Professional Documents
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SERVICE MANUAL
MaxxForce® 11 and 13
DIESEL ENGINE
Model Year 2010 and Up
DIESEL ENGINE
MaxxForce® 11 and 13
EGES-465-1
Table of Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Front Cover, Fan Drive, Cooling System and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
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II ENGINE SERVICE MANUAL
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449
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ENGINE SERVICE MANUAL 1
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2 ENGINE SERVICE MANUAL
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ENGINE SERVICE MANUAL 3
Three terms are used to stress your safety and safe • Install all shields, guards, and access covers
operation of the engine: Warning, Caution, and Note before operating engine.
Warning: A warning describes actions necessary to • Do not run engine with unprotected air inlets or
prevent or eliminate conditions, hazards, and unsafe exhaust openings. If unavoidable for service
practices that can cause personal injury or death. reasons, put protective screens over all openings
before servicing engine.
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause • Shut engine off and relieve all pressure in the
damage to the engine or vehicle. system before removing panels, housing covers,
and caps.
Note: A note describes actions necessary for correct,
efficient engine operation. • If an engine is not safe to operate, tag the engine
and ignition key.
Safety Instructions Fire Prevention
Work Area • Make sure charged fire extinguishers are in the
• Keep work area clean, dry, and organized. work area.
• Keep tools and parts off the floor. NOTE: Check the classification of each fire
extinguisher to ensure that the following fire types
• Make sure the work area is ventilated and well lit. can be extinguished.
• Make sure a First Aid Kit is available. 1. Type A — Wood, paper, textiles, and rubbish
Safety Equipment 2. Type B — Flammable liquids
• Use correct lifting devices. 3. Type C — Electrical equipment
• Use safety blocks and stands. Batteries
Protective Measures • Always disconnect the main negative battery
• Wear protective safety glasses and shoes. cable first.
• Wear correct hearing protection. • Always connect the main negative battery cable
last.
• Wear cotton work clothing.
• Avoid leaning over batteries.
• Wear sleeved heat protective gloves.
• Protect your eyes.
• Do not wear rings, watches or other jewelry.
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4 ENGINE SERVICE MANUAL
• Do not expose batteries to open flames or sparks. • Check for frayed power cords before using power
tools.
• Do not smoke in workplace.
Fluids Under Pressure
Compressed Air
• Use extreme caution when working on systems
• Use an OSHA approved blow gun rated at 207
under pressure.
kPa (30 psi).
• Follow approved procedures only.
• Limit shop air pressure to 207 kPa (30 psi).
Fuel
• Wear safety glasses or goggles.
• Do not over fill the fuel tank. Over fill creates a fire
• Wear hearing protection.
hazard.
• Use shielding to protect others in the work area.
• Do not smoke in the work area.
• Do not direct compressed air at body or clothing.
• Do not refuel the tank when the engine is running.
Tools
Removal of Tools, Parts, and Equipment
• Make sure all tools are in good condition.
• Reinstall all safety guards, shields, and covers
• Make sure all standard electrical tools are after servicing the engine.
grounded.
• Make sure all tools, parts, and service equipment
are removed from the engine and vehicle after all
work is done.
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ENGINE SYSTEMS 5
Table of Contents
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Emission Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Accessory Labels and Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Heavy Duty On Board Diagnostics (HD-OBD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Chassis Mounted Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
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6 ENGINE SYSTEMS
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ENGINE SYSTEMS 7
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8 ENGINE SYSTEMS
Engine Specifications
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ENGINE SYSTEMS 9
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10 ENGINE SYSTEMS
Heavy Duty On Board Diagnostics (HD-OBD) The overhead camshaft is supported by seven
bearings in the cylinder head. The camshaft gear
The EPA has added new regulations for 2010 to
is driven from the rear of the engine. The overhead
reduce heavy duty vehicle emissions. The HD-OBD
valve train includes roller rocker arms and dual
system is designed specifically for electronically
valves that open, using a valve bridge. For 2010,
controlled heavy duty engines. The key goal for
the camshaft has been redesigned to incorporate
HD-OBD regulation is to keep engine emissions in
six additional lobes. These new lobes are used
specification for as long as a given vehicle is in use.
with the engine brake housings for operation of the
HD-OBD is legislated to be implemented in three MaxxForce® Engine Brake.
phases:
The MaxxForce® 11 engines use aluminum pistons,
• 2010: First engine for each Original Equipment and the MaxxForce® 13 engines use one piece steel
Manufacture (OEM) becomes fully certified. pistons. All pistons use an offset piston axis and
centered combustion bowls. Crown markings show
• The lead engine is determined by a legislated
correct piston orientation in the crankcase.
equation based on projected sales volume &
useful life of the engine. The one-piece crankcase uses replaceable wet
cylinder liners that are sealed by dual crevice seals.
• For Navistar®, this is the EPA 2010
MaxxForce® 13 engine. The crankshaft has seven main bearings with fore
and aft thrust controlled at the sixth bearing. One
• 2013: One engine in each engine family becomes
fractured cap connecting rod is attached at each
fully certified.
crankshaft journal. The piston pin moves freely inside
• This will be the largest step of the three the connecting rod and piston. Piston pin retaining
phases. rings secure the piston pin in the piston. The rear oil
seal carrier is part of the flywheel housing.
• 2016: All engines must be fully HD-OBD certified.
A gerotor lube oil pump is mounted behind the front
The HD-OBD system continuously monitors for proper
cover and is driven by the crankshaft. Pressurized
engine operation, and will alert the vehicle operator to
oil is supplied to various engine components. All
emission-related faults using the Malfunction Indicator
MaxxForce® 11 and 13 engines also use an engine
Lamp (MIL).
oil cooler and a cartridge-style engine oil filter, which
The MIL is installed in the Electronic Instrument are located in the engine lube oil module.
Cluster. When a detected emissions fault occurs,
The low pressure fuel pump draws fuel from the
the MIL will be illuminated. Diagnostic information is
fuel tank(s) through a chassis mounted filter/water
also stored in the ECM, and may be accessed by the
separator. The low pressure fuel pump provides fuel
technician for diagnosis and repair of the malfunction.
for the engine mounted fuel module. Conditioned low
Diagnostic information is accessed by connecting the
pressure fuel is supplied from the engine mounted
Electronic Service Tool (EST) to the in-cab Diagnostic
fuel module to the high pressure fuel pump, cold start
Connector.
fuel solenoid, and the Downstream Injection (DSI)
unit.
Engine Description The high pressure fuel system is a direct fuel injected
common-rail system. the common-rail includes a high
The MaxxForce® 11 and 13 diesel engines are
pressure fuel pump, two fuel rail supply lines, fuel rail,
designed for increased durability, reliability, and ease
six fuel injectors, and pressure relief valve.
of maintenance.
The fuel injectors are installed in the cylinder head
The cylinder head has four valves per cylinder for
under the valve cover and are electronically actuated
increased airflow. The overhead valve train includes
by the ECM.
rocker arms and valve bridges to operate the four
valves. The fuel injector is centrally located between MaxxForce® 11 and 13 engines use a dual stage,
the four valves, directing fuel over the piston for fixed geometry turbocharger assembly. Each stage
improved performance and reduced emissions. includes a pneumatically operated wastegate, and
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ENGINE SYSTEMS 11
Charge Air Cooler (CAC). The Low Pressure Charge Chassis Mounted Equipment
Air Cooler (LPCAC) is mounted on the lower right
• The chassis mounted fuel filter/water separator
side of the engine, and uses the engine cooling
removes a majority of the water and foreign
system to regulate charge air temperatures. The High
particles that may enter the fuel system from the
Pressure Charge Air Cooler (HPCAC) is mounted in
supply tank(s). This filter works with the engine
front of the engine cooling package. The HPCAC is
mounted fuel module to eliminate foreign matter
an air-to-air type cooler, and requires no connections
and moisture from the fuel before entering the
to the engine’s cooling system.
fuel injection system.
