten bolts 90°.
c. Angle tighten bolts an additional 90°.
734 FLYWHEEL AND FLYWHEEL HOUSING

Pilot Bearing (Flywheel)

Figure 646 Pilot Bearing Installation Tool

1. Place pilot bearing in flywheel bore.

2. Using Pilot Bearing Installation Tool (page 737), tap pilot bearing into flywheel. When tool bottoms out, pilot
bearing is fully installed.
 FLYWHEEL AND FLYWHEEL HOUSING 735

Flywheel and Flexplate Assembly (Automatic Transmission)

Figure 647 Flywheel and flexplate assembly

1. Flexplate and flywheel assembly
2. 12PT flange bolt (10)
3. Guide pin (2)
4. Wear plate (reinforcement ring)

1. Install two guide pins (made locally) into crankshaft flange 180° apart (approximately 3 o’clock and 9 o’clock
positions).
2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft gear pin and slide flywheel onto
guide pins.
CAUTION: To prevent engine damage, always install new flywheel mounting bolts.
CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate
mounting bolts.
NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an
assembly.
3. Slide flexplate assembly over guide pins.
4. Slide wear plate (reinforcement plate) over guide pins with logo and part number visible towards rear and
install eight new 12PT flange bolts hand tight.
5. Remove guide pins and install remaining two 12PT flange bolts.
736 FLYWHEEL AND FLYWHEEL HOUSING

Figure 648 Flywheel and flexplate assembly bolt tightening sequence (typical)

NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from
turning.
6. Tighten 12PT flange bolts using sequence above as follows:
a. Tighten bolts to 110 N•m (81 lb·ft).
b. Angle tighten bolts 90°
c. Angle tighten bolts an additional 90°.
 FLYWHEEL AND FLYWHEEL HOUSING 737

Specifications
Flywheel and Flywheel Housing
Flywheel minimum thickness (dimension “A”) 46 mm (1.811 in)
Flywheel maximum surface runout 0.20 mm (0.0079 in)

Special Torque

12PT flange bolts See tightening steps in procedure.

Flywheel housing bolts, M10 x 30 and M10 x 40 65 N·m (48 lb·ft)
Lifting eye bolts, M16 x 150 280 N·m (207 lb·ft)
Timing hole cover screws 2 N·m (18 lb·in)

Special Service Tools

Description Tool Number

1-2 inch micrometer Obtain locally
Blind hole puller Obtain locally
Brake cleaner (non-caustic) Obtain locally
Dial indicator with magnetic base Obtain locally
Loctite 5900® Obtain locally
Wacker® A–442 RTV sealant Obtain locally
Pilot Bearing Installation Tool ZTSE4898
Rear Oil Seal Installer ZTSE4875
Slide hammer Obtain locally
738 FLYWHEEL AND FLYWHEEL HOUSING
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 739

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741

Oil Pan (Front Sump Shown, Rear Sump Similar, Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .741
Oil Pickup Tube - Front Sump (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742
Oil Fill Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744
Oil Pickup Tube – Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .747
Oil Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .748
Oil Pickup Tube – Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750
Oil Fill Tube Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .751

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753

Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
Oil Fill Tube Adapter Mount Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .754

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .755
Oil Pickup Tube — Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .755
Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756
Oil Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .758
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762
Oil Fill Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767

740 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 741

Exploded Views
Oil Pan (Front Sump Shown, Rear Sump Similar, Typical)

Figure 649 Oil pan (front sump shown, rear sump similar, typical)
1. Oil pan gasket 7. Cooling tube bracket (2) (right 11. Oil pan clamp – front right 599
2. Oil pan (front sump) angle) mm (23.5 in)
3. O-ring (heater, optional) 8. Extension bracket support 12. Oil drain M27 x 2 plug
4. Oil pan heater element (optional) (T-bracket) 13. O-ring (32.92 x 3.53)
5. Oil pan clamp – rear right 461 9. M8 x 40 bolt (22)
mm (18 in) 10. Oil pan clamp – front left 599
6. Oil pan clamp – rear left 461 mm mm (23.5 in)
(18 in)
742 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Pickup Tube - Front Sump (Typical)

Figure 650 Oil pickup tube - Front sump (typical)

1. O-ring, 32 x 5 4. Oil pickup tube support (2) 7. M8 x 16 bolt (2)
2. Prevailing torque nut (M8) (2) 5. M8 x 25 bolt (2)
3. D9/19/4 washer (2) 6. Pickup oil tube
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 743

Oil Fill Tube Assembly

Figure 651 Oil Fill Tube Assembly

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing
744 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the
parking brake, and block the wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, remove the ground cable from the negative
terminal of the main battery before disconnecting or connecting electrical components. Always
connect the ground cable last.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: Refer to the following service section for information on removal of components prior to this section.
• Engine Electrical — required for preheater removal.
Oil Pan
1. Remove oil drain plug and O-ring and drain oil into a suitable container.
2. If equipped, remove oil pan heater element and discard O-ring.
3. Recycle or dispose of oil according to applicable regulations.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 745

Figure 652 Cooling tube brackets and extension bracket support (typical)
1. M8 x 40 bolt (3)
2. Cooling tube bracket (right angle) (2)
3. Extension bracket support (T-bracket)

4. Remove three M8 x 40 bolts, two cooling tube brackets, and one extension bracket support.
746 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Figure 653 Oil pan clamps (typical)

1. M8 x 40 bolt (19)
2. Oil pan clamp – front left 599 mm (23.5 in)
3. Oil pan clamp – rear left 461 mm (18 in)
4. Oil pan clamp – rear right 461 mm (18 in)
5. Oil pan clamp – front right 599 mm (23.5 in)

5. Remove 19 M8 x 40 bolts.
6. Remove four oil pan clamps.
7. Remove oil pan and oil pan gasket as an assembly.
8. Clean and inspect the oil pan gasket. Discard gasket if damaged.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 747

Oil Pickup Tube – Front Sump

Figure 654 Oil pickup tube (front sump, typical)

1. M8 x 25 bolt (2)
2. Oil pickup tube
3. M8 x 16 bolt (2)

1. Remove two M8 x 16 bolts and pickup tube with supports as an assembly.

2. Only if required, remove the two M8 x 25 bolts, prevailing torque nuts, D9/19/4 washers and oil pickup tube
supports.

Figure 655 Oil pickup tube O-ring

3. Remove and discard oil pickup tube O-ring.

748 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Recovery

Figure 656 High-pressure pump support and plug

1. Plug
2. M14 x 30 bolt (2)
3. High-pressure pump support

1. Remove and save two M14 x 30 bolts that secure the high-pressure pump support.
2. Remove and save two M12 x 30 bolts that secure the high-pressure pump support. to the bottom of
high-pressure pump.
3. Remove and save the high-pressure support.
4. Remove plug from crankcase. Discard plug and seal ring.

Figure 657 Oil pickup tube

1. M8 x 16 bolt
2. Oil pickup tube support
3. M8 x 25 bolt and M8 nut
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 749

5. Remove M8 x 25 bolt and M8 nut that secure the oil pickup tube support to the clamp on the oil pickup tube.
Discard M8 x 25 bolt; save M8 nut.
6. Remove and discard M8 x 16 bolt that secures other end of oil pickup tube support .
7. Remove and save oil pickup tube support.
750 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Pickup Tube – Rear Sump

Figure 658 Oil pickup tube (rear sump)

1. M8 x 16 bolt (4)
2. M8 x 25 bolt (3)
3. Oil pickup tube
4. Tube support

1. Remove four M8 x 16 bolts holding oil pickup tube supports to crankcase.

2. Remove oil pickup tube and supports as an assembly.
3. Only if required, remove M8 x 25 bolts, prevailing torque nuts and D9/19/4 washers and supports.

Figure 659 Oil pickup tube O-ring

4. Remove and discard oil pickup tube O-ring.

 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 751

Oil Fill Tube Assembly Removal

Overview
This section provides instruction for removal of the oil fill tube assembly when not doing a complete engine
tear-down.

Equipment Condition
None

Special Tools Required

None

Procedure

Figure 660 Oil Fill Tube Assembly

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing

See Oil Fill Tube Assembly (Figure 660) to perform steps 1 and 2.
752 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

1. Remove oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support
bracket (3).
2. Loosen two oil fill tube hose clamps (5) securing oil fill tube hose (6) to oil fill tube (1) and oil fill tube adapter
(Figure 661) (Item 2).

Figure 661 Oil Fill Tube Assembly Removal

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump

See Oil Fill Tube Assembly Removal (Figure 661) to perform steps 3 through 5.
3. Remove oil fill tube (4) from oil fill tube hose (5) and oil fill tube hose (5) from oil fill tube adapter (2).
4. Discard two oil fill tube hose clamps (3).
5. If replacement is determined necessary, remove oil fill tube adapter (2) from accessory drive housing (1).
Discard oil fill tube adapter.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 753

Cleaning and Inspection

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
Oil Pan
1. Inspect bottom of oil pan for metallic debris or other evidence of engine damage. Investigate any
abnormalities as required.
2. Clean oil pan with a suitable solvent.
3. Dry with filtered compressed air.
4. Inspect oil pan for warping, dents and cracks. Replace the oil pan if necessary.

Oil Pickup Tube

1. Clean oil pickup tube and supports with a suitable solvent.
2. Dry with filtered compressed air.
3. Inspect oil pickup tube and supports for cracks, damage or pickup screen blockage. Replace if necessary.
754 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Fill Tube Adapter Mount Cleaning and Inspection

Figure 662 Oil Fill Tube Adapter Thread Mount

1. Accessory drive housing
2. Oil fill tube adapter threaded
mount

See Oil Fill Tube Adapter Thread Mount (Figure 662) to perform step 1.
1. Clean oil fill tube adapter threaded mount (2) in accessory drive housing (1) with a soft cloth.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 755

Installation
Oil Pickup Tube — Front Sump

Figure 663 Oil pickup tube O-ring

1. Install a new oil pickup tube O-ring. Lubricate O-ring with clean engine oil.

Figure 664 Oil pickup tube (front sump, typical)

1. M8 x 25 bolt (2)
2. Oil pickup tube
3. M8 x 16 bolt (2)

2. If required, position two oil pickup tube supports and loosely install two M8 x 25 bolts, prevailing torque nuts
and D9/19/4 washers.
3. Install oil pickup tube and two M8 x 16 bolts.
4. Tighten two M8 x 16 bolts to standard torque (page 881).
5. Tighten two prevailing torque nuts (M8) and M8 x 25 bolts to standard torque (page 881).
756 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Pickup Tube — Rear Sump

1. Lubricate a new oil pickup tube O-ring with clean engine oil and install onto tube.

Figure 665 Rear sump oil tube assembly

1. O-ring, 32 x 5
2. Prevailing torque nut (4)
3. D9/19/4 washers (4)
4. Supports (short) (3)
5. M8 x 25 bolt (4)
6. Support (long)
7. Oil pickup tube

2. If oil pickup tube supports were removed, loosely install with four M8 x 25 bolts, D9/19/4 washers and
prevailing torque nuts.
3. Install oil pickup tube and supports as an assembly.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 757

Figure 666 Oil pickup tube

1. M8 x 16 bolts (4)
2. M8 x 25 bolts (3)
3. Oil pickup tube
4. Tube support

4. Install four M8 x 16 bolts through oil pickup tube supports.

5. Tighten four M8 x 16 bolts to standard torque (page 881).
6. Tighten three M8 x 25 bolts and prevailing torque nuts to standard torque (page 881).
758 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Recovery

Figure 667 Straight fitting assembly and seal ring

1. Straight fitting assembly
2. Seal ring

1. Lubricate new seal ring with clean engine oil and put ring onto new straight fitting assembly.

Figure 668 Straight fitting assembly

2. Thread straight fitting assembly into the crankcase (where plug was removed in Figure 1) and tighten fitting
to 55 N·m (40 lb·ft).
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 759

Figure 669 Oil recovery support assembly and oil pickup tube
1. Oil recovery support assembly (includes M6 x 20 stud)
2. M8 x 30 bolt and M8 nut
3. Oil pickup tube support
4. M8 x 50 stud bolt
5. Spacer (30 mm)

3. Position new oil recovery support assembly onto saved oil pickup tube support. Secure by installing a new
M8 x 30 bolt and saved M8 nut. Tighten nut to 13 N·m (115 lb·in).
4. Position new 30 mm spacer onto other end of oil pickup tube support and install new M8 x 50 stud bolt.
Tighten bolt to 31 N·m (23 lb·ft).

Figure 670 P-clamps on oil recovery tube

1. P-clamp (3)
2. Brazed end

5. Position three new P-clamps onto mew oil recovery tube as shown.
760 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Figure 671 Oil recovery tube (brazed end)

6. Coat brazed end of oil recovery tube with P80® rubber lubricant or equivalent.
7. Insert brazed end of oil recovery tube into straight fitting assembly in crankcase; position P-clamp onto M6
x 20 stud in oil recovery support and P-clamp onto M8 x 50 stud bolt.

Figure 672 P-clamps

1. M6 nut
2. M8 nut
3. M8 x 60 bolt
4. Spacer (43 mm)

8. Install new M6 nut onto M6 x 20 stud on oil recovery support.

9. Install new M8 nut onto M8 x 50 stud bolt.
10. Position new 43 mm spacer under P-clamp and install new M8 x 60 bolt.
11. Tighten M8 nut and M8 x 60 bolt to 31 N·m (23 lb·ft).
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 761

12. Tighten M6 nut to 13 N·m (115 lb·in).

Figure 673 High-pressure pump support and straight fitting assembly

1. Straight fitting assembly
2. M14 x 30 bolt (2)
3. High-pressure pump support

13. Install high-pressure pump support.

14. Secure the high-pressure pump support to the bottom of the high-pressure pump using the previously saved
M12 x 30 bolts. Hand tighten bolts.
15. Secure the high-pressure pump support to the crankcase using the previously saved M14 x 30 bolts. Hand
tighten bolts.
16. Tighten M12 x 30 bolts to 105 N·m (77 lb·ft).
17. Tighten M14 x 30 bolts to 172 N·m (126 lb·ft).
762 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Oil Pan
1. Lubricate new or old oil pan gasket with clean engine oil and Install oil pan gasket onto oil pan.
2. Position oil pan and oil pan gasket as an assembly onto the crankcase.

Figure 674 Oil pan clamps (typical)

1. M8 x 40 bolt (19)
2. Oil pan clamp – front left 599 mm (23.5 in)
3. Oil pan clamp – rear left 461 mm (18 in)
4. Oil pan clamp – rear right 461 mm (18 in)
5. Oil pan clamp – front right 599 mm (23.5 in)

3. Installfour oil pan clamps and 19 M8 x 40 bolts (Figure 674). Do not installtwo cooling tube brackets, one
extension bracket support, and three M8 x 40 bolts (Figure 675).
4. Hand tighten 19 M8 x 40 bolts.

Figure 675 Cooling tube brackets and extension bracket support (typical)
1. M8 x 40 bolt (3)
2. Cooling tube bracket (right angle bracket) (2)
3. Extension bracket support (T-bracket)
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 763

5. Position two cooling tube brackets, and one extension bracket, install and hand tighten three M8 x 40 bolts.
764 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

Figure 676 Torque sequence for oil pan bolts

6. Follow the torque sequence and tighten 22 M8 x 40 bolts to 10 N·m (89 lb·in).
7. Tighten 22 M8 x 40 bolts in sequence to 35 N·m (26 lb·ft).
8. Retighten 22 M8 x 40 bolts in sequence to 35 N·m (26 lb·ft).
9. If engine is equipped with oil pan heater element, lubricate a new O-ring with clean engine oil and install
heater element into the oil pan. Tighten heater element to special torque (page 767).
If engine is not equipped with an oil pan heater element, install (oil pan heater drain plug) with a new O-ring
lubricated with clean engine oil. Tighten plug to special torque (page 767).
10. Lubricate a new oil pan drain plug O-ring with clean engine oil and put O-ring on the M27 x 2 drain plug.
11. Install M27 x 2 drain plug and tighten to special torque (page 767).
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 765

Oil Fill Tube Assembly Installation

Torque Specifications

Oil fill tube adapter 26 lb-ft (35 N·m)

Oil fill tube hose clamp 46 lb-in (5.1 N·m)

Procedure

Figure 677 Oil Fill Tube Assembly Installation

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump

See Oil Fill Tube Assembly Installation (Figure 677) to perform steps 1 through 9.
If not replacing oil fill tube adapter (2), go directly to step 4.
1. Apply Loctite 545 full 360° on first three threads of oil fill tube adapter (2).
2. Install oil fill tube adapter (2) to accessory drive housing (1).
3. Tighten oil fill tube adapter. See Torque Specifications (page 765).
4. Install oil fill tube hose (5) to oil fill tube adapter (2).
766 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE

5. Secure oil fill hose tube (5) to oil fill tube adapter (2) with oil fill tube hose clamp (3), observing proper
orientation of clamp.
6. Tighten oil fill tube hose clamp. See Torque Specifications (page 765).
7. Place second oil fill tube hose clamp over oil fill hose tube (5), observing proper orientation of clamp, then
install oil fill tube (2) to oil fill hose tube (5).
8. Position oil fill tube hose clamp (3) to secure oil fill tube (4) to oil fill hose tube (5).
9. Tighten oil fill tube hose clamp. See Torque Specifications (page 765).

