Workshop Manual

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Summary of content (442 pages)

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE TABLE OF CONTENTS 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 2.5 2.6 ROCKER COVER DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS ...................................................................................................... REMOVAL OF THE ROCKER COVER .................................................... CLEANING AND INSPECTION OF THE ROCKER COVER ................... INSTALLATION OF THE ROCKER COVER ............................................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6.5 7 7.1 7.2 7.3 7.4 8 8.1 8.2 8.3 8.4 8.5 9 9.1 9.2 9.3 9.4 9.5 10 10.1 10.2 10.3 11 11.1 11.2 11.3 11.4 11.5 12 12.1 12.2 12.3 12.4 ii DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY .............................................................................................. 6-10 COLD BOOST PIPE (CHARGE AIR PIPE) DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS .........................................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13 13.1 13.2 13.3 13.4 14 14.1 14.2 14.3 14.4 14.5 14.6 14.7 14.8 14.9 14.10 14.11 14.12 14.13 14.14 14.15 14.16 15 15.1 15.2 15.3 15.4 15.5 15.6 16 16.1 16.2 16.3 16.4 16.5 17 17.1 17.2 17.3 17.4 DD15 AXIAL POWER TURBINE GEAR BOX DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS ........................................................ REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX .........
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.5 17.6 17.7 17.8 REMOVAL OF CRANKSHAFT REAR OIL SEAL ..................................... INSTALLATION OF THE REAR OIL SEAL .............................................. REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL .......................... INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL .................. 17-14 17-15 17-17 17-18 18 18.1 LUBRICATION SYSTEM DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS ...........................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25.2 INSTALLATION OF THE OIL FILLER NECK ........................................... 26 26.1 26.2 26.3 26.4 26.5 OIL COOLANT MODULE DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE .. 26-3 REMOVAL OF THE OIL COOLANT MODULE ........................................ 26-5 INSTALLATION OF THE OIL COOLANT MODULE ................................ 26-7 REMOVAL OF THE OIL THERMOSTAT ..................................................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.9 INSTALLATION OF RING GEAR ............................................................. 34-14 35 35.1 FRONT ENGINE MOUNT/RADIATOR SUPPORT DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS ........................ REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT .. INSPECTION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT ................................................................................................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 40 40.1 40.2 40.3 POLY-V-BELTS REMOVAL OF THE POLY-V-BELTS ....................................................... INSPECTION OF THE POLY-V-BELTS ................................................... INSTALLATION OF THE POLY-V-BELTS ................................................ 40-3 40-6 40-9 41 41.1 41.2 41.3 41.4 AIR COMPRESSOR DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR .......... REMOVAL OF THE AIR COMPRESSOR .......................................
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE viii All information subject to change without notice.
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1 ROCKER COVER Section 1.1 Page DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS ...................................................................................................... 1-3 1.2 REMOVAL OF THE ROCKER COVER .................................................... 1-4 1.3 CLEANING AND INSPECTION OF THE ROCKER COVER ................... 1-6 1.4 INSTALLATION OF THE ROCKER COVER ............................................
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1-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1.1 DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS The rocker cover (2) is made of an aluminum or plastic material and uses an elastomer seal (1) which completely encloses the valve operating mechanism including the overhead camshafts, brake assemblies and the injector harness. 1. Gasket 4. Air Cleaner Bracket 2. Rocker Cover 5. Stud (Bolt) 3. Bolt Figure 1-1 Rocker Cover All information subject to change without notice.
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1.2 REMOVAL OF THE ROCKER COVER 1.2 REMOVAL OF THE ROCKER COVER Remove as follows: 1. Steam clean the engine. 2. Remove bolts (1) or nuts (if equipped) from the two air filter housing brackets (2) and remove housings from the rocker cover. 1-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Loosen the bolts (1) or stud bolts (2) (if equipped) and isolators (3); remove rocker cover. NOTE: Mark the location of the stud bolts. The stud bolts must be replaced in their original location during installation. 4. Remove rocker cover gasket from the rocker cover. All information subject to change without notice.
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1.3 CLEANING AND INSPECTION OF THE ROCKER COVER 1.3 CLEANING AND INSPECTION OF THE ROCKER COVER Clean as follows: 1. Clean cover in clean solvent or fuel. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 2. Blow dry with compressed air. 3. Check the rocker cover, breather passage and seal for damage. Replace as necessary. 4. Inspect the bolts. Replace if damaged.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1.4 INSTALLATION OF THE ROCKER COVER Install as follows: 1. Install rocker cover gasket into groove in rocker cover. 2. Install bolts (1) or stud bolts (2) (if removed) and isolators (3) into rocker cover. 3. Install rocker cover onto camshaft housing. 4. Finger tighten all bolts (1) and stud bolts; then torque to 20 N·m (14 lb·ft). All information subject to change without notice.
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1.4 INSTALLATION OF THE ROCKER COVER 5. Install the two air filter brackets (2) (if equipped), onto the rocker cover and torque the eight nuts to 20 N·m (14 lb·ft). ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always Engine operate the engine in a well-ventilated area. exhaust is toxic. 6. Start the engine and check for leaks. 1-8 All information subject to change without notice.
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2 CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Section 2.1 Page DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS ............... 2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY .............................................................................................. 2.3 2-16 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2.
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2-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS The engine uses a dual overhead camshaft and rocker shaft design. The intake and exhaust camshafts are timed to each other, through a geartrain, to the crankshaft. The camshaft housing houses the camshafts and valve train.
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2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS 2.1.1 Engine Braking The engine uses an integral engine brake. Engine braking is controlled electronically by the engine control system with an electric solenoid. When activated, the solenoid allows oil pressure to activate a piston on the exhaust rocker arm. Engine braking is accomplished with a single exhaust valve in each cylinder.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE For EPA07 engines, the exhaust rocker arm shaft lubricating oil passages direct pressurized oil to the rocker arms. The exhaust rocker arm has two additional oil passages to operate the engine brakes. Oil for cylinders 1 and 2 is supplied by the Front Engine Brake Solenoid Valve. Oil for cylinders 3 to 6 are supplied by the Rear Engine Brake Solenoid Valve. 1. Exhaust Rocker Arm 7. Exhaust Camshaft 2. Exhaust Rocker Arm with Actuator Piston 8.
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2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS For EPA10 engines, the exhaust rocker arm shaft lubricating oil passages direct pressurized oil to the rocker arms. The exhaust rocker arm has two additional oil passages to operate the engine brakes. Oil for cylinders 1 through 3 is supplied by the Front Engine Brake Solenoid Valve. Oil for cylinders 4 through 6 are supplied by the Rear Engine Brake Solenoid Valve. 1. Exhaust Rocker Arm 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Remove as follows: 1. Turn engine OFF, (key OFF, engine OFF). 2. Steam clean the engine. 3. Disconnect the battery power to the engine. Refer to OEM procedures. 4. Remove the air cleaner and the turbocharger inlet pipe and hose. Refer to OEM procedures. 5. Remove air cleaner housing. Refer to OEM procedures. 6. Remove the rocker cover. Refer to section 1.2. 7.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 9. Remove the Crankshaft Position Sensor (CKP) (1) from the rear of the flywheel housing. Refer to section . 10. To accurately locate TDC, install the flywheel housing crankshaft TDC Locating Pin (W470589001500) into the CKP sensor hole located in the rear of the flywheel housing. The plastic tip will protrude into the cutout in the tone wheel. TDC can be verified by the proper installation of the camshaft timing tool.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11. When the TDC dot (3) between two teeth on the flywheel aligns with the edge of pointer (2), the engine is at TDC firing stroke. 12. For EPA07 DD13: [a] Disconnect both 14-pin injector harness connectors (8). [b] Disconnect the 24 electrical terminals at the fuel injectors (7). [c] Disconnect two wiring terminals at each engine brake solenoid (6). All information subject to change without notice.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY [d] Loosen the Allen screws holding the intermediate frame (5) to the camshaft housing (1). Remove the intermediate frame . 13. For EPA10 engines: [a] 2-10 Remove the fuel injector electrical harness clips (2) from the 14-pin electrical connectors. All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE [b] Remove the bolts securing the two-piece fuel injector electrical harness (1 and 3) and remove the harness from the camshaft housing housing. 14. Remove the engine brake solenoids from the camshaft housing. NOTICE: Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts outward in 1/2 turn increments. The increment procedure needs to be followed to prevent the rocker shaft from breaking. 15.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 17. Using Rocker Arm Lifter / Spacer tool (W470589044000) for the DD13, or Rocker Arm Lifter / Spacer Intake tool (W470589004000) for the DD15, remove the intake rocker shaft assembly. NOTICE: Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts outward in 1/2 turn increments. The increment procedure needs to be followed to prevent the rocker shaft from breaking. 18.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20. Remove the remaining bolts (1) from the camshaft bearing caps (2). 21. Using tool Cam Bearing Cap Puller (J-48883) and Injector Unit Pump Puller (J-46375), remove the camshaft bearing caps (1) from the camshaft housing. All information subject to change without notice.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 22. Remove the intake and exhaust camshaft assemblies (1 & 2) from the camshaft housing (3). Use care not to damage intake cam tone wheel when handling. 2-14 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2.3 INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Inspect the camshaft and rocker shaft assemblies as follows: 1. Inspect the camshafts for lobe damage; replace if necessary. 2. Inspect the camshaft gears for damage; replace if necessary. 3. Inspect the rocker shaft for scoring or scuffing; replace if necessary. 4. Inspect rocker arms for roller and bushing damage; replace if necessary. 5.
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2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Install as follows: 1. Verify that the crankshaft is at top dead center (TDC) on cylinder number one using TDC Locating Pin (W470589001500) installed in crankshaft position sensor (CKP) hole located in the flywheel housing. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Locate the etched triangle on the camshaft gear teeth and mark the teeth with a paint pen. 4. Lubricate the lower camshaft bearing surfaces and camshaft journals before installing the camshafts. Install the exhaust and intake camshaft gear assemblies into the camshaft housing. 5. Align the marked gear teeth with the marks on the timing tool. 6.
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2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY [b] If there is excessive drag when installing the tool, the camshafts are out of time. If so, repeat this procedure at Step 3. 7. Verify that the marks on the gear teeth match the marks on the timing tool. NOTICE The camshaft caps are numbered and need to be installed correctly. 8. Install the seven camshaft caps onto intake and exhaust camshafts. 9.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10. Install the 30 bolts to camshaft caps; finger tighten the bolts. Refer to figure for proper bolt placement. 11. Using the torque sequence shown below torque the M10 camshaft cap bolts to the following: □ 20 N·m (15 lb·ft) □ Then torque to 50-55 N·m (37-40 lb·ft). All information subject to change without notice.
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2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 12. Using the torque sequence shown below, torque the nine 63 mm M8 bolts to 30 N·m (22 lb·ft). 13. Remove TDC Locating Pin (W470589001500) from CKP sensor hole in the flywheel housing. 14. Install crankshaft position sensor. Refer to section . 15. Install a dial indicator onto gear case and zero out the dial indicator. 16. Position the stem of dial indicator to rest between the teeth on the camshaft gear. 17.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18. The dial indicator should read 0.051 - 0.257 mm (0.002 - 0.010 in). If the gear lash is excessive between either camshaft gear and the number five idler gear, inspect the number five idler gear spindle, camshaft gear and camshaft housing. Repair as necessary. NOTICE: The camshaft journal area is lubricated by oil that has to travel through the rocker shaft. If the rocker shaft is installed incorrectly, oil passages do not line up.
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2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY NOTICE: The markings on the front of the rockers shafts must face the front of the engine for proper rocker arm lubrication and engine brake operation. NOTICE: Ensure when tightening the rocker shaft bolts that the bolts are drawn down from the inside bolts outward in 1/2 turn increments, before final torque. If the rocker shaft bolt is fully torqued without using the increment procedure the rocker shaft can break.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20. Using Rocker Arm Lifter / Spacer Intake (W470589044000) (1) for the DD13 or Rocker Arm Lifter / Spacer Intake (W470589004000) for the DD15, install the intake rocker shaft assembly to the camshaft cap and secure with seven clamping blocks and bolts. 21. Using the torque sequence shown below, torque the bolts to 50-55 N·m (36-41 lb·ft) +90°. All information subject to change without notice.
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2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 22. Using Rocker Arm Lifter / Spacer (W4705589074000) for the DD13 or Rocker Arm Lifter / Spacer Intake (W470589004000) for the DD15, install the exhaust rocker shaft assembly to the camshaft cap and secure with seven clamping blocks and bolts. 23. Using the torque sequence shown below, torque the bolts to 50-55 N·m (36-41 lb·ft) +90°. 24. Remove timing tools. 25. Install the fuel injectors, if removed. Refer to section . 26.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30. Install air cleaner housing. Refer to OEM procedures. 31. Install the turbocharger inlet pipe and hose, and air cleaner. Refer to OEM procedures. 32. Prime lubrication system. Refer to section 27.1. All information subject to change without notice.
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2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE Inspect as follows: 1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube 2. Hose 11. Banjo Bolt 20. Gasket 3. Coolant Crossover Pipe 12. Bolt 21. Bolt 4. Bolt 13. Bolt 22. Venturi 5. Support 14. Outlet Nipple 23. Mixer Pipe 6. Coolant Connecting Tube 15. Seal 24.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube / Lifting Eye 2. Hose 11. Banjo Bolt 20. Gasket 3. Coolant Crossover Pipe 12. Bolt 21. Bolt 4. Bolt 13. Bolt 22. Venturi 5. Support 14. Outlet Nipple 23. Mixer Pipe 6. Coolant Connecting Tube 15. Seal 24. Seal Ring 7. Exhaust Gas Connecting Tube 16. Exhaust Gas Recirculation Cooler Water Manifold Assembly 25. Bolt 8. Gasket 17. Clamps 26. Bolt 9. Seal Ring 18.
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2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE Check as follows: NOTICE: This procedure must be followed after replacing an engine brake solenoid due to any failure that could cause high DOC temperature codes, excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage. 1. Remove the marmon clamps (2) and EGR hot pipe (3) and inspect for any signs of liquid or moisture.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2. Remove the mixer pipe (1) from the cold boost pipe (2). 3. Remove the exhaust gas crossover tube / lifting eye (2) and venturi (6). 4. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. All information subject to change without notice.
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2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure. 5. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel, soot, and carbon. 6.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE Inspect as follows: 1. Venturi 9. Connecting Tube 17. Metal Seal 2. Bolt 10.Seal Ring 18. Hot Pipe 3. Gasket 11. Banjo Union 19. Water Manifold 4. Bolt 12. Banjo Bolt 20. Support 5. Exhaust Gas Crossover Tube 13. Exhaust Gas Cooler 21. Clamp 6. Bolt 14. Strap 22. Hose 7. Lifting Bracket 15. Shim 23. Mixer Pipe 8.
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2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 1. Venturi 9. Banjo Union 17. Water Manifold 2. Bolt 10. Banjo Bolt 18. Support 3. Gasket 11. Exhaust Gas Cooler 19. Clamp 4. Bolt 12. Strap 20. Hose 13. Shim 21. Mixer Pipe 6. Connecting Tube 14. Clamp 22. Coolant Delivery Pipe 7. Connecting Tube 15. Metal Seal 23. Seal Ring 8. Seal Ring 16. Hot Pipe 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE Check as follows: NOTICE: This procedure must be followed after replacing an engine brake solenoid due to any failure that could cause high DOC temperature codes, excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage. 1. Remove the clamps (2), exhaust pipe (4) and gaskets (3) from the EGR cooler (1) and inspect and inspect for any signs of liquid or moisture.
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2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2. Remove the mixer pipe (4) from the cold boost pipe (1). Refer to section . 3. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (3). 4. Place a towel over the outlet of the EGR cooler and retain it with a zip tie.
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3 CAMSHAFT HOUSING Section Page 3.1 REMOVAL OF THE CAMSHAFT HOUSING ........................................... 3-3 3.2 INSPECTION OF CAMSHAFT HOUSING ............................................... 3-8 3.3 INSTALLATION OF THE CAMSHAFT HOUSING ...................................
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3-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3.1 REMOVAL OF THE CAMSHAFT HOUSING The camshaft housing houses the camshafts and valve train. It has internal oil passages to supply oil from the block to the camshaft and rocker bearings along with pressurized oil to the engine brake rockers via the engine brake solenoids through the exhaust shaft. The camshaft housing is made of aluminium material. Remove as follows: 1. Steam clean the engine. 2. Remove the rocker cover. Refer to section 1.2. 3.
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3.1 REMOVAL OF THE CAMSHAFT HOUSING [c] Pressure Limiting Valve (PLV) return line from the fuel rail to the fuel filter module (4). Refer to section . 5. Remove the rocker shaft/engine brake and camshaft assemblies. Refer to section 2.2. 6. Disconnect the intake manifold temperature sensor (2). 3-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Disconnect the fuel rail pressure sensor (1). 8. Disconnect the camshaft position sensor (1) from the camshaft housing (2). 9. Unclip all of the electrical wiring harness attaching points from the camshaft housing. All information subject to change without notice.