The Exhaust Gas Recirculation (EGR) system
• The Low Temperature Radiator (LTR) regulates
circulates cooled exhaust into the stream in the
the temperature of the LPCAC and the low
air inlet duct. The dual stage EGR cooler provides
temperature stage of the EGR cooler. The LTR is
regulated cooling of the EGR gases before entering
mounted in front of the radiator cooling package,
the air intake duct. This cools the combustion process,
and requires connections to the engine cooling
and reduces Nitrogen Oxides (NOX) emissions.
system.
The open crankcase breather system uses a
• The HPCAC lowers the temperature of the after
centrifugal Crankcase Oil Separator (CCOS) to
the air is compressed by the turbochargers and
return oil mist to the crankcase, and vent the cleaned
has no connections to the engine cooling system.
crankcase gasses to the atmosphere. The CCOS is
The HPCAC is an air-to-air cooler. The HPCAC is
part of the oil module. The breather system has been
mounted in front of the radiator cooling package.
redesigned, and uses no crankcase breather filter
or external piping. Blowby gases enter the CCOS • The Diesel Oxidation Catalyst (DOC) oxidizes
directly through the side of the crankcase. hydrocarbons and carbon monoxide, provides
heat for exhaust system warm-up, aids in
The cold start assist system warms the incoming air
temperature management for the Diesel
supply prior to and during cranking.
Particulate Filter (DPF), and oxidizes NO into
The MaxxForce® Engine Brake by Jacobs® is NO2 for passive DPF regeneration. The DOC
optional for both MaxxForce® 11 and 13 engine is monitored by the ECM using one Diesel
displacements. The engine brake is a compression Oxidation Catalyst Inlet Temperature (DOCIT)
release system that provides additional vehicle sensor positioned at the DOC inlet, and one
braking performance. The operator can control the Diesel Oxidation Catalyst Outlet Temperature
engine brake for different operating conditions. (DOCOT) sensor positioned at the DOC outlet.
• The DPF temporarily stores carbon-based
particulates, oxidizes stored particulates, stores
Optional Equipment
non-combustible ash, and provides required
Optional cold climate features available are an oil pan exhaust back pressure for proper engine
heater and a coolant heater. Both heaters use an performance. The DPF is monitored by the
electric element to warm engine fluids in cold weather. ECM using one Diesel Particulate Filter Outlet
Temperature (DPFOT) sensor located at the
The oil pan heater warms engine oil to ensure
outlet of the DPF, and one Diesel Particulate
optimum oil flow to engine components.
Filter Differential Pressure (DPFDP) sensor
The coolant heater warms the engine coolant located on or near the DPF.
surrounding the cylinders. Warmed engine coolant
increases fuel economy and aids start-up in cold
weather.
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12 ENGINE SYSTEMS
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ENGINE SYSTEMS 13
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14 ENGINE SYSTEMS
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ENGINE SYSTEMS 15
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16 ENGINE SYSTEMS
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ENGINE SYSTEMS 17
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18 ENGINE SYSTEMS
Turbochargers
Figure 8 High and low pressure turbocharger components – inner and outer views
1. HP turbocharger compressor 5. HP turbocharger wastegate 10. LP turbocharger compressor
inlet actuator outlet
2. HP turbocharger turbine inlet 6. LP turbocharger 11. LP turbocharger compressor
3. LP turbocharger wastegate 7. LP turbocharger turbine outlet inlet
actuator 8. Oil supply line 12. HP turbocharger compressor
4. HP turbocharger 9. Oil return line outlet
MaxxForce® 11 and 13 engines are equipped with Exhaust gas flow: The HP turbocharger is
a pneumatically regulated two-stage turbocharging connected directly to the exhaust manifold through
system. The HP and LP turbochargers are installed the HP turbine inlet. Exhaust gases exit the HP
parallel on the right side of the engine. turbine outlet and are directed to the LP turbine inlet.
The HP and LP turbochargers are equipped with
Intake air flow: Filtered air enters the LP compressor,
wastegates, which are controlled by two pneumatic
where it is compressed and directed to the LPCAC.
actuators. Individual wastegates are used to regulate
Cooled LP air then enters the HP compressor, where
boost by controlling the amount of exhaust gases that
it is further compressed and directed into the HPCAC.
bypass the turbine of each turbocharger. When boost
Compressed air then goes through the ETV and the
demand is low, both wastegates are opened, allowing
intake throttle duct. This system provides high charge
part of the exhaust gas flow to bypass the HP and LP
air pressure to improve engine performance and to
turbines.
help reduce emissions.
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ENGINE SYSTEMS 19
Control system signals associated with the HP and LP control port, the EBPV control port, and the TC1TOP
turbochargers have been renamed for 2010. port. Although these components are integral to
the ACV, each circuit is controlled by the ECM. The
All signals related to the LP turbocharger are
ACV controls compressed air for each control valve.
designated as Turbocharger 1 (TC1) signals, and
The air supply port is connected to the vehicle’s air
are identified below:
system.
• Turbocharger 1 Wastegate Control (TC1WC)
The ECM provides a Pulse Width Modulate (PWM)
• Turbocharger 1 Turbine Outlet Pressure signal for operation of both wastegate control valves.
(TC1TOP) With no PWM signal, the control valves are open, and
vehicle air is supplied to the wastegate actuators. The
All signals associated with the HP turbocharger
air supplied will maintain both wastegates in the open
are designated as Turbocharger 2 (TC2), and are
position.
identified below:
When an increase in the charge air pressure is
• Turbocharger 2 Wastegate Control (TC2WC)
required, the ECM supplies PWM voltage to close
• Turbocharger 2 Compressor Inlet Pressure both control valves. Reduced air pressure is routed
(TC2CIP) from the closed air control valves to the wastegate
actuators causing the wastegate to close and vent
air pressure. This results in increased charge air
Air Control Valve (ACV)
pressures. The limit values of the PWM signals are
between approximately 9%, corresponding to a fully
opened air control valve, and 100% corresponding to
a closed air control valve.
The TC1TOP sensor and EBPV control valve are in
the ACV. The EBPV control valve is also operated
by the ECM using PWM, and the TC1TOP sensor
is monitored by the ECM. The EBPV control valve
operates the EPBV actuator.
Boost Control
Wastegate control valves, in the ACV, provide for
operation of a pneumatic wastegate actuator for
each turbocharger. Boost is controlled for each
turbocharger independently, by signals sent from the
ECM to the ACV. In normal operation the wastegates
are actuated by the ACV using vehicle compressed
air, regulated to 296 kPa (43 psi). Positioning of the
wastegates by the ACV is based on boost pressure
and temperature signals monitored by the ECM.
Figure 9 Air Control Valve (ACV) connections
Because of the ability to generate very high charge
1. Electrical connector air pressure levels and to avoid Charge Air Cooler
2. LP turbocharger wastegate control port (CAC) overloading, the wastegate actuator for each
3. Vehicle air supply port turbocharger is also spring loaded. When boost levels
4. EBPV control port increase above specification, boost pressure alone
5. TC1TOP sensor port will open the wastegates, and the exhaust gases will
6. HP turbocharger wastegate control port bypass the turbochargers. Exhaust back pressure is
constantly monitored by the ECM using TC1TOP. The
TC1TOP sensor is part of the ACV, and is connected
The ACV assembly contains the LP turbocharger
to the exhaust system by a steel line.
wastegate control port, HP turbocharger wastegate
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20 ENGINE SYSTEMS
Low Pressure Charge Air Cooler (LPCAC) input to the engine coolant control strategy. It also is
used for evaluation of on-board diagnostics to ensure
The LPCAC is installed between the HP and LP
proper functionality of the charge air cooling system.
turbochargers, and is mounted to the lower right side
of the engine. The LPCAC air inlet is connected to This temperature sensor is a thermistor and has
the low pressure turbocharger compressor outlet, two connections to the ECM. A thermistor varies
and uses engine coolant to regulate the LP charge resistance as temperature changes. When interfaced
air temperature. The LPCAC air outlet is connected to the ECM circuitry, a change in sensor resistance
to the compressor inlet of the HP turbocharger. results in a voltage change internal to the ECM.