Figure 678 Oil Fill Tube Assembly

1. Oil fill tube 3. Oil fill tube assembly support 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting bracket 6. Oil fill tube hose
bolt 4. High Pressure (HP) fuel pump 7. Accessory drive housing

See Oil Fill Tube Assembly (Figure 678) to perform steps 10 and 11.
10. Install oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support bracket
(3).
11. Tighten oil fill tube assembly mounting bolt (2) to standard torque.
 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE 767

Special Torque

Drain plug, M27 x 2 75 N·m (55 lb·ft)

Oil pan bolts, M8 x 40 See tightening steps in procedure.
Oil pan heater element or replacement drain plug 75 N·m (55 lb·ft)
768 OIL PAN, OIL PICKUP TUBE, AND OIL FILL TUBE
 OIL PUMP AND TIMING GEARS 769

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .771

Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .771
Front Timing Gears (Typical). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .772
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .773

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .777
Front Crank Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .779
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .780

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .782

Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .782
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .782

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .783
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .783
Front Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .787

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .789

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .789

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .789

770 OIL PUMP AND TIMING GEARS
 OIL PUMP AND TIMING GEARS 771

Exploded Views
Oil Pump

Figure 679 Oil pump

1. M6 x 25 bolt (8) 4. (Oil pump) ring gear 7. Axle for pinion (oil pump)
2. Oil pump cover 5. M10 x 35 socket-head cap screw 8. O-ring 22 x 2
3. Pinion (gear) for oil pump 6. Spring pin 4 x 14 ST 9. O-ring 25.12 x 1.78
772 OIL PUMP AND TIMING GEARS

Front Timing Gears (Typical)

Figure 680 Front timing gears (typical)

1. (Front) idler gear 3. M12 x 50 socket-head cap screw 4. Front crank gear
2. Gear stud (not flywheel side) (3)
 OIL PUMP AND TIMING GEARS 773

Rear Timing Gears

Figure 681 Rear timing gears

1. M8 x 30 socket-head cap screw 5. Air compressor coupled idler 10. Large idler gear
(3) gear assembly 11. Gear stud big
2. Gear stud small 6. Air compressor gear stud 12. M14 x 80 bolt (4)
3. Crankcase idler gear 7. M12 x 55 bolt (3)
4. Thrust washer (for gear stud air 8. Rear crank gear assembly
compressor) 9. Small idler gear
774 OIL PUMP AND TIMING GEARS

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Front Cover, Fan Drive, Cooling System and Related Components
• Cylinder Head, Camshaft and Valve Train
• Flywheel and Flywheel Housing
Preliminary Checks

Figure 682 (Front) idler gear backlash measurement (typical)

 OIL PUMP AND TIMING GEARS 775

1. Rotate engine and look for any damaged gear teeth. See Crankshaft Rotation Procedure(page 660).
Replace damaged gears as necessary.
2. Place dial indicator with magnetic base (page 789) on front of crankcase with indicator tip on front idler gear.
Position dial indicator tangent (90°) relative to plane of gear tooth.
3. Turn front idler gear clockwise and zero dial indicator.
4. Turn front idler gear back and forth while reading dial indicator. Compare dial indicator reading with
specifications (page 789).
5. If front idler gear backlash exceeds specification, replace gear.

Figure 683 (Rear) large idler gear backlash measurement (typical)

6. Place dial indicator with magnetic base (page 789) on rear of crankcase with indicator tip on large idler gear
tooth. Position dial indicator tangent (90°) relative to plane of gear tooth.
7. Turn large idler gear clockwise and zero dial indicator.
8. Turn large idler gear back and forth while reading dial indicator. Compare dial indicator reading with
specifications (page 789).
9. If backlash exceeds specification, replace large idler gear.
776 OIL PUMP AND TIMING GEARS

Figure 684 Crankcase idler gear backlash measurement (typical)

10. Place dial indicator with magnetic base (page 789) on top rear of crankcase with indicator tip on crankcase
idler gear. Position dial indicator tangent (90°) relative to plane of gear tooth.
11. Turn crankcase idler gear clockwise and zero dial indicator.
12. Turn crankcase idler gear back and forth while reading dial indicator. Compare dial indicator reading with
specifications (page 789).
13. If crankcase idler gear backlash exceeds specification, replace crankcase idler gear.
 OIL PUMP AND TIMING GEARS 777

Oil Pump

Figure 685 Oil pump cover (typical)

1. M6 x 25 bolt (8)
2. Oil pump cover

1. Remove eight M6 x 20 bolts or M6 x 25 bolts.

2. Remove oil pump cover.
3. Remove and discard O-ring.

Figure 686 Oil pump pinion (gear) and ring gear

1. (Oil pump) ring gear
2. Oil pump pinion (gear)
3. Marks for reassembly (towards front)

CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their
orientation. Do not use paint or temporary markers.
778 OIL PUMP AND TIMING GEARS

4. Use a permanent marker to mark the front of oil pump pinion (gear) and ring gear for correct assembly
orientation.
5. Remove oil pump pinion gear and ring gear.

Figure 687 (Oil pump) pinion axle

1. M10 x 35 socket-head cap screw
2. (Oil pump) pinion axle
3. O-ring 22 x 2

6. Remove M10 x 35 socket-head cap screw and oil pump pinion axle.
7. Remove and discard O-ring 22 x 2.
 OIL PUMP AND TIMING GEARS 779

Front Crank Gears

Figure 688 Front crank gear (typical)

1. Using a gear puller (page 789), remove front crank gear.

Figure 689 (Front) idler gear (typical)

1. M12 x 50 socket-head cap screw (3)
2. Gear stud (front idler)
3. Idler gear

2. Remove three M12 x 50 cap screws, gear stud and idler gear.
780 OIL PUMP AND TIMING GEARS

Rear Timing Gears

Figure 690 Idler gear assembly and timing marks

1. M14 x 80 bolt (4)
2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear)
5. Timing mark (rear crank gear)

1. Remove four M14 x 80 bolts, big gear stud and idler gear assembly.

Figure 691 Crankcase idler gear (typical)

1. M8 x 30 socket-head cap screw (3)
2. Small gear stud
3. Crankcase idler gear

2. Remove three M8 x 30 cap screws, small gear stud and crankcase idler gear.
 OIL PUMP AND TIMING GEARS 781

Figure 692 Rear crank gear assembly (typical)

1. Rear crank gear
2. Pin 8 x 60-ST

3. Using a gear puller (page 789), remove rear crank gear assembly.

Figure 693 Air compressor coupled idler gear assembly (typical)

1. M12 x 55 bolt (3)
2. Air compressor gear stud
3. Air compressor idler gear assembly

4. Remove three M12 x 55 bolts and air compressor gear stud, air compressor idler gear assembly and thrust
washer for air compressor gear stud (not shown, behind gear assembly).
782 OIL PUMP AND TIMING GEARS

Cleaning and Inspection

Timing Gears

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
1. Wash timing gears and gear pins with a stiff brush and suitable solvent. Dry all with filtered compressed air.
2. Inspect timing gears for irregular wear pattern and worn or damaged teeth. Replace as necessary.
3. Inspect timing gear shafts for worn or damaged bearing surfaces. Replace as necessary.

Oil Pump
1. Wash all parts thoroughly in a suitable solvent.
2. Dry with filtered compressed air.
3. Inspect pinion (gear) for oil pump, oil pump ring gear and oil pump cover for nicks, burrs or scoring.
4. Replace any damaged components.
5. Temporarily install oil pump components in crankcase without O-ring and tighten M6 x 25 bolts to standard
torque (page 881). See Oil Pump (page 787).

Figure 694 Pinion (gear) for oil pump and ring gear end play measurement (typical)

6. Using a feeler gauge (page 789), measure end play between oil pump cover and oil pump gears.
NOTE: There are two oil pump assemblies. When replacing oil pump parts, be sure you are ordering the correct
set.
7. If end play exceeds specification (page 789), replace oil pump cover, pinion (gear) for oil pump and ring
gear as a set.
8. Remove oil pump components for final assembly.
 OIL PUMP AND TIMING GEARS 783

Installation
Rear Timing Gears

Figure 695 Air compressor coupled idler gear assembly (typical)

1. M12 x 55 bolt (3)
2. Air compressor gear stud
3. Air compressor idler gear assembly

CAUTION: To prevent engine damage, install thrust washer for air compressor gear stud with larger chamfer
side facing crankcase.
1. Install air compressor thrust washer (with larger chamfer side facing crankcase), air compressor gear stud
and air compressor coupled idler gear assembly.
2. Install three M12 x 55 bolts. Tighten bolts to special torque (page 789).

Figure 696 Crankshaft alignment pin hole (typical)

3. Rotate crankshaft so that alignment pin hole is at 6 o'clock position. See Crankshaft Rotation Procedure
(page 660). This positions cylinder No. 1 at Top Dead Center (TDC).
784 OIL PUMP AND TIMING GEARS

Figure 697 Rear crank gear assembly (typical)

1. Rear crank gear
2. Pin 8 x 60-ST

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
4. Using a hammer and brass drift, install rear crank gear so pin in gear engages crankshaft alignment pin
hole.

Figure 698 Crankcase idler gear (typical)

1. M8 x 30 socket-head cap screw (3)
2. Small gear stud
3. Crankcase idler gear

CAUTION: To prevent engine damage, insert the crankcase idler gear into the crankcase with the flatter contact
surface facing outwards.
5. Install crankcase idler gear and small gear stud.
 OIL PUMP AND TIMING GEARS 785

6. Install three crankcase idler gear M8 x 30 socket-head cap screws. Tighten cap screws to special torque
(page 789).

Figure 699 Large Idler gear assembly and timing marks

1. M14 x 80 bolt (4)
2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear)
5. Timing mark (rear crank gear)

NOTE: Large idler gear has two timing marks 180° apart; either may be used.
7. Install big gear stud and large idler gear, aligning timing mark with timing mark on rear crank gear (flywheel
side).
8. Install four M14 x 80 bolts. Tighten bolts to special torque (page 789).
786 OIL PUMP AND TIMING GEARS

Front Timing Gears

Figure 700 (Front) idler gear (typical)

1. M12 x 50 socket-head cap screw (3)
2. Gear stud (not flywheel side)
3. Idler gear

1. Install idler gear and gear stud.

2. Install three front idler gear M12 x 50 cap screws. Tighten screws to special torque (page 789).

Figure 701 Front crank gear (typical)

3. Install two suitable alignment bolts 180° apart through front crank gear into front of crankshaft.

WARNING: To prevent personal injury or death, wear safety glasses with side shields.
4. Using a hammer and brass drift, carefully install front crank gear.
5. Remove two alignment bolts.
 OIL PUMP AND TIMING GEARS 787

Oil Pump
1. Lubricate new O-ring 22 x 2 with clean engine oil and install oil pump pinion axle.

Figure 702 Pinion axle (oil pump)

1. M10 x 35 socket-head cap screw
2. Pinion axle (oil pump)
3. O-ring 22 x 2

2. Install oil pump pinion axle and M10 x 35 cap screw. Tighten screw to special torque (page 789).

Figure 703 Pinion (gear) for oil pump and ring gear
1. (Oil pump) ring gear
2. Pinion (gear) for oil pump
3. Marks for reassembly (toward front)
788 OIL PUMP AND TIMING GEARS

3. Lubricate pinion (gear) for oil pump and ring gear with clean engine oil.
4. Install pinion gear and ring gear with previously made index marks facing towards front.
5. Lubricate new oil pump cover O-ring with clean engine oil and install on cover.

Figure 704 Oil pump cover (typical)

1. M6 x 25 bolt (8)
2. Oil pump cover

6. Install oil pump cover.

7. Install eight M6 x 20 or M6 x 25 bolts. Tighten bolts to standard torque (page 881).
 OIL PUMP AND TIMING GEARS 789

Specifications
Oil Pump and Timing Gears

Front Timing Gears

(Front) idler gear backlash 0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump
Oil pump pinion (gear) and ring gear end play 0.030 - 0.120 mm (0.0012 - 0.0047 in)
Rear Timing Gears
Idler larger gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Large idler gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)

Special Torque

Air compressor coupled idler gear, M12 x 55 bolts 107 N·m (79 lb·ft)
Crankcase idler gear, M8 x 30 socket-head cap screws 30 N·m (22 lb·ft)
(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lb·ft)
Larger idler gear, M14 x 80 bolts 175 N·m (129 lb·ft)
Oil pump pinion axle, M10 x 35 socket-head cap screw 65 N·m (48 lb·ft)

Special Service Tools

Description Tool Number

Dial indicator with magnetic base Obtain locally
Feeler gauge Obtain locally
Gear puller Obtain locally
790 OIL PUMP AND TIMING GEARS
 POWER CYLINDERS 791

Table of Contents

Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .793

Piston and Connecting Rod (Typical) and Cylinder Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .793

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .795
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .795
Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .797
Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .801

Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .802

Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .802
Piston Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .803
Piston Ring Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .805
Connecting Rod Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .806
Connecting Rod Bore Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .808
Piston Pin Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .809
Cylinder Sleeve Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .811

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .813
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .813
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .814
Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .816

Engine Run-in Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .823

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .824

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .824

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .825

792 POWER CYLINDERS
 POWER CYLINDERS 793

Exploded Views
Piston and Connecting Rod (Typical) and Cylinder Sleeve

Figure 705 Piston and connecting rod (typical)

1. Compression top ring (6) 7. Connecting rod assembly (6) 11. Connecting rod bearing, lower
2. Taper face compression ring (6) (includes items 8, 9, 10) (6)
3. Bevelled oil ring (6) 8. Connecting rod 12. Connecting rod bearing, upper
4. Piston (6) 9. Connecting rod cap (6)
5. Piston pin retainer (12) 10. Connecting rod bolt (2 each 13. Front of engine
6. Piston pin (6) assembly)
794 POWER CYLINDERS

Figure 706 Cylinder sleeve

1. Cylinder sleeve (6) 2. Cylinder sleeve O-ring (12)
 POWER CYLINDERS 795

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Inlet Air Heater
• Aftertreatment System
• N13 Engine Brake by Jacobs
• Turbochargers
• Fuel System
• Oil Cooler, Filter Housing, and Crankcase Ventilation
• Exhaust Gas Recirculating (EGR) System
• Air Intake Throttle Duct and Exhaust Manifold
• Cylinder Head, Camshaft, and Valve Train
• Flywheel and Flywheel Housing (as needed)
• Oil Pan and Oil Suction Tube
Preliminary Checks
NOTE: Evaluate piston protrusion before removing any piston and connecting rod assemblies. This helps identify
bent or twisted connecting rods.
796 POWER CYLINDERS

Figure 707 Piston protrusion check

NOTE: Piston protrusion readings are done in line with piston pin, eliminating rocking movement of piston at
any other position of measurement.
1. Check piston protrusion as follows:
a. Make sure crankcase deck surface is clean.
b. Zero dial indicator with magnetic base (page 825) on crankcase deck surface.
c. Position dial indicator tip over piston head at 3 o'clock position.
d. Rotate crankshaft in direction of normal rotation to raise piston to its maximum outward protrusion at
cylinder Top Dead Center (TDC). Push down on piston crown before taking reading. Read this maximum
protrusion on dial indicator.
e. Reposition dial indicator tip on piston head at 9 o'clock position.
f. Rotate crankshaft to raise piston to its maximum protrusion. Push down on piston crown before taking
reading. Read maximum protrusion on dial indicator.
g. Average the two readings. Replace piston and connecting rod if protrusion is not within specification
(page 824).
 POWER CYLINDERS 797

Piston and Connecting Rod

CAUTION: To prevent engine damage, check for a carbon ridge on top of cylinder sleeves. If found, remove
carbon ridge with a suitable tool before removing rod and piston assemblies.
1. Scrape carbon ridge from top of cylinder bore, if necessary. Use care not to damage sleeve bore surface.
CAUTION: To prevent engine damage, mark with permanent marker or tag each connecting rod and cap with the
correct cylinder number. This engine has “cracked” (fractured) type connecting rods. Do not alter or damage
fractured mating surfaces of the rod and cap. A cap from one connecting rod is NOT interchangeable with
another connecting rod. The matching connecting rod and cap numbers or symbols indicate a matched set.
CAUTION: To prevent engine damage, install connecting rod cap and connecting rod with matching serial
numbers on the same side. If the rod cap is reversed or not installed on its matching connecting rod, the fractured
mating surfaces will be damaged. A new connecting rod assembly must be installed. Do NOT attempt to reuse
a rod that has been mis-assembled to its cap, assembled with the wrong cap or has been cross-threaded while
attempting assembly. Serious engine damage can result.
2. Rotate crankshaft to position journals for removal of connecting rod assemblies. Mark connecting rod
locations.

Figure 708 Connecting rod cap

1. Connecting rod bolt M12 x 64 (2)
2. Connecting rod cap

CAUTION: To prevent engine damage, assemble connecting rod cap and connecting rod with their fractured
mating surfaces in the original orientation. Matching numbers must be next to each other.
NOTE: When removed, make sure matching connecting rod and connecting rod cap numbers stay together as
a set. A cap from one connecting rod is not interchangeable with any other connecting rod.
3. Using Exhaust Manifold Bolt Torx® Socket (page 825), remove two connecting rod bolts and connecting rod
cap. Save bolts for reuse during connecting rod bore check procedure.
CAUTION: To prevent engine damage, do not push on fractured surface of connecting rod.
CAUTION: To prevent engine damage, do not damage piston cooling jet when removing connecting rod and
piston assembly. If jet is bent during piston assembly or removal, replace jet.
798 POWER CYLINDERS

Figure 709 Anti-polish Ring (APR) Removal

1. Piston 2. Anti-Polish Ring (APR) 3. Cylinder sleeve

See Anti-polish Ring (APR) Removal (Figure 709) to perform step 5.

4. Remove Anti-polish ring (2).
 POWER CYLINDERS 799

Figure 710 Piston and Connecting Rod Assembly

1. Piston 3. Connecting rod assembly
2. Piston ring (3) 4. Cylinder sleeve

See Piston and Connecting Rod Assembly (Figure 710) to perform steps 6 through 9.
5. Use a wooden or plastic handle to push piston (1) and connecting rod assembly (2) from underneath
crankcase up through cylinder sleeve (4).
6. Once piston rings (2) are free of cylinder sleeve, remove piston and connecting rod assembly from cylinder
sleeve.
7. Using a permanent marker, mark each piston and rod assembly with cylinder number from which each was
removed.
8. Remove connecting rod upper and lower bearings by pushing out. Mark connecting rod bearings for position
and orientation and set aside for inspection.
800 POWER CYLINDERS

Piston Disassembly

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 711 Piston pin retainer (typical)

1. Using a pair of pliers, remove two piston pin retainers.

CAUTION: To prevent engine damage, do not mark piston pin for cylinder and location on outer diameter; place
mark only on flat end or tapered inside surface.
2. Remove piston pin from its bore by hand and separate connecting rod from piston.