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3.1 REMOVAL OF THE CAMSHAFT HOUSING 10. Remove the bolt (2) securing the doser coolant line (1) and the P-clip to the camshaft housing (3). 11. Remove the remaining two bolts (29 and 30) securing the camshaft housing to the cylinder head. 12. Attach a lifting device to the camshaft housing and lift the camshaft housing off of the cylinder head. 3-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. All information subject to change without notice.
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3.2 INSPECTION OF CAMSHAFT HOUSING 3.2 INSPECTION OF CAMSHAFT HOUSING Inspect the camshaft housing as follows: 1. Inspect the camshaft journals for scoring or scratches, replace if damaged. 2. Inspect the camshaft caps for cracks, replace if damaged. 3. Inspect the camshaft housing for cracks and damage to the bolt hole threads in the housing, replace if damaged. 4. Inspect the camshaft housing sealing surfaces for damage.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3.3 INSTALLATION OF THE CAMSHAFT HOUSING Install as follows: 1. Install a new seal into the camshaft housing. 2. Using an appropriate lifting device install camshaft housing onto the cylinder head. PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. 3.
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3.3 3-10 INSTALLATION OF THE CAMSHAFT HOUSING All information subject to change without notice.
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4 CAMSHAFT TIMING Section Page 4.1 CAMSHAFT TIMING VERIFICATION ...................................................... 4-3 4.2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED ........
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4-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 4.1 CAMSHAFT TIMING VERIFICATION Verify the camshaft timing as follows: 1. Remove the rocker cover. Refer to section 1.2. 2. Bar the engine to top dead center (TDC) with Engine Barring Tool (J-46392) (3) on cylinder No.1 with the No. 6 valve in overlap. The dot (2) that is located inside the flywheel tone ring is aligned with the edge of the pointer (1). 3.
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4.1 CAMSHAFT TIMING VERIFICATION 5. Install the flywheel TDC Locating Pin (W470589001500), through the crankshaft position sensor hole in the flywheel housing and engage into the flywheel notch. 6. Install the rear Camshaft Timing Tool (W470589054000) for EPA07 DD15, (W470589104000) for EPA10 DD15, and (W470589034000) for DD13 (1) onto the camshaft housing. 4-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install the rear Camshaft Timing Tool (W470589054000) for EPA07 DD15, (W470589104000) for EPA10 DD15, and (W470589034000) for DD13 (1) into the grooves cut into the cams and pin it into the camshaft housing with a bolt. 8. Verify that the marks on the gear teeth match the marks on the timing tool. If the marks do not match, research the root cause of incorrect camshaft timing. All information subject to change without notice.
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4.2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED 4.2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED Time as follows: 1. Bar the crankshaft over to TDC cylinder No. 1 and lock with W470589001500 through the crankshaft position sensor hole. 2. Install the rear Camshaft Timing Tool (W470589054000) for EPA07 DD15, (W470589104000) for EPA10 DD15, and (W470589034000) for DD13 (1) onto the rear of the camshaft housing. 3.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE installing or removing could indicate the camshafts being out of time. Install a bolt into the tool to hold it into place. All information subject to change without notice.
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4.2 4-8 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED All information subject to change without notice.
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5 GEAR TRAIN AND ENGINE TIMING Section 5.1 Page DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS ...................................................................................................... 5-3 5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING ............................ 5-8 5.3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED .............................................................................
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5-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5.1 DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS The gear train is located at the rear of the engine. The gear train consists of intake and exhaust camshaft gears, idler gears No. 1, 2, 3, 4, and 5, crankshaft gear, oil pump gear, fuel pump gear, air compressor gear, and Axial Power Turbine (APT) gear. All information subject to change without notice.
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5.1 DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS 1. Idler Gear No. 1 9. Crankshaft Gear 2. Idler Gear No. 2 10. Oil Pump Gear 3. Idler Gear No. 3 11. Camshaft Gear Exhaust 4. Idler Gear No. 4 12. Camshaft Gear Intake 5. Idler Gear No. 5 A. Level A 6. Air Compressor Gear B. Level B 7. Fuel Pump Gear C. Level C 8. Axial Power Turbine Gear x. To Front of Engine Figure 5-1 5-4 DD15 Engine Gear Train All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE The gear train on the DD Platform engines is located at the rear of the engine and has three levels. Level A consists of the outermost gears (closest to the flywheel), Level B consists of the middle gears, and Level C consists of the innermost gears (closest to the block). The gears in the gear train are both directly and indirectly driven by the crankshaft gear.
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5.1 DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS 1. Idler Gear No. 1 9. Crankshaft Gear 2. Idler Gear No. 2 10. Oil Pump Gear 3. Idler Gear No. 3 11. Camshaft Gear Exhaust 4. Idler Gear No. 4 12. Camshaft Gear Intake 5. Idler Gear No. 5 A. Level A 6. Air Compressor Gear B. Level B 7. Fuel Pump Gear C. Level C 8. Axial Power Turbine Gear x. To Front of Engine Figure 5-2 5-6 DD15 Engine Gear Train All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE Multiply Crankshaft Speed by Effective Ratio to Attain Individual Component Speed Component Effective Ratio Crankshaft Speed ________ RPM Camshafts 0.50 ________ RPM Idler #1 0.79 ________ RPM Idler #2 0.86 ________ RPM Idler #3 0.75 ________ RPM Idler #4 1.33 ________ RPM Idler #5 0.45 ________ RPM Water Pump 2.22 ________ RPM Air Compressor 1.41 ________ RPM Fuel Pump 1.50 ________ RPM Oil Pump 1.
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5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING 5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING Install and time the gear train as follows: NOTE: Coat the inside of the gears, bushings and gear train with clean oil before installation. 1. Install the crankshaft gear on the crankshaft. 2. Rotate the crankshaft to top dead center (TDC) on cylinder number one. Install and lock Crankshaft TDC Locating Tool (J-48630) into place with bolt. 3. Install spindle into idler gear number five. 4.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install Installation Cantilever tool (J-47487) onto idler gear number three. 8. Install two bolts into the spindle and idler gear No. 3; snug the bolts. NOTE: When idler gear No. 3 and timing tool J–47487 are installed to the gear case, timing tool J–47487 should come off of the gear with ease. If the timing tool is not easily removed, that is a indication that the gears are not timed. 9. Check the gear lash between idler gear No. 3 and idler gear No. 5.
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5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING NOTE: For ease of installation on idler gear number one, roll the gear into idler gear number two. 18. Install the spindle, thrust washers, idler gear number one, and gear plate onto the cylinder block by engaging the teeth of idler gear number one into the crankshaft gear teeth first, then roll upward into idler gear number two. Torque to 100 N·m (73 lb·ft). 19. Install the air compressor. Refer to section 41.4.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 27. Install Camshaft Timing Tool (1) (W470589054000) for EPA07 DD15 - shown, (W470589104000) for EPA10 DDl5, and (W470589034000) for DD13 into the holes at the rear of the camshaft housing and secure to the camshaft housing with two bolts. 28. Install both of the intake and exhaust camshafts into the camshaft housing. Refer to section 2.4. 29.
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5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING 30. Install Camshaft Timing Tool (1) (W470589054000) for EPA07 DD15 - shown, (W470589104000) for EPA10 DDl5, and (W470589034000) for DD13 into the holes at the slot in the front of the camshaft housing and secure to the camshaft housing with one bolt. 31. Ensure timing marks on the camshaft gears are at TDC and aligned to the marks on the tool. 32. Install the seven camshaft caps onto intake and exhaust camshafts.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 33. Prior to engine brake solenoid installation, replace the O-rings on the engine brake solenoids. NOTE: There are 30 bolts retaining the camshaft assemblies; fourteen 120 mm (M10) bolts, seven 108 mm (M10) bolts and nine 63 mm (M8) bolts. 34. Install the thirty bolts to camshaft caps; finger tighten the bolts. Refer to figure for proper bolt placement. All information subject to change without notice.
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5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING 35. Using torque sequence shown below, torque the 120 mm and 108 mm (M10) camshaft cap bolts to the following: □ 20 N·m (15 lb·ft) □ Then torque to 50-55 N·m (37-40 lb·ft) 1. Using the torque sequence, torque the nine 63 mm (M8) bolts to 30 N·m (22 lb·ft). 5-14 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2. Verify correct camshaft timing by checking that the marks on the camshaft gears still align with the timing tool. 3. Remove timing tools from gears and camshaft housing. 4. Install the closing cover and two bolts to the rear of the cylinder head. Torque the closing cover bolts to 30 N·m (22 lb·ft). All information subject to change without notice.
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5.3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED 5.3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED This is performed with camshaft housing removed. Check and adjust as follows: 1. Remove the camshaft housing if not already removed. Refer to section 3.1. 2. Install a magnetic base-dial indicator gauge on engine block. 3. Set the dial indicator on the idler gear number five gear tooth. 4.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9. Turning idler gear number five by hand will change gear lash from zero lash to maximum lash. NOTE: Rotating idler gear number five counterclockwise (viewed from front of engine) will result in zero lash. Rotating idler gear number five clockwise (viewed from front of engine) will result in maximum lash. 10. Install a magnetic base-dial indicator gauge on engine block. 11. Set the dial indicator on the number five gear tooth.
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5.3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED 12. Turn idler gear number five counterclockwise (viewed from front of engine) until “0” lash is present, then zero the gauge on the dial indicator. 13. Push idler gear number five clockwise (viewed from front of engine) till desired gear lash is present. 14. Tighten the two bolts on the number three gear. 15. Check gear lash by turning idler gear number five stop-to-stop; verify the lash reading on the dial indicator should be 0.043 - 0.
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6 WATER MANIFOLD Section 6.1 Page DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS .......................................... 6-3 6.2 REMOVAL OF THE DD15 & DD16 WATER MANIFOLD ......................... 6-5 6.3 CLEANING AND INSPECTION OF THE DD15 & DD16 WATER MANIFOLD ............................................................................................... 6-7 6.4 INSTALLATION OF THE DD15 & DD16 WATER MANIFOLD ................. 6-8 6.
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6-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6.1 DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS Coolant flows from the cylinder head through an opening next to each exhaust port and into the water manifold in the DD15 engine. The water manifold is attached to the cylinder head by a total of nineteen bolts, including two that are shared with the coolant outlet elbow. Two 3-port gaskets are used between the water manifold and the cylinder head. 1. Connecting Pipe 7.
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6.1 DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS 1. Bolt M8 x 40 (6 qty.) 4. Cylinder Head 2. Bolt M8 x 80 (5 qty.) 5. Connecting Pipe 3. Bolt M8 x 100 (6 qty.) 6. Water Manifold Figure 6-2 6-4 DD15 & DD16 Water Manifold and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6.2 REMOVAL OF THE DD15 & DD16 WATER MANIFOLD Remove as follows: 1. Disconnect the batteries. 2. Drain the engine coolant. 3. Remove the air cleaner. 4. Remove the exhaust manifold heat shields. 5. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section . NOTE: Hold water manifold doser coolant line fitting with a separate wrench while removing the coolant lines. 6. Disconnect and remove doser coolant lines and remove retaining clips. 7.
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6.2 REMOVAL OF THE DD15 & DD16 WATER MANIFOLD NOTE: Note bolt length differences for installation. 13. Remove eleven upper water manifold bolts. 14. Loosen six lower water manifold bolts. 15. Remove two bolts from the retaining strap for the water manifold outlet to the coolant crossover pipe. 16. Remove water manifold. 17. Remove and discard water manifold gaskets. 6-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6.3 CLEANING AND INSPECTION OF THE DD15 & DD16 WATER MANIFOLD Clean and inspect as follows: 1. Clean the water manifold. 2. Inspect the water manifold for damage or cracks; replace if necessary. 3. Replace the gaskets. All information subject to change without notice.
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6.4 INSTALLATION OF THE DD15 & DD16 WATER MANIFOLD 6.4 INSTALLATION OF THE DD15 & DD16 WATER MANIFOLD Install as follows: NOTICE: Ensure when installing the connecting pipe, that the pipe is lubricated with clean oil. see Figure 6-1 If it is not lubricated, the connecting pipe cannot be fully installed and the rubber can be cut. NOTICE: Do not use sealant when installing water manifold to the cylinder head. 1. Install water manifold gaskets and connecting pipe onto the water manifold. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install coolant outlet elbow (2) with four bolts (1) and torque to 30 N·m (22 lb·ft). 8. Install upper radiator hose. 9. Install EGR actuator coolant outlet line. Torque outlet line to 35 N·m (26 lb·ft). 10. Connect the outlet coolant temperature sensor. 11. Connect the EGR cooler vent line. 12. Connect doser coolant lines. Torque to 15 N·m (11 lb·ft). 13. Install the EGR hot pipe. Refer to section . 14. Install the exhaust manifold heat shields.
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6.5 6.5 DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY Refer to the following: □ □ Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly, refer to section . Removal of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly, refer to section . Inspection of the DD13 EGR Cooler Water Manifold Assembly, refer to section .
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7 COLD BOOST PIPE (CHARGE AIR PIPE) Section 7.1 Page DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS ............................................ 7-3 7.2 REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ............. 7-4 7.3 INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) ................ 7-5 7.4 INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ....
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7-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7.1 DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS The cold boost pipe (Charge Air Pipe) is installed onto the intake manifold and is a component of the EGR System. 1. Bolt 8. Cold Boost Pipe 2. Bracket 9. Spacer 3. Bolt 10. Isolators 4. Adaptor 11. Washer 5. Gasket 12. Bracket to Oil Coolant Module 6. Intake Throttle Valve 13. Bolt 7. Gasket 14.
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7.2 REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) 7.2 REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) Remove the cold boost pipe (charge air pipe) as follows: 1. Remove mixer pipe. 2. Disconnect sensor harness. 3. Remove Charge Air Cooler (CAC) hose clamp at the CAC. 4. Remove the four bolts securing the cold boost pipe to the intake manifold. 5. Remove two bolts at cold boost pipe bracket on oil module. 6. Remove the cold boost pipe. 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7.3 INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) Inspect the cold boost pipe for cracks, flange damage, blockage and leaks; replace if necessary. NOTICE: If the cold boost pipe is damaged on the interior the pipe needs to be replaced. All information subject to change without notice.
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7.4 INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) 7.4 INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) Install the cold boost pipe as follows: 1. If the Intake Throttle Valve was removed refer to section . 2. Install seal onto intake manifold. 3. Secure cold boost pipe to intake manifold with four bolts. Torque bolts to 30 N·m (22 lb·ft). 4. Attach support bracket to oil module with two bolts. 5. Install EGR mixer pipe. 6.
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8 AIR INTAKE MANIFOLD Section 8.1 Page DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS .................................................................................... 8-3 8.2 REMOVAL OF AIR INTAKE MANIFOLD .................................................. 8-6 8.3 CLEANING OF THE AIR INTAKE MANIFOLD ........................................ 8-7 8.4 INSPECTION OF THE AIR INTAKE MANIFOLD ..................................... 8-8 8.5 INSTALLATION OF AIR INTAKE MANIFOLD ...
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8-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8.1 DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS On diesel engines, the intake charge air is routed to an intake manifold that is bolted to the cylinder head with thirteen bolts. Air is then routed through the manifold and into the cylinders. The mating surfaces of the manifold and the cylinder head are machined. The intake manifold is sealed to the cylinder head with six rubber and steel gaskets.
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8.1 DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS 1. Hex Head Bolt 12. Clamp, Outlet Pipe 2. Bracket 13. O-ring, Elbow Turbo Outlet 3. Intake Pipe Bracket 14. Turbocharger Outlet Pipe 4. Air Temperature Sensor (EPA10 Engine - Plug Only) 15. Gasket, Intake Manifold 5. Gasket 16. Seal Ring 6. EGR Throttle Valve 17. Intake Manifold Temperature Sensor 7. Cold Boost Pipe 18. Gasket, Cold Boost Pipe 8. Flanged Screw, Intake Manifold to Cylinder Head 19.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt 9. Flanged Screw, Intake Manifold to Cylinder Head 17. Bolt, Cold Boost Pipe to Intake Manifold 2. Adaptor 10. Seal Ring, Charge Air Sensor 18. Cold Boost Pipe 3. Gasket 11. Clamp, turbocharger outlet pipe 19. Bolt, Combination Temperature and Pressure Sensor 4. EGR Throttle Valve 12. Turbocharger Outlet Pipe 20. Charge Air Pressure Sensor 5. Air Temperature Sensor Guard 13.Intake Manifold Air Temperature Sensor 21.
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8.2 REMOVAL OF AIR INTAKE MANIFOLD 8.2 REMOVAL OF AIR INTAKE MANIFOLD Remove as follows: 1. Drain the cooling system. 2. Drain the fuel filter module. Refer to section . 3. Remove the poly-V-belts. Refer to section 40.1. 4. Remove the Exhaust Gas Recirculation (EGR) mixer pipe and delivery pipe, refer to section . 5. Remove cold boost pipe. Refer to section 7.2. 6. Remove the fuel filter module. Refer to section . 7. Remove the oil coolant module. Refer to section 26.2 8.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8.3 CLEANING OF THE AIR INTAKE MANIFOLD Clean as follows: 1. Remove loose gasket material from the cylinder head and intake manifold mating surfaces. 2. Wash all of the parts in clean fuel oil. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 3. Blow dry with compressed air. All information subject to change without notice.