A transfer function contained in the ECM software
translates the measured voltage to a temperature
High Pressure Charge Air Cooler (HPCAC) value.
The HPCAC is installed between the HP turbocharger The ECM continuously monitors the voltage resulting
and the intake throttle duct. The HPCAC air inlet from the thermistor’s changing resistance. High and
is connected to the HP compressor outlet, and uses low diagnostic voltage thresholds are evaluated to
ambient airflow entering the front of the vehicle to ensure that the output voltage is within a valid range.
reduce the charge air temperature. The HPCAC air
outlet is connected directly to the intake throttle duct.
Low Pressure Boost Pressure (LPBP) Sensor and
Low Pressure Boost Temperature (LPBT) Sensor
High Pressure Boost Pressure (HPBP) Sensor
This is a combination pressure and temperature
This sensor monitors the pressure of the charge air sensor.
entering the duct. The primary function of the sensor
This sensor is a dual function sensor that detects
is to provide information used to ensure proper boost
pressure and temperature of the charge air entering
control. It is also used as part of EGR control.
the HP compressor. It is installed in the piping
Pressure sensor works by providing an analog voltage between the LP compressor outlet and the HP
output to the ECM which is proportional to pressure compressor inlet. This sensor is used for evaluation
being applied to an internal diaphragm in the sensor. by on-board diagnostics to ensure proper functionality
The sensor is connected to the control module of the charge air cooling system.
through the Reference Voltage (VREF), signal, and
This sensor consists of a thermistor which varies
signal ground wires. A transfer function contained
resistance as temperature changes. When interfaced
in the ECM software converts the analog voltage
to the ECM circuitry, a change in sensor resistance
to a pressure value which is then used by software
results in a voltage change internal to the ECM. An
strategies requiring the pressure information.
internal diaphragm which deflects due to pressure
The ECM continuously monitors the pressure sensor changes results in an analog voltage output to the
output voltage for determination of charge air ECM which is proportional to the pressure. Transfer
pressure. High and low diagnostic voltage thresholds functions contained in the ECM software translate the
are evaluated to ensure that output voltage is within measured voltages into a temperature and a pressure
a valid range. value.
The ECM continuously monitors the voltages resulting
from changes in both the temperature and pressure.
High Pressure Boost Temperature (HPBT) Sensor
High and low diagnostic voltage thresholds are
This sensor monitors the temperature of the charge evaluated to ensure that the output voltage is within
air entering the duct. The temperature measured is an a valid range.
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ENGINE SYSTEMS 21
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22 ENGINE SYSTEMS
EGR System Overview monitors and provides an EGRV position signal to the
ECM.
The EGR system reduces NOX engine emissions by
introducing inert cooled exhaust gas into the air inlet The O2S is installed in the exhaust, in front of the
duct. NOX forms during a reaction between nitrogen aftertreatment fuel injector. The O2S has a heater
and oxygen at high temperatures during combustion. element that heats the sensor to its normal operating
temperature of 780 °C (1436 °F). During initial engine
The ECM monitors signals from the CACOT sensor,
warm-up, the O2S heater element is activated only
Oxygen sensor (O2S), Engine Coolant Temperature
after the engine coolant reaches 40 °C (104 °F) and
1 (ECT1) sensor, EGRT sensor to control the EGR
the exhaust gas temperature DOCIT sensor exceeds
system.
100 °C (212 °F) for more than 30 seconds.
EGR is switched off (EGRV closed) if any of the
following conditions are present: EGRV Control
• Engine coolant temperature less than 10 °C (50
°F) will close the EGR valve
• Intake manifold temperatures less than 7 °C (45
°F) will close the EGR valve
• During engine brake operation
EGR Flow
Exhaust gas from the exhaust manifold flows through
the EGR inlet tubes to the EGRV. When EGR function
is activated, the EGRV opens and allows exhaust gas
to enter the EGR cooler. Cooled exhaust gas flows
from the front of the EGR cooler, through the EGR Figure 11 EGRV position control
outlet tubes, and into the intake throttle duct where it 1. EGR position monitored by ECM
is mixed with filtered air. 2. ECM
3. ECM commands EGR to desired position
EGR System Control 4. EGRV to desired position
The EGR system consists of the EGRV, ETV, and 5. EGRV
O2S. The EGRV contains a PWM controlled valve and 6. EGRV position matches ECM command
Exhaust Gas Recirculation Position (EGRP) sensor. 7. EGR position sent to ECM
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ENGINE SYSTEMS 23
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24 ENGINE SYSTEMS
The AFT system, part of the larger exhaust system, • May cancel regeneration in the event of catalyst
processes engine exhaust to meet emission or sensor failure
requirements. The AFT system traps particulate
• Monitors the level of soot accumulation in the DPF
matter (soot) and prevents it from leaving the tailpipe.
• AFT control system initiates regeneration
The AFT system performs the following functions:
automatically when DPF is full with soot and
• Monitors exhaust gas temperatures DOC in, control engine operating parameters to increase
DOC out, and DPF out temperature and delta temperature to have successful regeneration
pressure across the DPF. It controls engine
• Maintains vehicle and engine performance during
operating parameters for emission control and
regeneration
failure recognition
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ENGINE SYSTEMS 25
Diesel Particulate Filter (DPF) • Provides heat for exhaust system warm-up
The DPF does the following: • Aids in system temperature management for the
DPF
• Captures and temporarily stores carbon-based
particulates in a filter
• Allows for oxidation (regeneration) of stored Aftertreatment (AFT) System Conditions and
particulates once loading gets to a particular level Responses
(restriction)
The operator is alerted of system status either audibly
• Provides the required exhaust back pressure drop or with instrument panel indicators. Automatic or
for engine performance manual regeneration is required when levels of soot
exceed acceptable limits. For additional information,
• Stores non-combustible ash
see the applicable vehicle Operator’s Manual and the
vehicle visor placard.
Diesel Oxidation Catalyst (DOC)
The DOC does the following:
• Oxidizes hydrocarbons and carbon monoxide
(CO) in exhaust stream
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26 ENGINE SYSTEMS
The DSI system injects fuel into the exhaust system the DSI unit), and control operation when downstream
to increase temperature of the exhaust gases, and injection (regeneration) is required. The ECM also
is necessary for DPF regeneration. DSI is controlled controls the Aftertreatment Shutoff Valve (AFTSV)
by the ECM. The ECM receives signals from the (located in the DSI unit) which controls the volume of
Aftertreatment Fuel Doser (AFTFD) sensor (located in fuel sent to the AFI in case of AFTFD malfunction.
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ENGINE SYSTEMS 27
Downstream Injection (DSI) Unit The DSI unit is connected to the clean side of the
low pressure fuel system, and will provide a metered
amount of fuel to the AFI. The DSI unit provides
pressurized fuel injection pulses to the AFI. The AFI
is a mechanical poppet type injector, and will only
inject fuel when fuel line pressure is increased above
a specific pressure. The DSI unit is installed on the
left side of the engine, to the rear of the fuel module.
The AFTFIS and AFTFP2 sensors monitor fuel
pressure and temperature in the DSI system, and
provide constant feedback to the ECM.
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28 ENGINE SYSTEMS
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ENGINE SYSTEMS 29
Crankcase ventilation is provided using the CCOS. CCOS housing. The separated oil mist drains from
Excess crankcase vapors are filtered by the CCOS, the oil separator, through the crankcase, and into the
and are then vented to the atmosphere. oil pan. The oil separator is an integral part of the oil
module.