Figure 712 Piston ring removal (typical)

NOTE: Only expand piston rings enough to fit over top of piston.
NOTE: Keep piston rings organized for each cylinder.
3. Using piston ring expansion pliers (page 825), remove top compression ring, taper face compression ring,
and bevelled oil ring.
 POWER CYLINDERS 801

Cylinder Sleeves

Figure 713 Cylinder sleeve removal

CAUTION: To prevent engine damage, use permanent markers to identify internal engine components and their
orientation. Do not use paint or temporary markers.
NOTE: Care must be taken not to damage piston cooling jets during cylinder sleeve removal.
1. Remove six cylinder sleeves from crankcase as follows:
a. Insert Cylinder Sleeve Puller (page 825) into cylinder sleeve.
b. Engage removal tool hooks under bottom edge of cylinder sleeve.
c. Position removal tool feet diagonally on crankcase deck surface.
d. Turn threaded shaft clockwise to extract cylinder sleeve.
e. Mark cylinder sleeves for position and set aside for inspection.
2. Remove and discard two cylinder sleeve O-rings from each crankcase cylinder sleeve.
802 POWER CYLINDERS

Cleaning and Inspection

Cleaning
CAUTION: To prevent engine damage, do not use caustic solvents, wire brushes or bead blasting media to
clean aluminum pistons.
CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface
of connecting rods.
1. Use a soap and water solution to clean pistons. Soak piston first and then clean with a non-metallic brush.
2. Clean piston ring grooves thoroughly.
3. The following disassembled components may be cleaned using a suitable solvent:
• Piston pins
• Piston pin retainers
4. Thoroughly clean connecting rod bolt holes and threads.
 POWER CYLINDERS 803

Piston Inspection
1. Inspect pistons for scuffed or scored skirts, cracked or worn ring lands and cracked or scuffed pin bores.
Replace damaged pistons.

Figure 714 Second and third ring groove clearance check (typical)

NOTE: It is not possible to measure side clearance of top compression ring groove.
2. Check side clearance of taper face compression ring groove as follows:
a. Place edge of a new taper face compression ring in its respective ring groove. Roll taper face
compression ring all around ring groove to ensure ring is free in its groove.
b. With edge of taper face compression ring in taper face compression ring groove, use a feeler gauge
(page 825) to measure side clearance between ring and groove.
c. Compare taper face compression ring side clearance to specification (page 824). Excessive side
clearance indicates ring groove wear and requires piston replacement.
3. Check side clearance of bevelled oil ring groove as follows:
a. Place edge of a new bevelled oil ring in its respective ring groove. Roll bevelled oil ring all around ring
groove to ensure ring is free in its groove.
b. With edge of bevelled oil ring in the bevelled oil ring groove, use a feeler gauge (page 825) to measure
side clearance between ring and groove.
c. Compare bevelled oil ring side clearance to specification (page 824). Excessive side clearance indicates
ring groove wear and requires piston replacement.
804 POWER CYLINDERS

Figure 715 Piston skirt diameter measurement

4. Using a 4 - 5 inch micrometer (page 825), measure diameter of piston at intervals given in specifications
(page 824). If measurements do not meet specification, replace piston.
 POWER CYLINDERS 805

Piston Ring Inspection

CAUTION: To prevent engine damage, install new piston rings if a piston is removed. Faulty piston rings cannot
always be detected visually.
1. Inspect new piston rings for cleanliness.

Figure 716 Piston ring end gap clearance in cylinder bore

2. Before installing new piston rings, check ring gap for each ring as follows:
a. Push piston ring down into cylinder bore. Make sure the piston ring is square with cylinder wall. An
inverted piston head can be used to push piston ring to desired location of measurement (usually at top
of piston stroke).
b. Use a feeler gauge (page 825) to measure ring gap between ends of each piston ring.
c. If gap ring does not meet specification (page 824), select another ring or recheck cylinder sleeve wear.
806 POWER CYLINDERS

Connecting Rod Inspection

CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or
connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other
surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure.
CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface
of connecting rods.
1. Inspect connecting rod bolt threads for nicks or damage. Replace as required.
2. Inspect connecting rod and cap mating surfaces and bearing bore for any indication of damage. Bore must
be smooth and free of scoring or nicks. Replace connecting rod if necessary.
 POWER CYLINDERS 807

Figure 717 Inside diameter of piston pin bore

3. Inspect connecting rod piston pin bore for wear as follows:

a. Using a telescoping gauge (page 825) and a 2 - 3 inch micrometer (page 825), measure piston pin bore
at two locations 90° apart.
b. If inside diameter of piston pin bore exceeds specification (page 824), replace connecting rod.
808 POWER CYLINDERS

Connecting Rod Bore Check

CAUTION: To prevent engine damage, do not use power tools to remove or install connecting rod cap bolts.
Threads will be damaged if a bolt or nut is rotated too quickly.
1. Lightly lubricate USED connecting rod bolts with clean engine oil. Assemble cap to connecting rod without
bearings. Tighten bolts to an initial torque of 100 N·m (74 lb·ft).
2. Rotate each rod bolt 90° clockwise (1/4 turn).

Figure 718 Connecting rod bore measurement

3. Using a telescoping gauge (page 825) and a 3 - 4 inch micrometer (page 825), measure connecting rod
bearing bore diameter in three locations. If connecting rod bore diameter does not meet specification (page
824), replace connecting rod.
4. After all connecting rod bores are inspected, disassemble connecting rods and discard used connecting rod
bolts.
5. With connecting rod cap removed, inspect surface finish of connecting rod bearing bore. Bore must be
smooth and free of scoring, nicks, or burrs. Replace connecting rod assembly as necessary.
 POWER CYLINDERS 809

Piston Pin Inspection

1. Inspect piston pins for scoring or wear. Replace as necessary.

Figure 719 Piston pin measurement

2. Using a 2 - 3 inch micrometer (page 825), measure piston pin outside diameter at two locations 90° apart.
Measure each end of pin. If outside diameter of any piston pin is less than minimum specification (page
824), replace piston pin.

Figure 720 Piston pin bore inside diameter measurement (typical)

NOTE: These pistons have “profiled” pin bores and must be measured carefully to get an accurate result.
NOTE: Measure each piston pin bore inside diameter in front and in rear of piston at one location each,
horizontally in the pin bore the specified distance from the center line of the piston.
3. Using a telescoping gauge (page 825) and 2 - 3 inch micrometer (page 825), measure each piston pin bore
inside diameter at one location horizontally the specified distance from center of piston. If piston pin bore
inside diameter is not within specification (page 824), replace piston.
810 POWER CYLINDERS

4. To check piston pin running clearance, subtract outside diameter of piston pin from inside diameter of piston
pin bore. If clearance exceeds specification (page 824), replace piston pin and check piston pin clearance
using new piston pin.
 POWER CYLINDERS 811

Cylinder Sleeve Inspection

1. Install six cylinder sleeves (without cylinder sleeve O-rings) into crankcase.

Figure 721 Cylinder sleeve bore measurement

2. Using a dial bore gauge (page 825), measure the cylinder sleeve inside diameter at 120° intervals, at four
different depths of cylinder sleeve. If cylinder sleeve inside diameter is not within specification (page 824),
replace cylinder sleeve.

Figure 722 Cylinder sleeve protrusion measurement

1. Dial indicator with magnetic base
2. Sleeve Protrusion Hold Down Clamp

3. Check cylinder sleeve protrusion above crankcase deck as follows:

a. Install Sleeve Protrusion Hold Down Clamps (page 825) using four included bolts. Torque bolts to special
torque (page 824).
b. Place dial indicator with magnetic base (page 825) on crankcase deck surface.
812 POWER CYLINDERS

c. Position dial indicator tip on crankcase deck adjacent to cylinder sleeve flange. Zero dial indicator.
d. Carefully pivot dial indicator until tip is resting on cylinder sleeve flange. Record reading.
e. Measure cylinder sleeve protrusion at three locations evenly spaced around the cylinder sleeve.
f. If any of the three readings of cylinder sleeve protrusion are not within specification (page 824), fit new
cylinder sleeve and repeat steps a through e.
g. If after trying all available new cylinder sleeves and specification still cannot be met, contact Tech Central
at 1-800-336-4500.
h. Remove six cylinder sleeves and continue with installation.
 POWER CYLINDERS 813

Installation
Cylinder Sleeves
1. Lubricate two new cylinder sleeve O-rings with clean engine oil and install in crankcase cylinder sleeve bore.
2. Using a soft-faced hammer, install cylinder sleeve by striking evenly until seated.
814 POWER CYLINDERS

Piston Assembly

WARNING: To prevent personal injury or death, wear safety glasses with side shields.

Figure 723 Piston ring installation (typical)

CAUTION: To prevent engine damage, install piston rings correctly. Both top compression and taper face
compression rings have the same identification markings. The marking must face up for the ring to be installed
correctly. The taper face compression ring has a rectangular cross section and goes in the middle groove. The
top compression ring has a keystone cross section and goes in the top groove.
NOTE: Only expand piston rings enough to fit over top of piston.
1. Using piston ring expansion pliers (obtain locally) , install piston rings. Be careful not to “wind” ring into
groove.
a. Install expansion spring component of bevelled oil ring into bottom piston groove.
b. Install oil scraper component of bevelled oil ring over expansion spring with the gap 180° from the spring
wire latch.
c. Install taper face compression ring into middle piston groove. Make sure ring is installed with
identification mark facing up.
d. Install top compression ring into top piston groove. Make sure ring is installed with identification mark
facing up.
2. Space ring gaps approximately 120° apart after ring installation.
3. Connect piston to connecting rod as follows:
a. Lubricate connecting rod piston pin bore, piston pin bore and piston pin with clean engine oil.
b. Set piston crown down so arrow mark stamped on piston crown is at 6 o'clock position.
c. Using pliers, install one piston pin retainer into groove. Be sure that retainer is fully seated in groove
and that tang ends point up.
d. Hold connecting rod so open end faces 3 o'clock position of piston when installed.
e. Place connecting rod into piston.
 POWER CYLINDERS 815

Figure 724 Piston pin retainer

f. Slide piston pin through piston holes, stopping at installed piston pin retainer.
g. Using pliers, install second piston pin retainer.
816 POWER CYLINDERS

Piston and Connecting Rod

CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or
connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other
surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure.
1. Verify proper connecting rod orientation. Assemble connecting rod cap to connecting rod with matching
identification code on same crankshaft journal from which it was removed. Be certain that longer leg of
connecting rod is positioned towards left side of crankcase.

Figure 725 Connecting rod chamfer pointing to front of engine

1. Connecting rod cap
2. Chamfer
3. Connecting rod bolt (2)
4. Arrow pointing to front of engine

2. Secure connecting rod cap (Figure 725) (Item 1) with two connecting rod bolts (Figure 725) (Item 3).
Finger-tighten only.
3. Verify chamfer (Figure 725) (Item 2) on connecting rod cap is pointing in same direction as arrow mark
stamped on top of piston (Figure 726). If chamfer is not pointing in same direction as arrow mark on piston,
reinstall piston on connecting rod (page 814).
4. Remove connecting rod cap from connecting rod.
5. Turn crankshaft so crank pin (connecting rod journal) on the cylinder to receive piston installation is at the
bottom of its stroke.
NOTE: Upper connecting rod bearings have an oil hole and lower connecting rod bearings do not.
 POWER CYLINDERS 817

6. Install connecting rod bearings in connecting rod and cap. Bearings with oil hole go in the upper position.
Coat bearings with clean engine oil.
Be sure that all bearing locator tabs and oil holes are in alignment with connecting rod and cap and that
bearings are flush to fractured mating faces of rod and cap.

Figure 726 Arrow mark on piston (typical)

CAUTION: To prevent engine damage, the arrow stamped on top of piston must face front of engine.
CAUTION: To prevent engine damage, do not damage piston cooling jet when installing connecting rod and
piston assembly. If jet is bent during piston assembly installation, replace jet.
NOTE: Before installing piston and connecting rod assembly, make sure all piston cooling jets are installed.
7. Lightly coat piston and piston rings with clean engine oil.
8. Coat cylinder sleeve walls, crankshaft journals and Piston Coping Tool with clean engine oil.
818 POWER CYLINDERS

Figure 727 Coping Tool

1. Cylinder sleeve 3. Coping tool
2. Cylinder sleeve ridge 4. Coping tool lip

See Coping Tool (Figure 727) to perform step 9.

9. Install coping tool (3) onto cylinder sleeve (1), seating coping tool lip (4) in cylinder sleeve ridge (2).
 POWER CYLINDERS 819

Figure 728 Piston Installation

1. Piston 3. Connecting rod assembly
2. Piston ring (3) 4. Coping tool

See Piston Installation (Figure 728) to perform steps 10 through 13.

10. Position piston rings (2) so ring openings are staggered 120⁰ from adjacent rings for proper orientation.
11. Press back of piston rings into piston ring grooves so ring openings are extended out from piston (1).
12. Carefully insert piston (1) and connecting rod assembly (3) into tapered opening of piston coping tool (4)
with arrow mark facing towards front of engine.
13. Use a rubber mallet to tap piston (1) through piston coping tool (4) and into cylinder sleeve. Guide connecting
rod in place on crankshaft. Do not let edges of connecting rod or fractured mating face of rod touch the
crankshaft journal. Before installing cap with bearing and starting bolts, be sure that bearings are still flush
with connecting rod and cap fractured mating faces and have NOT rotated.
820 POWER CYLINDERS

Figure 729 Anti-polish Ring (APR) Installation

1. Piston 2. Anti-Polish Ring (APR) 3. Cylinder sleeve

See Anti-polish Ring (APR) Installation (Figure 729) to perform step 14.
14. Install Anti-polish ring (2).
 POWER CYLINDERS 821

Figure 730 Correct connecting rod and cap joint fit

CAUTION: To prevent engine damage, clean fractured mating surfaces of the connecting rod and rod cap with
filtered compressed air.
15. Use filtered compressed air to clean debris from fractured mating surfaces of the connecting rod and rod
cap.
CAUTION: To prevent engine damage, install connecting rods with correct caps in the correct direction. If a rod
cap is reversed, an offset will be seen at the mating surfaces. If a reverse assembly is installed on the crankshaft,
the connecting rod must be replaced. Also, check crank pin (connecting rod journal) fillets for damage that would
require replacement of the crankshaft.
16. Assemble cap to connecting rod with matching identification code on same crankshaft journal from which it
was removed. Be certain that longer leg of connecting rod is positioned towards left side of crankcase.

Figure 731 Connecting rod cap (typical)

1. Connecting rod bolt (2)
2. Connecting rod cap

CAUTION: To prevent engine damage, install new connecting rod bolts.

822 POWER CYLINDERS

CAUTION: To prevent engine damage, do not use powered tools to install connecting rod bolts; rotating bolts
too quickly can damage threads.
CAUTION: To prevent engine damage, do not rotate crankshaft until connecting rod bolts are fully tightened, as
this may cause bearings to rotate in place.
17. Install two New connecting rod bolts (Figure 731) (Item 1).
18. Using Exhaust Manifold Bolt Torx® Socket ZTSE4843, tighten connecting rod bolts evenly to an initial torque
of 100 N·m (74 lb·ft).
19. Rotate (tighten) connecting rod bolts an additional 90 degrees (1/4 turn).
20. Repeat installation procedure for remaining piston and connecting rod assemblies.
 POWER CYLINDERS 823

Engine Run-in Procedure

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.
Use the following engine run-in procedure after installing new pistons, piston rings, piston pins, or cylinder
sleeves:
1. Start engine and run at low idle with no load. If engine does not exceed 138 kPa (20 psi) oil pressure within
20 to 30 seconds, shutdown engine and correct the problem.
2. Run engine at low idle with no load for 5 minutes and check for any of the following problems:
• Unusual noise
• Coolant leaks
• Oil leaks
• Fuel leaks
• Air leaks
• Excessive exhaust smoke
• Excessive vibration
• Loose turbocharger mounting
3. Turn engine off and correct any of these problems to prevent engine or turbocharger damage.
4. Wait 15 minutes for oil level to stabilize, then check engine oil level. Add oil if needed. See appropriate
Engine Operation and Maintenance Manual for correct grade and viscosity of engine oil.
5. Start engine and drive vehicle (unloaded) for 30 minutes in city mode, then drive vehicle (unloaded) for an
additional 60 minutes in highway mode. Verify no loss in power.
6. Return to idle and check for leaks.
7. Turn off engine and repair any leaks.
824 POWER CYLINDERS

Specifications

Connecting Rods
Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)
Connecting rod bearing bore diameter
95.000 to 95.022 mm (3.7402 to 3.7402 in)
(crankshaft end)
Pistons — N13
Skirt diameter measured 26.9 mm from piston
bottom edge, 90° to piston pin axis in “window” 125.950 ± 0.013 mm (4.9587 ± 0.0005 in)
on skirt graphite layer, where applicable
Piston protrusion measured from crankcase
0.3 ± 0.22 mm (0.0118 ± 0.009 in)
deck to piston
Piston pin bore inside diameter, measured
52.04 - 52.05 mm (2.0490 - 2.0492 in)
horizontally 26 mm from piston center
Piston pin running clearance 0.040 - 0.058 mm (0.0016 - 0.0023 in)
Piston Pins
Outside diameter 51.992 - 52.000 mm (2.0469 - 2.0472 in)
Piston Rings — N13
Top compression ring
Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Taper face compression ring
Ring gap 1.00 - 1.20 mm (0.0394 - 0.0472 in)
Side clearance 0.09 - 0.13 mm (0.0035 - 0.0051 in)
Bevelled oil ring
Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)
Side clearance 0.05 - 0.09 mm (0.0020 - 0.0035 in)
Cylinder sleeve dimensions — N13
Sleeve protrusion 0.050 - 0.085 mm (0.0019 - 0.0033 in)
Sleeve inside diameter (bore) 126 ± 0.01 mm (4.9606 ± 0.0004 in)

Special Torque

Connecting rod bolts See tightening steps in procedure

Sleeve Protrusion Hold Down Clamp bolts 80 N·m (59 lb·ft)
 POWER CYLINDERS 825

Special Service Tools

Description Tool Number

2 - 3 inch micrometer Obtain locally
3 - 4 inch micrometer Obtain locally
4 - 5 inch micrometer Obtain locally
Cylinder Sleeve Puller ZTSE2536
Dial bore gauge Obtain locally
Dial indicator with magnetic base Obtain locally
Exhaust Manifold Bolt Torx® Socket ZTSE4843
Feeler gauge Obtain locally
Piston ring compressor Obtain locally
Piston ring expansion pliers Obtain locally
Sleeve Protrusion Hold Down Clamps ZTSE4825
Telescoping gauge Obtain locally
826 POWER CYLINDERS
 CRANKCASE AND CRANKSHAFT 827

Table of Contents

Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829

Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .829

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .830
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .832
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .833
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .835

Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .836

Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .836
Crankshaft Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837
Main Bearings Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .839
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .841

Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .842
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .842
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .843

Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .847

Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .847

Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .847

828 CRANKCASE AND CRANKSHAFT
 CRANKCASE AND CRANKSHAFT 829

Exploded View
Crankcase and Crankshaft

Figure 732 Crankcase and crankshaft

1. M18 x 2 x 160.5 collar bolt (14) 5. M6 x 12 bolt (6) 9. Lower thrust washer (main
2. Lower main bearing (7) 6. Crankcase bearing) (2)
3. Crankshaft 7. Piston cooling jet (6)
4. Upper main bearing (with oil 8. Upper thrust washer (main
hole) (7) bearing) (2)
830 CRANKCASE AND CRANKSHAFT

Removal

GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.

WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.

WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.

WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.

WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
 CRANKCASE AND CRANKSHAFT 831

NOTE: When performing specific component removal, only remove components necessary for access.

For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section.
• Engine Electrical
• Mounting Engine on Stand
• Inlet Air Heater
• Aftertreatment System
• Exhaust Back Pressure Control
• Turbochargers
• Air Compressor and Power Steering
• Fuel System
• Oil Cooler, Filter Housing and Crankcase Ventilation
• Exhaust Gas Recirculating (EGR) System
• Air Intake Throttle Duct and Exhaust Manifold
• Front Cover, Fan Drive, Cooling System and Related Components
• N13 Engine Brake by Jacobs (if equipped)
• Cylinder Head, Camshaft and Valve Train
• Flywheel and Flywheel Housing
• Oil Pan and Oil Pickup Tube
• Oil Pump and Timing Gears
• Power Cylinders
832 CRANKCASE AND CRANKSHAFT

Preliminary Checks

Figure 733 Crankshaft end play

1. Check crankshaft end play as follows:

a. Mount dial indicator with magnetic base (page 847) on crankcase with indicator tip on end of crankshaft
as shown.
b. Move crankshaft forward with pry bar and zero the dial indicator.
c. Move crankshaft back and forth while reading dial indicator. Compare dial indicator reading with
specification (page 847).
d. If end play exceeds specified limits, replace main bearing thrust washers.
 CRANKCASE AND CRANKSHAFT 833

Crankshaft
1. Position engine so that bottom of main bearing caps are facing upwards.
CAUTION: To prevent engine damage, use permanent markers to identify internal components or their
orientation. Do not use paint or temporary markers.
2. Mark main bearing caps for location and orientation.

Figure 734 Main bearing caps

1. M18 x 160.5 collar bolt (14)
2. Main bearing cap (7)

CAUTION: To prevent engine damage, do not drop main bearing caps. Damage to the fractured mating surface
of a main bearing cap will require replacement of the crankcase and mated main bearing caps.
3. Remove 14 M18 x 160.5 collar bolts and seven main bearing caps. Save bolts for Main Bearings
Measurement procedure (page 839).
4. Remove seven lower main bearings and two lower thrust washers from main bearing caps by pushing out.
CAUTION: To prevent engine damage, use permanent markers to identify internal components or their
orientation. Do not use paint or temporary markers.
5. Number removed lower main bearings and lower thrust washers on back side (not running surface) and set
aside for inspection.
834 CRANKCASE AND CRANKSHAFT

Figure 735 Crankshaft removal

WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a
safety latch on hook.
CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft.
NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables.
6. Attach lifting sling (page 847) to crankshaft. Lift crankshaft up and out of crankcase and set aside for
inspection.
7. Remove upper main bearings and upper thrust washers from crankcase by pushing out.
8. Number removed upper main bearings and upper thrust washers on back side (not running surface) to match
the previously removed lower main bearings and lower thrust washers and set aside for inspection.
 CRANKCASE AND CRANKSHAFT 835

Piston Cooling Jets

Figure 736 Piston cooling jet

1. M6 x 12 bolt (6)
2. Piston cooling jet (6)

1. Remove six M6 x 12 bolts and six piston cooling jets.

836 CRANKCASE AND CRANKSHAFT

Cleaning, Inspection and Testing

Crankcase

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
CAUTION: To prevent engine damage, do not use chlorinated solvents on bolts or crankcase tapped holes.
Parts should be clean, dry and free of any chemicals other than engine oil.
NOTE: Thoroughly clean and inspect crankcase before and after reconditioning.
1. Clean crankcase in a chemical bath or hot tank. This removes all carbonized material and mineral deposits
in coolant passages.
CAUTION: To prevent engine damage, do not use a wire brush to clean the fractured mating surface of crankcase
and main bearing caps.
2. If a hot tank is not available, do the following steps:
a. Use non-metallic stiff bristle brushes and scrapers to clean gasket material from machined surfaces of
crankcase.
b. Clean crankcase in solvent.
c. Dry with filtered compressed air.

Figure 737 Cylinder head bolt holes

CAUTION: To prevent engine damage, clean and dry threads in the crankcase bolt holes with filtered
compressed air. Dirt or oil in holes may cause binding and incorrect torque readings.
3. Clean cylinder head bolt holes with Head Bolt Bottoming Tap (page 847).
4. Clean collar bolt holes with Main Bolt Bottoming Tap (page 847).
5. Clean out debris with filtered compressed air.
 CRANKCASE AND CRANKSHAFT 837

Crankshaft Measurement
1. Clean and inspect crankshaft and main bearings.
2. Clean crankshaft with a suitable solvent.
3. Use a stiff nylon brush to clean oil passages in crankshaft. Loosen accumulated dirt, sludge and deposits.
4. Flush oil passages with a suitable solvent.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
5. Dry with filtered compressed air.
6. Inspect crankshaft journals (main and connecting rod) for scratches, grooves and scoring.
838 CRANKCASE AND CRANKSHAFT

Figure 738 Crankshaft main bearing journal measurement

Figure 739 Crankshaft connecting rod bearing journal measurement

CAUTION: To prevent engine damage, do not rework bearings or bearing caps to reduce journal-to-bearing
running clearances. Grind or install new crankshaft.
7. Use a 3 - 4 inch micrometer (page 847) to measure diameter of each connecting rod journal, and a 4 - 5
inch micrometer (page 847) to measure diameter of each main journal. Measure each journal at both sides
next to fillet radius at two directions 90° apart. Move micrometer over entire width of journal. If journal wear
exceeds specification (page 847), have crankshaft machined, or replace crankshaft.
 CRANKCASE AND CRANKSHAFT 839

Main Bearings Measurement

Figure 740 Main bearing uninstalled outside diameter (free spread) measurement

1. Inspect each main bearing for scratches, grooves, scoring, pitting and wear. Replace bearings as required.
2. Using a flat surface, place an individual bearing half on the surface as shown.
3. Using a 4 - 5 inch micrometer (page 847), measure across the ends of the bearing half as shown.
4. If the measurement falls outside of the uninstalled bearing outside diameter (free spread) specification (page
847), replace upper and lower bearing halves as a set. Measure all upper and lower bearing halves and
replace bearings as required.
5. Install upper main bearings into crankcase and lower main bearings into main bearing caps in their original
positions and orientation.
CAUTION: To prevent engine damage, install main bearing caps with their fractured mating surfaces in the
original orientation.
6. Lightly coat used collar bolt threads and under bolt heads with clean engine oil. Do not use new bolts for
this inspection procedure.
7. With crankshaft still removed, install seven main bearing caps and 14 previously removed M18 x 160.5 collar
bolts.
8. Tighten M18 x 160.5 collar bolts in main bearings caps as follows:
a. Tighten collar bolts at No. 6 main bearing cap to 10 N·m (88 lb·in).
b. Tighten remaining collar bolts to 10 N·m (88 lb·in).
c. Tighten collar bolts at No. 6 main bearing cap to 100 N·m (74 lb·ft).
d. Tighten remaining collar bolts to 100 N·m (74 lb·ft).
e. Tighten collar bolts at No. 6 main bearing cap to 300 N·m (221 lb·ft).
f. Tighten remaining collar bolts to 300 N·m (221 lb·ft).
g. Turn collar No. 6 main bearing cap an additional 90° clockwise.
h. Turn remaining collar bolts an additional 90° clockwise.
840 CRANKCASE AND CRANKSHAFT

Figure 741 Main bearing installed diameter measurement

9. Using a dial bore gauge (page 847), measure main bearing installed inside diameter. If measurement does
not meet specification (page 847), replace main bearings.
10. Remove 14 M18 x 160.5 collar bolts, seven main bearing caps, upper main bearings and lower main
bearings. Discard used collar bolts.
 CRANKCASE AND CRANKSHAFT 841

Piston Cooling Jets

1. Hold each piston cooling jet under running water. Water should stream from jet end.

WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 207 kPa (30 psi).
2. Clear blocked piston cooling jets using filtered compressed air. Replace piston cooling jet if blockage cannot
be cleared.
3. Replace any cracked or bent jets.
842 CRANKCASE AND CRANKSHAFT

Installation
Piston Cooling Jets

Figure 742 Piston cooling jet

1. M6 x 12 bolt (6)
2. Piston cooling jet (6)

1. Install six piston cooling jets and six M6 x 12 bolts.

2. Tighten bolts to special torque (page 847).
 CRANKCASE AND CRANKSHAFT 843

Crankshaft
NOTE: Make sure crankshaft and bearings have been inspected per instructions in this section before
proceeding.
1. Use a lint-free cloth to wipe crankcase bearing saddles free of oil.

Figure 743 Main bearing

NOTE: When inserting main bearings, make sure oil is not between back side of bearing and crankcase bearing
saddles.
2. Place upper main bearings in crankcase. Make sure locking tabs on bearings are snapped into saddle and
oil holes in bearings line up with oil holes in crankcase.
3. Lubricate running surface of bearings with clean engine oil.

Figure 744 Crankshaft installation

WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a
safety latch on hook.
844 CRANKCASE AND CRANKSHAFT

CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft.

NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables.
4. Attach lifting sling (page 847) to crankshaft. Orient crankshaft with front flange (8 bolt holes) and rear flange
(10 bolt holes) at crankcase front and rear, respectively. Carefully lower crankshaft down into crankcase.

Figure 745 Thrust washer installation

NOTE: Make sure oil grooves on thrust washers face outward towards crankshaft thrust surface.
5. Install two upper thrust washers into crankcase at No. 6 main location as follows:
a. Set upper thrust washer on top of crankshaft at No. 6 main journal with grooves towards crankshaft
thrust surface.
b. Pivot upper thrust washer around crankshaft and down into position.
6. Install two lower thrust washers onto No. 6 main bearing cap. Make sure lower thrust washer locking tabs
align with notches in main bearing cap.
7. Place lower main bearings in main bearing caps. Make sure locking tabs on bearings are snapped into main
bearing caps.
8. Lubricate bearings with clean engine oil.
 CRANKCASE AND CRANKSHAFT 845

Figure 746 Main bearing caps

1. Collar M18 x 160.5 bolt (14)
2. Main bearing cap (7)

CAUTION: To prevent engine damage, install main bearing caps with their fractured mating surfaces in the
original orientation.
CAUTION: To prevent engine damage, do not drop main bearing caps. Damage to the fractured mating surface
of a main bearing cap will require replacement of the crankcase and mated main bearing caps.
9. Install seven main bearing caps and 14 new M18 x 160.5 collar bolts.
846 CRANKCASE AND CRANKSHAFT

10. Tighten collar bolts as follows:

a. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 10 N·m (88 lb·in).
b. Tighten remaining collar bolts to 10 N·m (88 lb·in).
c. Rotate crankshaft to verify that crankshaft does not bind. Correct as required.
d. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 100 N·m (74 lb·ft).
e. Tighten remaining collar bolts to 100 N·m (74 lb·ft).
f. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 300 N·m (221 lb·ft).
g. Tighten remaining collar bolts to 300 N·m (221 lb·ft).
h. Turn two collar bolts at No. 6 (thrust washer location) main bearing cap bolts an additional 90°.
i. Turn remaining collar bolts an additional 90°.
 CRANKCASE AND CRANKSHAFT 847

Specifications

Crankshaft
Main Bearing:
Journal diameter 103.98 - 104.00 mm (4.0937 - 4.0945 in)
Installed bearing inside diameter 104.044 - 104.09 mm (4.0962 - 4.0980 in)
Uninstalled bearing outside diameter (free
111.20 - 112.40 mm (4.3779 - 4.4252 in)
spread)
Connecting Rod Bearing:
Journal diameter 89.98 - 90.00 mm (3.5425 - 3.5433 in)
Crankshaft end play:
Maximum service 0.200 - 0.401 mm (0.0079 - 0.0158 in)

Special Torque

Collar bolts (main bearing cap), M18 x 160.5 See tightening procedure and sequence
(page 845)
Piston cooling jet bolts, M6 x 12 13 N·m (115 lb·in)

Special Service Tools

Description Tool Number

3 - 4 inch micrometer Obtain locally
4 - 5 inch micrometer Obtain locally
Dial bore gauge Obtain locally
Dial indicator with magnetic base Obtain locally
Head Bolt Bottoming Tap ZTSE4855
Lifting sling Obtain locally
Main Bolt Bottoming Tap ZTSE4854
848 CRANKCASE AND CRANKSHAFT
 ABBREVIATIONS AND ACRONYMS 849

Table of Contents

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .851

850 ABBREVIATIONS AND ACRONYMS
 ABBREVIATIONS AND ACRONYMS 851

Abbreviations and Acronyms

A or amp – Ampere
AAT – Ambient Air Temperature
ABDC – After Bottom Dead Center
ABS – Antilock Brake System
AC – Alternating Current
A/C – Air Conditioner
ACC – Air Conditioner Control
ACCEL – Accelerate
ACD – Air Conditioner Demand
ACM – Aftertreatment Control Module
ACT PWR GND – Actuator Power Ground
ACV – Air Control Valve
AF – Air to Fuel ratio
AFT – Aftertreatment
AFTFD – Aftertreatment Fuel Doser
AFTFDH – Aftertreatment Fuel Doser High
AFTFDL – Aftertreatment Fuel Doser Low
AFTFIT – Aftertreatment Fuel Inlet Temperature
AFTFIS – Aftertreatment Fuel Inlet Sensor
AFTFP – Aftertreatment Fuel Pressure
AFTFP1 – Aftertreatment Fuel Pressure 1
AFTFP2 – Aftertreatment Fuel Pressure 2
AFTFSH – Aftertreatment Fuel Shutoff High
AFTFSL – Aftertreatment Fuel Shutoff Low
AFTFSV – Aftertreatment Fuel Shutoff Valve
Amb – Ambient
amp or A – Ampere
AMS – Air Management System
API – American Petroleum Institute
APP – Accelerator Pedal Position
APP1 – Accelerator Pedal Position 1
APP2 – Accelerator Pedal Position 2
ASTM – American Society for Testing and Materials
ATA – American Trucking Association
ATAH – American Trucking Association Link High
ATAL – American Trucking Association Link Low
ATDC – After Top Dead Center
AWG – American Wire Gauge
B+ or VBAT – Battery Voltage
BARO – Barometric Absolute Pressure
BBDC – Before Bottom Dead Center
BDC – Bottom Dead Center
bhp – Brake Horsepower
BOO – Brake On / Off
BPP – Brake Pedal Position
BPS – Brake Pressure Switch
BTDC – Before Top Dead Center
BTU – British Thermal Unit
C – Celsius
CAC – Charge Air Cooler
852 ABBREVIATIONS AND ACRONYMS

CACOT – Charge Air Cooler Outlet Temperature

CAN – Controller Area Network
CAP – Cold Ambient Protection
CARB – California Air Resources Board
cc – Cubic centimeter
CCA – Cold Cranking Ampere
CCOSS – Crankcase Oil Separator Speed
cfm – Cubic feet per minute
cfs – Cubic feet per second
CFV – Coolant Flow Valve
CID – Cubic Inch Displacement
CKP – Crankshaft Position
CKPH – Crankshaft Position High
CKPL – Crankshaft Position Low
CKPO – Crankshaft Position Out
cm – Centimeter
CMP – Camshaft Position
CMPH – Camshaft Position High
CMPL – Camshaft Position Low
CMPO – Camshaft Position Out
CMV – Coolant Mixer Valve
CO – Carbon Monoxide
COO – Cruise On / Off switch
CPU – Central Processing Unit
CTC – Coolant Temperature Compensation
Cyl – Cylinder
DB – Decibel
DCA – Diesel Coolant Additive
DDI – Digital Direct Fuel Injection
DDS – Driveline Disengagement Switch
DLC – Data Link Connector
DME – Dimethyl Ether
DMM – Digital Multi-meter
DOC – Diesel Oxidation Catalyst
DOCIT – Diesel Oxidation Catalyst Inlet Temperature
DOCOT – Diesel Oxidation Catalyst Outlet Temperature
DPF – Diesel Particulate Filter
DPFDP – Diesel Particulate Filter Differential Pressure
DPFIT – Diesel Particulate Filter Inlet Temperature
DPFOT – Diesel Particulate Filter Outlet Temperature
DSI – Down Stream Injection
DT – Diesel Turbocharged
DTC – Diagnostic Trouble Code
DTRM – Diesel Thermo Recirculation Module
EBP – Exhaust Back Pressure
EBPD – Exhaust Back Pressure Desired
EBPV – Exhaust Back Pressure Valve
ECB – Engine Compression Brake
ECB1 – Engine Compression Brake 1
ECB2 – Engine Compression Brake 2
ECBP – Engine Compression Brake Pressure
 ABBREVIATIONS AND ACRONYMS 853