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8.4 INSPECTION OF THE AIR INTAKE MANIFOLD 8.4 INSPECTION OF THE AIR INTAKE MANIFOLD Inspect as follows: 1. Visually inspect the manifold for any cracks, dents or other damage. Pay particular attention to the bolt areas. [a] If a crack is found, replace the intake manifold. [b] If no cracks are found, reuse the intake manifold. 2. Inspect the manifold mating surface for imperfections that could affect its sealing to the cylinder head.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8.5 INSTALLATION OF AIR INTAKE MANIFOLD Install as follows: 1. Install six gaskets to the air intake manifold. 2. Install thirteen flanged screws and isolator gaskets to the air intake manifold. Secure air intake manifold to cylinder head. Torque the bolts to 25 N·m (18 lb·ft). 3. Re-install electrical harness connectors to appropriate sensors. 4. Install oil coolant module. Refer to section 26.3. 5. Install fuel module. Refer to section . 6.
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8.5 8-10 INSTALLATION OF AIR INTAKE MANIFOLD All information subject to change without notice.
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9 DD13 TURBOCHARGER Section 9.1 Page DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS ............................................................................ 9-3 9.2 REMOVAL OF THE DD13 TURBOCHARGER ........................................ 9-5 9.3 INSPECTION OF THE DD13 TURBOCHARGER ................................... 9-9 9.4 INSTALLATION OF THE DD13 TURBOCHARGER ................................ 9-10 9.
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9-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9.1 DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS Compression of air in the turbocharger causes an air mass to flow into the combustion chamber. The turbocharger consists of a turbine and a compressor which are attached to a shaft. The exhaust gas flows to the turbine wheel and causes it to turn. This turning motion is transmitted to the shaft and the compressor impeller.
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9.1 DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS 1. Bolt 7. Heat Shield 13. Clamp 2. Washer 8. Nut 14. Seal 3. Turbocharger Bracket 9. Stud 15. Turbo Outlet Elbow Pipe 4. Bracket 10. Gasket 16. Heat Shield 5. Stud (6 qty.) 11. Turbocharger 17. Air Hose 6. Bolt 12. Turbo Inlet Pipe 18. Electronic Proportioning Valve Figure 9-1 9-4 EPA10 DD13 Turbocharger and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9.2 REMOVAL OF THE DD13 TURBOCHARGER Cleaning the turbocharger is necessary before removal. PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed, install an air inlet screen shield over the turbocharger air inlet.
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9.2 REMOVAL OF THE DD13 TURBOCHARGER 3. Disconnect and remove the CAC ducting at the compressor housing. Remove the compressor outlet elbow and inlet elbow. 4. Remove the turbocharger oil supply and drain lines from the engine block and from the turbocharger. Remove the O-ring from the cylinder block. 5. Remove the fuel inlet line and coolant inlet and outlet lines from the doser injection valve. 6.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. For EPA10 DD13 engines, remove the clamp (2) from the Electronic Proportioning Valve (EPV) air hose to the turbocharger and remove the hose (1) from the EPV. NOTE: Leave the air hose (1) connected to the turbocharger. 9. Remove the right side radiator support mount from the engine block. 10. Remove flange exhaust manifold from turbocharger housing. 11. Remove the four nuts from the studs attaching turbocharger to the exhaust manifold center section.
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9.2 REMOVAL OF THE DD13 TURBOCHARGER PERSONAL INJURY To avoid injury from improper use of chemicals, follow the chemical manufacturer’s usage, handling, and disposal instructions. Observe all manufacturer’s cautions. 17. Clean the exterior of the turbocharger with a non-caustic cleaning solvent. 9-8 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9.3 INSPECTION OF THE DD13 TURBOCHARGER Check as follows: 1. Remove the exhaust pipe from the turbine outlet and remove the air intake pipe from the compressor inlet. 2. Visually inspect the turbine and compressor wheels for missing blades or blade damage. 3. Inspect the turbine and compressor wheels for heavy deposits of dirt, coke or carbon. 4. Using a flashlight, check the wheels and housings for signs of rubbing. 5.
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9.4 INSTALLATION OF THE DD13 TURBOCHARGER 9.4 INSTALLATION OF THE DD13 TURBOCHARGER Install as follows: PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. 1. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. 10. For EPA10 DD13 engines, connect the air line supply (1) to the EPV (2). 11. Connect the turbocharger speed sensor connector to the engine wiring harness. 12. Reconnect the flange to the exhaust manifold. 13.
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9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE 9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE Inspect as follows: 1. Clamp 10. Banjo Union 19. EGR Crossover Tube 2. Hose 11. Banjo Bolt 20. Gasket 3. Coolant Delivery Pipe 12. Bolt 21. Bolt 4. Bolt 13. Bolt 22. Venturi 5. Support 14. Coolant Outlet Elbow 23. Mixer Pipe 6. Connecting Tube 15. Gasket 24. O-ring 7. Connecting Tube 16.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube / Lifting Eye 2. Hose 11. Banjo Bolt 20. Gasket 3. Coolant Crossover Pipe 12. Bolt 21. Bolt 4. Bolt 13. Bolt 22. Venturi 5. Support 14. Outlet Nipple 23. Mixer Pipe 6. Coolant Connecting Tube 15. Seal 24. Seal Ring 7. Exhaust Gas Connecting Tube 16. Exhaust Gas Recirculation Cooler Water Manifold Assembly 25. Bolt 8. Gasket 17. Clamps 26. Bolt 9. Seal Ring 18.
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9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE Check as follows: NOTICE: This cleaning procedure must be followed after replacing a DD13 turbocharger so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Remove the EGR Mixer Pipe (2) from the cold boost pipe (1). Refer to section . 4. Remove the Exhaust Gas Crossover Tube (2), gasket (4), venturi (6), lifting eye (8) and connecting tube (1) from the EGR cooler. All information subject to change without notice.
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9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE 5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 6.
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10 DD13 WASTEGATE SOLENOID Section 10.1 Page DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID ............................................................................................... 10-3 10.2 REMOVAL OF THE DD13 WASTEGATE SOLENOID ............................. 10-4 10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID .....................
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10-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10.1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID For EPA10, the DD13 uses an wastegate solenoid to control the turbocharger wastegate. The MCM uses a PWM signal to activate the wastegate solenoid to control the available air pressure to the wastegate on the turbocharger. There are many operating conditions that require use of the wastegate solenoid. All information subject to change without notice.
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10.2 REMOVAL OF THE DD13 WASTEGATE SOLENOID 10.2 REMOVAL OF THE DD13 WASTEGATE SOLENOID Remove as follows: 1. Disconnect the electrical harness connector (1) from the wastegate solenoid. 2. Remove the hose clamp (2) and remove the air line (1) from the wastegate solenoid. 10-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Remove the vehicle air supply (1) to the wastegate solenoid. 4. Remove the bolt (3) and the nut (2) from the stud (1) and remove the wastegate solenoid from the cylinder block. All information subject to change without notice.
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10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID 10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID Install as follows: 1. If removed, install the stud to the cylinder block boss. Torque the stud to 10 N·m (7.4 lb·ft). 2. Install the wastegate solenoid on the cylinder block. 3. Install the bolt (3) and the nut (2). Torque each to 30 N·m (22 lb·ft). 4. Install the vehicle air supply (1) to the wastegate solenoid. Torque to 25 N·m (18 lb·ft). 10-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5. Install the air line to the wastegate solenoid and tighten hose clamp. 6. Connect the wastegate solenoid connector. All information subject to change without notice.
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10.3 10-8 INSTALLATION OF THE DD13 WASTEGATE SOLENOID All information subject to change without notice.
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11 DD15 TURBOCHARGER Section 11.1 Page DESCRIPTION AND OPERATION OF TURBOCHARGER AND RELATED PARTS .................................................................................... 11-3 11.2 REMOVAL OF DD15 TURBOCHARGER ................................................ 11-5 11.3 INSPECTION OF DD15 TURBOCHARGER ........................................... 11-7 11.4 INSTALLATION OF DD15 TURBOCHARGER ........................................ 11-8 11.
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11-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11.1 DESCRIPTION AND OPERATION OF TURBOCHARGER AND RELATED PARTS Compression of air in the turbocharger causes an air mass to flow into the combustion chamber. The turbocharger consists of a turbine and a compressor which are attached to a shaft. The exhaust gas flows to the turbine wheel and causes it to turn. This turning motion is transmitted to the shaft and the compressor impeller.
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11.1 DESCRIPTION AND OPERATION OF TURBOCHARGER AND RELATED PARTS 1. Bolt (M10 x 120 mm) 9. Locking Dowel 17. P-clip 25. Bracket 2. Bolt (M10 x 35 mm) 10. Bolt (M10 x 20 mm) 18. Interstage Duct 26. Bolts (6 qty.) 3. Bolt 11. Bracket 19. Clamp 27. O-ring 4. Bolt (M10 x 90 mm) 12. Bolt (M10 x 20 mm) 20. Bolt 28. Turbo Speed Sensor 5. Gear Box 13. Axial Power Turbine 21. Gasket 29. Clamp 6. Bolt (M10 x 65 mm) 14. Clamp 22. Turbocharger 30. Turbo Outlet Elbow 7. Gasket Seal 15.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11.2 REMOVAL OF DD15 TURBOCHARGER Cleaning the turbocharger is necessary before removal. PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. PERSONAL INJURY To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping removed, install an air inlet screen shield over the turbocharger air inlet. The shield prevents contact with rotating parts.
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11.2 REMOVAL OF DD15 TURBOCHARGER 3. Remove APT air feed line from the compressor housing. 4. Remove the turbocharger oil supply and drain line from the center housing. 5. Remove and discard O-ring from the cylinder block and gasket from center section. 6. Remove large marmon clamp connecting APT to the interstage duct. 7. Loosen the bolts attaching the turbocharger support bracket to the cylinder block. 8. Remove four bolts attaching the turbocharger to the exhaust manifold center section. 9.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11.3 INSPECTION OF DD15 TURBOCHARGER Check as follows: 1. Remove the exhaust pipe from the turbine outlet and remove the air intake pipe from the compressor inlet. 2. Visually inspect the turbine and compressor wheels for missing blades or blade damage. 3. Inspect the turbine and compressor wheels for heavy deposits of dirt, coke or carbon. 4. Using a flashlight, check the wheels and housings for signs of rubbing. 5.
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11.4 INSTALLATION OF DD15 TURBOCHARGER 11.4 INSTALLATION OF DD15 TURBOCHARGER Install as follows: 1. If removed, install the gear box. Refer to section 13.4. 2. If removed, install the axial power turbine. Refer to section 12.4. 3. If removed, loosely install the install turbocharger support bracket to the cylinder block 4. Install interstage duct onto turbocharger.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14. Install the turbocharger oil drain line, using a new gasket and O-ring between the opening in the bottom side of the turbocharger center housing and the drain line that runs to the cylinder block. Torque the bolts to 30-38 N·m (22-28 lb·ft). 15. Install turbocharger oil supply line. Torque line to 30 N·m (22 lb·ft). 16. Install heat shields. 17. Install compressor elbow and charge air compressor plumbing. Torque clamps to 6 N·m (4 lb·ft).
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11.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE 11.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE Observe the following: 1. Venturi 10. Seal Ring 19. Water Manifold 2. Bolt 11. Banjo Union 20. Support 3. Gasket 12. Banjo Bolt 21. Clamp 4. Bolt 13. Exhaust Gas Cooler 22. Hose 5. Exhaust Gas Crossover Tube 14. Strap 23. Mixer Pipe 6. Bolt 15. Shim 24. Coolant Crossover Pipe 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Venturi 9. Banjo Union 17. Water Manifold 2. Bolt 10. Banjo Bolt 18. Support 3. Gasket 11. Exhaust Gas Cooler 19. Clamp 4. Bolt 12. Strap 20. Hose 13. Shim 21. Mixer Pipe 6. Connecting Tube 14. Clamp 22. Coolant Delivery Pipe 7. Connecting Tube 15. Metal Seal 23. Seal Ring 8. Seal Ring 16. Hot Pipe 5.
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11.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE Check as follows: NOTICE: This cleaning procedure must be followed after replacing a DD15 turbocharger so that any failure will not cause excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure could cause severe engine damage. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 4. Remove the exhaust gas crossover tube/lifting eye (2) Refer to section and venturi (3). Refer to section . 5. Place a towel over the outlet of the EGR cooler and retain it with a zip tie. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 6.
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11.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE 11-14 All information subject to change without notice.
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12 DD15 AXIAL POWER TURBINE Section 12.1 Page DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS ............................................................................ 12-3 12.2 REMOVAL OF DD15 AXIAL POWER TURBINE ..................................... 12-5 12.3 INSPECTION OF THE DD15 AXIAL POWER TURBINE ........................ 12-6 12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE .............................
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12-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS The Axial Power Turbine (APT) increases the efficiency and the economy of the engine by converting the thermal energy in the exhaust flow from the turbocharger into mechanical energy, delivering the resulting torque to the crankshaft. The rated speed of the turbine wheel of the APT device is about 50,000 rpm.
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12.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS 1. Bolt (M10 x 120 mm) 9. Locking Dowel 17. P-clip 25. Bracket 2. Bolt (M10 x 35 mm) 10. Bolt (M10 x 20 mm) 18. Interstage Duct 26. Bolts (6 qty.) 3. Bolt 11. Bracket 19. Clamp 27. O-ring 4. Bolt (M10 x 90 mm) 12. Bolt (M10 x 20 mm) 20. Bolt 28. Turbo Speed Sensor 5. Gear Box 13. Axial Power Turbine 21. Gasket 29. Clamp 6. Bolt (M10 x 65 mm) 14. Clamp 22. Turbocharger 30. Turbo Outlet Elbow 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.2 REMOVAL OF DD15 AXIAL POWER TURBINE Remove as follows: NOTICE: Ensure turbocharger and axial power turbine are supported prior to removal. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Drain coolant. 3. Remove the turbocharger and APT heat shields. 4. Disconnect the doser injector housing lines and remove the exhaust S-pipe from APT outlet by removing the marmon clamp. 5.
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12.3 INSPECTION OF THE DD15 AXIAL POWER TURBINE 12.3 INSPECTION OF THE DD15 AXIAL POWER TURBINE Inspect as follows: 1. Inspect axial power turbine for damage to the turbine and housing; replace if necessary. 2. Inspect the gear box for damage; replace if necessary. 12-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE Install as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. If removed, install the gear box to cylinder block with four bolts. Torque bolts to 55–60 N·m (41–45 lb·ft). 3. Install axial power turbine gasket, graphite seal, and O-ring. If removed, install the oil passage tube. DO NOT press into Gear Box, then install into APT. 4.
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12.4 12-8 INSTALLATION OF DD15 AXIAL POWER TURBINE All information subject to change without notice.
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13 DD15 AXIAL POWER TURBINE GEAR BOX Section 13.1 Page DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS ........................................................ 13-3 13.2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX ......... 13-5 13.3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX ............. 13-6 13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX ............
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13-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS The gear box is located on the right side of the engine between the axial power turbine and cylinder block. All information subject to change without notice.
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13.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS 1. Bolt (M10 x 120 mm) 9. Locking Dowel 17. P-clip 25. Bracket 2. Bolt (M10 x 35 mm) 10. Bolt (M10 x 20 mm) 18. Interstage Duct 26. Bolts (6 qty.) 3. Bolt 11. Bracket 19. Clamp 27. O-ring 4. Bolt (M10 x 90 mm) 12. Bolt (M10 x 20 mm) 20. Bolt 28. Turbo Speed Sensor 5. Gear Box 13. Axial Power Turbine 21. Gasket 29. Clamp 6. Bolt (M10 x 65 mm) 14. Clamp 22. Turbocharger 30. Turbo Outlet Elbow 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX Remove as follows: 1. Remove the turbocharger. Refer to section 11.2. 2. Remove the Axial Power Turbine (APT). Refer to section 12.2. 3. Remove the oil line from cylinder block to gear box. 4. Remove four bolts from the axial power turbine gear box to the cylinder block and remove the axial power turbine gear box. All information subject to change without notice.
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13.3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX 13.3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX Inspect the gear box for damage; replace if necessary. 13-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX Install as follows: NOTICE: Ensure the gear box gear and idler gear located in the gear case housing are meshed. Failure to mesh gears correctly will cause damage. 1. Install the gear box to cylinder block; ensuring the gears are meshed together when installed. NOTICE: Ensure the correct bolt length is used when the gear box is installed.
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13.4 13-8 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX All information subject to change without notice.
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14 CYLINDER HEAD Section 14.1 Page DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS ...................................................................................................... 14-3 14.2 REMOVAL OF THE DD13 CYLINDER HEAD ......................................... 14-10 14.3 INSTALLATION OF THE DD13 CYLINDER HEAD .................................. 14-12 14.4 REMOVAL OF THE DD15 CYLINDER HEAD ......................................... 14-15 14.5 CLEANING OF THE CYLINDER HEAD ....