A centrifugal oil separator, driven by engine oil
pressure, separates and directs oil mist to the side of
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30 ENGINE SYSTEMS
MaxxForce® 11 and 13 engines are equipped with The fuel system is controlled by the ECM, various
a high pressure common rail injection system. sensors, and the Fuel Pressure Metering Unit (FPMU)
The common rail fuel injection system provides located in the HP pump. For additional information,
pressurized fuel to the fuel injectors for optimal fuel refer to LP Fuel System and HP Fuel System in this
atomization in the combustion chamber. section.
All excess fuel is returned to the chassis mounted filter
separator, before returning to the fuel tank.
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ENGINE SYSTEMS 31
Fuel Flow
Fuel is pumped from the tank, through the chassis pump supplies high pressure fuel to the fuel rail, which
mounted fuel filter/water separator using the LP fuel feeds the injectors through individual tubes. The LP
pump. Fuel is pumped from the LP fuel pump to fuel pump and HP fuel pump are assembled as one
the engine mounted fuel filter assembly, before being gear driven unit, and are serviced as an assembly.
supplied to the HP fuel pump. The high pressure fuel
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32 ENGINE SYSTEMS
The LP fuel pump pumps fuel from the tank through Water In Fuel (WIF) sensor and optional fuel heater.
the chassis mounted fuel filter/water separator, fuel Refer to Section 5 “Chassis Filter/Water Separator
strainer element and engine filter element, then to the Maintenance and Inspection” in this manual for more
high pressure fuel system, cold start assist system, information.
and DSI.
Fuel Primer Pump Assembly
In addition to providing high pressure fuel to the
injectors, the fuel system provides filtered low During fuel system priming, fuel is drawn from
pressure fuel to the downstream Injection and cold the tank through the chassis mounted filter/water
start assist systems. separator by the fuel primer pump assembly. The
fuel primer pump assembly has an integrated fuel
Chassis Mounted Filter/Water Separator strainer element that can be cleaned. The fuel primer
pump assembly is manually operated, and is used to
The chassis mounted filter/water separator removes
prime the low pressure fuel system anytime the fuel
debris and water from the fuel before it enters the
system has been emptied. The primer pump provides
fuel primer pump and low pressure fuel pump. The
unrestricted fuel flow to the low pressure pump during
chassis mounted filter/water separator includes a
normal engine operation.
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ENGINE SYSTEMS 33
Low Pressure (LP) Fuel Pump assembly, which measures fuel pressure between the
LP fuel pump and the filter element. The fuel filter
The LP fuel pump and the HP fuel pump are housed as
assembly also has a drain screw that allows water
one assembly. Fuel is drawn through the fuel primer
and dirt to be drained periodically. Because water
pump assembly and into the LP fuel pump. The LP
may accumulate inside the fuel filter assembly, use the
pump supplies fuel to the fuel filter housing assembly
drain screw to drain water per maintenance schedule
at pressures varying between 496 kPa (72 psi) at idle,
in the Engine Operation and Maintenance Manual. An
and 896 kPa (130 psi) at rated speed. The LP fuel
additional function of the fuel filter assembly is fuel
pump is equipped with an internal pressure regulator
system self-deaeration. The air separated from fuel
that relieves the fuel pressure internally if the pressure
is pushed back into the fuel tanks through the return
exceeds 1300 kPa (189 psi).
line. The fuel filter assembly also provides filtered fuel
to the DSI and cold start assist system. An orifice
Fuel Filter Assembly
regulator is integrated into the fuel filter assembly, and
The fuel filter assembly is located on the left side of the regulates the fuel pressure for the cold start assist
engine and has a disposable filter element. An EFP system to 70 kPa (10 psi).
sensor is installed on the front side of the fuel filter
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34 ENGINE SYSTEMS
Pressurization and injection are separate in the in cylinder pressure when combustion begins.
common rail injection system. The optimal injection The second injection is the main injection. This
pressure is generated by the high pressure pump at injection allows high temperatures to be maintained
any engine speed. High pressure fuel quantity from during combustion, but not long enough to allow
high pressure pump is controlled by the FPCV. The generation of large soot amounts. The third injection
injection timing and quantity are calculated in the is done during the power stroke to maximize cylinder
ECM and implemented by solenoid valve controlled temperature and reduce engine soot generation.
injectors. The use of solenoid valve controlled
The high pressure fuel system consists of the
injectors allows three injections per cycle.
high pressure pump with integrated Fuel Pressure
The first injection is used to reduce combustion Metering Unit (FPMU), pressure pipe rail, high
noise and emissions by introducing a small amount pressure fuel lines, injectors, FRP sensor, and
of fuel into the cylinder, preventing a rapid rise pressure relief valve.
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ENGINE SYSTEMS 35
Fuel Rail
The fuel rail is a HP fuel storage unit. The storage
volume of the fuel rail is designed to reduce pressure
pulses caused by the HP pump and injectors, and to
maintain constant fuel pressure even when large fuel
quantities are injected into the cylinders. Connection
between the fuel rail and injectors are made through
two individual injection lines.
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36 ENGINE SYSTEMS
Figure 21 Cold Start Fuel Ignitor (partial cut When the truck operator turns the ignition switch to
away view) ON, the wait-to-start lamp in the instrument cluster
illuminates. Based on the temperature readings from
1. Electrical connection the ECT, the ECM activates the CSR heater element.
2. Insulation The CSR then energizes the CSFI for approximately
3. CSFI fuel line connection 35 seconds.
4. Metering device
5. Vaporizer filter Once the CSFI is heated to approximately 1000 °C
6. Vaporizer tube (1832 °F), the wait-to-start lamp starts to flash and the
7. Heater element operator needs to crank the engine. When the engine
8. Protective sleeve starts rotating, the CSS valve opens and allows fuel to
enter the CSFI. Inside the CSFI, fuel passes through
the vaporizer tube. The vaporized fuel then mixes with
The CSFI has an internal fuel metering device, a in coming air and ignites in contact with the heater
vaporizer filter, a vaporizer tube, a heater element, element.
and a protective sleeve. The protective sleeve has Once the engine starts, the CSFI remains energized
holes that allow enough air to pass through the CSFI and fuel continues to be injected, and the wait-to-start
to enable fuel vaporization and combustion. lamp continues to flash for a maximum of four minutes.
The CSFI is installed on the left front side of the When the wait-to-start lamp stops flashing, the CSFI
engine, in the intake throttle duct. and the CSS valve are deactivated. If the operator
accelerates while the wait-to-start lamp is flashing, the
Cold Start Relay (CSR) cold start assist system will shutdown.
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ENGINE SYSTEMS 37
Unfiltered oil is drawn from the oil pan through the flows around the plates to cool the surrounding oil.
pickup tube and front cover passage by the crankshaft An oil return shutoff valve installed at the exit from
driven gerotor pump. The pressurized oil is moved the oil cooler prevents oil from draining through the
through a vertical crankcase passage and into the oil oil pump and back into the oil pan when the engine is
module. stopped. If oil pressure coming out of the oil pump is
too high, a pressure relief valve allows the excess oil
Inside the oil module, unfiltered oil flows through
to return through the crankcase and into the oil pan
plates in the oil cooler heat exchanger. Engine coolant
before entering the oil cooler.
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38 ENGINE SYSTEMS
Oil that exits the oil cooler flows through a return pump, air compressor, intermediate gears, and
shutoff valve that prevents the oil from draining back turbochargers. The crankshaft has cross-drillings that
into the oil pan. From the return shutoff valve, oil direct oil to the connecting rods.
enters the oil filter element and flows from the outside
Oil sprayer nozzles continuously direct cooled oil to
to the inside of the filter element to remove debris.
the bottom of the piston crowns.
When the filter is restricted, an oil filter bypass valve
opens and allows oil to bypass the filter so engine The turbochargers are lubricated with filtered oil from
lubrication is maintained. If the oil pressure inside an external supply tube that connects the main oil
the oil filter element is too high, an oil pressure relief gallery from the crankcase to the center housing of
valve, located at the bottom of the oil filter element each turbocharger. Oil drains back to the oil pan
housing, allows the excess oil to return to the oil pan. through the low and high pressure turbocharger oil
return pipes connected to the crankcase.