ECI – Engine Crank Inhibit

ECL – Engine Coolant Level
ECM – Engine Control Module
ECM GND – Engine Control Module Ground
ECM PWR – Engine Control Module Power
ECS – Engine Coolant System
ECSR – Engine Controlled Shutdown Request
ECT – Engine Coolant Temperature
ECT1 – Engine Coolant Temperature 1
ECT2 – Engine Coolant Temperature 2
EFAN – Engine Fan
EFC – Engine Fan Control
EFRC – Engine Family Rating Code
EFS – Engine Fan Speed
EFT – Engine Fuel Temperature
EG – Ethylene Glycol
EGC – Electronic Gauge Cluster
EGBP – Exhaust Gas Back Pressure
EGDP – Exhaust Gas Differential Pressure
EGR – Exhaust Gas Recirculation
EGRC – Exhaust Gas Recirculation Control
EGRH – Exhaust Gas Recirculation High control
EGRL – Exhaust Gas Recirculation Low control
EGROT – Exhaust Gas Recirculation Outlet Temperature
EGRP – Exhaust Gas Recirculation Position
EGRT – Exhaust Gas Recirculation Temperature
EGT – Exhaust Gas Temperature
EGT1 – Exhaust Gas Temperature 1
EGT2 – Exhaust Gas Temperature 2
EGT3 – Exhaust Gas Temperature 3
EMI – Electromagnetic Interference
EMP – Exhaust Manifold Pressure
EMT – Exhaust Manifold Temperature
EOL – Engine Oil Level
EOP – Engine Oil Pressure
EOT – Engine Oil Temperature
EPA – Environmental Protection Agency
EPR – Engine Pressure Regulator
ESC – Electronic System Controller
ESN – Engine Serial Number
EST – Electronic Service Tool
ETC – Engine Throttle Control
ETCH – Engine Throttle Control High
ETCL – Engine Throttle Control Low
ETP – Engine Throttle Position
ETV – Engine Throttle Valve
EWPS – Engine Warning Protection System
F – Fahrenheit
FCV – Fuel Coolant Valve
FDP – Fuel Delivery Pressure
FEL – Family Emissions Limit
854 ABBREVIATIONS AND ACRONYMS

fhp – Friction horsepower

FMI – Failure Mode Indicator
FPC – Fuel Pump Control
FPCV – Fuel Pressure Control Valve
fpm – Feet per minute
FPM – Fuel Pump Monitor
fps – Feet per second
FRP – Fuel Rail Pressure
ft – Feet
FVCV – Fuel Volume Control Valve
GND – Ground (electrical)
gal – Gallon
gal/h – U.S. Gallons per hour
gal/min – U.S. Gallons per minute
GCW – Gross Combined Weight
GCWR – Gross Combined Weight Rating
GPC – Glow Plug Control
GPD – Glow Plug Diagnostic
GPR – Glow Plug Relay
GVW – Gross Vehicle Weight
H2O – Water
HC – Hydrocarbons
HEST – High Exhaust System Temperature
HFCM – Horizontal Fuel Conditioning Module
Hg – Mercury
hp – Horsepower
HPCAC – High-Pressure Charge Air Cooler
HPCR – High-Pressure Common Rail
HPFP – High-Pressure Fuel Pump
hr – Hour
HS – Humidity Sensor
Hyd – Hydraulic
IAH – Inlet Air Heater
IAHC – Inlet Air Heater Control
IAHD – Inlet Air Heater Diagnostic
IAHFI – Inlet Air Heater Fuel Igniter
IAHFS – Inlet Air Heater Fuel Solenoid
IAHR – Inlet Air Heater Relay
IAT – Inlet Air Temperature
IC – Integrated Circuit
ICP – Injection Control Pressure
ICPR – Injection Control Pressure Regulator
ICG1 – Injector Control Group 1
ICG2 – Injector Control Group 2
ID – Inside Diameter
IGN – Ignition
ILO – Injector Leak Off
IMP – Intake Manifold Pressure
IMT – Intake Manifold Temperature
in – Inch
inHg – Inch of mercury
 ABBREVIATIONS AND ACRONYMS 855

inH2O – Inch of water

INJs – Injectors
IPR – Injection Pressure Regulator
IPR PWR – Injection Pressure Regulator Power
ISC – Interstage Cooler
ISIS – International® Service Information System
IST – Idle Shutdown Timer
ITP – Internal Transfer Pump
J1939H – J1939 Data Link High
J1939L – J1939 Data Link Low
JCT – Junction (electrical)
kg – Kilogram
km – Kilometer
km/h – Kilometers per hour
km/l – Kilometers per liter
KOEO – Key-On Engine-Off
KOER – Key-On Engine-Running
kPa – Kilopascal
L – Liter
L/h – Liters per hour
L/m – Liters per minute
L/s – Liters per second
lb – Pound
lb – Pounds of force
lb/s – Pounds per second
lb ft – Pounds of force per foot
lb in – Pounds of force per inch
lbm – Pounds of mass
LSD – Low Sulfur Diesel
m – Meter
m/s – Meters per second
MAF – Mass Air Flow
MAF GND – Mass Air Flow Ground
MAG – Magnetic
MAP – Manifold Absolute Pressure
MAT – Manifold Air Temperature
mep – Mean effective pressure
mi – Mile
MIL – Malfunction Indicator Lamp
mm – Millimeter
mpg – Miles per gallon
mph – Miles per hour
MPR – Main Power Relay
MSDS – Material Safety Data Sheet
MSG – Micro Strain Gauge
MSM – Multiplex System Module
MY – Model Year
NC – Normally closed (electrical)
NETS – Navistar Electronics Technical Support
Nm – Newton meter
NO – Normally Open (electrical)
856 ABBREVIATIONS AND ACRONYMS

NOX – Nitrogen Oxides

O2S – Oxygen Sensor
O2SH – Oxygen Sensor Heater
OAT – Organic Acid Technology
OCC – Output Circuit Check
OCP – Overcrank Protection
OD – Outside Diameter
OL – Over Limit
ORH – Out-of-Range High
ORL – Out-of-Range Low
OSHA – Occupational Safety and Health Administration
OWL – Oil/Water Lamp
PID – Parameter Identifier
P/N – Part Number
PDOC – Pre-Diesel Oxidation Catalyst
ppm – Parts per million
PROM – Programmable Read Only Memory
psi – Pounds per square inch
psia – Pounds per square inch absolute
psig – Pounds per square inch gauge
pt – Pint
PTO – Power Takeoff
PWM – Pulse Width Modulate
PWR – Power (voltage)
qt – Quart
RAM – Random Access Memory
RAPP – Remote Accelerator Pedal Position
RAS – Resume / Accelerate Switch (speed control)
REPTO – Rear Engine Power Takeoff
RFI – Radio Frequency Interference
rev – Revolution
rpm – Revolutions per minute
RPRE – Remote Preset Power Take Off
RSE – Radiator Shutter Enable
RVAR – Remote Variable
SAE – Society of Automotive Engineers®
SCA – Supplemental Cooling Additive
SCCS – Speed Control Command Switches
S – CSFSpeed Control Switch
SHD – Shield (electrical)
SID – Subsystem Identifier
SIG GND – Signal Ground
SIG GNDB – Signal Ground Body
SIG GNDC – Signal Ground Chassis
SIG GNDE – Signal Ground Engine
S/N – Serial Number
SPEEDO – Speedometer
SPN – Suspect Parameter Number
SW – Switch (electrical)
SWBAT – Switch Battery
SYNC – Synchronization
 ABBREVIATIONS AND ACRONYMS 857

TACH – Tachometer output signal

TBD – To Be Determined
TC2CIS – Turbocharger 2 Compressor Inlet Sensor
TC1TOP – Turbocharger 1 Turbine Outlet Pressure
TC2TOP – Turbocharger 2 Turbine Outlet Pressure
TC1WC – Turbocharger 1 Wastegate Control
TC2WC – Turbocharger 2 Wastegate Control
TCAPE – Truck Computer Analysis of Performance and Economy
TCM – Transmission Control Module
TDC – Top Dead Center
TDE – Transmission Driving Engaged
TOP – Transmission Oil Pressure
TOSS – Transmission Output Shaft Speed
TOT – Transmission Oil Temperature
TTS – Transmission Tailshaft Speed
ULSD – Ultra Low Sulfur Diesel
UVC – Under Valve Cover
V – Volt
VBAT or B+ – Battery Voltage
VC – Volume Control
VEPS – Vehicle Electronics Programming System
VIGN – Ignition Voltage
VIN – Vehicle Identification Number
VOP – Valve Opening Pressure
VRE – Vehicle Retarder Enable
VREF – Reference Voltage
VREFB – Reference Voltage Body
VREFC – Reference Voltage Chassis
VREFE – Reference Voltage Engine
VSO – Vehicle Speed Output
VSS – Vehicle Speed Sensor
VSSH – Vehicle Speed Sensor High
VSSL – Vehicle Speed Sensor Low
WTSL – Wait to Start Lamp
WEL – Warn Engine Lamp
WIF – Water In Fuel
WIFL – Water In Fuel Lamp
WTEC – World Transmission Electronically Controlled automatic transmissions (Allison)
XCS – Transfercase
XMSN – Transmission
858 ABBREVIATIONS AND ACRONYMS
 TERMINOLOGY 859

Table of Contents

Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .861
Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .861
860 TERMINOLOGY
 TERMINOLOGY 861

Terminology
Terms
Accelerator Pedal Position (APP) sensor – A potentiometer sensor that indicates the position of the throttle
pedal.
Accessory work – The work per cycle required to drive engine accessories (normally, only those essential to
engine operation).
Actuator – A device that performs work in response to an input signal.
Actuator Control – The ECM controls the actuators by applying a low-level signal (low-side driver) or a high-level
signal (high side driver). When switched on, both drivers complete a ground or power circuit to an actuator.
Aeration – The entrainment of air or combustion gas in coolant, lubricant, or fuel.
Aftercooler (Charge Air Cooler) – A heat exchanger mounted in the charge air path between the turbocharger
and engine intake manifold. The aftercooler reduces the charge air temperature by transferring heat from the
charge air to a cooling medium (usually air).
Aftertreatment Fuel Doser (AFTFD) – A part of the Downstream Injection (DSI) unit that sends pressurized
fuel to the Hydrocarbon Injector (HCI) assembly to inject fuel into the exhaust pipe.
Aftertreatment (AFT) system – A part of the exhaust system that processes engine exhaust to meet emission
requirements and traps particulate matter (soot) to prevent it from leaving the tailpipe.
Air Control Valve (ACV) – Contains the LP turbocharger wastegate control port, HP turbocharger wastegate
control port, the EBPV control port, and the TC1TOP port. Although these components are integral to the ACV,
each circuit is controlled by the ECM. The ACV controls compressed air for each control valve.
Ambient temperature – The environmental air temperature in which a unit is operating. In general, the
temperature is measured in the shade (no solar radiation) and represents the air temperature for other engine
cooling performance measurement purposes. Air entering the radiator may or may not be the same ambient
due to possible heating from other sources or recirculation. (SAE J1004 SEP81)
Ampere (amp) – The standard unit for measuring the strength of an electrical current. The flow rate of a charge
in a conductor or conducting medium of one coulomb per second. (SAE J1213 NOV82)
Analog – A continuously variable voltage.
Analog to digital converter (A/D) – A device in the ECM that converts an analog signal to a digital signal.
American Trucking Association (ATA) Datalink – A serial datalink specified by the American Trucking
Association and the SAE.
Boost pressure – 1. The pressure of the charge air leaving the turbocharger.
2. Inlet manifold pressure that is greater than atmospheric pressure. Obtained by turbocharging.
Bottom Dead Center (BDC) – The lowest position of the piston during the stroke.
Brake Horsepower (bhp) – The power output from an engine, not the indicated horsepower. The power output
of an engine, sometimes-called flywheel horsepower, is less than the indicated horsepower by the amount of
friction horsepower consumed in the engine.
Brake Horsepower (bhp) net – Net brake horsepower is measured with all engine components. The power of
an engine when configured as a fully equipped engine. (SAE J1349 JUN90)
Calibration – ECM programming strategy to solve engine performance equations and make decisions.
Calibration values are stored in ROM and put into the processor during programming to allow the engine to
operate within certain parameters.
862 TERMINOLOGY

Camshaft Position (CMP) sensor – A magnetic pickup sensor that provides the ECM with a camshaft speed
and position signal.
Carbon Monoxide (CO) – A colorless, odorless, highly poisonous gas that is formed by the incomplete
combustion of carbon burning diesel engine. It is present in the exhaust gases of diesel engines.
Catalyst – A substance that produces a chemical reaction without undergoing a chemical change itself.
Catalytic converter – An antipollution device in the exhaust system that contains a catalyst for chemically
converting some pollutants in the exhaust gases (carbon monoxide, unburned hydrocarbons, and oxides of
nitrogen) into harmless compounds.
Cavitation – A dynamic condition in a fluid system that forms gas-filled bubbles (cavities) in the fluid.
Cetane number – 1. The auto-ignition quality of diesel fuel.
2. A rating applied to diesel fuel similar to octane rating for gasoline.
3. A measure of how readily diesel fuel starts to burn (self-ignites) at high compression temperature.
Diesel fuel with a high cetane number self-ignites shortly after injection into the combustion chamber. Therefore,
it has a short ignition delay time. Diesel fuel with a low cetane number resists self-ignition. Therefore, it has a
longer ignition delay time.
Charge air – Dense, pressurized, heated air discharged from the turbocharger.
Charge Air Cooler (CAC) – See Aftercooler.
Charge Air Outlet Temperature (CACOT) sensor – A thermistor sensor that monitors the temperature of
charge air entering the intake air duct.
Closed crankcase – A crankcase ventilation that recycles crankcase gases through a breather, then back to
the clean air intake.
Closed loop operation – A system that uses sensors to provide feedback to the ECM. The ECM uses the
sensor input to continuously monitor variables and adjust actuators to match engine requirements.
Cloud point – The point when wax crystals occur in fuel, making fuel cloudy or hazy. Usually below -12 °C (10
°F).
Cold cranking ampere rating (battery rating) – The sustained constant current (in amperes) needed to
produce a minimum terminal voltage under a load of 7.2 volts per battery after 30 seconds.
Inlet Air Heater Fuel Igniter (IAHFI) – The IAHFI heats the intake air by vaporizing and igniting fuel in the air
inlet duct.
Inlet Air Heater Fuel Solenoid (IAHFS) – As the engine is cranked, the ECM energizes the IAHFS valve,
introducing fuel into the IAHFI, which ignites and warms the air being drawn into the engine.
Inlet Air Heater Relay (IAHR) – The IAHR provides voltage to the IAHFI, and is controlled by the ECM.
Controller Area Network (CAN) – A J1939 high speed communication link.
Coolant – A fluid used to transport heat from one point to another.
Coolant level switch – A switch sensor used to monitor coolant level.
Coolant Flow Valve (CFV) – The CFV is ECM controlled and redirects coolant through the fuel cooler, based
on EFT, when directed.
Coolant Mixer Valve (CMV) – Controls coolant flow through the low-temperature radiator.
 TERMINOLOGY 863

Continuous Monitor Test – An ECM function that continuously monitors the inputs and outputs to ensure that
readings are within set limits.
Crankcase – The housing that encloses the crankshaft, connecting rods, and allied parts.
Crankcase breather – A vent for the crankcase to release excess interior air pressure.
Crankcase Oil Separator Speed (CCOSS) sensor – The CCOSS sensor sends the ECM information about
the speed of the crankcase oil separator internal components.
Crankcase pressure – The force of air inside the crankcase against the crankcase housing.
Crankshaft Position (CKP) sensor – A magnetic pickup sensor that determines crankshaft position and speed.
Current – The flow of electrons passing through a conductor. Measured in amperes.
Damper – A device that reduces the amplitude of torsional vibration. (SAE J1479 JAN85)
Deaeration – The removal or purging of gases (air or combustion gas) entrained in coolant or lubricating oil.
Deaeration tank – A separate tank in the cooling system used for one or more of the following functions:
• Deaeration
• Coolant reservoir (fluid expansion and afterboil)
• Coolant retention
• Filling
• Fluid level indication (visible)
Diagnostic Trouble Code (DTC) – 2010 model year vehicles no longer utilize DTC identification by number.
DTCs are now identified using the Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI) identifiers
only.
Diesel Particulate Filter (DPF) – A diesel particulate filter, sometimes called a DPF, is a device designed to
remove diesel particulate matter or soot from the exhaust gas of a diesel engine.
Diesel Oxidation Catalyst (DOC) – A DOC is part of the diesel exhaust Aftertreatment system. DOCs
are devices that use a chemical process to break down pollutants in the exhaust stream into less harmful
components. More specifically, DOCs utilize rare metals such as palladium and platinum to reduce hydrocarbon
based Soluble Organic Fraction (SOF) and carbon monoxide content of diesel exhaust by simple oxidation.
The DOC can be used during an active regeneration to create higher exhaust temperatures, thereby reducing
soot in the DPF.
Digital Multimeter (DMM) – An electronic meter that uses a digital display to indicate a measured value.
Preferred for use on microprocessor systems because it has a very high internal impedance and will not load
down the circuit being measured.
Disable – A computer decision that deactivates a system and prevents operation of the system.
Displacement – The stroke of the piston multiplied by the area of the cylinder bore multiplied by the number of
cylinders in the engine.
Downstream Injection (DSI) Unit – The DSI unit provides a metered amount of fuel to the Hydrocarbon Injector
(HCI) assembly.
Driver (high side) – A transistor within an electronic module that controls the power to an actuator circuit.
Driver (low side) – A transistor within an electronic module that controls the ground to an actuator circuit.
864 TERMINOLOGY