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14-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS This section explains the description(s) and operation(s) of the following systems within the cylinder head: □ □ □ Cylinder Head Valve Springs and related components Intake and Exhaust Valves 14.1.1 Cylinder Head The cylinder head has been designed with a compacted graphic iron material. There are two intake and two exhaust valves per cylinder.
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14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS 1. Water Transfer Holes from Cylinder Block to Cylinder Head Figure 14-2 Water Hole Location on Fire Deck of Cylinder Head 1. Upper Cooling Level Figure 14-3 14-4 2. Water Return Openings from Cylinder Head to Cylinder Block 2. Lower Cooling Level Cooling Levels All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Holes for Installing the Intake Manifold Figure 14-4 14.1.2 2. Inlet Ducts Cylinder Head Inlet Duct Location Intake and Exhaust Valves There are four valves per cylinder; two intake valves and two exhaust valves. Valves are made of heat-treated alloys, with precision-ground heads and stems. Stem ends are hardened to minimize wear in contact with the valve rocker buttons. All valves are retained by valve spring caps and two-piece tapered valve locks.
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14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS The exhaust valves use a nickel-based alloy and are identified by a smaller dimple on the combustion face. The intake valves are an iron based alloy and are identified from the exhaust valve by a larger dimple on the combustion face. 1. Exhaust Rocker Arm 8. Valve Spring 2. Exhaust Rocker Arm with Actuator 9. Intake Rocker Arm 3. Brake Rocker Arm 10. Intake Rocker Arm Shaft 4. Exhaust Rocker Arm Shaft 11.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Cylinder Head Gasket 10. Valve Keeper 2. Exhaust Valve Seat Ring 11. Exhaust Valve Spring 3. Intake Valve Seat Ring 12. Spring Retainer 4. Exhaust Valve 13. Intake Valve Spring 5. Intake Valve 14. Water Jacket Cover Plug 6. Cylinder Head 15. Water Jacket Seal Ring Plug 7. Washer 16.Water Protection Sleeve Seal Ring 8. Valve Guide 17.Injector Cup 9. Valve Stem Seal 18.
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14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS 1. Exhaust Valve 4. Valve Clearance Adjusting Element 2. Valve Springs 5. Exhaust Rocker Arm with Actuator 3. Exhaust Rocker Arm 6. Exhaust Rocker Arm Figure 14-7 Exhaust Valve Assembly 1. Intake Valves 3. Drive Gear and Timing Wheel for Intake Camshaft 2. Valve Springs Figure 14-8 14-8 Intake Valve Assembly All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1.Inlet Valves Figure 14-9 2. Exhaust Valves Intake and Exhaust Valve Location All information subject to change without notice.
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14.2 REMOVAL OF THE DD13 CYLINDER HEAD 14.2 REMOVAL OF THE DD13 CYLINDER HEAD Because optional and accessory equipment varies with the engine application, these procedures covers only the basic engine. If the engine is equipped with accessories that affect cylinder head removal, note the mounting details of each accessory to assure correct installation at reassembly. Remove the cylinder head as follows: 1. Steam clean the engine. 2. Disconnect the batteries. Refer to OEM procedure. 3.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18. Remove the EGR crossover tube. Refer to section . 19. Remove the two bolts attaching the cold boost pipe to the support bracket. 20. Using Flywheel and Main Pulley Socket tool (J-45390), remove the 40 bolts securing the cylinder head to the cylinder block. 21. If the dipstick hose is attached to the intake throttle valve bracket, remove the clip attaching it.
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14.3 INSTALLATION OF THE DD13 CYLINDER HEAD 14.3 INSTALLATION OF THE DD13 CYLINDER HEAD Install the cylinder head as follows: 1. Inspect the head bolt holes in both block and head for the presence of oil, water, dirt, or damaged threads; clean or re-tap as necessary. Ensure piston domes, cylinder head, and cylinder block fire deck surfaces are clean and free of foreign matter. 2. Verify that the cylinder liner protrusion heights are within specification prior to installing the cylinder head.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Lift the cylinder head into position using Cylinder Head/Engine Lifting Bar tool (W470589006200). Lower cylinder head into place over the guide studs and dowel pins until it is seated on the engine block. 7. Remove the guide studs. 8. Remove the lifting hooks from the cylinder head. 9. Coat the threads and underside of bolt heads with clean engine oil before installation. 10. Install the 40 cylinder head bolts into the cylinder head.
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14.3 INSTALLATION OF THE DD13 CYLINDER HEAD 21. Install the mixer pipe. Refer to section . 22. Install the venturi. Refer to section . 23. Install the fuel injectors. Refer to section . 24. Install the engine brake solenoids and injector harness. 25. Install the amplification needle and pressure limiting valve (PLV). Refer to section . 26. Install the high pressure feed lines from high pressure pump to common fuel rail. Refer to section . 27. Install the injector feed lines from fuel rail.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.4 REMOVAL OF THE DD15 CYLINDER HEAD Because optional and accessory equipment varies with the engine application, this procedure covers only the basic engine. If the engine is equipped with accessories that affect cylinder head removal, note the mounting details of each to assure correct installation at reassembly.
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14.4 REMOVAL OF THE DD15 CYLINDER HEAD [b] For NAFTA DD Platform engines, remove Two Piece Fuel Injector Wiring Harness. Refer to section . 13. Remove the rocker arm shafts. Refer to section 2.2. 14. Remove coolant lines from the water manifold to the fuel doser injector housing. 15. Remove the Exhaust Gas Recirculation (EGR) vent (de-aeration) line. 16. Remove the intake and exhaust camshafts. Refer to section 2.2. 17. Remove the camshaft housing. Refer to section . 18.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.5 CLEANING OF THE CYLINDER HEAD Clean the cylinder head as follows: 1. Keep parts segregated according to original position to assure proper reassembly, if parts are to be reused. 2. Remove all plugs. 3. Steam clean the cylinder head once it has been stripped. 4. Clean the head in a de-scaling bath.
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14.6 ASSEMBLY OF CYLINDER HEAD 14.6 ASSEMBLY OF CYLINDER HEAD Assembly the cylinder head as follows: 1. Install all of the required cup plugs using a good grade of non-hardening sealant, such as Loctite® 620 or equivalent, on the cup plugs. Use Cup Plug Installation Set (J–35653). 2. Ensure that all cup plugs on the front face of the cylinder head are flush or below the surface. 3. Install valves, valve stem seals, valve springs and keepers. 14-18 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.7 INSTALLATION OF THE DD15 CYLINDER HEAD Install the cylinder head as follows: 1. Inspect the head bolt holes in both block and head for the presence of oil, water, dirt, or damaged threads, clean or re-tap as necessary. Ensure piston domes and the cylinder head and cylinder block deck surfaces are clean and free of foreign matter. 2. Verify that the cylinder liner protrusion heights are all the same prior to installing the cylinder head. 3.
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14.7 INSTALLATION OF THE DD15 CYLINDER HEAD 6. Lift the cylinder head into position using Cylinder Head/Engine Lifting Bar tool (W470589006200). Lower into place over the guide studs and dowel pins until it is seated on the engine block. 7. Remove the guide studs. 8. Remove the lifting hooks from the cylinder head. 9. Coat the threads and underside of bolt heads with clean engine oil before installation. 10. Install the 40 cylinder head bolts into the cylinder head. 11.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 20. Prime engine lubrication system. Refer to section 27.1. 21. Start the engine and check for fuel, coolant or oil leaks. 22. Shut down the engine. All information subject to change without notice.
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14.8 REMOVAL OF VALVE SPRING (CYLINDER HEAD INSTALLED) 14.8 REMOVAL OF VALVE SPRING (CYLINDER HEAD INSTALLED) Remove and clean as follows: 1. Steam clean the engine. 2. Drain the fuel system. Refer to section . 3. Remove the rocker cover. Refer to section 1.2. 4. Remove the rocker arm assemblies. Refer to section 2.2. 5. Remove the intake and exhaust camshafts. Refer to section 2.2. 6. Remove the camshaft housing. Refer to section 3.1.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10. Position the spring compressor cage portion of the valve spring compressor(J–47406) directly over the valve spring to be compressed. Engage the dowel of the cage in the closest slot of the valve spring compressor handle. NOTICE: Do not contact the valve with the compressor tool. 11. Compress the valve spring and remove the valve locks using a small magnet to prevent the locks from falling into the cylinder head oil return galleries. 12.
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14.9 REMOVAL OF THE VALVE SPRING (CYLINDER HEAD REMOVED) 14.9 REMOVAL OF THE VALVE SPRING (CYLINDER HEAD REMOVED) With the cylinder head assembly removed from the engine, remove the valve springs as follows: 1. Remove the valve locks using valve spring compressor(J–47406), compressing each valve spring. 2. Release the spring and remove the valve, valve cap and valve spring. 3. Remove the valve stem oil seal and discard the seal. 4. Remove the valve spring seat. 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.10 REMOVAL OF INTAKE AND EXHAUST VALVES Remove as follows: 1. Remove the cylinder head. [a] For the DD13 ONLY: Refer to section 14.2. [b] For the DD15 ONLY: Refer to section 14.4. 2. Remove the valve spring(s). Refer to section 14.9. All information subject to change without notice.
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14.11 CLEANING OF VALVES AND RELATED PARTS 14.11 CLEANING OF VALVES AND RELATED PARTS Clean the valves and parts as follows: EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 1. Using proper eye protection, clean all of the disassembled parts with fuel oil and dry with compressed air. 2. Clean the carbon from the valve stems and wash the valves with fuel oil. 3.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.12 INSPECTION OF VALVE SPRINGS Inspect the valve springs and replace any that are pitted or cracked. The entire spring should be inspected. When a broken spring is replaced, the spring retainer and valve locks for that valve and spring should also be replaced. NOTE: If a valve is removed through a stem seal, the stem seal must be replaced. All information subject to change without notice.
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14.13 INSPECTION OF VALVE 14.13 INSPECTION OF VALVE The valve stems must be free from scratches or scuff marks, and the valve faces must be free from ridges or cracks. Some pitting of the valve face is normal, and is acceptable as long as no leak paths are evident. If leak paths exist, re-face the valves or install new valves. If the valve heads are warped or the valve stem is bent, replace the valves. See Figures 14-10 and 14-11.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.14 INSTALLATION OF VALVE, SPRING, SEAL AND VALVE CAP Install as follows: 1. Position the cylinder head on a work bench for valve installation, if removed. Lubricate the valve stems with clean engine lubricating oil and slide them into their respective valve guides and against the valve seats. If reusing valves, install them to their original positions. NOTE: Clean valve guide of old seal material and oil before installing the new seal.
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14.14 INSTALLATION OF VALVE, SPRING, SEAL AND VALVE CAP 11. If the cylinder head is removed from engine, install cylinder head. [a] For the DD13 ONLY: refer to section 14.3. [b] For the DD15 ONLY: refer to section 14.7. 12. Prime fuel system. Refer to section . 13. Close any drain cocks that were opened and fill the cooling system. Purge the air from the system using the vent in the thermostat housing. Complete filling of the cooling system is essential for proper engine operation.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.15 VALVE LASH ADJUSTMENTS Accurate adjustment of clearance between intake and exhaust valves is important if maximum performance and economy are to be obtained. NOTE: Every time the valve lash is adjusted the engine brake lash will also need to be set. NOTE: Adjust the valve lash before setting the engine brake lash.
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14.15 VALVE LASH ADJUSTMENTS 9. Using a feeler gauge (1), lash exhaust valves one, three and five to 0.6 mm (0.024 in.). 10. Bar the engine over 360° until cylinder number six is at TDC compression stroke. (J-46392) 11. Lash intake valves three, five, and six to 0.4 mm (0.016 in.). 12. Lash exhaust valves two, four and six to 0.6 mm (0.024 in.). 13. Torque the locknut valve adjusting screw to 50 N·m (37 lb·ft). 14. Remove any tools used for this procedure. 15. Set the engine brake lash.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.16 SETTING THE ENGINE BRAKE LASH Set the brake lash as follows: 1. Set the lash on all the exhaust adjusting screws first (all the adjusting screws in direct contact with the exhaust valves). 2. Rotate the engine until a given cylinder is at maximum intake lift. When this is reached, the brake lash can be set on this cylinder. 3. Lash the engine brakes in the following firing order; one, five, three, six, two, then four. 4.
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14.16 14-34 SETTING THE ENGINE BRAKE LASH All information subject to change without notice.
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15 PISTON AND CONNECTING ROD ASSEMBLY Section 15.1 Page DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS ................................................................... 15-3 15.2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY ............. 15-5 15.3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY ..... 15-7 15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY ........ 15-8 15.5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY ........... 15-9 15.
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15-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS The connecting rods are forged from a high strength steel. A connecting rod bushing is pressed into the small end of the connecting rod. 1. Connecting Rod Bolt (2 qty.) 6. Oil Control Ring 2. Connecting Rod Bushing 7. Compression Ring 3. Retaining Ring (2 qty.) 8. Fire Ring 4. Piston Pin 9. Connecting Rod 5.
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15.1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS Each piston has an oil control ring (6), a middle compression ring (7), and a fire ring (8). 1. Piston Skirt 8. Fire Ring 2. Cover Plate (EPA07 pistons only) 9. Cooling Galley 3. Piston Pin 10. Combustion Bowl 4. Retaining Clip 11. Piston Dome 5. Piston Boss 12. Top Land 6. Oil Control Ring 13. Second Land 7. Compression Ring Figure 15-2 15-4 Piston All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY Remove the piston and connecting rod assembly as follows: 1. Drain the engine cooling system. 2. Drain the engine oil. 3. Remove the oil pan. Refer to section 19.2 4. Remove the camshaft housing and associated parts. Refer to section 3.1 5. Remove the cylinder head and gasket. [a] For DD13 ONLY: refer to section 14.2 [b] For DD15 ONLY: refer to section 14.4 6.
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15.2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY 7. Remove the piston cooling nozzles (1) from the base of the cylinder bores and discard the nozzles. 8. Position the crankshaft for each piston and connecting rod assembly to be removed at bottom dead center. 9. Remove the connecting rod bearing cap with lower bearing shell from the connecting rod. NOTICE The connecting rod assembly is a cracked rod design. Ensure when the bearing cap is removed that it is placed on its side.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY Piston assembly components should be segregated by cylinder and match-marked during disassembly to ensure they are assembled in the same position and orientation. NOTICE: Stamping cylinder numbers on the piston assembly will damage the components. Disassemble piston and connecting rod assembly as follows: 1. Place the piston, dome down, on the table. 2.
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15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY 15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY Inspect as follows: 1. Inspect the connecting rod and bearing cap for damage; replace as necessary. 2. Inspect the piston, wrist pin and piston rings for damage; replace as necessary. 15-8 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY Assemble as follows: 1. Using appropriate flat-nosed pliers, install one of the retaining rings into a retaining ring recess in the piston. Orient the retaining ring gap (1) to either the 12 o'clock or 6 o'clock position. 2. Liberally lubricate the piston pin bore, the piston pin, and the connecting rod bushing in the small end of the connecting rod with 80/90w oil (or equivalent).
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15.5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY 3. Position the long end of the connecting rod (2) on the same side as the valve relief (1) in the top of the piston. 4. Install piston pin into the pin bore, through the rod, until it rests against the previously installed retaining ring. 5. Using the appropriate flat-nosed pliers, install the other retaining ring into the retaining ring recess in the piston boss to lock the pin in place.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY Install as follows: 1. If the rings have been removed, install them into the grooves of the piston and rotate 120° apart as follows: [a] Install the oil ring expander in the lowest groove in the piston. [b] Install the oil ring (top label up) in the lowest groove around the oil expander ring. [c] Install the compression ring (top label up) in the middle groove.
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15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY 6. Coat the piston skirt liberally with the engine oil, saturating the piston rings and ring lands. 7. Coat the inside diameter of the piston ring compression tool with clean engine oil. 15-12 [a] For the DD13, use Piston Ring Compressor tool (W470589005900). [b] For the DD15, use Piston Ring Compressor tool (J-47386). All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE [c] For the DD15, Piston Ring Compressor tool (W470589015900) may also be used. 8. Place piston on a bench with dome side down, install piston ring compressor tool. 9. Once the ring compressor is clamped, ensure the piston can rotate freely. If rotation is hindered, remove the compressor and reposition the dome and rings, or inspect for ring damage. 10. Lubricate the inside of the cylinder liner with clean engine oil. 11.
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15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY front of the engine. The connecting rod has a serial number printing that must also face towards the exhaust side of the engine. 13. Align the ring compressor guide pins (if equipped) over the two bolt holes on the top of the cylinder block. NOTICE: DO NOT force the piston into the liner. Considerable force on the piston could scratch or otherwise damage the inside of the cylinder liner.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19. Torque the connecting rod bolts alternately to the following: Connecting Rod Bolt Torque DD13 DD15 DD16 190 N·m (140 lb·ft) + 90° torque turn 115 N·m (85 lb·ft) + 180° torque turn 115 N·m (85 lb·ft) + 180° torque turn Bearing Cap to Rod Bolt Cap Bolt Maximum Length DD13 DD15 DD16 79 mm (3.11 in.) 82.3 mm (3.240 in.) 82.3 mm (3.240 in.) All information subject to change without notice.