After passing through the oil filter element, oil flow is
directed to the cylinder head and crankcase. A service oil drain valve, located at the bottom of the
filter element cavity, opens automatically when the
Clean oil enters the cylinder head through an external
filter element is lifted for replacement, and allows the
flange elbow connected directly to the oil module.
oil from the oil filter element cavity to drain into the oil
Inside the cylinder head, oil flows through passages to
pan.
lubricate the camshaft bearings, rocker arms, exhaust
valve bridges, and cylinder intermediate gear. Oil is also supplied to the MaxxForce® Engine
Brake housings (under valve cover) through specially
Clean oil enters the crankcase directly from the oil
designed rocker mounting bolts.
module to lubricate the crankshaft, high pressure
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ENGINE SYSTEMS 39
Figure 23 Oil module w/crankcase oil separator assembly (inner and outer views)
1. CCOS 7. Oil return from cylinder head 13. CCOS oil return
2. CCOS vent outlet 8. Oil supply to cylinder head 14. Oil module pressure relief port
3. CCOSS sensor 9. Crankcase gas inlet 15. Oil out to crankcase
4. Filter cover 10. Oil cooler inlet 16. Oil cooler outlet to crankcase
5. Oil filter assembly 11. Oil supply from oil pump 17. EOP sensor
6. EOT sensor 12. Regulator
The oil module contains a canister style filter, oil directs crankcase emissions to the CCOS. The oil
cooler, EOP and EOT sensors, a pressure relief that separates from the crankcase emissions, before
valve, an oil filter bypass valve, and an oil return it reaches the CCOS, is drained back into the oil pan
shutoff valve. The oil module also collects, and then through the oil return port.
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40 ENGINE SYSTEMS
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ENGINE SYSTEMS 41
The water pump is installed on the water distribution Coolant flow to the radiator is controlled by two
housing and draws coolant from the radiator through thermostats. When the thermostats are closed,
the coolant inlet. coolant flowing out of the EGR cooler is directed
through a bypass port inside the front cover into the
MaxxForce® 11 and 13 engines have no coolant
water pump. When the thermostats are open the
passages between the crankcase and cylinder head
bypass port is blocked, and coolant is directed from
through the cylinder head gasket. This eliminates
the engine into the radiator.
the possibility of coolant leaks at the cylinder head
gasket. Coolant in and out of the crankcase and Coolant passes through the radiator and is cooled
cylinder head is directed through external passages. by air flowing through the radiator from ram air and
Coolant flows through the crankcase and cylinder operation of the coolant fan. The coolant returns to
head from front to rear. This coolant flows around the the engine first through the transmission cooler, then
cylinder liners and combustion chambers to absorb through the engine coolant inlet elbow.
heat from combustion.
The air compressor is cooled with coolant supplied by
Coolant exiting the crankcase and cylinder head at a hose from the left side of the crankcase. Coolant
the rear of the engine is directed through an external passes through the air compressor cylinder head and
coolant pipe to the high temperature stage of the returns through a coolant return line to the engine
EGR cooler. Coolant passes between the EGR crankcase.
cooler plates, travels parallel to the exhaust flow,
The oil module receives coolant from a passage in
travels through a transfer passage in the left side of
the crankcase. Coolant passes between the oil cooler
the low temperature EGR cooler, into the EGR cooler
plates and returns back to the water pump suction
return manifold and into the thermostat housing. A
passage.
deaeration port on the top of the high temperature
EGR cooler directs coolant and trapped air to the
coolant surge tank.
Thermostat Operation
Coolant from the water pump also flows through the
MaxxForce® 11 and 13 engines are fitted with
low temperature EGR Cooler and then through the
two thermostats in a common housing to ensure
LPCAC to regulate the charge air temperature. Flow
sufficient coolant flow in all operating conditions. The
through the low temperature EGR cooler/charge air
thermostat housing is installed on top of the water
cooler is controlled by the Coolant Mixer Valve (CMV)
distribution housing.
and Coolant Flow Valve (CFV). Depending on the
coolant flow, CMV sends coolant through the low The thermostat housing assembly has two outlets.
temperature EGR Cooler, or bypass indirectly to the One directs coolant to the radiator when the engine is
LPCAC, after going through the LTR located in front at operating temperature. The second outlet directs
of the main coolant radiator. When the charge air coolant to the water pump until the engine reaches
temperature is too low, CMV bypasses the LTR and operating temperature. The thermostats begin to
directs all the coolant through the CAC. When the open at 83 °C (181 °F) and are fully open at 91 °C
charge air temperature increases, CMV directs a (196 °F).
percentage of the coolant to the LTR before it enters
When engine coolant is below 83 °C (181 °F), the
the CAC to cool the charge air. If the engine coolant
thermostats are closed, blocking coolant flow to the
temperature is too high, CMV sends all of the coolant
radiator.
flow through the LTR and through the LPCAC to help
cool the engine faster. When coolant temperature reaches the opening
temperature of 83 °C (181 °F), the thermostats
Both CMV and CFV are controlled by the ECM based
open allowing some coolant to flow to the radiator.
on signals from the Engine Coolant Temperature
When coolant temperature exceeds 91 °C (196 °F),
(ECT) sensor, ECT2 sensor, and the Intake Manifold
the lower seat blocks the bypass port directing full
Pressure (IMP)/Air Inlet Temperature 2 (MAP/AIT2)
coolant flow to the radiator.
sensors.
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42 ENGINE SYSTEMS
Coolant Control Valve (CCV) operation LPCAC. The CFV will close to reduce the coolant flow
through the LPCAC when the engine is operating at
The CCV is installed on the upper right side of the
high speeds.
water distribution housing and controls the coolant
flow to the CACs.
Coolant Mixer Valve (CMV)
The CCV has two separate solenoid actuated valves
The CMV is installed on the upper side of CCV and
based on the charged air temperature and the two
controls the coolant flow through the LTR. When the
engine coolant temperature sensors; CMV, and CFV.
temperature of the charge air and coolant coming out
The CMV and the CFV are part of the CCV assembly
of the LPCAC is low, the CMV directs the coolant
and cannot be serviced separately. The CMV and
through a LTR bypass directly into the LPCAC.
CFV solenoids are controlled by two separate PWM
This helps the engine reach its normal operating
signals from the ECM. The PWM signal duty cycles
temperature faster. If the temperature of the charge
vary between 0% and 100% depending on the coolant
air and coolant coming out of the LPCAC is high, the
and charge air temperature.
CMV directs the coolant flow through the LTR. This
prevents overheating of the LPCAC, which can result
Coolant Flow Valve (CFV)
in LPCAC failure.
The CFV is installed on the lower side of CCV and
controls the amount of coolant flow through the
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ENGINE SYSTEMS 43
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44 ENGINE SYSTEMS
The MaxxForce® Engine Brake by Jacobs® braking 2. Activation of the engine brake is
system is standard equipment on the PROSTAR® communicated by the ECM using the
and optional equipment on the TRANSTAR® and J1939 data link. When activated, the
WORKSTAR® for the MaxxForce® 11 and 13 energized solenoid valve permits engine lube
engines. The braking system is a hydro-mechanical oil to flow under pressure through the control
device that mounts under the engine’s valve cover. valve to both the master piston and slave
It turns your power-producing diesel engine into a piston circuits.
power-absorbing air compressor.
3. Oil pressure causes the master piston roller
Here’s how: when the driver releases the accelerator assembly to move down, picking up the
pedal, the forward momentum of the truck continues motion of the cam (dedicated braking lobe)
to turn the drivetrain and engine. The pistons continue pushing the piston back into the housing
to move up and down. Once activated, the engine creating high pressure oil.
brake opens the exhaust valves near the peak of the
4. The high pressure oil flows back through the
compression stroke, releasing the highly compressed
master piston, slave piston and control valve
air through the exhaust systems. Little energy is
circuits.
returned to the piston, and as the cycle repeats, the
energy of the truck’s forward motion is now directed 5. The check ball in the control valve seats,
toward motoring the diesel engine, thus reducing the trapping oil in the circuit creating a high
forward motion causing the truck to slow down. pressure link between the slave piston and
master piston.