Dual Stage Turbocharger – An assembly of two turbochargers (low-pressure and high-pressure) in series to
provide a wide range of charge air pressures efficiently.
Duty cycle – A control signal that has a controlled on/off time measurement from 0 to 100%. Normally used to
control solenoids.
EGR Cooler – A cooler that allows heat to dissipate from the exhaust gasses before they enter the intake
manifold.
Engine Control Module (ECM) – An electronic processor that monitors and controls the engine.
Engine Back Pressure Valve (EBPV) – The ECM commands the EBPV to control the Exhaust Brake.
Engine Compression Brake (ECB) valve – The ECB valve controls pressure entering the brake oil gallery
from the high-pressure oil rail gallery. This activates the brake actuator pistons and opens the exhaust valves.
Engine Compression Brake 1 (ECB1) solenoid – The ECB1 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake 2 (ECB2) solenoid – The ECB2 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake Pressure (ECBP) sensor – A high-pressure sensor that provides a feedback
signal to the ECM indicating brake control pressure.
Engine Coolant Level (ECL) sensor – A switch sensor that monitors coolant level.
Engine Coolant Temperature 1 (ECT1) sensor – A thermistor sensor that detects engine coolant temperature.
Engine Coolant Temperature 2 (ECT2) sensor – A thermistor sensor that detects engine coolant temperature.
Engine Fuel Temperature (EFT) sensor – A thermistor sensor that measures fuel temperature.
Engine lamp – An instrument panel lamp that comes on when DTCs are set. DTCs can be read as flash codes
(red and amber instrument panel lamps).
Engine OFF tests – Tests that are done with the ignition switch ON and the engine OFF.
Engine Oil Pressure (EOP) sensor – A variable capacitance sensor that measures oil pressure.
Engine Oil Temperature (EOT) sensor – A thermistor sensor that measures oil temperature.
Engine rating – Engine rating includes Rated hp and Rated rpm.
Engine RUNNING tests – Tests done with the engine running.
Engine Throttle Valve (ETV) and Engine Throttle Position Sensor – The ETV valve is used to control airflow
during a regeneration process of the aftertreatment system. The ETV valve is also used to ensure a smooth
engine shut down by restricting airflow to the engine at shut down.
Engine Warning Protection System (EWPS) – Safeguards the engine from undesirable operating conditions
to prevent engine damage and to prolong engine life.
Exhaust Back Pressure (EBP) – The pressure present in the exhaust system during the exhaust period.
Exhaust Back Pressure Valve (EBPV) – A valve that regulates the amount of air pressure applied to the EBPV
pneumatic actuator.
Exhaust brake – A brake device using engine exhaust back pressure as a retarding medium.
Exhaust Gas Recirculation (EGR) – A system used to recirculate a portion of the exhaust gases into the power
cylinder in order to reduce oxides of nitrogen.
Exhaust Gas Temperature (EGT) – The temperature of exhaust gases.
 TERMINOLOGY 865

Exhaust Gas Recirculation Temperature (EGRT) sensor – A thermistor sensor that detects the exhaust gas
temperature entering the EGR cooler.
Exhaust Gas Recirculation (EGR) valve – The EGRV controls the flow of exhaust gases to the intake manifold.
The EGRV is integrated with an EGR Position (EGRP) sensor.
Exhaust manifold – Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.
Exhaust Manifold Pressure (EMP) sensor – A variable capacitance sensor used to indicate air pressure in
the exhaust manifold.
Exhaust Manifold Temperature (EMT) sensor – A thermistor style sensor used to indicate air temperature in
the exhaust manifold.
Fault detection/management – An alternate control strategy that reduces adverse effects that can be caused
by a system failure. If a sensor fails, the ECM substitutes a good sensor signal or assumed sensor value in its
place. A lit amber instrument panel lamp signals that the vehicle needs service.
Failure Mode Indicator (FMI) – Identifies the fault or condition effecting the individual component.
Filter restriction – A blockage, usually from contaminants, that prevents the flow of fluid through a filter.
Flash code – See Diagnostic Trouble Code (DTC).
Fuel Delivery Pressure (FDP) sensor – A variable capacitance sensor that monitors fuel pressure coming from
the fuel tank and sends a signal to the ECM.
Fuel inlet restriction – A blockage, usually from contaminants, that prevents the flow of fluid through the fuel
inlet line.
Fuel pressure – The force fuel exerts on the fuel system as it is pumped through the fuel system.
Fuel Pressure Control Valve (FPCV) – The FPCV controls the fuel pressure to the fuel rails and is controlled
by the ECM. FPCV control depends on fuel pressure and fuel temperature.
Fuel Rail Pressure (FRP) – The amount of pressure in the fuel rail.
Fuel Rail Pressure (FRP) sensor – A variable capacitance sensor that monitors fuel pressure in the fuel rail
and sends a signal to the ECM.
Fuel strainer – A pre-filter in the fuel system that keeps larger contaminants from entering the fuel system.
Fuel Volume Control Valve (FVCV) – The FVCV regulates the volume of flow sent to the HPFP. The FVCV
allows a sufficient quantity of fuel to be delivered to the HPFP depending on engine load, speed, injector quantity,
fuel temperature, and number of injections per cycle.
Fully equipped engine – A fully equipped engine is an engine equipped with only those accessories necessary
to perform its intended service. A fully equipped engine does not include components that are used to power
auxiliary systems. If these components are integral with the engine or, for any reason are included on the test
engine, the power absorbed may be determined and added to the net brake power. (SAE J1995 JUN90)
Fusible link (fuse link) – A fusible link is a special section of low tension cable designed to open the circuit
when subjected to an extreme current overload. (SAE J1156 APR86)
Gradeability – The maximum percent grade, which the vehicle can transverse for a specified time at a specified
speed. The gradeability limit is the grade upon which the vehicle can just move forward. (SAE J227a)
Gross Combined Weight Rating (GCWR) – Maximum combined weight of towing vehicle (including
passengers and cargo) and the trailer. The GCWR indicates the maximum loaded weight that the vehicle is
allowed to tow.
866 TERMINOLOGY

Gross brake horsepower – The power of a complete basic engine, with air cleaner, without fan, and alternator,
and air compressor not charging.
H-Bridge Circuit – An H-Bridge (bipolar) circuit operates like putting a power source on one side of a motor and
connecting the other side of the motor to a ground. This turns the motor. By shifting the leads on the motor, it
will turn in the opposite direction.
Hall effect – The development of a transverse electric potential gradient in a current-carrying conductor or
semiconductor when a magnetic field is applied.
Hall effect sensor – Transducer that varies its output voltage in response to changes in a magnetic field.
Commonly used to time the speed of wheels and shafts.
High-Pressure Fuel Pump (HPFP) assembly – The HPFP is a volumetric pump that supplies fuel at
high-pressure. The HPFP is mounted in the rear valley on the top of the engine and is driven by the camshaft.
High-pressure Piezo Common Rail (HPCR) – The HPFP pumps fuel through separate tubes to each fuel rail.
Each fuel rail has four fuel tubes, one for each injector, that maintain constant pressure from the high-pressure
pump to each injector.
High speed digital inputs – Inputs to the ECM from a sensor that generates varying frequencies (engine speed
and vehicle speed sensors).
Horsepower (hp) – Horsepower is the unit of work done in a given period of time, equal to 33,000 pounds
multiplied by one foot per minute. 1hp = 33,000 lb x 1 ft /1 min.
Humidity Sensor (HS) – A sensor that measures the moisture content of filtered air entering the intake system.
Hydrocarbons – Organic compounds consisting of hydrogen and carbon (fuel and oil).
Hydrocarbon Injector Assembly – Injects fuel into the exhaust system to increase temperature of the exhaust
gases.
Injection Pressure Regulator (IPR) valve – A valve that is used to maintain desired injection control pressure.
Injection Control Pressure (ICP) sensor – Provides a feedback signal to the ECM indicating injection control
pressure.
Inlet Air Heater (IAH) – The IAH is primarily used to assist in starting the engine during cold weather. In addition,
it helps to reduce white smoke emissions by heating the incoming air.
Inlet Air Temperature (IAT) sensor – A thermistor sensor that monitors intake air temperature.
Intake manifold – Engine component that evenly supplies air to each intake port in the cylinder head(s).
Intake Manifold Pressure (IMP) sensor – A variable capacitance sensor used to indicate air pressure in the
intake manifold.
Intake Manifold Temperature (IMT) sensor – A thermistor sensor used to indicate air temperature in the intake
manifold.
Internal Transfer Pump (ITP) – The ITP is part of the HPFP assembly and driven off the same shaft as the
HPFP assembly. The ITP supplies fuel at a slightly higher pressure and flow to the HPFP though the Fuel Volume
Control Valve (FVCV). The ITP also provides fuel for cooling and lubrication of the HPFP. Fuel is rerouted as
pump return flow through the HPFP cooling and lubrication valve. Pressure is maintained at the inlet of the
HPFP piston pump by an ITP regulator.
International NGV Tool Utilized for Next Generation Electronics (INTUNE) – The diagnostics software for
chassis related components and systems.
 TERMINOLOGY 867

Interstage Cooler (ISC) – Uses cooled coolant to lower the charged air temperature that exits from the
turbocharger low-pressure compressor and enters the turbocharger high-pressure compressor.
Low speed digital inputs – Switched sensor inputs that generate an on/off (high/low) signal to the ECM. The
input to the ECM from the sensor could be from a high input source switch (usually 5 or 12 volts) or from a
grounding switch that grounds the signal from a current limiting resistor in the ECM that creates a low signal (0
volts).
Low temperature radiator thermostat – Coolant flow to the low temperature radiator is regulated by the low
temperature radiator thermostat.
Lubricity – Lubricity is the ability of a substance to reduce friction between solid surfaces in relative motion
under loaded conditions.
Lug (engine) – A condition when the engine is run at an overly low RPM for the load being applied.
Manifold Absolute Pressure (MAP) – Boost pressure in the manifold that is a result of the turbocharger.
Manifold Absolute Pressure (MAP) sensor – A variable capacitance sensor that measures boost pressure.
Manometer – A double-leg liquid-column gauge, or a single inclined gauge, used to measure the difference
between two fluid pressures. Typically, a manometer records in inches of water.
Mass Air Flow – The intake airflow in an engine.
Mass Air Flow (MAF) sensor – The MAF sensor is used for closed loop control of the EGR valve and ITV. The
ECM monitors the MAF signal so that the ECM can control the EGR and intake throttle systems.
MasterDiagnostics® (MD) – Diagnostics software for engine related components and systems.
Magnehelic Gauge – A gauge that measures pressure in inches of water.
Magnetic Pickup Sensor – A magnetic pickup sensor generates an alternating frequency that indicates speed.
Magnetic pickups have a two-wire connection for signal and ground. This sensor has a permanent magnetic
core surrounded by a wire coil. The signal frequency is generated by the rotation of the gear teeth that disturb
the magnetic field.
Microprocessor – An integrated circuit in a microcomputer that controls information flow.
Micro Strain Gauge (MSG) Sensor – A MSG sensor measures pressure. Pressure exerts force on a pressure
vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the
pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage output.
Nitrogen Oxides (NOx) – Nitrogen oxides form by a reaction between nitrogen and oxygen at high temperatures
and pressures in the combustion chamber.
Normally closed – Refers to a switch that remains closed when no control force is acting on it.
Normally open – Refers to a switch that remains open when no control force is acting on it.
Ohm (Ω) – The unit of electrical resistance. One ohm is the value of resistance through which a potential of one
volt will maintain a current of one ampere. (SAE J1213 NOV82)
On demand test – A self-test the technician initiates using the EST that is run from a program in the software.
Output Circuit Check (OCC) – An on-demand test done during an Engine OFF self-test to check the continuity
of selected actuators.
Oxides of Nitrogen (NOx) – Nitrogen oxides formed by a reaction between nitrogen and oxygen at high
temperatures.
Oxygen Sensor (O2S) – A sensor that monitors oxygen levels in the exhaust.
868 TERMINOLOGY

pH – A measure of the acidity or alkalinity of a solution.

Particulate matter – Particulate matter includes mostly burned particles of fuel and engine oil.
Piezometer – An instrument for measuring fluid pressure.
Power – Power is a measure of the rate at which work (force x distance) is done during a specific time. Compare
with Torque.
Power TakeOff (PTO) – Accessory output, usually from the transmission, used to power a hydraulic pump for
a special auxiliary feature (garbage packing, lift equipment, etc).
Pulse Width Modulation (PWM) – Succession of digital electrical pulses, rather than an analog signal. Efficient
method of providing power between fully on and fully off.
Random Access Memory (RAM) – Computer memory that stores information. Information can be written to and
read from RAM. Input information (current engine speed or temperature) can be stored in RAM to be compared
to values stored in Read Only Memory (ROM). All memory in RAM is lost when the ignition switch is turned off.
Rated gross horsepower – Engine gross horsepower at rated speed as declared by the manufacturer. (SAE
J1995 JUN90)
Rated horsepower – Maximum brake horsepower output of an engine as certified by the engine manufacturer.
The power of an engine when configured as a basic engine. (SAE J1995 JUN90)
Rated net horsepower – Engine net horsepower at rated speed as declared by the manufacturer. (SAE J1349
JUN90)
Rated speed – The speed, as determined by the manufacturer, at which the engine is rated. (SAE J1995
JUN90)
Rated torque – Maximum torque produced by an engine as certified by the manufacturer.
Ratiometric Voltage – In a Micro Strain Gauge (MSG) sensor, pressure to be measured exerts force on a
pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface
of the pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage
output.
Reference voltage (VREF) – A 5 volt reference supplied by the ECM to operate the engine sensors.
Reserve capacity – Time in minutes that a fully charged battery can be discharged to 10.5 volts at 25 amperes.
Return Fuel System – The return fuel system moves unused fuel from the fuel injectors to the fuel cooler.
Excess fuel out of the FVCV and the FPCV mix with fuel from the fuel injectors on the way to the fuel cooler.
ServiceMaxx™ software – Diagnostics software for engine related components and systems.
Signal Conditioner – The signal conditioner in the internal microprocessor converts analog signals to digital
signals, squares up sine wave signals, or amplifies low-intensity signals to a level that the ECM microprocessor
can process.
Signal ground – The common ground wire to the ECM for the sensors.
Speed Control Command Switches (SCCS) – A set of switches used for cruise control, Power TakeOff (PTO),
and remote hand throttle system.
Steady state condition – An engine operating at a constant speed and load and at stabilized temperatures and
pressures. (SAE J215 JAN80)
Strategy – A plan or set of operating instructions that the microprocessor follows for a desired goal. Strategy
is the computer program itself, including all equations and decision making logic. Strategy is always stored in
ROM and cannot be changed during calibration.
 TERMINOLOGY 869

Stroke – The movement of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC).
Substrate – Material that supports the wash coating or catalytic materials.
Suspect Parameter Number (SPN) – A 19-bit number used to identify the item for which diagnostics are being
reported. The SPN is used for multiple purposes, some that are specific to diagnostics are as follows;
• Identify the least repairable subsystem that has failed.
• Identify subsystems or assemblies that may not have hard failures but may be exhibiting abnormal operating
performance.
• Identify a particular event or condition that will be reported.
• Report a component and non-standard failure mode.
System restriction (air) – The static pressure differential that occurs at a given airflow from air entrance through
air exit in a system. Usually measured in inches (millimeters) of water. (SAE J1004 SEP81)
Tachometer output signal – Engine speed signal for remote tachometers.
Thermistor – A semiconductor device. A sensing element that changes resistance as the temperature changes.
Thermistor Sensor – Changes electrical resistance with changes in temperature. Resistance in the thermistor
decreases as temperature increases, and increases as temperature decreases. Thermistors work with a resistor
that limits current to form a voltage signal matched with a temperature value.
Thrust load – A thrust load pushes or reacts through a bearing in a direction parallel to the shaft.
Top Dead Center (TDC) – The uppermost position of the piston during the stroke.
Torque – A force having a twisting or turning effect. For a single force, the cross product of a vector from some
reference point to the point of application of the force within the force itself. Also known as moment of force or
rotation moment. Torque is a measure of the ability of an engine to do work.
Truck Computer Analysis of Performance and Economy (TCAPE) – A computer program that simulates the
performance and fuel economy of trucks.
Turbocharger – A turbine driven compressor mounted on the exhaust manifold. The turbocharger increases
the pressure, temperature and density of intake air to charge air.
Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor – A variable capacitance sensor that monitors
exhaust back-pressure.
Turbocharger 2 Compressor Inlet (TC2CIS) sensor – The TC2CIS sensor includes a thermistor sensor that
monitors the temperature of charge air entering the HP turbocharger. This sensor also monitors boost pressure
for the LP turbocharger.
Turbocharger Wastegate Control (TCWC) solenoid – Controls the TCWC actuator by regulating the amount
of charge air pressure supplied to the TCWC actuator. The TCWC solenoid is controlled by signals from the
ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
Turbocharger 1 Wastegate Control (TC1WC) solenoid – Controls the TC1WC actuator by regulating the
amount of charge air pressure supplied to the TC1WC actuator. The TC1WC solenoid is controlled by signals
from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
The TC1WC actuator is part of the turbocharger assembly.
Turbocharger 2 Wastegate Control (TC2WC) solenoid – Controls the TC2WC actuator by regulating the
amount of charge air pressure supplied to the wastegate actuator. The TC2WC solenoid is controlled by signals
from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
The TC2WC actuator is part of the turbocharger assembly.
870 TERMINOLOGY

Variable capacitance sensor – A variable capacitance sensor measures pressure. The pressure forces a
ceramic material closer to a thin metal disc in the sensor, changing the capacitance of the sensor.
Vehicle Electronic System Programming System – The computer system used to program electronically
controlled vehicles.
Vehicle Retarder Enable/Engage – Output from the ECM to a vehicle retarder.
Vehicle Speed Sensor (VSS) – Normally a magnetic pickup sensor mounted in the tailshaft housing of the
transmission, used to indicate ground speed.
Viscosity – The internal resistance to the flow of any fluid.
Viscous fan – A fan drive that is activated when a thermostat, sensing high air temperature, forces fluid through
a special coupling. The fluid activates the fan.
Volt (v) – A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm.
Voltage – Electrical potential expressed in volts.
Voltage drop – Reduction in applied voltage from the current flowing through a circuit or portion of the circuit
current multiplied by resistance.
Voltage ignition – Voltage supplied by the ignition switch when the key is ON.
Washcoat – A layer of alumina applied to the substrate in a monolith-type converter.
Water In Fuel (WIF) sensor – A switch sensor that measures the amount of water in the fuel.
 APPENDIX A – SPECIFICATIONS 871

Table of Contents

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873

Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .873
Oil Pump, Low Mount Fan Drive, and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .874
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .874
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .875
872 APPENDIX A – SPECIFICATIONS
 APPENDIX A – SPECIFICATIONS 873

Fuel System

Fuel System
Fuel strainer filtration 300 microns
Fuel filter element filtration 3-5 microns

Air Inlet Duct and Exhaust Manifolds

Exhaust Manifolds
Exhaust manifold maximum allowable warpage 0.1 mm (0.003 in)

Engine Brake

Engine Brake

Solenoid resistance:

Cold – 0.1 mm (0.003 in)

Cold — 25° C (77° F) 8.7–10 ohms
Hot — 121° C (250° F) 12–15.5 ohms

Cylinder Head, Camshaft and Valve Train

Table 2 Cylinder Head, Camshaft and Valve Train

Camshaft
Camshaft bearing inside diameter 39.925 – 39.950 mm (1.57185 – 1.57283 in)
Camshaft end play 0.25 – 0.85 mm (0.0098 – 0.0334 in)
Valve Lash Adjustment
Exhaust valve clearance 0.8 mm (0.0315 in)
Intake valve clearance 0.5 mm (0.0197 in)
Cylinder Head Idler Gear Cup Plug
Cup plug, DMR 63.10 Recess 2.3 mm (0.9 in)

Flywheel and Flywheel Housing

Flywheel and Flywheel Housing

Flywheel minimum thickness (dimension “A”) 46 mm (1.811 in)

Flywheel maximum surface runout 0.20 mm (0.0079 in)

874 APPENDIX A – SPECIFICATIONS

Oil Pump, Low Mount Fan Drive, and Timing Gears

Oil Pump, Low Mount Fan Drive, and Timing Gears

Front Timing Gears

Front intermediate gear backlash 0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump
Oil pump pinion and oil pump ring gear end play 0.0030 - 0.120 mm (0.0012 - 0.0047 in)
Rear Timing Gears
Big intermediate gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Crankcase intermediate gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)

Power Cylinders

Power Cylinders
Connecting Rods

Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)

Connecting rod bearing bore diameter

95.000 to 95.022 mm (3.7402 to 3.7402 in)
(crankshaft end)
Pistons — N13
Skirt diameter measured 26.9 mm from piston
bottom edge, 90° to piston pin axis in “window” 125.950 ± 0.013 mm (4.9587 ± 0.0005 in)
on skirt graphite layer, where applicable
Piston protrusion measured from crankcase
0.3 ± 0.22 mm (0.0118 ± 0.009 in)
deck to piston
Piston pin bore inside diameter, measured
52.04 - 52.05 mm (2.0490 - 2.0492 in)
horizontally 26 mm from piston center
Piston pin running clearance 0.040 - 0.058 mm (0.0016 - 0.0023 in)
Piston Pins
Outside diameter 51.992 - 52.000 mm (2.0469 - 2.0472 in)
Piston Rings — N13
Top compression ring

Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)

Taper face compression ring

Ring gap 1.00 - 1.20 mm (0.0393 - 0.0472 in)

 APPENDIX A – SPECIFICATIONS 875

Power Cylinders (cont.)