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15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY 20. Check connecting rod axial clearance by moving the rod from side to side on the crank journal. If there is no clearance, check for proper bearing cap installation. Connecting Rod Axial Clearance DD13 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.) DD15 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.) DD16 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.) Table 15-2 21. Install the remaining piston and rod assemblies in the same manner.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24. Allowable piston protrusion (A) is in the table below: 1. Piston 2. Cylinder Liner A. Allowable Piston Protrusion Engine Minimum Maximum DD13 -0.201 mm (-0.0079 in) 0.2215 mm (0.0087 in.) DD15 -0.213 mm (-0.0090 in.) 0.2075 mm (0.0081 in.) DD16 -0.213 mm (-0.0090 in.) 0.2075 mm (0.0081 in.) Table 15-3 Allowable Piston Protrusion 25.
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15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY 27. Install the cylinder head. □ For DD13, refer to section 14.3. □ For DD15, refer to section 14.7. 28. Install the lubricating oil pump inlet pipe and screen assembly, and the lubricating oil pump. Refer to section 21.4. NOTE: Debris from a failed bearing can damage the internal components of the oil pump. If debris is found in the oil pan, replace the oil pump as necessary. 29. Install the oil pan. Refer to section 19.7. 30.
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16 CYLINDER LINER Section 16.1 Page DESCRIPTION AND OPERATION OF CYLINDER LINER AND RELATED PARTS .................................................................................... 16-3 16.2 REMOVAL OF CYLINDER LINER ........................................................... 16-4 16.3 INSPECTION OF CYLINDER LINER ...................................................... 16-5 16.4 CLEANING OF THE CYLINDER LINER .................................................. 16-7 16.
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16-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.1 DESCRIPTION AND OPERATION OF CYLINDER LINER AND RELATED PARTS The cylinder liners feature a “bottom stop” design, which means that the cylinder liners are installed with a lower collar in the cylinder block. This design allows for a shorter distance between cylinders and a more compact design for the cylinder block.
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16.2 REMOVAL OF CYLINDER LINER 16.2 REMOVAL OF CYLINDER LINER Remove as follows: NOTICE: The proper method must be followed when removing the cylinder liner. Damage to the liners and cylinder block may occur if the proper tools and procedures are not used. 1. Remove the piston and connecting rod. Refer to section 15.2. 2. Install cylinder liner removal tool (J-45876) into the cylinder liner. 3. Remove cylinder liner (2).
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.3 INSPECTION OF CYLINDER LINER Inspect as follows: 1. Inspect the cylinder liner. [a] Check the cylinder liner for cracks or scoring. If cracks or scoring are present, replace the liner. NOTICE: Cavitation is due to poor cooling system maintenance. If uncorrected, it will eventually make holes through the liner.
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16.3 INSPECTION OF CYLINDER LINER 4. Inspect the block bore and cylinder liner. [a] Measure the block bore and the outside diameter of the liner. Location DD13 DD15 DD16 A 158.98 to 159 mm (6.2590 to 6.2598 in.) 166.98 to 167 mm (6.5740 to 6.5748 in.) 166.98 to 167 mm (6.5740 to 6.5748 in.) B 141.97 to 141.95 mm (5.589 to 5.588 in.) 148.95 to 148.97 mm (5.864 to 5.865 in.) 148.95 to 148.97 mm (5.864 to 5.865 in.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.4 CLEANING OF THE CYLINDER LINER Clean as follows: NOTE: If using de-greasing solution to clean cylinder liner when finished, an application of clean engine oil will need to be applied to protect the cylinder liner from corrosion. 1. If cleaning a new or used liner, use a clean cloth and clean engine oil.
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16.5 INSTALLATION OF THE CYLINDER LINER 16.5 INSTALLATION OF THE CYLINDER LINER Install as follows: 1. Wipe the inside and outside of the liner clean. NOTE: Thoroughly clean the cylinder block, liner, and counter bores to remove any foreign material. Foreign material in the cylinder liner counter bores can cause the liner to seat improperly. Clean with a wire brush. 2. Install the two new seal rings (1, 3) onto the cylinder liner (2).
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5. Seat the liner into the block using cylinder liner installation tool J-47407 for the DD15, for the and tool J-47407-128 for the DD13. 6. Install the cylinder liner protrusion tool J-47415 onto the cylinder block. Thread four cylinder head bolts through the tool and into a head bolt hole and alternately torque the four bolts to 10 N·m (7 lb·ft). All information subject to change without notice.
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16.5 INSTALLATION OF THE CYLINDER LINER 7. Install a dial indicator. 8. Measure the distance from the top of the liner flange to the top of the block. Allowable liner protrusion is 0.18-0.27 mm (0.007-0.010 in). 16-10 [a] If the liner protrusion exceeds the maximum allowable, remove the piston and connecting rod assembly (if installed) and then remove the liner to check for debris under the liner flange.
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17 CRANKSHAFT Section 17.1 Page DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS ...................................................................................................... 17-3 17.2 REMOVAL OF CRANKSHAFT ................................................................. 17-6 17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS ............. 17-9 17.4 INSTALLATION OF CRANKSHAFT ......................................................... 17-10 17.
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17-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS The crankshaft is made out of induction-hardened steel. The crankshaft bearing journals and connecting rod journals are hardened in the boundary layer and then are ground. In order to avoid vibrations, counterweights are cast onto the guide-ways. The crankshaft is mounted with seven crankshaft bearing journals in the crankcase.
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17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS 1. Bolt 6. Thrust Washer 2. Vibration Damper 7. Bolt 3. Cover Plate 8. Flywheel 4. Crankshaft Bearings 9. Ring Gear 5. Connecting Rod Bearings Figure 17-2 17-4 10. Crankshaft DD15 & DD16 Crankshaft and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt 7. Vibration Damper 2. Main Bearing Caps 8. Upper Crankshaft Bearing Shells 3. Lower Crankshaft Bearing Shells 9. Thrust Washer 4. Lower Connecting Rod Bearing Shells 10. Crankshaft 5. Upper Connecting Rod Bearing Shells 11. Thrust Washer 6. Cylinder Block Figure 17-3 DD13 Crankshaft and Related Parts All information subject to change without notice.
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17.2 REMOVAL OF CRANKSHAFT 17.2 REMOVAL OF CRANKSHAFT When removal of the crankshaft becomes necessary, first remove the transmission, then proceed as follows: 1. Steam clean the engine. 2. Drain the cooling system. Refer to OEM procedures. 3. Drain the lubricating oil. Refer to OEM procedures.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5. Remove and inspect all of the accessories and assemblies with their attaching parts, as necessary, to permit the engine block adaptor to be bolted to the intake (left) side of the cylinder block. Mount the engine to the overhaul stand (J–29109) with adaptor (J–35635–A). 6. Remove the oil pan. Refer to section 19.2. 7. Remove the oil pump. Refer to section 21.2. 8. Remove the flywheel. Refer to section 34.4. 9. Remove flywheel housing. Refer to section 34.2.
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17.2 REMOVAL OF CRANKSHAFT 15. Loosen and remove the main bearing cap bolts. Using Main Bearing Cap Puller tool (J–48884), remove the main bearing caps for inspection. NOTE: Paint-mark the main bearing caps so that they can be installed to their respective, original positions. The main bearing caps must be kept in sequence, so that they are installed to their original positions. 16. Remove the thrust washers from each side of the No. 6 main bearing cap. 17. Remove the crankshaft.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS Inspect as follows: EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 1. Inspect the crankshaft for cracks. 2. If the crankshaft shows evidence of excessive overheating, replace the crankshaft since the heat treatment has probably been destroyed. 3.
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17.4 INSTALLATION OF CRANKSHAFT 17.4 INSTALLATION OF CRANKSHAFT Install the crankshaft using the following procedure: EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 1. Steam clean the crankshaft to remove the rust preventive and blow out the oil passages with compressed air. 2. Install the upper main bearing shells in the block.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. Apply a small quantity of clean engine oil to the bolt threads and underside of the bolt heads. Install the main bearing cap bolts and draw them up snug. 9. Torque main bearing cap bolt torque to 50 N·m (36 lb·ft). 10. Check the crankshaft end play as follows: [a] Move the crankshaft toward the gauge with a small 304 mm (less than 12 in.) pry bar. Keep a constant pressure on the pry bar and zero the pointer on the dial indicator.
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17.4 INSTALLATION OF CRANKSHAFT 12. For the DD15, torque all of the main bearing cap bolts, in four steps, using the sequence shown below. Torque the main bearing cap bolts to: [a] 150 N·m (110 lb·ft) [b] 250 N·m (184 lb·ft) [c] 1st 90° torque turn [d] 2nd 90° torque turn NOTE: If the bearings have been installed properly, the crankshaft will turn freely with all of the main bearing cap bolts drawn to the specified torque. 13. Install the piston and connecting rod assemblies. Refer to section 15.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 23. Install the oil pan. Refer to section 19.7. PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. 24. Use a Cylinder Head/Engine Lifting Bar tool (W470589006200) with hooks attached to the lifting brackets at each end of the engine and remove the engine from the overhaul stand. 25.
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17.5 REMOVAL OF CRANKSHAFT REAR OIL SEAL 17.5 REMOVAL OF CRANKSHAFT REAR OIL SEAL Remove as follows: PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 1. Remove the flywheel from the flywheel housing (1). NOTICE: When drilling pilot holes in the seal, ensure that the drill is straight and perpendicular to the seal.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.6 INSTALLATION OF THE REAR OIL SEAL Install as follows: NOTE: The standard size rear oil seal has an inside diameter of 138 mm (5.433 in.). 1. Inspect the contact area of the flywheel for damage and wear. If it is scored or worn, replace it. 2. Install the new rear seal (2) onto the Rear Crankshaft Seal Installer & Remover tool (W470589004300).
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17.6 INSTALLATION OF THE REAR OIL SEAL 4. Install the seal by turning the forcing screw until the tool bottoms out on the end of the crankshaft. 5. Remove tool W470589004300 and visually check the seal and sealing lip for correct installation. 6. Install the flywheel into the flywheel housing (1). Refer to section 34.6. 17-16 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.7 REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL To remove the front crankshaft oil seal, use Front Crankshaft Seal Installer/Remover tool (W541589023300). Remove as follows: 1. Remove the poly-V-belts. Refer to section 40.1. 2. Remove the vibration damper pulley. Refer to section 36.1. 3. Install Front Crankshaft Seal Installer / Remover tool W541589023300.
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17.8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL 17.8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL Install as follows: NOTE: The standard size front seal has an inside diameter of 100 mm (3.937 in.). NOTE: Handle the new seal with care. Do not bend the seal lip; bending the lip will damage the seal and cause it to leak. EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Install seal (1) and plastic installation tool (2) into the front cover (3) and crankshaft; remove plastic seal installation tool (2) and discard. 4. Install Front Crankshaft Seal Installer/Remover tool (W541589023300) to the crankshaft. 5. Install the seal by turning the forcing screw until the tool bottoms out on the end of the crankshaft. 6. Remove the tool and visually check the seal and sealing lip for correct installation.
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17.8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL 7. Install the vibration damper pulley and torque the eight bolts to 200 N·m (147.5 lb·ft). Refer to section 36.2. 8. Install the poly-V belts. Refer to section 40.3. 17-20 All information subject to change without notice.
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18 LUBRICATION SYSTEM Section 18.1 Page DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS ..............................................................
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18-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18.1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS A schematic of the lubrication system in the following illustration shows the oil flow to the engine components. For the DD13 engine, see Figure18-1. For the DD15 engine, see Figure 18-2. 1. Engine Brake 6. Backflow Valve 11. Oil Refill 2. Turbocharger 7. Suction Pipe 12. Intake Rocker Arm Supply Spindle 3. Crankcase Breather 8. Oil Spray Nozzle 13. Engine Brake Supply 4.
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18.1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS 1. Engine Brake 10. Oil Cooler and Housing 2. Turbocharger 11. Oil Filter 3. Axial Power Turbine 12. Oil Refill 4. Crankcase Breather 13. Intake Rocker Arm Spindle Supply 5. Oil Pump 14. Engine Brake Supply 6. Pressure Valve 15. Exhaust Rocker Arm Spindle Supply 7. Backflow Valve 16. Gear Train Oil Supply 8. Suction Pipe 17. Main Bearing Supply 9.
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19 OIL PAN Section 19.1 Page DESCRIPTION AND OPERATION OF OIL PAN AND RELATED COMPONENTS ....................................................................................... 19-3 19.2 REMOVAL OF OIL PAN ........................................................................... 19-4 19.3 CLEANING OF OIL PAN .......................................................................... 19-5 19.4 INSPECTION OF OIL PAN ...................................................................... 19-6 19.
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19-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.1 DESCRIPTION AND OPERATION OF OIL PAN AND RELATED COMPONENTS Depending on manufacturer, the oil pan is either glass fiber reinforced plastic or aluminum. Sealing of the oil pan takes place using a metal elastomer pre-formed gasket for the aluminum pan or an elastomer gasket for the plastic pan. The oil pan seal has high sealing reliability and noise reduction. In order to determine the engine oil level, there is a conventional oil dipstick. 13.
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19.2 REMOVAL OF OIL PAN 19.2 REMOVAL OF OIL PAN Remove as follows: 1. Open the oil filter and cap. 2. Remove the drain plug and drain the engine oil. 3. Remove the dipstick. 4. Loosen the dipstick tube on the oil pan. Refer to section 20.2. 5. Remove bolt at harness P-clamp on front center of oil pan. 6. Loosen the eighteen oil pan bolts. Bolts will remain installed to the pan. 7. Remove the oil pan, taking care not to damage the oil pump inlet pipe and screen. 8.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.3 CLEANING OF OIL PAN Clean as follows: 1. Clean the oil pan and attaching hardware with clean fuel oil or solvent. To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure. 2. Dry with compressed air. NOTICE: Do not use solvents to clean gaskets. Damage to the gasket will result. 3.
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19.4 INSPECTION OF OIL PAN 19.4 INSPECTION OF OIL PAN Inspect as follows: 1. Check bolts and isolator assemblies for dryness, tears, or damage. Replace as necessary. 2. Check oil pan for dents, cracks or damage. Replace as necessary. 3. Inspect threaded inserts for cracks or damage. Replace as necessary. 4. Clean seals and lubricate seal grooves (if applicable) with clean fuel oil and inspect for cracks or tears. If damage is found, replace oil pan. 19-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.5 REMOVAL OF THREADED INSERT — PLASTIC OIL PAN ONLY Remove as follows: 1. Remove oil pan. Refer to section 19.2. 2. Remove threaded insert using Snap-On® tool GLD139, or equivalent. Discard O-ring. All information subject to change without notice.
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19.6 INSTALLATION OF THREADED INSERT — PLASTIC OIL PAN ONLY 19.6 INSTALLATION OF THREADED INSERT — PLASTIC OIL PAN ONLY Install as follows: 1. Install new O-ring on threaded insert. 2. Install threaded insert into oil pan. 3. Install threaded insert connecting nut and torque to 100 N·m (73 lb·ft). 4. Install the oil pan. Refer to section 19.7. 19-8 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.7 INSTALLATION OF OIL PAN Install as follows: 1. When a plastic pan is used, insert the raised lip portion of the seal into the groove in the oil pan. Press down on the isolator seal and insert it completely around the oil pan. Be careful not to stretch or bunch the seal. For best results, install the seal at each corner, then at points half way between the corners. Continue in this manner, halving the distance and seating the seal. 2.
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19.7 INSTALLATION OF OIL PAN 7. Ensure that the seal has not been disturbed. Torque the eighteen oil pan bolt assemblies to 20 N·m (15 lb·ft) using the proper sequence. 8. Install the oil pan drain plug and torque the plug to 45 N·m (33 lb·ft). 9. Install bolt at harness P-clamp on front center of oil pan. 10. Install dipstick tube fitting if removed from pan and torque to specification listed in Table 19-1. Fitting Thread Size Torque Spec Fitting to pan M20x1.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 17. Start the engine and inspect for leaks. All information subject to change without notice.
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19.7 19-12 INSTALLATION OF OIL PAN All information subject to change without notice.
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20 OIL DIPSTICK TUBE Section 20.1 Page DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND RELATED COMPONENTS ...................................................................... 20-3 20.2 REMOVAL OF THE OIL DIPSTICK TUBE ............................................... 20-4 20.3 INSTALLATION OF THE OIL DIPSTICK TUBE .......................................
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20-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20.1 DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND RELATED COMPONENTS DD Platform engines share a similar oil dipstick tube design. The dipstick inserts into the oil pan through the dipstick guide tube and oil pan adaptor. A lower dipstick bracket and hose clamp secure the assembly to the cylinder block. The oil dipstick tube and oil pan adaptor allow the dipstick to extend into the oil.