Engine Brake System Operation 6. Once the high pressure link is created, the
master piston follows the cam profile causing
The engine brake system consists of two hydraulic
the slave piston to move down, momentarily
braking housings, activated using two ECM actuated
opening exhaust valve (single valve opening),
brake solenoids, and an exhaust bridge (pin). The
while the engine piston is near its top
engine brake depends on engine oil for operation;
dead center position, releasing compressed
minimum oil temperature for engine brake activation
cylinder air to the exhaust manifold.
is 40 °C (104 °F).
7. Compressed air escapes to atmosphere
The operation of the engine brake is fully automatic
completing compression braking cycle.
once it is turned on by an ON/OFF switch by the
operator. When the clutch is fully engaged and you NOTE:
remove your foot completely from the throttle, the
1. The MaxxForce® Engine Brake by Jacobs®
engine brake is automatically activated.
will disengage during Anti-lock Brake System
NOTE: The operator can select various retarding (ABS) braking.
levels by pressing a HIGH/MEDIUM/LOW switch
2. Will interact with the vehicle cruise control for
depending on the retarding performance required.
smooth operation during engine braking
Activation occurs through the following steps:
3. Will interact with the UltraShift™
1. Engine oil pressure fills the housing passages Transmission for smooth up-shifts under
up to the solenoid. fueling conditions
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ENGINE SYSTEMS 45
Electronic Control System and command the necessary outputs for correct
performance of the engine.
Electronic Control System Components
MaxxForce® 11 and 13 engines are equipped with
one control module; the Engine Control Module Diagnostic Trouble Codes
(ECM).
Diagnostic Trouble Codes (DTCs) are stored by
the ECM if inputs or conditions do not comply with
expected values. Diagnostic codes for the 2010
Operation and Function
MY are communicated using the Suspect Parameter
The ECM monitors and controls engine operation Number (SPN) and Failure Mode Indicator (FMI)
to ensure maximum performance and adherence identifiers, and are accessed using an electronic
to emissions standards. The ECM, performs the service tool with ServiceMaxx® diagnostic software
following functions: or a generic scan tool as well.
• Provide reference voltage (VREF)
• Condition input signals Microprocessor Memory
• Process and store control strategies The ECM microprocessor includes Read Only
Memory (ROM) and Random Access Memory (RAM).
• Control actuators
ROM
Reference Voltage (VREF) ROM stores permanent information for calibration
tables and operating strategies. Permanently stored
The ECM supplies 5 volt VREF signals to various
information cannot be changed or lost when the
input sensors in the electronic control system. By
ignition switch is turned to OFF or when power to
comparing the 5 volt VREF signal sent to the sensors
the control modules is interrupted. ROM includes the
with their respective returned signals, the ECM
following:
determines pressures, positions, and other variables
important to engine and vehicle functions. • Vehicle configuration, modes of operation, and
options
• Engine Family Rating Code (EFRC)
Signal Conditioner
• Engine warning and protection modes
Signal conditioning circuitry in the ECM converts
analog signals to digital signals, squares up sine
RAM
wave signals, and amplifies low intensity signals.
RAM stores temporary information for current engine
conditions. Temporary information in RAM is lost
Microprocessor when the ignition switch is turned to OFF or power
to control module is interrupted. RAM information
The microprocessor, located inside the ECM,
includes the following:
processes stored operating instructions (control
strategies) and value tables (calibration parameters). • Engine temperature
The microprocessor compares stored instructions
• Engine rpm
and values with conditioned input values to determine
the correct strategy for all engine operations. • Accelerator pedal position
Diagnostic strategies are also programmed into the
ECM. Some strategies monitor inputs continuously
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46 ENGINE SYSTEMS
Actuators
The ECM controls engine operation with the following: Exhaust Gas Recirculation (EGR) Valve
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ENGINE SYSTEMS 47
The CSR delivers battery voltage (VBAT) to the Aftertreatment Fuel Doser (AFTFD)
heater element for a set time, depending on engine
The AFTFD is used to provide HP fuel flow to the
coolant temperature and altitude. The ground circuit
aftertreatment fuel injector. The AFTFD is controlled
is supplied directly from the battery ground at all
through an PWM signal sent by the ECM. The AFTFD
times. The relay is controlled by switching on a
is housed in the DSI unit, which is located to the rear
voltage source from the ECM, and is installed to the
of the fuel filter assembly.
rear of the ECM.
The CSS valve controls fuel flow to the CSFI during The AFTSV is used to prevent fuel flow to the
cold start assist operation. aftertreatment fuel injector (AFI), and prevents all
uncontrolled fuel delivery for the aftertreatment
When cold start assist is required, the ECM provides system during a AFTFD valve malfunction. The
voltage to open the CSS valve during cranking. AFTSV is controlled through an on-off signal sent by
The CSS valve is mounted on the intake throttle duct, the ECM. The AFTSV is housed in the DSI unit, which
on the top left side of the engine. is located to the rear of the fuel filter assembly.
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© 2011 Navistar, Inc. All rights reserved
48 ENGINE SYSTEMS
A thermistor sensor has two electrical connectors, Engine Coolant Temperature (ECT) Sensors
signal return and ground. The output of a thermistor
The ECT1 and ECT2 sensors are thermistor-type
sensor is a non-linear analog signal.
sensors that detect engine coolant temperature.
Thermistor type sensors include the following:
The ECT1 signal is monitored by the ECM for
• Aftertreatment temperature sensors operation of the instrument panel temperature
gauge, coolant temperature compensation, charge
• Engine Coolant Temp sensors
air temperature control, EGR system control, optional
• EOT sensor Engine Warning Protection System (EWPS), and the
wait to start lamp. The ECM uses ECT1 sensor input
• TC2CIS
as a backup, if EOT sensor values are out of range.
• CACOT sensor
The ECT1 sensor is installed in the underside of
• IMT sensor the EGR coolant crossover manifold, at the back of
the engine. The ECT2 sensor is installed in the low
• EGRT
temperature stage of the EGR cooler, on the right
• Ambient Air Temperature (AAT) sensor side of the engine.
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ENGINE SYSTEMS 49
The IMT sensor is installed in the intake side of the Variable capacitance sensors include the following:
cylinder head, on the left side of the engine.
• DPFDP sensor
Exhaust Gas Recirculation Temperature (EGRT) • EFP sensor
Sensor
• EOP sensor
The EGRT sensor is a thermistor sensor that detects
• FRP sensor
the exhaust gas temperature entering the EGR cooler.
• IMP sensor
The EGRT signal is monitored by the ECM.
• AFTFI sensor
The EGRT sensor is installed in the front of the low
temp EGR cooler on the left side. • AFTFP2 sensor
• TC1TOP
Ambient Air Temperature (AAT) Sensor
The AAT sensor is a thermistor sensor that detects the DPF Differential Pressure (DPFDP) Sensor
temperature of ambient.
The DPFDP sensor provides a feedback signal to the
The AAT signal is monitored by the ECM. ECM indicating the pressure difference between the
inlet and outlet of the particulate filter.
The AAT sensor is installed in various places on the
vehicle. The DPFDP sensor is a differential pressure sensor
with two tap-offs installed at the DPF. A tap-off is
located before and after the DPF.
Variable Capacitance Sensors
Engine Fuel Pressure (EFP) Sensor
The EFP sensor is a variable capacitance sensor that
measures fuel supply pressure.
The EFP sensor provides feedback to the ECM for the
LP fuel system.
The EFP sensor is installed in the front of the fuel filter
assembly on the left side of the engine.