Side clearance 0.09 - 0.13 mm (0.0035 - 0.0051 in)

Bevelled oil ring

Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance 0.03 - 0.07 mm (0.0012 - 0.0028 in)

Piston Rings — N13

Top compression ring
Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Taper face compression ring
Ring gap 1.00 - 1.20 mm (0.0394 - 0.0472 in)

Side clearance 0.09 - 0.13 mm (0.0035 - 0.0051 in)

Bevelled oil ring

Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)

Side clearance 0.05 - 0.09 mm (0.0020 - 0.0035 in)

Cylinder sleeve dimensions — N13
Sleeve protrusion 0.050 - 0.085 mm (0.0019 - 0.0033 in)
Sleeve inside diameter (bore) 126 ± 0.01 mm (4.9606 ± 0.0004 in)

Crankcase and Crankshaft

Crankcase and Crankshaft

Crankshaft
Main Bearing:
Journal diameter 103.98 - 104.00 mm (4.0937 - 4.0945 in)
Installed bearing inside diameter 104.044 - 104.09 mm (4.0962 - 4.0980 in)
Uninstalled bearing outside diameter (free
111.20 - 112.40 mm (4.3779 - 4.4252 in)
spread)
Connecting Rod Bearing:
Journal diameter 89.98 - 90.00 mm (3.5425 - 3.5433 in)
Crankshaft end play:
Maximum service 0.200 - 0.401 mm (0.0079 - 0.0158 in)
876 APPENDIX A – SPECIFICATIONS
 APPENDIX B – TORQUES 877

Table of Contents

General Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879

Bolt Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879
General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .880
Standard Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .881
Using a Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .882

Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .883

Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .883
Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .883
Inlet Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .884
Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .884
Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .885
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .885
Air Compressor and Power Steering/Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .886
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .887
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .888
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .888
Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .889
Front Cover, High Mount Fan Drive, Cooling System, Related Components. . . . . . . . . . . . . . . . . . . . . .889
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .890
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .891
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .892
Oil Pan and Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893
Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .893
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894
878 APPENDIX B – TORQUES
 APPENDIX B – TORQUES 879

General Torque
Bolt Identification

Figure 747 Metric fasteners – Classification and identification

Figure 748 Special fasteners – Classification and identification

880 APPENDIX B – TORQUES

General Torque Guidelines

CAUTION: To prevent engine damage, do not substitute fasteners. All original equipment fasteners are
hardened and phosphate coated.
NOTE: Inspect parts for cleanliness and defects before assembly.
Many conditions affect torque and the results of torque applications. The major purpose in tightening a fastener
to a specified torque is to obtain a clamping load which exceeds any possible loading imposed on parts.
New phosphate coated fasteners do not require oil lubrication during assembly and torque application. Reused
fasteners (even if originally phosphate coated) do require oil lubrication to threads and under head area for
correct torque application.
Threads that are dry, excessively rough, battered, or filled with dirt require considerable effort just to rotate. Then
when the clamping load is developed or the bolt tension is applied, the torque reading mounts rapidly (due to
thread friction) to the specified torque value. However, the desired bolt tension and correct clamping load is not
achieved. This condition can lead to failure of the fastener to maintain component integrity. The correct bolt
tension and clamping effect can never be attained if the fastener is dry. Fastener threads must be new condition
phosphate coated or have a film of clean lubricant (engine oil) to be considered lubricated.
 APPENDIX B – TORQUES 881

Standard Torque Charts

CAUTION: To prevent engine damage, do not use this standard torque chart with other International brand
engines or engines made by other manufacturers.
Standard torque chart provides tightening values for all hardware that do not require special torque.

Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs
Thread Diameter (mm) Thread Pitch (mm) Torque
6 1 13 N·m (115 lb·in)
8 1.25 31 N·m (23 lb·ft)
10 1.5 62 N·m (45 lb·ft)
12 1.75 107 N·m (79 lb·ft)
14 2 172 N·m (127 lb·ft)
15 2 216 N·m (159 lb·ft)
16 2 266 N·m (196 lb·ft)
18 2.5 368 N·m (272 lb·ft)
20 2.5 520 N·m (384 lb·ft)

Example: Tighten four M6 x 12 pulley bolts to standard torque. What is the size and standard torque for these
four bolts?
M6 x 12 refers to the bolts thread diameter and length. These bolts have a thread diameter of 6 mm and are 12
mm long.
To find the standard torque for a M6 x 12 bolt look at the torque chart above. We see the standard torque for a
6 mm thread diameter class 10.9 bolt should be 13 N·m (115 lb·in).
882 APPENDIX B – TORQUES

Using a Torque Wrench Extension

Occasionally an extension, crowfoot, or other adapter is necessary to use with a torque wrench to torque a bolt
or line fitting. Adding adapters or extensions will alter the torque on the fastener from what the torque wrench
reads. Use the following formula to calculate the correct torque wrench setting to achieve a specific torque value.

Figure 749 Torque wrench and extension

• F - Force applied by technician

• L - Total length through which force is applied to fastener
• TW - Torque applied at end of torque wrench
TS = TE (LW / (LW + LE))
• TS - Torque wrench setting
• TE - Torque specified at fastener
• LW - Length of torque wrench
• LE - Length of extension
Example: A component requires a specified torque value of 65 lb·ft and a 6 inch extension is required to reach
it. What should the torque wrench setting (TS) be to compensate for the extension?
• Torque specified at fastener (TE) = 65 lb·ft
• Length of torque wrench (LW) = 12 inches
• Length of extension (LE) = 6 inches
TS = TE (LW / (LW + LE))
TS = 65 lb·ft (12 inches / (12 inches + 6 inches)
TS = 65 lb·ft (12 inches / (18 inches)
TS = 65 lb·ft (0.666)
TS = 43.33 lb·ft
 APPENDIX B – TORQUES 883

Special Torques
Mounting Engine on Stand

Mounting Engine on Stand

M14 x 50 engine front mount support bolts 225 N·m (166 lb·ft)
Oil drain plug 75 N·m (55 lb·ft)

Engine Electrical

Engine Electrical
Camshaft Position (CMP) sensor, M6 x 12 bolt 8 N·m (71 lb·in)
Charger Air Cooler Outlet Temperature (CACOT)
11 N·m (97 lb·in)
sensor
Crankcase Oil Separator Speed (CCOSS) sensor,
10 N·m (89 lb·in)
M6 x 14 bolt
Crankshaft Position (CKP) sensor, M6 x 16 bolt 8 N·m (71 lb·in)
10 N·m (89 lb·in)
Engine Control Module (ECM), M6 x 30 bolt
See procedure for tightening sequence
Engine Control Module (ECM) support, M8 x 40 bolt 13 N·m (115 lb·in)
Engine Coolant Temperature 1 (ECT1) sensor 45 N·m (33 lb·ft)
Engine Coolant Temperature 2 (ECT2) sensor 45 N·m (33 lb·ft)
Engine injector harness retainer clip, M6 x 30 bolt 10 N·m (89 lb·in)
Engine Oil Pressure (EOP) sensor 45 N·m (33 lb·ft)
Engine Oil Temperature (EOT) sensor 45 N·m (33 lb·ft)
Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT)
37 N·m (27 lb·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lb·ft)
Humidity / Inlet Air Temperature (IAT) sensor, M6
9 N·m (80 lb·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lb·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lb·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lb·in)
Oxygen Sensor (O2S) 50 N·m (37 lb·ft)
Fuel Rail Pressure (FRP) sensor 70 N·m (52 lb·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lb·in)
M6 x 16 bolt
884 APPENDIX B – TORQUES

Inlet Air Heater

Inlet Air Heater

Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts 15 N·m (11 lb·ft)
Banjo M8 x 1 bolt 8 N·m (71 lb·in)
Fuel supply inlet air heater hose fitting nut 10 N·m (11 lb·ft)
Glow plug locking nut 25 N·m (18 lb·ft)
Relay assembly M6 x 20 bolts 10 N·m (89 lb·in)
Solenoid valve M6 x 20 bolts 6 N·m (53 lb·in)

Aftertreatment System

Aftertreatment System
Coolant supply (straight) fitting at coolant manifold 35 N·m (26 lb·ft)
Fitting (quick-connect adapter) at DSI unit 35 N·m (26 lb·ft)
Fitting (straight union orifice) at DSI unit 35 N·m (26 lb·ft)
HCI coolant supply and return tube nut at tube M10 elbow 15 N·m (11 lb·ft)
fittings
HCI coolant supply tube nut at coolant manifold 25 N·m (18 lb·ft)
HCI fuel 1 tube assembly nut at HCI fuel 2 tube fitting (brazed) 25 N·m (18 lb·ft)
HCI fuel 1 tube assembly nut at DSI unit 25 N·m (18 lb·ft)
HCI fuel 2 tube assembly nut at hydrocarbon injector assembly 18 N·m (13 lb·ft)
Hydrocarbon injector assembly M8 x 45 bolt See tightening steps in procedure.
Hydrocarbon injector assembly body to assembly (if 20 N·m (15 lb·ft)
accidentally loosened during fuel tube nut service)
Metering unit bracket bolt, M8 x 16 31 N·m (23 lb·ft)
PDOC V-band clamp 7 N·m (62 lb·in)
PDOC M10 x 50 bolts 36 N·m (27 lb·ft)
Tube M10 elbow fittings at hydrocarbon injector assembly 17.5 N·m (13 lb·ft)
 APPENDIX B – TORQUES 885

Exhaust Back Pressure Control

Exhaust Back Pressure Control

Air supply tube (at bulkhead fitting) 17.5 N·m (13 lb·ft)
Air supply tube nut (at air control valve) 12 N·m (106 lb·in)
Exhaust back pressure valve tube nut (at actuator) 15 N·m (11 lb·ft)
Exhaust back pressure valve tube nut (at air control valve) 15 N·m (11 lb·ft)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lb·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lb·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting 15 N·m (11 lb·ft)

Turbochargers

Turbochargers
3/4 inch and 1 inch worm gear hose clamps 3.5 N·m (31 lb·in)
High-pressure-to-low-pressure turbine bolts, M10 x 55 47 N·m (35 lb·ft)
High-pressure wastegate actuator bolts, M8 x 14 16 N·m (12 lb·ft)
Male stud connector 70 N·m (52 lb·ft)
M24 threaded fitting 60 N·m (44 lb·ft)
See tightening steps
Oil return low-pressure turbocharger tube (at crankcase)
in procedure.
See tightening steps
Oil return low-pressure turbocharger tube fitting nut
in procedure.
Turbocharger oil supply tube assembly fitting nut to male stud connector 27 N·m (20 lb·ft)
886 APPENDIX B – TORQUES

Air Compressor and Power Steering/Fuel Pump

Air Compressor and Power Steering/Fuel Pump

1-1/16" 90 degree elbow lock nut 55 N·m (40 lb·ft)
1/2" 90 degree tube elbow lock nut 45 N·m (33 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (one cylinder) 35 N·m (26 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (two cylinder) 31 N·m (23 lb·ft)
(Two cylinder) Air compressor M10 x 110 bolt 67 N·m (49 lb·ft)
High-pressure tube fitting nut 62 N·m (45 lb·ft)
M16 straight fitting 35 N·m (26 lb·ft)
M16 45° fitting 17.5 N·m (13 lb·ft)
M18 straight fitting 37.5 N·m (28 lb·ft)
Low-pressure tube fitting nut 164 N·m (120 lb·ft)
Power steering pump M10 x 40 bolt 67 N·m (49 lb·ft)
 APPENDIX B – TORQUES 887

Fuel System

Fuel System
Banjo bolt, M14 30 N·m (22 lb·ft)
Check valve 35 N·m (26 lb·ft)
Forcing screw adapter plate M10 x 40 bolts 27 N·m (20 lb·ft)
Fuel drain line fitting nut 26 N·m (19 lb·ft)
Fuel filter bracket M8 x 30 bolt 35 N·m (26 lb·ft)
Fuel filter housing assembly M8 x 45 bolt 35 N·m (26 lb·ft)
Fuel filter cap 25 N·m (18 lb·ft)
Fuel filter stand pipe 12 N·m (106 lb·in)
Fuel primer pump assembly M8 x 25 bolt 30 N·m (22 lb·ft)
Fuel rail M8 x 40 bolt 35 N·m (26 lb·ft)
Fuel strainer cover 10 N·m (89 lb·in)
Fuel supply adapter 30 N·m (22 lb·ft)
Fuel to rail supply clamp assembly screws 5 N·m (44 lb·in)
High-pressure connector (body) retaining nut See tightening steps in procedure
Drive housing M12 x 40, M12 x 90, M12 x 130 bolt 105 N·m (77 lb·ft)
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lb·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lb·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lb·ft)
Holding plate M12 bolts 47 N·m (35 lb·ft)
Injector harness nut 1.8 N·m (16 lb·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Pressure limiting valve 110 N·m (81 lb·ft)
Quick-connect M16 x 1.5 connector 30 N·m (22 lb·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lb·ft)
888 APPENDIX B – TORQUES

Oil Module Assembly

Oil Module Assembly

Heater return tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Heater return tube assembly tube nut 11 N·m (97 lb·in)
Oil cooler bolts, M8 x 45 and M8 x 90 25 N·m (18 lb·ft)
Oil filter cover 40 N·m (30 lb·ft)
Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110 65 N·m (48 lb·ft)
Oil module flange bolts, M8 x 45 24 N·m (18 lb·ft)
Oil pressure relief valve 40 N·m (30 lb·ft)
Open breather tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Water pump bolt, M8 x 150 (front side of oil module) 35 N·m (26 lb·ft)

Exhaust Gas Recirculation (EGR) System

EGR System
Coolant manifold, M8 x 18 bolt 22 N·m (16 lb·ft)
Coolant manifold, M8 x 25 heat–resistant bolt 24 N·m (18 lb·ft)
Coolant manifold, M8 x 45 bolt and M8 x 50 x 16 stud bolt 35 N·m (26 lb·ft)
EGR dual flap valve, M8 x 30 heat-resistant bolt See tightening steps in procedure.
EGR inlet (cylinders 1-3) tube, M8 x 25 heat-resistant bolt See tightening steps in procedure.
EGR inlet (cylinders 4-6) tube, M8 x 25 heat-resistant bolt See tightening steps in procedure.
EGR module cover, M8 x 85 bolts and M8 x 90 stud bolt 24 N·m (18 lb·ft)
EGR cooler assembly M10 x 45 bolts 62 N·m (45 lb·ft)
EGR cooler assembly M10 x 170 bolt 62 N·m (45 lb·ft)
EGR outlet tube hose clamps 5 N·m (45 lb·in)
EGR valve coolant supply tube nut 26 N·m (19 lb·ft)
Front EGR cooler cleaning adapter M8 bolts 24 N·m (18 lb·ft)
Heat protection (cylinders 4–6) shield, M8 x 25 heat–resistant bolts 24 N·m (18 lb·ft)
HT EGR cooler mounting studs 7/16 - 14 nuts 41 N·m (30 lb·ft)
Leak Detection Plate KL20060-4 M8 x 30 bolts 24 N·m (18 lb·ft)
Low-temperature and high-temperature EGR coolers, M8 x 55 hex See tightening steps in procedure.
socket screws
LT EGR cooler mounting studs 3/8 - 14 nuts 41 N·m (30 lb·ft)
Rear EGR cooler cleaning adapter M8 bolts 24 N·m (18 lb·ft)
 APPENDIX B – TORQUES 889

Air Inlet Duct and Exhaust Manifolds

Figure 750 Exhaust manifold tightening sequence

Air Intake Throttle Duct and Exhaust Manifolds

Air intake throttle duct bolts, M8 31 N·m (23 lb·ft)
Exhaust manifold Torx® bolts, M10 x 57 See tightening procedure and sequence in steps

Front Cover, High Mount Fan Drive, Cooling System, Related Components

Figure 751 High mount fan drive bolt tightening sequence

890 APPENDIX B – TORQUES

Front Cover, Fan Drive, Cooling System and Related Components

Automatic belt tensioner countersunk screw,
47 N·m (35 lb·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lb·ft)
M8 x 60
Coolant heater 41 N·m (30 lb·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lb·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lb·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lb·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lb·ft)
Front belt- or gear-driven fan cover bolts,
• M8 31 N·m (23 lb·ft)
• M12 x 75 115 N·m (85 lb·ft)
• M12 x 30 115 N·m (85 lb·ft)
High mount fan drive clutch assembly bolts,
See tightening steps in procedure
M10
High mount fan drive tensioner countersunk
47 N·m (35 lb·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lb·ft)
Idler pulley bolt, M12 x 55 60 N·m (44 lb·ft)
Low mount fan drive bolt, M10 x 110 37 N·m (27 lb·ft)
Vibration damper socket-head cap screws,
See tightening steps in procedure
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lb·ft)
Water pump assembly bolts, M8 35 N·m (26 lb·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lb·ft)