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20.2 REMOVAL OF THE OIL DIPSTICK TUBE 20.2 REMOVAL OF THE OIL DIPSTICK TUBE Remove as follows: 1. Loosen the hose clamp (6) attaching oil dipstick tube (2) to the oil pan adaptor. 2. Remove all P-clips (4) attaching oil dipstick tube to bracket (1) and upper bracket on the DD15 and DD16. 3. Remove oil dipstick tube from engine. 20-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20.3 INSTALLATION OF THE OIL DIPSTICK TUBE 1. Install oil dipstick tube (2) onto the oil pan adaptor. 2. Attach all P-clips (4) to the bracket (1) and upper bracket on DD15 and DD16. 3. Tighten the hose clamp (6) attaching the oil dipstick tube to the adaptor. All information subject to change without notice.
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20.3 20-6 INSTALLATION OF THE OIL DIPSTICK TUBE All information subject to change without notice.
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21 OIL PUMP Section 21.1 Page DESCRIPTION AND OPERATION OF OIL PUMP AND RELATED COMPONENTS ....................................................................................... 21.2 REMOVAL OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES ....................................................................................................... 21.3 21-4 INSPECTION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES ...................................................................................
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21-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 21.1 DESCRIPTION AND OPERATION OF OIL PUMP AND RELATED COMPONENTS The oil pump supplies all of the engine oil circuits with engine oil. The oil pump ensures that engine oil is available under all operating conditions, in adequate quantities, at the required pressure, and to the respective locations. A crankshaft drive gear drives the oil pump drive gear. The oil pump drive gear drives the two impellers within the oil pump housing.
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21.2 REMOVAL OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES 21.2 REMOVAL OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES Remove as follows: 1. Remove oil drain plug from the oil pan and drain the oil. 2. Remove the oil pan. Refer to section 19.2. 3. Remove the four bolts (2) securing the oil suction manifold (1) to the engine block (3). 4. Remove the oil suction manifold (1), oil lines (6 and 11) and O-rings (5 and 10). Discard the O-rings. 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 21.3 INSPECTION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES Inspect as follows: To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure. 1. Wash all parts in clean fuel oil and dry them with compressed air. 2. Clean the suction and pressure pipe and screen in clean fuel oil and blow dry with compressed air.
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21.4 INSTALLATION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES 21.4 INSTALLATION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES Install as follows: 1. Check the oil pump part number to be sure it is correct for this application. 2. Position the oil pump on the cylinder block so that the drive gear of the oil pump meshes with the crankshaft gear. 3. Install oil pump with three bolts. Torque the bolts to 30 N·m (22 lb·ft). 4. Install oil lines with new O-rings on each end. 5.
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22 CRANKCASE BREATHER Section Page 22.1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER ........ 22-3 22.2 REMOVAL OF THE CRANKCASE BREATHER ...................................... 22-5 22.3 INSPECTION OF THE CRANKCASE BREATHER ................................. 22-6 22.4 INSTALLATION OF THE CRANKCASE BREATHER ..............................
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22-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 22.1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER The crankcase breather is located below the turbocharger on DD Platform engines, next to the starter on the right hand side of the cylinder block. The crankcase breather has the primary task of regulating the pressure in the crankcase as well as cleaning discharged blow-by gases. The gases from the crankcase contain engine oil that can lead to adverse effects on engine emission levels.
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22.1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER 1. Bolt 7. Bracket 2. Crankcase Breather Housing 8. O-ring 3. Gasket 9. Screw 4. Threaded Fitting 10. Speed Sensor 5. Breather Pipe 11. O-ring 6. Screw Figure 22-2 22-4 EPA10 Crankcase Breather and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 22.2 REMOVAL OF THE CRANKCASE BREATHER Remove as follows: 1. Disconnect speed sensor electrical harness connection, on EPA10 engines, from the crankcase breather and unclip the electrical harness from the crankcase breather assembly. NOTE: Note orientation of bracket located on top bolt. 2. On EPA07 engines, remove the two bolts and gasket from the breather pipe. Discard gasket. 3. On EPA10 engines, disconnect the quick-connect fitting at the cylinder block. 4.
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22.3 INSPECTION OF THE CRANKCASE BREATHER 22.3 INSPECTION OF THE CRANKCASE BREATHER Inspect as follows: 1. Clean the gasket surface of the engine block prior to installation of crankcase breather. 2. Inspect the tubes, clamps and hoses for wear or damage; replace if necessary. 3. Inspect the crankcase breather for cracks or damage; replace if necessary. 4. Inspect the sensor and replace, if necessary. 22-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 22.4 INSTALLATION OF THE CRANKCASE BREATHER Install as follows: 1. Install the crankcase breather to the engine block with a new gasket and four bolts. Torque the bolts to 60 N·m (44 lb·ft). NOTE: Bracket is installed on top bolt. 2. On EPA07 engines, install the breather pipe and new gasket to the engine block. Torque the two bolts to 30 N·m (22 lb·ft). 3. On EPA10 engines, snap the breather pipe to the fitting on the cylinder block.
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22.4 22-8 INSTALLATION OF THE CRANKCASE BREATHER All information subject to change without notice.
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23 OIL FILTER Section 23.1 Page REPLACEMENT OF THE OIL FILTER ....................................................
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23-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 23.1 REPLACEMENT OF THE OIL FILTER “Oil Filter Removal Video” Remove as follows: 1. Using a 36-mm socket, unscrew the oil filter cap (1) and filter (3), and allow the oil to drain into the housing. After draining is complete, remove the assembly from the housing (4). NOTE: For EVO Bus, when removing the filter, separate the cap from the filter before pulling out of the module. Remove as two separate components.
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23.1 23-4 REPLACEMENT OF THE OIL FILTER All information subject to change without notice.
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24 OIL SAMPLE VALVE Section Page 24.1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE .............................. 24-3 24.2 REMOVAL OF OIL SAMPLE VALVE ....................................................... 24-4 24.3 INSTALLATION OF OIL SAMPLE VALVE ................................................
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24-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24.1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE Replace oil plug with oil sample valve as follows: 1. Using a 17 mm Allen tool remove the Allen head plug from the oil priming port on the oil coolant module. 2. Install the oil sample valve onto the oil coolant module. Torque to 80 N·m (59 lb·ft). All information subject to change without notice.
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24.2 REMOVAL OF OIL SAMPLE VALVE 24.2 REMOVAL OF OIL SAMPLE VALVE Remove as follows: Remove the oil sample valve and washer from the oil coolant module. 24-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24.3 INSTALLATION OF OIL SAMPLE VALVE Install as follows: Install the oil sample valve and washer onto the oil coolant module and torque to 80 N·m (59 lb·ft). All information subject to change without notice.
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24.3 24-6 INSTALLATION OF OIL SAMPLE VALVE All information subject to change without notice.
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25 OIL FILLER NECK Section Page 25.1 REMOVAL OF THE OIL FILLER NECK ................................................... 25-3 25.2 INSTALLATION OF THE OIL FILLER NECK ...........................................
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25-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25.1 REMOVAL OF THE OIL FILLER NECK 1. Remove three bolts (5) from the oil filler neck (2). 2. Remove oil filler neck (2) from the oil coolant module (6). 3. Discard O-ring (1). All information subject to change without notice.
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25.2 INSTALLATION OF THE OIL FILLER NECK 25.2 INSTALLATION OF THE OIL FILLER NECK 1. Install new O-ring (1). 2. Install oil filler neck (2) on the oil coolant module (6). 3. Install three bolts (5) and torque to 27-31 N·m (20-22 lb·ft). 25-4 All information subject to change without notice.
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26 OIL COOLANT MODULE Section Page 26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE .. 26-3 26.2 REMOVAL OF THE OIL COOLANT MODULE ........................................ 26-5 26.3 INSTALLATION OF THE OIL COOLANT MODULE ................................ 26-7 26.4 REMOVAL OF THE OIL THERMOSTAT .................................................. 26-9 26.5 INSTALLATION OF THE OIL THERMOSTAT ..........................................
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26-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE The oil filter unit is an integral part of the oil coolant module. The oil coolant module is located on the left side of the engine. The oil filter unit ensures engine oil filtering. Engine oil flows through the oil water heat exchanger and then to the main oil stream feed into the oil filter unit.
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26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE 1. Bolt 5. Water Pump Seal 2. Pulley 6. Oil Cooler Module 3. Bolt 7. Thermostat Seal 4. Water Pump 8. Thermostat 9. Bolt Figure 26-2 26-4 Oil Coolant Module and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.2 REMOVAL OF THE OIL COOLANT MODULE Remove as follows: 1. Drain coolant from the radiator. Refer to OEM procedures. 2. Open the drain plug (1) on the cylinder block located next to the oil coolant module and t. 3. Remove engine harness connectors from the coolant temperature sensor, Intake Air Temperature Sensor, and Throttle Valve. Unclip the harness from the oil coolant module. 4.
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26.2 REMOVAL OF THE OIL COOLANT MODULE 12. Remove and discard the gasket. 26-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.3 INSTALLATION OF THE OIL COOLANT MODULE Install as follows: 1. Install thermostat to oil coolant module with four bolts. Torque to 20-25 N·m (15-19 lb·ft). 2. Install Exhaust Manifold Guide Studs tool (J–36107) into the cylinder block to assist in guiding the oil coolant module onto the cylinder block. 3. Install new gasket. 4. Install the oil coolant module onto the guide studs and cylinder block. 5.
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26.3 INSTALLATION OF THE OIL COOLANT MODULE 14. If open, close the drain plug on the cylinder block located next to the oil coolant module. NOTE: Before installing coolant crossover pipe, check the coupler hose for damage. Replace as necessary. 15. Install EGR coolant delivery pipe and hose to oil coolant module and tighten the two hose clamps. 16. Install the two EGR coolant delivery pipe bolts to the oil coolant module and torque to 30 N·m (22 lb·ft). 17.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.4 REMOVAL OF THE OIL THERMOSTAT Remove as follows: 1. Place a suitable oil capturing device under the oil coolant module. 2. Unclip electrical harness from the oil thermostat cover. 3. Remove four bolts (2) attaching the oil thermostat cover (1) to the oil coolant module (3). 4. Using tool W470589030900, remove the thermostat from the oil coolant module housing. All information subject to change without notice.
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26.4 REMOVAL OF THE OIL THERMOSTAT 5. Discard the seal (3) and the O-ring (4). 26-10 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.5 INSTALLATION OF THE OIL THERMOSTAT Install as follows: 1. Install a new O-ring (4) on the oil thermostat (5). 2. Using tool W470589030900, install the thermostat to the oil coolant module housing. Torque to 50 N·m (37 lb·ft). All information subject to change without notice.
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26.5 INSTALLATION OF THE OIL THERMOSTAT 3. Install new seal, install the oil thermostat cover (1) to the oil coolant module (3) using four bolts (2). Torque the bolts to 30 N·m (22 lb·ft). 4. Connect the electrical harness to the sensor. 5. Clip electrical harness to the oil thermostat cover. 26-12 All information subject to change without notice.
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27 PRIMING THE LUBRICATION SYSTEM Section 27.1 Page PRIMING THE ENGINE LUBRICATION SYSTEM ..................................
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27-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 27.1 PRIMING THE ENGINE LUBRICATION SYSTEM Prime the oil system as follows: 1. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port on the oil coolant module. NOTE: Tool J–49181 is used to adapt the J–45299 priming pump. 2. If equipped with an oil sample valve, remove the valve and washer. All information subject to change without notice.
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27.1 PRIMING THE ENGINE LUBRICATION SYSTEM 3. Install Oil System Priming Adaptor tool (J–49181) into the oil priming port (1) in the oil coolant module. 4. Install Engine Preluber Kit (J–45299) to the fitting adaptor (1). 5. Fill the canister with eight quarts of oil. 6. Open the valve on the primer and start pumping until the container is empty. 7. Fill the container with an additional eight quarts of oil and pump until the canister is empty. 8. The oil system is now primed with sixteen quarts of oil.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9. Close the valve and loosen the fitting; do not completely remove it from the adaptor. 10. Remove the priming adaptor (1) from the oil coolant module (2) with the line attached to keep the oil from flowing out of the module. 11. Install the allen head plug or oil sample valve to the module and torque to 70-80 N·m (51-59 lb·ft). ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
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27.1 27-6 PRIMING THE ENGINE LUBRICATION SYSTEM All information subject to change without notice.
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28 COOLING SYSTEM Section 28.1 Page DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS ......................................................................
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28-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS A schematic of the cooling system in the following illustration shows the coolant flow to the engine components. 1. Coolant Pump 10. Fan 19. Heat Exchanger M. Engine 2. Oil Cooler 11. Radiator 20. Doser R. Auto Trans Cooler Flow 3. Crankcase 12. Reservoir A97. EGR Actuator V. Coolant Feed 4. Cylinder Head 13. Coolant Filter B65. 1 Inlet Temp Sensor VA.
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28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS 1. Water Pump 8. Water Manifold 2. Coolant Filter 9. Cylinder Head 3. Short Circuit Line 10. Cylinder Block 4. Coolant Return Flow 11. Air Compressor 5. Coolant Outlet to Cooler Circuit 12. Fuel Cooler 6. Exhaust Gas Recirculation Cooler 13. Oil/Water Heat Exchanger 7. Coolant Return Flow 14. Thermostat Figure 28-2 28-4 Cooling System Components All information subject to change without notice.
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29 ENGINE WATER PUMP Section Page 29.1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP ............ 29-3 29.2 REMOVAL OF THE WATER PUMP ......................................................... 29-4 29.3 INSPECTION OF THE WATER PUMP .................................................... 29-5 29.4 INSTALLATION OF THE WATER PUMP .................................................
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29-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 29.1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP The water pump is located on the left side of the engine, mounted on the front of the oil coolant module. The water pump circulates the coolant in the cooling circuit. The water pump pulley is mounted to the water pump with five bolts. The water pump is driven by the poly-V-belt that is installed onto the water pump pulley. The rotary motion of the pulley is transmitted by the hub to the shaft.
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29.2 REMOVAL OF THE WATER PUMP 29.2 REMOVAL OF THE WATER PUMP Remove as follows: 1. Drain the coolant from radiator. Refer to OEM procedures. 2. Disconnect the batteries. 3. Loosen the five bolts securing the water pump pulley to the water pump. PERSONAL INJURY To avoid injury to hands and fingers from the spring-loaded auto belt tensioner violently snapping back, do not cut the belt to remove it. 4. Remove the accessory drive belt. Refer to section 40.1. 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 29.3 INSPECTION OF THE WATER PUMP Slight weeping from the weep hole in the bottom of water pump is normal. The water pump should only be replaced if there is a heavy leak from the weep hole. The water pump should only be replaced after all of the following inspections have been performed. Inspect as follows: NOTICE: Before replacing the water pump for a belt noise there are some basic checks that need to be done.
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29.4 INSTALLATION OF THE WATER PUMP 29.4 INSTALLATION OF THE WATER PUMP Install as follows: 1. Install the water pump seal (5) to the water pump (4). 2. Install the water pump (4) to the oil coolant module (6) with nine bolts (3) and torque to 30 N·m (22 lb·ft). 3. Install the water pump pulley (2) to the water pump with five bolts (1) and finger tighten and install belt. 4. Install the poly-V-belt. Refer to section 40.3. 5. Torque the water pump pulley bolts to 25 N·m (18 lb·ft). 6.
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30 COOLANT THERMOSTAT Section Page 30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT ........ 30-3 30.2 REMOVAL OF COOLANT THERMOSTAT AND SEAL ........................... 30-5 30.3 INSPECTION OF COOLANT THERMOSTAT AND SEAL ....................... 30-6 30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL ....................
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30-2 All information subject to change without notice.
PAGE 331
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT The coolant thermostat is located on the left side of the engine on the oil coolant module. The coolant thermostat regulates the coolant inlet temperature in a range from 87°C (188° F) to 95°C (203°F). 1. Oil Coolant Module 3. Thermostat 2. Seal Figure 30-1 Thermostat and Related Parts The coolant thermostat regulates coolant flow from the engine to the radiator.
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30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT Thermostat Operating Modes The coolant from the radiator and the radiator bypass mix in the thermostat housing. The thermostat regulates the temperature of this mixed flow circuit. Three different operating conditions occur due to the coolant mixed flow temperature: □ □ □ Bypass mode: When the coolant mixed flow temperature is below 87°C (188°F), the circulating thermostat is closed.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.2 REMOVAL OF COOLANT THERMOSTAT AND SEAL Remove as follows: HOT COOLANT To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature. Wear adequate protective clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure. 1. Drain the cooling system. 2.
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30.3 INSPECTION OF COOLANT THERMOSTAT AND SEAL 30.3 INSPECTION OF COOLANT THERMOSTAT AND SEAL Inspect thermostat as follows: 1. Visually inspect all parts for wear or damage. [a] If wear or damage is found, replace parts. [b] If wear or damage is not found, reuse parts. 2. Visually inspect thermostat body seal for damage, cracks or nicks. [a] If any damage is noted, replace seal. [b] If no damage is found, reuse parts. 3. Visually inspect the tip of the thermostat for wear or damage.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL Install as follows: 1. Install seal (2) onto thermostat housing (3). 2. Install thermostat into hose and onto oil cooler module (1). 3. Torque four bolts to 30 N·m (22 lb·ft). 4. Tighten clamp at the hose. 5. Fill engine with coolant to the correct level. ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 6.