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50 ENGINE SYSTEMS
The sensor measures back pressure in the exhaust The CKP sensor is a magnetic pickup sensor that
system. A tap for the TC1TOP is located in the indicates crankshaft speed and position.
exhaust, between the LP turbocharger and EBPV. The CKP sensor sends a pulsed signal to the Engine
The TC1TOP sensor is located in the Air Control Control Module (ECM) as the crankshaft turns.
Valve, on the right side of the engine. The CKP sensor reacts to holes drilled into the
flywheel adjacent to the ring gear. For crankshaft
position reference, teeth 59 and 60 are missing. By
comparing the CKP signal with the CMP signal, the
ECM calculates engine rpm and timing requirements.
The CKP sensor is installed in the top left of the
flywheel housing.
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ENGINE SYSTEMS 51
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52 ENGINE SYSTEMS
Additional Sensors
Oxygen Sensor (O2S)
The O2S monitors oxygen levels in the exhaust.
Figure 30 Switch example
The O2S is used to control the EGR flow to a
specified air-to-fuel ratio by monitoring the level of
Switch sensors indicate position, level, or status. unused oxygen in the exhaust stream.
They operate open or closed, regulating the flow of The O2S compares oxygen levels in the exhaust
current. A switch sensor can be a voltage input switch stream with oxygen levels in the outside air. The
or a grounding switch. A voltage input switch supplies sensor generates an analog voltage and is monitored
the control module with a voltage when it is closed. by the ECM. The level of voltage generated by the
A grounding switch grounds the circuit when closed, O2S directly corresponds to the oxygen levels in the
causing a zero voltage signal. Grounding switches exhaust stream.
are usually installed in series with a current limiting
resistor. The O2S is installed in the turbocharger exhaust pipe,
directly after the EBPV.
Switches include the following:
• Driveline Disengagement Switch (DDS)
Humidity Sensor (HS)
• Engine Coolant Level (ECL)
The HS measures the moisture content of filtered air
• Oil Level Sensor (OLS) entering the intake system.
Driveline Disengagement Switch (DDS) Using the HS, the ECM will adjust in order to prevent
condensation of airborne water particles (moisture).
The DDS determines if a vehicle is in gear. For The HS also houses the AIT sensor, which is used
manual transmissions, the clutch switch serves as by the ECM for calculating fuel delivery.
the DDS. For automatic transmissions, the neutral
indicator switch functions as the DDS. The DDS signal
is sent to the Body Controller (BC) and transmitted on
the J1939 datalink to the engine ECM.
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MOUNTING ENGINE ON STAND 53
Table of Contents
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Follow all warnings, cautions, and notes.
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54 MOUNTING ENGINE ON STAND
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MOUNTING ENGINE ON STAND 55
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56 MOUNTING ENGINE ON STAND
8. Remove open breather tube assembly. See 10. Remove four M14 x 50 bolts and engine front
“TURBOCHARGERS” for procedure. mount support (right).
9. Remove Low-Pressure Charge Air Cooler 11. Remove starter motor assembly.
(LPCAC). See “TURBOCHARGERS” for
procedure.
WARNING: To prevent personal injury or
death, use a chain hoist rated for the weight of
the engine, follow manufacturer’s installation and
safety instructions, and attach safety latch lifting
hooks to lifting eyes on the engine.
12. Attach hoist hook lifting bracket to engine lifting
eyes. Use safety catches on hoist hooks when
lifting engine.
NOTE: For reinstallation of engine front mount Figure 33 Engine Stand Adapter Plate
support, tighten M14 x 50 bolts to special torque (mounting bracket)
(page 58).
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58 MOUNTING ENGINE ON STAND
Special Torque
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ENGINE ELECTRICAL 59
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Mass Air Flow (MAF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Humidity / Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Rail Fuel Pressure (RFP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .78
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80
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60 ENGINE ELECTRICAL
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Turbocharger 2 Compressor Inlet Sensor (TC2CIS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Exhaust Gas Recirculation Temperature (EGRT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Air Control Valve (ACV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Coolant Control Valve (CCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Rail Fuel Pressure (RFP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Humidity / Air Inlet Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Mass Air Flow (MAF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
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ENGINE ELECTRICAL 61
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62 ENGINE ELECTRICAL
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ENGINE ELECTRICAL 63
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64 ENGINE ELECTRICAL
The ECT1 and ECT2 sensors are thermistor sensors Engine Oil Pressure (EOP) Sensor
that detect engine coolant temperature.
The ECT1 and ECT2 signals are monitored
by the ECM for operation of the instrument
panel temperature gauge, coolant temperature
compensation, charge air temperature control,
Exhaust Gas Recirculation (EGR) system control,
optional Engine Warning Protection System (EWPS)
and the wait to start lamp. The ECM uses ECT1
sensor input as a backup, if Engine Oil Temperature
(EOT) sensor values are out of range.
The ECT1 sensor is installed in the underside of
the EGR coolant crossover manifold at the back
of the engine. The ECT2 sensor is installed in the
low-temperature stage of the EGR cooler on the right
side of the engine.
Figure 41 EOP sensor
Engine Oil Temperature (EOT) Sensor
The EOP sensor is a variable resistance sensor
that detects engine oil pressure. The EOP signal is
monitored by the ECM for operation of the instrument
panel pressure gauge and optional EWPS. The EOP
sensor is installed in the oil module, on the right side
of the engine.
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ENGINE ELECTRICAL 65
oil separator, located on the oil centrifuge on the oil The FPCV is a variable-position actuator that controls
module assembly. the flow of fuel to the suction side of the high-pressure
fuel pump.
The FPCV changes valve position through
Fuel Delivery Pressure (FDP) Sensor
pulse-width modulated signals from the ECM.
The FPCV is mounted on the upper side of
the high-pressure fuel pump. The FPCV and
high-pressure fuel pump are serviced as an assembly.
Figure 44 FPCV
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66 ENGINE ELECTRICAL
Humidity / Air Inlet Temperature (IAT) Sensor The CACOT sensor is a thermistor sensor that
monitors the temperature of charge air entering the
intake air duct.
The CACOT signal is monitored by the ECM for
control of the EGR system.
The CACOT sensor is installed on the air intake
throttle duct, before the Engine Throttle Valve (ETV).
Figure 46 IAT
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ENGINE ELECTRICAL 67
Rail Fuel Pressure (RFP) Sensor The IMT sensor is a thermistor sensor that monitors
the temperature of the mixture of recirculated exhaust
gas and fresh intake air.
EGR system operation is shut down under certain
temperature conditions, to prevent acids from
condensing under cold charge-air temperatures
and to protect the engine from excessively hot intake
air in the event of an EGR fault.
The IMT sensor is installed in the intake channel of the
cylinder head, on the left side of the engine.
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68 ENGINE ELECTRICAL
The ETV controls the flow of filtered air (boosted The Coolant Mixer Valve (CMV) and Coolant Flow
and cooled) into the engine’s air intake through the Valve (CFV) are a combined solenoid assembly that
Charge Air Cooler (CAC) to help heat the exhaust regulates coolant flow and temperature through the
aftertreatment during regeneration, and to assist Low-Pressure Charge Air Cooler (LPCAC) and the
when heavy EGR is requested. The electronic portion low temperature EGR cooler. The CMV and CFV are
of the ETV contains a microprocessor that monitors housed in the CCV assembly.
valve position, electronic chamber temperature,
controls the electric motor and reports diagnostic The CFV controls the rate of coolant flow through the
faults to the ECM. The ETV changes position in CAC and the CMV regulates the temperature of the
response to ECM signals. coolant by directing the coolant either through the low
temperature radiator or through an internal bypass.
The ETV is integrated into the air intake throttle duct Both valves are controlled by the ECM.
at the front top left side of the engine.
The CCV is mounted on the right side of the water
distribution housing.