Engine Brake

Engine Brake
Brake housing M10 x 90 bolt 75 N·m (55 lb·ft)
Brake housing M12 x 100 (socket-head) screw 105 N·m (77 lb-ft)
Brake housing solenoid harness connector nut 3.5 N·m (31 lb·in)
Slave piston adjusting screw M10 (jam) nut 25 N·m (18 lb·ft)
Solenoid M6 x 10 socket-head cap screw 12.5 N·m (110 lb·in)
 APPENDIX B – TORQUES 891

Cylinder Head, Camshaft and Valve Train

Figure 752 Cylinder Head Bolts Tightening Sequence

Figure 753 Valve Cover Base Tightening Sequence

892 APPENDIX B – TORQUES

Cylinder Head, Camshaft and Valve Train

Camshaft gear M8 x 30 bolt See tightening steps in procedure
(Camshaft) bearing cap M8 x 35 bolt 25 N·m (18 lb·ft)
Cylinder head idler gear M8 x 30 socket-head cap screw 30 N·m (22 lb·ft)
Cylinder head M18 x 246 Torx® bolt See tightening steps in procedure
Rocker arm assembly M12 x 60 (socket-head) screw 105 N·m (77 lb·ft)
Upper valve cover M8 x 30 bolt 9 N·m (80 lb·in)
Valve cover base screw with damper 11 N·m (97 lb·in)
Valve lash adjustment M10 nut 45 N·m (33 lb·ft)

Flywheel and Flywheel Housing

Figure 754 Flywheel bolt tightening sequence

Flywheel and Flywheel Housing

12PT flange bolts See tightening steps in procedure.
Flywheel housing bolts, M10 x 30 and M10 x 40 65 N·m (48 lb·ft)
Lifting eye bolts, M16 x 150 280 N·m (207 lb·ft)
Timing hole cover screws 2 N·m (18 lb·in)
 APPENDIX B – TORQUES 893

Oil Pan and Oil Suction Tube

Figure 755 Torque sequence

Oil Pan Components

Drain plug, M27 x 2 75 N·m (55 lb·ft)
Oil pan bolts, M8 x 40 See tightening steps in procedure.
Oil pan heater element or replacement drain plug 75 N·m (55 lb·ft)

Oil Pump and Timing Gears

Oil Pump and Timing Gears

Air compressor coupled idler gear, M12 x 55 bolts 107 N·m (79 lb·ft)
Axle for pinion (oil pump), M10 x 35 socket-head cap screw 65 N·m (48 lb·ft)
Crankcase idler gear, M8 x 30 socket-head cap screws 30 N·m (22 lb·ft)
(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lb·ft)
Idler large gear, M14 x 80 bolts 175 N·m (129 lb·ft)

Power Cylinders

Power Cylinders
Connecting rod bolts See tightening steps in procedure
Sleeve Protrusion Hold Down Clamp bolts 80 N·m (59 lb·ft)
894 APPENDIX B – TORQUES

Crankcase and Crankshaft

Crankcase and Crankshaft

Collar bolts (main bearing cap), M18 x 160.5 See tightening procedure and sequence
(page 845)
Piston cooling jet bolts, M6 x 12 13 N·m (115 lb·in)
 APPENDIX C – SPECIAL SERVICE TOOLS 895

Table of Contents

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897

Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .897
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898
Air Compressor and Power Steering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899
Oil Cooler, Filter Housing and Crankcase Ventilation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .899
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
Air Inlet Throttle Duct and Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
Front Cover, Fan Drive, Cooling System and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
N13 Engine Brake by Jacobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .901
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .901
Oil Pump, Fan Drive and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .902

Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .904

Essential Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .904
896 APPENDIX C – SPECIAL SERVICE TOOLS
 APPENDIX C – SPECIAL SERVICE TOOLS 897

Special Tools
Contact Information
For concerns or ordering information regarding special tools for the N13 engines, refer to the Service Resource
Center on Service Portal, or call 1-800-365-0088.

Mounting Engine on Stand

Mounting Engine on Stand

Description Tool Number
Disposable Air and Fuel Caps ZTSE4891
Engine Stand Adapter Plate 12-051-01

Engine Electrical

Engine Electrical
Description Tool Number
Disposable Air and Fuel Caps ZTSE4891

Aftertreatment System

Aftertreatment System
Description Tool Number
Fuel Line Disconnect Tool 11.8 mm ZTSE4773
P-80® rubber lubricant or equivalent Obtain locally

Exhaust Back Pressure Control

Exhaust Back Pressure Control

Description Tool Number
Crimping pliers Obtain locally
Superlub™ synthetic high heat lubricant Obtain locally
898 APPENDIX C – SPECIAL SERVICE TOOLS

Turbochargers

Turbochargers
Description Tool Number
3-inch couplers and clamps Obtain locally
Charge Air Cooler Test Kit ZTSE6042
Crimping pliers Obtain locally
Extension Tube Installer ZTSE6043
P-80® rubber lubricant or equivalent Obtain locally
Turbo Alignment Bracket ZTSE6041

Air Compressor and Power Steering

Air Compressor and Power Steering

Description Tool Number
Coolant Line Release Tool ZTSE4778
Loctite® 5900 sealant or Wacker® A-442 RTV Obtain locally
P80® rubber lubricant or equivalent Obtain locally
 APPENDIX C – SPECIAL SERVICE TOOLS 899

Fuel System

Fuel System
Description Tool Number
Crowfoot wrench Obtain locally
Disposable Air and Fuel Caps ZTSE4891
Fan Hub/High Pressure Drive Seal Installer ZTSE6066
Forcing Screw 12-454-01-05
Forcing Screw Adapter 12-454-01-04
Forcing Screw Adapter Holding Plate 12-454-01-01
Fuel Injector Cups ZTSE4892
Fuel Injector Rack Holder ZTSE4299B
Fuel Injector Tip Cleaning Brush ZTSE4301
Fuel Line Disconnect Tool 11.8 mm ZTSE4773
Fuel System Priming Tool 15-922-01
Guide Stud 12-454-01-02
High-Pressure Pump Removal Tool 12-454-01
Holding Plate ZTSE6044
Injector Installer ZTSE4777
Injector Puller ZTSE4770
Injector Sleeve Brushes ZTSE4751
P80® Rubber Lubricant or equivalent Obtain locally
Socket Head Bolt 12-454-01-03
Wacker® A-442 RTV sealant or equivalent Obtain locally
Slide hammer Obtain locally

Oil Cooler, Filter Housing and Crankcase Ventilation

Oil Cooler, Filter Housing and Crankcase Ventilation

Description Tool Number
Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
P-80® rubber lubricant or equivalent Obtain locally
900 APPENDIX C – SPECIAL SERVICE TOOLS

Exhaust Gas Recirculation (EGR) System

EGR System
Description Tool Number
Cleaning Management System 12-353-01
Coolant Management Tool KL5007NAV
EGR Cooler Alignment Tool 12-892-01A
Exhaust Gas Recirculation (EGR) Cooler Leak
KL 20060 NAV
Detection Tool
Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
P-80® rubber lubricant or equivalent Obtain locally

Air Inlet Throttle Duct and Exhaust Manifold

Air Inlet Throttle Duct and Exhaust Manifold

Description Tool Number
Feeler gauge Obtain locally
FEY Rings Installation Tools ZTSE6030
Straightedge Obtain locally
Wacker® A-442 RTV sealant or equivalent Obtain locally

Front Cover, Fan Drive, Cooling System and Related Components

Front Cover, Fan Drive, Cooling System and Related Components

Description Tool Number
Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
Fan Seal Installer ZTSE6066
Front Crankshaft Seal Installer ZTSE4873
P-80® rubber lubricant or equivalent Obtain locally
Slide hammer Obtain locally

N13 Engine Brake by Jacobs

N13 Engine Brake by Jacobs

Description Tool Number
Jacobs® Slave Piston Removal Tool ZTSE6068
 APPENDIX C – SPECIAL SERVICE TOOLS 901

Cylinder Head, Camshaft and Valve Train

Cylinder Head, Camshaft and Valve Train

Description Tool Number
1 - 2 inch micrometer Obtain locally
Bearing installer Obtain locally
Connecting Rod Bolt Torx® Socket ZTSE4835
Cylinder Head Lifting Bracket ZTSE4869
Dial indicator with magnetic base Obtain locally
Feeler gauge (Jacobs® 96-020949) Obtain from Jacobs
Head Bolt Bottoming Tap ZTSE4855
Head Bolt Torx® Socket ZTSE4787
Injector Sleeve Brushes ZTSE4751
Lash Gauge 0.5 mm (0.020 in) ZTSE6076-5A
Lash Gauge 0.8 mm (0.031 in) ZTSE6076-7A
Loctite® 262™ Threadlocker Obtain locally
Loctite® 5127 sealant Obtain locally
Loctite® 5900 sealant or equivalent Obtain locally
M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally

Flywheel and Flywheel Housing

Flywheel and Flywheel Housing

Description Tool Number
1-2 inch micrometer Obtain locally
Blind hole puller Obtain locally
Brake cleaner (non-caustic) Obtain locally
Dial indicator with magnetic base Obtain locally
Loctite 5900® Obtain locally
Wacker® A–442 RTV sealant Obtain locally
Pilot Bearing Installation Tool ZTSE4898
Rear Oil Seal Installer ZTSE4875
Slide hammer Obtain locally
902 APPENDIX C – SPECIAL SERVICE TOOLS

Oil Pump, Fan Drive and Timing Gears

Oil Pump, Fan Drive and Timing Gears

Description Tool Number
Dial indicator with magnetic base Obtain locally
Feeler gauge Obtain locally
Gear puller Obtain locally

Power Cylinders

Power Cylinders
Description Tool Number
2 - 3 inch micrometer Obtain locally
3 - 4 inch micrometer Obtain locally
4 - 5 inch micrometer Obtain locally
Cylinder Sleeve Puller ZTSE2536
Dial bore gauge Obtain locally
Dial indicator with magnetic base Obtain locally
Exhaust Manifold Bolt Torx® Socket ZTSE4843
Feeler gauge Obtain locally
Piston ring compressor Obtain locally
Piston ring expansion pliers Obtain locally
Sleeve Protrusion Hold Down Clamps ZTSE4825
Telescoping gauge Obtain locally

Crankcase and Crankshaft

Crankcase and Crankshaft

Description Tool Number
3 - 4 inch micrometer Obtain locally
4 - 5 inch micrometer Obtain locally
Dial bore gauge Obtain locally
Dial indicator with magnetic base Obtain locally
Head Bolt Bottoming Tap ZTSE4855
Lifting sling Obtain locally
Main Bolt Bottoming Tap ZTSE4854
903 APPENDIX C – SPECIAL SERVICE TOOLS
904 APPENDIX C – SPECIAL SERVICE TOOLS

Special Tools
Essential Tools

Figure 756 KL 20060 NAV EGR Cooler Pressure Test Kit

Figure 757 ZTSE2536 Cylinder Sleeve Puller

 APPENDIX C – SPECIAL SERVICE TOOLS 905

Figure 758 ZTSE4299B Fuel Injector Rack Holder

Figure 759 ZTSE4301 Fuel Injector Tip Cleaning Brush

Figure 760 ZTSE4751 Injector Sleeve Brushes

906 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 761 ZTSE4770 injector puller

Figure 762 ZTSE4773 fuel line disconnect tool 11.8 mm

 APPENDIX C – SPECIAL SERVICE TOOLS 907

Figure 763 ZTSE4777 injector installer

Figure 764 ZTSE4778 coolant line release tool

908 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 765 12-051-01 Engine Stand Adapter Plate

Figure 766 ZTSE4825 Sleeve Protrusion Hold Down Clamps

 APPENDIX C – SPECIAL SERVICE TOOLS 909

Figure 767 ZTSE4787 Head Bolt Torx® Socket (E24)

Figure 768 ZTSE4843 Exhaust Manifold Bolt Torx® Socket

910 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 769 ZTSE4854 Main Bolt Bottoming Tap

Figure 770 ZTSE4855 Head Bolt Bottoming Tap

 APPENDIX C – SPECIAL SERVICE TOOLS 911

Figure 771 ZTSE4869 Cylinder Head Lifting Bracket

Figure 772 ZTSE4873 Front Crankshaft Seal Installer

912 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 773 ZTSE4891 Disposable Air and Fuel Caps

Figure 774 ZTSE4892 Fuel Injector Caps (6)

 APPENDIX C – SPECIAL SERVICE TOOLS 913

Figure 775 ZTSE4898 Pilot Bearing Installation Tool

Figure 776 ZTSE6030 FEY Rings Installation Tools

914 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 777 ZTSE6042 Charger Air Cooler Test Kit

Figure 778 ZTSE6043 Extension Tube Installer

Figure 779 ZTSE6046 Extension Tube Installer Large

 APPENDIX C – SPECIAL SERVICE TOOLS 915

Figure 780 ZTSE6047 Extension Tube Installer Small

Figure 781 ZTSE6051–1 Extension Tube Installer Large

Figure 782 ZTSE6051–2 Extension Tube Installer Small

916 APPENDIX C – SPECIAL SERVICE TOOLS

Figure 783 ZTSE6063 Engine Oil Cooler Pressure Test Plate

Figure 784 ZTSE6066 Fan Hub/High Pressure Drive Seal Installer

 APPENDIX C – SPECIAL SERVICE TOOLS 917

Figure 785 ZTSE6076–5A Lash Gauge

Figure 786 ZTSE6076–7A Lash Gauge

Figure 787 15-922-01 Fuel System Priming Tool

918 APPENDIX C – SPECIAL SERVICE TOOLS
 APPENDIX D: COMPONENT LOCATOR 919

Table of Contents

Top View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .921

Front View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .922

Left Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .923

Right Side View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .924

Back View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .925

Component Locator Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .926

SCR Switchback Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .928

920 APPENDIX D: COMPONENT LOCATOR
 APPENDIX D: COMPONENT LOCATOR 921

Top View
922 APPENDIX D: COMPONENT LOCATOR

Front View
 APPENDIX D: COMPONENT LOCATOR 923

Left Side View

924 APPENDIX D: COMPONENT LOCATOR

Right Side View

 APPENDIX D: COMPONENT LOCATOR 925

Back View
926 APPENDIX D: COMPONENT LOCATOR

Component Locator Table

Component Location
Aftertreatment Fuel Doser (AFTFD) Module (AFTFD G-38
contains AFTFSO and AFTFP)
Aftertreatment Fuel Injector (AFTFI) E-49
Aftertreatment Purge Air Valve (AFTPAV) F-39
Air compressor I-41
Air Control Valve (ACV) Assembly A-55, C-6
Air inlet duct B-6, B-17
Camshaft Position (CMP) sensor C-42
Charge-Air-Cooler Outlet Temperature (CACOT) B-29, B-32, K-13
sensor
Crankcase Oil Separator (CCOS) breather tube K-55
Coolant Control Valve (CCV) assembly (CCV D-18, D-59
contains CMV and CFV)
Crank Shaft Position (CKP) sensor F-66
Emission label G-9
Engine coolant inlet L-19
Engine coolant outlet D-28
Engine Control Module (ECM) with Barometric C-35
Pressure (BARO) internal sensor
Engine Coolant Temperature 1 (ECT1) sensor C-70
Engine Coolant Temperature 2 (ECT2) sensor B-56 (behind Turbocharger 1 Inlet)
Engine mounted secondary fuel filter F-37
Engine Oil Level (EOL) sensor I-37
Engine Oil Pressure (EOP) F-37
Engine Oil Temperature (EOT) sensor C-59 (behind CCV), D-21
Engine Throttle Valve (ETV) C-32
Exhaust Back Pressure Valve (EBPV) E-50
Exhaust Gas Recirculation (EGR) cooler coolant E-13
manifold
Exhaust Gas Recirculation (EGR) cooler (high E-10
temperature stage)
Exhaust Gas Recirculation (EGR) cooler E-4
(low-temperature stage)
Exhaust Gas Recirculation (EGR) cooler outlet pipe G-3
(coolant)
 APPENDIX D: COMPONENT LOCATOR 927

Exhaust Gas Recirculation (EGR) cooler outlet tubes G-2

(gases)
Exhaust Gas Recirculation Gas Temperature B-22
(EGRGT) sensor
Exhaust Gas Recirculation (EGR) Valve A-40, A-69
Flywheel Housing I-43
Fuel Delivery Pressure (FDP) sensor F-36
Fuel Pressure Control Valve (FPCV) F-36 (back of high-pressure fuel pump)
Fuel primer pump assembly E-36
Fuel rail Pressure (FRP) sensor (behind ECM, at D-35
front of the fuel rail)
High Pressure (HP) fuel pump F-35
High Pressure (HP) pump pulley H-26
High Pressure (HP) turbocharger D-54
High Pressure (HP) turbocharger compressor outlet F-56
Humidity / Inlet Air Temperature (IAT) sensor C-16, C-56
Injector harness B-37
Intake Air Heater Fuel Ignitor (IAHFI) B-31, C-27
Intake Air Heater Relay (IAHR) C-37, J-7
Intake Air Heater Fuel Solenoid (IAHFS) B-33, J-4
Intake Manifold Pressure (IMP) sensor B-28
Intake Manifold Temperature (IMT) sensor D-37, J-3
Intake throttle duct assembly C-29
Low Pressure Charge Air Cooler (LPCAC) I-54
Low Pressure (LP) fuel pump G-35
Low Pressure (LP) fuel pressure test port E-36
Low Pressure (LP) turbocharger F-53
NOx IN sensor: (Behind EBPV) E-50, E-72
NOx IN sensor module D-65
Oil filter cap D-57
Oxygen Sensor (O2S) E-50 (behind EBPV), E-72
Thermostat housing D-23
Turbocharger 2 compressor inlet sensor (TC2CIS) D-56
Vibration damper J-23
Coolant distribution housing F-20
928 APPENDIX D: COMPONENT LOCATOR

SCR Switchback Assembly