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30.4 30-8 INSTALLATION OF COOLANT THERMOSTAT AND SEAL All information subject to change without notice.
PAGE 337
31 COOLANT FILTER Section Page 31.1 DESCRIPTION AND OPERATION OF COOLANT FILTER ..................... 31-3 31.2 REMOVAL OF THE COOLANT FILTER .................................................. 31-4 31.3 INSTALLATION OF THE COOLANT FILTER ..........................................
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31-2 All information subject to change without notice.
PAGE 339
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 31.1 DESCRIPTION AND OPERATION OF COOLANT FILTER DD Platform engine cooling systems are protected by a coolant filter element that may contain supplemental corrosion inhibitors. All information subject to change without notice.
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31.2 REMOVAL OF THE COOLANT FILTER 31.2 REMOVAL OF THE COOLANT FILTER Remove as follows: 1. Using a 36 mm wrench, remove the cap (1) from the oil coolant module (4). 2. Pull the coolant filter (3) out of the oil coolant module. 3. Discard the O-ring (2) in the cap. 31-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 31.3 INSTALLATION OF THE COOLANT FILTER Install as follows: 1. Install a new O-ring (2) onto the cap. 2. Install a new coolant filter (3) into the cap (1). 3. Install coolant filter and cap into the oil coolant module (4). Torque cap to 55-60 N·m (41-44 lb·ft). All information subject to change without notice.
PAGE 342
31.3 31-6 INSTALLATION OF THE COOLANT FILTER All information subject to change without notice.
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32 COOLANT FILTER SERVICE MODULE Section Page 32.1 REMOVAL OF COOLANT FILTER SERVICE MODULE ......................... 32-3 32.2 INSTALLATION OF COOLANT FILTER SERVICE MODULE ..................
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32-2 All information subject to change without notice.
PAGE 345
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 32.1 REMOVAL OF COOLANT FILTER SERVICE MODULE Remove as follows: 1. Drain coolant. 2. Remove hose clamps and remove hoses. 3. Remove ten bolts from the Coolant Filter Service Module and remove service module from engine. 4. Discard the O-rings (3 and 4) and the seals (5). All information subject to change without notice.
PAGE 346
32.2 INSTALLATION OF COOLANT FILTER SERVICE MODULE 32.2 INSTALLATION OF COOLANT FILTER SERVICE MODULE Install as follows: 1. Install new O-rings and seals. Lubricate with clean coolant. 2. Install Coolant Filter Service Module on the oil cooler module. 3. Install the ten bolts and torque to 37 N·m (27 lb·ft). 4. Install hoses and hose clamps. 5. Fill coolant to appropriate level. ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always Engine operate the engine in a well-ventilated area.
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33 COOLANT INLET ELBOW Section Page 33.1 REMOVAL OF THE COOLANT INLET ELBOW ...................................... 33-3 33.2 INSTALLATION OF THE COOLANT INLET ELBOW ..............................
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33-2 All information subject to change without notice.
PAGE 349
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 33.1 REMOVAL OF THE COOLANT INLET ELBOW Remove as follows: 1. Drain coolant. 2. Remove two bolts from the coolant inlet elbow. 3. Remove the coolant inlet elbow from the coolant service filter module. 4. Remove and discard the O-ring. All information subject to change without notice.
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33.2 INSTALLATION OF THE COOLANT INLET ELBOW 33.2 INSTALLATION OF THE COOLANT INLET ELBOW Install as follows: 1. Install new O-ring. 2. Install the coolant inlet elbow to the coolant filter service module with two bolts. 3. Torque bolts to 30 N·m (22 lb·ft). 4. Fill coolant to appropriate level. ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 5. Start engine and check for leaks.
PAGE 351
34 FLYWHEEL AND FLYWHEEL HOUSING Section 34.1 Page DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS .......................................................... 34-3 34.2 REMOVAL OF FLYWHEEL HOUSING .................................................... 34-6 34.3 INSTALLATION OF FLYWHEEL HOUSING ............................................ 34-7 34.4 REMOVAL OF THE FLYWHEEL .............................................................. 34-9 34.5 INSPECTION OF FLYWHEEL ......
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34-2 All information subject to change without notice.
PAGE 353
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.1 DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS This section explains the description(s) and operation(s) of the following components: □ □ □ Flywheel Ring Gear Flywheel Housing 34.1.1 Flywheel The flywheel is attached to the rear end of the crankshaft with twelve bolts. The bolt holes in the crankshaft and flywheel are equally spaced. 34.1.2 Ring Gear The steel ring gear and flywheel is a two-piece assembly.
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34.1 DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS 34.1.3 Flywheel Housing The flywheel housing is a one-piece aluminum casting mounted against the rear of the engine. It provides a cover for the gear drive and houses the flywheel. The crankshaft rear oil seal, which is pressed into the housing, may be removed or installed without removing the housing. The power steering pump on some applications may be mounted on the flywheel housing.
PAGE 355
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt M10 x 90 (3 qty.) 9. Bolt M8 x 45 (2 qty.) 2. Bolt M14 x 1.5 x 70 (1 qty.) 10. Flywheel Housing 3. Bolt M14 x 1.5 x 90 (6 qty.) 11. Gasket 4. Bolt M10 x 45 (6 qty.) 12. Stud (1 qty.) 5. Gasket (1 qty.) 13. Nut M12-10 (1 qty.) 6. Cover (1 qty.) 14. Cover 7. Bolt M8 x 30 (2 qty.) 15. Bolt (2 qty.) 8. Bolt M14 x 1.5 x 180 (1 qty.) Figure 34-2 Front of Flywheel Housing and Related Parts All information subject to change without notice.
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34.2 REMOVAL OF FLYWHEEL HOUSING 34.2 REMOVAL OF FLYWHEEL HOUSING Remove as follows: 1. If the engine is removed from the vehicle, mount the engine on an overhaul stand. 2. Drain engine oil and remove the oil pan. 3. Remove the doser injector feed line. 4. Remove the Crankshaft Position Sensor (CKP). Refer to section . 5. Remove the flywheel. Refer to section 34.4. 6. Remove two bolts securing exhaust pipe bracket to flywheel housing. 7.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.3 INSTALLATION OF FLYWHEEL HOUSING Install as follows: 1. Thread two guide studs (J–43431) for 14 mm bolts, into the cylinder block to guide the housing in place. 2. Install a new gasket. BODILY INJURY To avoid injury from a falling component, ensure a proper lifting device is used. Never stand beneath a suspended load. 3. Using a lifting sling support the flywheel housing and position it onto the cylinder block. 4.
PAGE 358
34.3 INSTALLATION OF FLYWHEEL HOUSING 1. Bolt, M8 x 16 (2 qty.) 30 N·m (22 lb·ft) 6. Bolt, M8 x 45 (2 qty.) 30 N·m (22 lb·ft) 2. Bolt, M14 x 1.5 x 90 (6 qty.) 120 N·m (88 lb·ft) 7. Bolt, M8 x 30 (2 qty.) 30 N·m (22 lb·ft) 3. Bolt, M10 x 45 (6 qty.) 60 N·m (44 lb·ft) 8. Bolt, M14 x 1.5 x 70 (1 qty.) 120 N·m (88 lb·ft) 4. Bolt, M10 x 90 (3 qty.) 60 N·m (44 lb·ft) 9. Stud, (1 qty.) 5. Bolt, M14 x 1.5 x 180 (1 qty.) 120 N·m (88 lb·ft) 10. Nut, M12-10 (1 qty.) 100 N·m (74 lb·ft) 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.4 REMOVAL OF THE FLYWHEEL Pre-cleaning is not necessary. Remove as follows: 1. Remove the crankshaft position sensor (CKP). Refer to section . 2. Remove eleven of the twelve flywheel attaching bolts, leaving one bolt at the 12 o'clock position. 3. Install two flywheel guide studs (J–41672) through the flywheel and into the crankshaft at the 3 and 9 o'clock positions. 4.
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34.5 INSPECTION OF FLYWHEEL 34.5 INSPECTION OF FLYWHEEL Inspect as follows: 1. Inspect the clutch contact base of the flywheel. [a] Check clutch contact base for scoring, wear, or cracks. [b] The flywheel may be re-faced if the clutch contact face is scored or worn. [c] The flywheel must be replaced if the clutch contact face shows cracks. 2. Inspect the ring gear. [a] Check ring gear for excessively worn or damaged gear teeth. [b] If damaged gear teeth are detected, replace the ring gear. 3.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.6 INSTALLATION OF FLYWHEEL Install as follows: 1. Install two flywheel guide studs (J–36235) into two of the tapped holes in the crankshaft at the 3 and 9 o'clock position. NOTICE: Maximum flywheel bolt length for reuse is 88mm, if bolt length exceeds this, replace the used bolts with new bolts. 2. Properly attach the flywheel lifting tool to the flywheel and, using a chain hoist, position the flywheel in the flywheel housing.
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34.7 INSPECTION OF FLYWHEEL HOUSING AND REAR OIL SEAL AREA OF CRANKSHAFT 34.7 INSPECTION OF FLYWHEEL HOUSING AND REAR OIL SEAL AREA OF CRANKSHAFT Inspect as follows: 1. Inspect flywheel housing for cracks and any other damage. [a] Check sealing surface for damage. [b] Check flywheel housing for cracks. [c] If damaged or cracked, repair is not possible; replace the part. 2. Inspect the flywheel where the rear oil seal makes contact. Check for groove in flywheel; if grooved, replace flywheel.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.8 REMOVAL OF RING GEAR Remove the ring gear as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the transmission. 3. Remove the flywheel. 4. Using an acetylene torch, cut the ring gear 1/2 to 3/4 of the way through, without allowing the flame to touch the flywheel. 5. The uncut portion will now yield. Tap the ring gear to remove it from the flywheel.
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34.9 INSTALLATION OF RING GEAR 34.9 INSTALLATION OF RING GEAR Install the ring gear as follows: 1. Support the flywheel, ring gear side up, on a solid flat surface. BURNS To avoid injury from burning, use lifting tools and heat-resistant gloves when handling heated components. NOTICE: Do not, under any circumstances, heat the gear over 204°C (399°F). Excessive heat may destroy the original heat treatment.
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35 FRONT ENGINE MOUNT/RADIATOR SUPPORT Section 35.1 Page DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS ........................ 35-3 35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT .. 35-4 35.3 INSPECTION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT ................................................................................................ 35.4 35-5 INSTALLATION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT ..............................................
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35-2 All information subject to change without notice.
PAGE 367
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 35.1 DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS The front engine mount/radiator support is mounted to the cylinder block with four bolts. 1. Front Engine Mount/Radiator Support 3. Engine Block 2. Bolts Figure 35-1 Front Engine Mount/Radiator Support and Related Parts All information subject to change without notice.
PAGE 368
35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT 35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT Remove as follows. 1. Drain the coolant from radiator. Refer to OEM procedures. 2. Remove the charge air cooler (CAC) hoses. 3. Remove the air cooling components. Refer to OEM guidelines. 4. Remove the four bolts securing the front engine mount/radiator support and remove front engine mount/radiator support. 35-4 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 35.3 INSPECTION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT Inspect the front engine mount/radiator support for damage; replace as necessary. All information subject to change without notice.
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35.4 INSTALLATION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT 35.4 INSTALLATION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT Install as follows: 1. Install the front engine mount/radiator support to the cylinder block with four bolts. Torque bolts to 250 N·m (184 lb·ft). 2. Install CAC hoses. 3. Install air cooling components refer to OEM guidelines. 4. Fill with coolant to the appropriate levels. 35-6 All information subject to change without notice.
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36 VIBRATION DAMPER Section Page 36.1 REMOVAL OF THE VIBRATION DAMPER ............................................. 36-3 36.2 INSTALLATION OF THE VIBRATION DAMPER .....................................
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36-2 All information subject to change without notice.
PAGE 373
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 36.1 REMOVAL OF THE VIBRATION DAMPER Remove as follows: 1. Remove the poly-V-belt. Refer to section 40.1. 2. Remove the eight bolts (1) attaching the vibration damper (2) to the crankshaft (4). 3. Using guide studs tool J-43431, remove the vibration damper. 4. Remove the splash ring (3). All information subject to change without notice.
PAGE 374
36.2 INSTALLATION OF THE VIBRATION DAMPER 36.2 INSTALLATION OF THE VIBRATION DAMPER Install as follows: 1. Install the splash ring (1) with cup-side (2) toward end of crankshaft. 2. Using guide studs tool (J-43431), install the vibration damper onto the crankshaft. 3. Install the eight bolts attaching the vibration damper to the crankshaft. Torque to 200 N·m (147.5 lb·ft). Refer to section 36.2. 4. Install the poly-V-belt. Refer to section 40.3. 36-4 All information subject to change without notice.
PAGE 375
37 FRONT ENGINE COVER Section Page 37.1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE COVER .. 37-3 37.2 REMOVAL OF THE FRONT ENGINE COVER ........................................ 37-4 37.3 INSPECTION OF THE FRONT ENGINE COVER ................................... 37-5 37.4 INSTALLATION OF THE FRONT ENGINE COVER ................................
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37-2 All information subject to change without notice.
PAGE 377
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 37.1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE COVER The front cover housing seals the cylinder block to the oil pan, while also holding the front radial seal to the machined surface of the crankshaft nose. The front radial seal prevents oil leaks at the crankshaft. 1. Front Mounting Bracket Bolt (4 qty.) 7. Front Cover Mounting Bolts (10 qty.) 2. Front Mounting Bracket 8. Front Cover 3. Vibration Damper Mounting Bolts (8 qty.) 9.
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37.2 REMOVAL OF THE FRONT ENGINE COVER 37.2 REMOVAL OF THE FRONT ENGINE COVER Remove as follows: 1. Shut off engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the poly-V-belt. Refer to section 40.1. 3. Remove the eight bolts attaching the vibration damper to the crankshaft. Refer to section 36.1. 4. Remove the splash ring. NOTE: The oil pan must be completely removed to clean the gasket and groove to prevent potential oil leaks. 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 37.3 INSPECTION OF THE FRONT ENGINE COVER Inspect as follows: 1. Inspect the front cover housing for leaks, cracks or any other signs of damage. Replace as necessary. 2. Clean the front engine cover with clean engine oil. All information subject to change without notice.
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37.4 INSTALLATION OF THE FRONT ENGINE COVER 37.4 INSTALLATION OF THE FRONT ENGINE COVER Install as follows: 1. Install a new front cover housing gasket on the cylinder block. 2. Install the front cover housing to the cylinder block. Torque the front cover mounting bolts to 60 N·m (44 lb·ft) in the sequence shown. 3. Install the oil pan to cylinder block. Refer to section 19.7. 4. Install the splash ring on the front of the crankshaft. 5.
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38 ENGINE LIFTER BRACKETS Section 38.1 Page DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS ............................................................................ 38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF ..................................................... 38.3 38-3 38-8 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF .................................................................. 38-9 38.
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38-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS The engine lifter brackets on the DD Platform engines are utilized when removing or replacing an engine. All DD Platform engines have two lifting brackets that are located on the rear of the engine, bolted to the cylinder head. A third engine lifter bracket is located on the front which is part of the Exhaust Gas Recirculation (EGR) system crossover tube. 1. Venturi 7.
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38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS 1. Venturi 11. EGR Cooler / Water Manifold Assembly 2. Bolt 12. Coolant Crossover Tube 3. Gasket 13. Cylinder Head 4. Mounting Bolt 14. Bolt 5. Bolt 15. Rear Lifting Bracket — Left Side 6. Bolt (6 qty.) 16. Rear Lifting Bracket — Right Side 7. Exhaust Gas Crossover Tube 17. Mixer Pipe 8. Exhaust Gas Connecting Tube 18. Clamp 9. Bolt 19. Connector Hose 10. Plate 20.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Venturi 11. Exhaust Gas Recirculation Cooler 2. Bolt 12. Water Manifold 3. Gasket 13. Coolant Crossover Tube 4. Bolt 14. Cylinder Head 5. Bolt (6 qty.) 15. Bolt 6. Bolt 16. Rear Lifter Bracket — Left Side 7. Exhaust Gas Crossover Tube/Lifting Eye 17. Rear Lifter Bracket — Right Side 8. Exhaust Gas Connector Tube 18. Mixer Pipe 9. Bolt 19. Clamp 20. Connector Hose 10.
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38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS 1. Venturi 12. Water Manifold 2. Bolt 13. Coolant Crossover Tube 3. Gasket 14. Cylinder Head 4. Bolt 15. Bolt 5. Bolt 16. Rear Lifter Bracket — Left Side 6. Bolt (6 qty.) 17. Rear Lifter Bracket — Right Side 7. Exhaust Gas Crossover Tube 18. Mixer Pipe 8. Exhaust Gas Connector Tube 19. Clamp 9. Bolt 20. Connector Hose 21. Lifter Bracket 10. Plate 11.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE To avoid injury from a falling engine, do not use a damaged lifter bracket when lifting the engine. To avoid injury from a falling engine, ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling. All information subject to change without notice.
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38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF 38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF For EPA10 engines, remove as follows: 1. Remove the two bolts (1) from the front engine lifter bracket. 2. Remove the front engine lifter bracket. 38-8 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.3 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF For EPA07 engines, remove as follows: 1. Loosen the two hose clamps on the venturi to mixer pipe hose. 2. Slide the connector hose fully on the mixer pipe. If hose is cut, torn, or cracked, then remove and discard it. 3. Remove the two bolts attaching the venturi to the exhaust gas crossover tube/lifting eye. 4.
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38.4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS 38.4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS Remove as follows: 1. Remove the bolts securing the lifter brackets to the engine. 2. Remove lifter bracket. 38-10 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.5 INSPECTION OF THE ENGINE LIFTER BRACKETS Inspect the lifter brackets for cracks, bending, or other damage. Replace the bracket if any of these conditions exist. All information subject to change without notice.
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38.6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS 38.6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS Install the rear lifter brackets as follows: 1. Install the two rear lifter brackets with four bolts to the cylinder head. 2. Torque the bolts to 180 N·m (132 lb·ft). 38-12 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF For EPA10 engines, install as follows: 1. Install the front engine lifter bracket to the engine. 2. Install the two bolts. Torque to 160 N·m (110 lb·ft). All information subject to change without notice.
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38.8 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF 38.8 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF For EPA07 engines, install as follows: 1. Install a new EGR connector tube, if needed, onto EGR cooler and install EGR exhaust gas crossover tube/lifting eye to cylinder head. 2. Loosely install six bolts to exhaust gas crossover tube/lifting eye. 3.
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39 BELT DRIVE TENSIONER SYSTEM Section 39.1 Page DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS .................................................................................... 39-3 39.2 REMOVAL OF THE BELT TENSIONER .................................................. 39-5 39.3 INSTALLATION OF THE BELT TENSIONER .......................................... 39-6 39.4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET .. 39-7 39.
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39-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.1 DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS The engine uses two poly-V-belts. Since this type of belt is very flexible, a number of major assemblies can be driven by one poly-V-belt. The alternator, refrigerant compressor, and coolant pump are driven by one eight-ribbed poly-V-belt. The fan clutch and the engine fan are driven by one ten-ribbed poly-V-belt. The belt tensioners are firmly bolted onto the accessory bracket.
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39.1 DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS There is a square hole in each tensioning arm to install a 1/2 in socket tool for removal and installation of the poly-V-belts. The outer poly-V-belt must be removed before removing the inner poly-V-belt. 1. Crankcase Damper 8. Accessory Mounting Bracket 2. Poly-V-Belt for the Fan 9. Belt Tensioner 3. Alternator 10. Fan Clutch 4. Pulley 11. Pulley and Spacer 5.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.2 REMOVAL OF THE BELT TENSIONER Remove as follows: 1. Remove the two poly-V-belts. Refer to section 40.1. 2. Remove the three bolts from the tensioner. 3. Remove the tensioner from the bracket. All information subject to change without notice.
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39.3 INSTALLATION OF THE BELT TENSIONER 39.3 INSTALLATION OF THE BELT TENSIONER Install as follows: 1. Install the tensioner to the bracket. 2. Install the three bolts attaching the tensioner to the bracket. Torque to 60 N·m (44 lb·ft). 3. Install the two poly-V-belts. Refer to section 40.3. 39-6 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET Remove as follows: 1. Remove the two poly-V-belts. Refer to section 40.1. 2. Remove the idler pulley from the idler pulley bracket. 3. Remove the two bolts from the idler pulley bracket and remove the idler pulley bracket from the engine. All information subject to change without notice.
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39.5 INSTALLATION OF THE IDLER PULLEY AND IDLER PULLEY BRACKET 39.5 INSTALLATION OF THE IDLER PULLEY AND IDLER PULLEY BRACKET Install as follows: 1. Install the idler pulley bracket to the engine. 2. Install the two bolts to the idler pulley bracket. Torque to 60 N·m (44 lb·ft). 3. Install the idler pulley to the idler pulley bracket. Torque to 60 N·m (44 lb·ft). 4. Install the two poly-V-belts. Refer to section 40.3. 39-8 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.6 REMOVAL OF NON-BRACKETED IDLER PULLEY Remove as follows: 1. Remove the two poly-V-belts. Refer to section 40.1. 2. Remove the bolt from the idler pulley. Remove the idler pulley and spacer from the engine block. All information subject to change without notice.
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39.7 INSTALLATION OF NON-BRACKETED IDLER PULLEY 39.7 INSTALLATION OF NON-BRACKETED IDLER PULLEY Install as follows: 1. Insert bolt through idler pulley and spacer. 2. Install bolt to engine block. Torque to 60 N·m (44 lb·ft). 3. Install the two poly-V-belts. Refer to section 40.3. 39-10 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.8 REMOVAL OF THE ACCESSORY MOUNTING BRACKET Remove as follows: 1. Remove the two poly-V-belts. Refer to section 40.1. 2. Remove the three bolts from the belt tensioner. 3. Remove the belt tensioner from the accessory mounting bracket. 4. Remove the air conditioner compressor. Refer to OEM procedures. 5. Remove the alternator. Refer to OEM procedures. 6. Remove the six bolts attaching the accessory mounting bracket to the engine. 7.
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39.9 INSTALLATION OF THE ACCESSORY MOUNTING BRACKET 39.9 INSTALLATION OF THE ACCESSORY MOUNTING BRACKET Install as follows: 1. Install the accessory mounting bracket to the engine. 2. Install the six bolts attaching the accessory mounting bracket to the engine. Torque to 60 N·m (44 lb·ft). 3. Install the alternator. Refer to OEM procedures. 4. Install the air conditioner compressor. Refer to OEM procedures. 5. Install the accessory mounting to the belt tensioner bracket. 6.
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40 POLY-V-BELTS Section Page 40.1 REMOVAL OF THE POLY-V-BELTS ....................................................... 40-3 40.2 INSPECTION OF THE POLY-V-BELTS ................................................... 40-6 40.3 INSTALLATION OF THE POLY-V-BELTS ................................................
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40-2 All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 40.1 REMOVAL OF THE POLY-V-BELTS Remove as follows: NOTICE: Use a half-inch socket tool (with extension) is used. Do not use more than a 6 inch extension on the socket tool to reduce the danger of cracking the tensioner. Apply smooth pressure to tensioner. Jerking or sudden pressure could cause damage to tensioner. NOTE: Never pre-tension the non-grooved pulley idler arm before the grooved idler pulley arm is pre-tensioned.
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40.1 REMOVAL OF THE POLY-V-BELTS 2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100 N·m (66-73 lb·ft). 3. Insert an M10x80 bolt (or equivalent pin), into the bracket hole (2) in the idler arm. 4. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position. 5. Remove the belt. 6. Install a half-inch extension into the square hole (V) on the non-grooved pulley idler arm (1). 7. Turn the non-grooved pulley idler arm counterclockwise.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. Insert an M10x80 bolt (or equivalent pin), into the bracket hole in the non-grooved pulley idler arm (2). 9. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position. 10. Remove the belt from the pulleys, then remove the alternator and refrigerant compressor. All information subject to change without notice.
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40.2 INSPECTION OF THE POLY-V-BELTS 40.2 INSPECTION OF THE POLY-V-BELTS Inspect as follows: 1. Inspect the belt contact surfaces for chips, flaking, cracks and discoloration. 40-6 ABRASION CHUNK-OUT IMPROPER INSTALL CRACKING PILLING UNEVEN RIB WEAR All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE MISALIGNMENT GRAVEL PENETRATION 2. Inspect the bearings in the idler pulleys and accessories by rotating the pulleys to look for bearing slop or choppy feeling bearings. NOTE: Inspect the area for oil leaking at the spring area. Change the assembly if oil is present. 3. Inspect the springs on the tensioner. If the rubber is damaged or if the spring is damaged, change the assembly. 4. Inspect the pulleys for damage and excessive wear.
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40.2 INSPECTION OF THE POLY-V-BELTS 5. Check wear pattern on all idler pulleys. 40-8 [a] If wear pattern location is incorrect (A), change the pulley and bracket. [b] If wear pattern location is correct (B), idler and bracket can be reused. All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 40.3 INSTALLATION OF THE POLY-V-BELTS Install as follows: NOTE: If tensioners are pre-tensioned, start at step 9. 1. Install a half-inch extension into the square hole on the grooved pulley idler arm. 2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100 N·m (66-73 lb·ft). 3. Insert an M10x80 bolt (or equivalent pin), into the bracket hole in the grooved pulley idler arm. 4. Release the idler arm.
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40.3 40-10 INSTALLATION OF THE POLY-V-BELTS All information subject to change without notice.
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41 AIR COMPRESSOR Section Page 41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR .......... 41-3 41.2 REMOVAL OF THE AIR COMPRESSOR ................................................ 41-5 41.3 INSPECTION OF THE AIR COMPRESSOR ........................................... 41-6 41.4 INSTALLATION OF THE AIR COMPRESSOR ........................................
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41-2 All information subject to change without notice.
PAGE 419
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR The air compressor is mounted to the rear of the cylinder block on the left side of the engine. The engine provides a continuous supply of oil to the compressor. Oil is routed from the oil passage in the gear case to the compressor oil inlet. The air compressor is designed to permit direct installation of the compressor onto the gear case. Detroit Diesel offers two sizes of air compressors.
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41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR 1. Bolt 9. Two Cylinder Air Compressor 2. Bolt 10. O-ring 3. Bracket 11. Gear 4. Bolt 12. Nut 5. Cover 13. Clamp (OEM provided) 6. O-ring 14. Bolt (OEM provided) 7. Coolant Return Line Assembly 15. Intake Line (OEM provided) 8. Coolant Inlet Line Assembly 16. Bolt Figure 41-2 41-4 Two Cylinder Air Compressor and Related Parts All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 41.2 REMOVAL OF THE AIR COMPRESSOR 1. Disconnect the batteries. 2. Drain the coolant from radiator. Refer to OEM procedures. NOTICE: Ensure the air pressure has been released from the air lines before removing the lines from the air compressor. 3. Relieve air pressure from tanks. 4. Disconnect the air lines to and from the compressor. 5. Disconnect and drain the coolant supply and return lines at the air compressor. 6.
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41.3 INSPECTION OF THE AIR COMPRESSOR 41.3 INSPECTION OF THE AIR COMPRESSOR Troubleshooting information for the Bendix® air compressor can be found on the Bendix web site at http:\\www.bendix.com or call the Bendix Technical Assistance Center at 1-800-AIR-BRAKE, (1-800-247-2725). Check as follows: 1. Check for oil present in the air dryer or air tanks. [a] If no oil is present, check for a worn or damaged valve guide/seal or cylinder kit. Refer to section 14.13. [b] If oil is present, go to step 2. 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Remove the air compressor from the engine. Refer to section 41.2. To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 7. Start and run the engine. 8. Perform a crankcase pressure test. Refer to section . [a] If the engine crankcase pressure exceeds 1.25 kPa (5 in. H2O), check for a defective turbocharger. Refer to section . Shut down the engine.
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41.4 INSTALLATION OF THE AIR COMPRESSOR 41.4 INSTALLATION OF THE AIR COMPRESSOR 1. Clean all foreign material from the mating surfaces of the air compressor and the cylinder block. 2. Install a new O-ring on the air compressor hub and a new O-ring on the oil supply and then install the air compressor on the cylinder block. Torque the four bolts to 60 N·m (44 lb·ft). NOTICE: Ensure the correct bolt length is used when the air compressor is installed.
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42 CYLINDER BLOCK Section 42.1 Page DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS .................................................................................... 42-3 42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE .... 42-9 42.3 CLEANING THE CYLINDER BLOCK ...................................................... 42-12 42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK ................
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42-2 All information subject to change without notice.
PAGE 427
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS The cylinder block is the basic engine structure, establishing and maintaining the alignment of all engine working parts. The cylinder block is made from an iron material. High strength and low noise are features of the cylinder block, and is a result of the vertical and horizontal reinforcements and the design of the oil return ducts.
PAGE 428
42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS The cylinder liners are designed as "bottom stop" cylinder liners which means that the cylinder liners are installed with a lower collar in the cylinder block. This design allows for a shorter distance between cylinders and a more compact design for the cylinder block.
PAGE 429
EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Coolant Return for Cylinder Head Coolant Manifold 5. Coolant Connection for EGR Cooler 2. Coolant Feed for Oil Water Heat Exchanger 6. Coolant Transfer Hole to Cylinder Head 3. Coolant Connection for Fuel Heat Exchanger 7. Coolant Return from Cylinder Head 4. Coolant Connection for Air Compressor Figure 42-3 Cylinder Block All information subject to change without notice.
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42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS 1. Oil Holes 8. Holes for Feed Gear Drive 2. Connection for Oil Pressure Sensor 9. Connection for Oil Feed to Axial Power Turbine 3. Connection for Engine Oil Temperature Sensor 10. Oil Feed Connection for Cylinder Block Ventilation 4. Oil Return for Oil Filter Change 11. Oil Feed Connection Turbocharger 5. Oil Return Connection from Oil Water Heat Exchanger 12. Oil Hole 6. Oil Feed Connection to Oil Water Heat Exchanger 13.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Oil Return to Oil Pan Figure 42-5 2. Oil Feed Bore Bottom of Cylinder Block Oil Hole Location All information subject to change without notice.
PAGE 432
42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS 1. Oil Feed Hole for Main Bearing and Connecting Rod Bearing Figure 42-6 42-8 2. Oil Feed Hole for Oil Spray Nozzles Bottom of Cylinder Block Oil Hole Location All information subject to change without notice.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE Before mounting an engine on an overhaul stand, it must be disconnected from the transmission. Details for removing an engine will vary from one application to another. However, the following steps will be necessary, regardless of application: 1. Steam clean the engine. 2. Disconnect the battery cable(s) from the battery(s). 3. Drain the cooling system. Refer to OEM procedures. 4.
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42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE FALLING ENGINE To avoid injury from a falling engine, ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling. 18. Separate the engine from the transmission. 19. Remove the fuel filter module. Refer to section . 20. Remove high pressure pump. Refer to section . 21. Use engine overhaul stand (J–29109) for support when stripping an engine cylinder block. 22.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25. With the engine mounted on the overhaul stand, remove all of any remaining subassemblies and parts from the cylinder block. [a] Remove the rocker cover. Refer to section 1.2. [b] Remove the engine lifter brackets. Refer to section 38.2. [c] Remove the vibration damper. Refer to section 36.1. [d] Remove the flywheel. Refer to section 34.4. [e] Remove flywheel housing. Refer to section 34.2. [f] Remove idler gears. Refer to section 5.2.
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42.3 CLEANING THE CYLINDER BLOCK 42.3 CLEANING THE CYLINDER BLOCK Before removing cylinder liners for block cleaning, the liner bores should be gauged to determine whether liner replacement is necessary. Refer to section 42.3.1. Remove cylinder liners with the cylinder liner removal tool (J–45876) before putting the block in cleaning or de-scaling baths, to avoid trapping cleaning agents in block liner seating bores. Clean the cylinder block as follows: 1.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Be certain that all water passages and oil galleries have been thoroughly cleaned and dried. Install new cup plugs using a coating of good grade non-hardening sealant such as Loctite® 620 or equivalent." 42.3.1 Inspection of the Cylinder Block Perform the following for cylinder block inspection: 1. Remove the cylinder liners and check to determine whether liner replacement is necessary. Refer to section 16.2. 2.
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42.3 CLEANING THE CYLINDER BLOCK 42.3.2 Inspection of Main Bearing Bores Perform the following steps for main bearing bore inspection: 1. Install the main bearing caps in their original positions. Lubricate the cap bolt threads and head contact surfaces with a small quantity of clean engine oil Figure 42-7 Main Bearing Cap Torque Sequence Bolt Length Main Bearing Cap Bolt Table 42-2 DD13 DD15 DD16 175.5 mm (6.909 in.) 200.5 mm (7.894 in.) 200.5 mm (7.894 in.) Main Bearing Cap Bolt Length 2.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.3.3 General Inspection Check all machined surfaces for nicks or burrs that could affect the fit of mating parts. Clean up as necessary by stoning. Also inspect all tapped holes for thread damage and re-tap or install helical thread inserts as necessary. Replace any loose or damaged dowel pins. 42.3.4 Rust Prevention After inspection, if the cylinder block is not to be used immediately, spray the machined surfaces with engine oil.
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42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK 42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK After the cylinder block has been cleaned and inspected, assemble the engine as follows: EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 1.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 4. Install the main bearing caps in their original positions. NOTICE: Always check to make sure cooling nozzles are open and aligned after piston installation. An obstructed, misaligned, bent, or damaged nozzle may not provide proper piston cooling. A loosened nozzle may cause a loss of main gallery oil pressure. In either case, piston overheating or lack of adequate lubrication may result in severe engine damage.
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42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK [h] Install the flywheel. Refer to section 34.6. [i] Install the cylinder head. For DD13, refer to section 14.3. For DD15, refer to section 14.7. [j] Install camshaft housing. Refer to section 3.3. [k] Install the vibration damper. Refer to section 36.2. [l] Install the crankshaft pulley. [m] Install the engine lifter brackets. Refer to section 38.7. [n] Install the rocker cover. Refer to section 1.4.