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ENGINE ELECTRICAL 69
Air Control Valve (ACV) Assembly The EGR valve regulates the flow of exhaust gases
through the EGR system. The desired valve position
is controlled by commands from the ECM.
The EGR valve is mounted on the rear of the EGR
cooler on top of the engine.
Figure 54 ACV
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70 ENGINE ELECTRICAL
Turbocharger 2 Compressor Inlet Sensor The TC2CIS sensor includes a thermistor sensor
(TC2CIS) that monitors the temperature of charge air entering
the high-pressure turbocharger. This sensor also
monitors boost pressure for the low-pressure
turbocharger.
The TC2CIS sensor is monitored by the ECM, and
is used to check for proper thermostat operation and
charge air cooling.
The TC2CIS is installed in the piping between
the low-pressure compressor outlet and the
high-pressure compressor inlet.
Figure 57 TC2CIS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 71
WARNING: To prevent personal injury or 2. Press release lever and disconnect harness
death, do not let engine fluids stay on your skin. connector from CKP sensor installed in top left of
Clean skin and nails using hand cleaner and wash flywheel housing.
with soap and water. Wash or discard clothing 3. Remove M6 x 16 bolt from CKP sensor.
and rags contaminated with engine fluids.
4. Remove CKP sensor and discard O-ring.
CAUTION: To prevent engine damage, do not tug on
wiring harnesses; if resistance is felt, find the problem
and free connectors or clips.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
72 ENGINE ELECTRICAL
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 73
Engine Coolant Temperature 2 (ECT2) Sensor Engine Oil Temperature (EOT) Sensor
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
74 ENGINE ELECTRICAL
Engine Oil Pressure (EOP) Sensor Crankcase Oil Separator Speed (CCOSS) Sensor
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 75
Fuel Delivery Pressure (FDP) Sensor 1. Pull out yellow locking tab on FPCV harness
connector.
2. Press release tab and disconnect harness
connector from FPCV mounted at upper rear
of high-pressure fuel pump.
3. See (High-pressure Fuel Pump (HPFP) and Drive
Housing, page 210) for removal of high-pressure
pump with integral FPCV if the FPCV requires
replacement.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
76 ENGINE ELECTRICAL
Humidity / Intake Air Temperature (IAT) Sensor Charger Air Cooler Outlet Temperature (CACOT)
Sensor
Figure 68 IAT
Figure 69 CACOT sensor
1. M6 x 16 bolt (2)
2. Harness connector 1. CACOT sensor
3. IAT 2. Harness connector
3. Standoff tie strap
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 77
Intake Manifold Pressure (IMP) Sensor Rail Fuel Pressure (RFP) Sensor
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
78 ENGINE ELECTRICAL
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 79
Figure 75 CCV
Figure 74 ETV 1. Coolant Mixer Valve (CMV) terminal
2. Coolant Flow Valve (CFV) terminal
1. ETV harness connector
2. ETV
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
80 ENGINE ELECTRICAL
1. Press release tab and disconnect harness 1. Press release tab to disconnect wiring harness
connector from ACV mounted on EGR cooler lead from EGR valve connector.
assembly high-temperature housing at top right
2. Remove dual flap EGR valve. See (EGR Dual
of engine.
Flap Valve, page 261) in “EXHAUST GAS
2. Remove ACV. See (Air Control Valve , page 140) RECIRCULATION (EGR) SYSTEM” for removal
in ”EXHAUST BACK PRESSURE CONTROL” procedure.
section for removal procedure.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 81
Figure 79 TC2CIS
1. M6 x 16 bolt (2)
2. TC2CIS
Figure 78 EGRT sensor harness connector 1. Pull out yellow lock tab on TC2CIS harness
1. EGR module cover connector.
2. EGRT sensor 2. Press release tab and disconnect harness lead
from TC2CIS.
1. Pull out red locking tab on EGRT sensor 3. Remove two M6 x 16 bolts and sensor from
connector. high-pressure turbocharger air supply duct.
Discard O-ring seal.
2. Press release tab to disconnect harness
connector from EGRT sensor.
NOTE: The EGRT has a non-serviceable crush Wiring Harness ECM Connections
washer for sealing. If sensor is removed, the complete
sensor must be replaced. WARNING: To prevent personal injury
3. Only if required, remove EGRT sensor from EGR or death, remove ground cable from negative
module cover and discard. terminal of main battery before disconnecting
or connecting electrical components. Always
connect ground cable last.
CAUTION: To prevent engine damage, do not tug on
wiring harnesses; if resistance is felt, find the problem
and free connectors or clips.
1. If not done, disconnect ground (–) cable from the
negative terminal of the battery.
2. Note location of wire ties for reinstallation. Cut
wire ties securing engine injector, engine sensor
and chassis harness connector lock levers at
ECM.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
82 ENGINE ELECTRICAL
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 83
EGES-465-1
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Follow all warnings, cautions, and notes.
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84 ENGINE ELECTRICAL
1. Disconnect harness connectors at IAT, MAF, 4. Remove two M8 x 16 bolts attaching harness clip
TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and to EGR module cover.
EOT terminals.
5. At left front, disconnect harness connectors at
2. Starting on right side at front, cut tie straps EGRT, CACOT, IMP, RFP, FDP and EOL sensors.
securing sensor harness at ACV, CCV and to air
supply tube.
3. Remove M8 x 12 bolt attaching harness clip to
EGR cooler low-temperature housing.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 85
Figure 84 Sensor harness attachment points at left front (air intake throttle duct removed for clarity)
1. Tie strap (3) 2. M6 x 16 bolt 3. Other attachments
6. Cut tie straps securing sensor harness to back of 8. Remove other attachments as necessary.
air intake throttle duct and at back and bottom of
9. At left rear, disconnect harness connectors at
ECM support.
CMP, CKP, ECT1 sensors and EGR valve.
7. Remove M6 x 16 bolt attaching harness clip to
coolant outlet manifold.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
86 ENGINE ELECTRICAL
10. At left side and rear of engine, cut tie straps 13. Remove sensor harness from engine using care
securing sensor harness to harness support and to avoid damage to harness as it is removed from
coolant manifold. around components.
11. Disconnect harness from M8 stud at coolant 14. Remove 21-way connector from harness bracket.
manifold.
12. At left center of engine, remove two M8 x 16 bolts
attaching harness bracket to crankcase.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 87
1. Remove eight M6 x 30 bolts and remove ECM 2. Remove CSR from ECM support. See (Relay
from support. Assembly, page 110) in “COLD START ASSIST”
section to remove CSR.
3. Remove CSS from ECM support. See (Fuel
Supply Solenoid Hose, page 111) in “COLD
START ASSIST” section to remove CSS.
4. Remove three M8 x 40 bolts, six EDC bracket
insulators (three on each side of support) and
ECM support from cylinder head.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
88 ENGINE ELECTRICAL
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 89
Installation
Engine Control Module (ECM) and Support
CAUTION: To prevent engine damage, do not tug on
wiring harnesses; if resistance is felt, find the problem
and free connectors or clips.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
90 ENGINE ELECTRICAL
2. Install two M8 x 16 bolts to attach harness 5. Attach 21-way connector to harness bracket.
bracket to crankcase. Tighten bolts to special
6. At left rear, connect harness connectors at CMP,
torque (page 106).
CKP, ECT1 sensors and EGR valve.
3. Attach harness clip to M8 stud at coolant manifold.
4. Install three tie straps to secure sensor harness to
harness support and coolant manifold.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 91
Figure 92 Sensor harness attachment points at left front (air intake throttle duct removed for clarity)
1. Tie strap (3) 2. M6 x 16 bolt 3. Other attachments
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
92 ENGINE ELECTRICAL
11. Install two M8 x 16 bolts to attach harness clip 13. Install tie straps to secure sensor harness at ACV,
to EGR module cover. Tighten bolts to special EGR cooler, CCV and to air supply tube.
torque (page 106).
14. Connect harness connectors at IAT, MAF,
12. Install M8 x 12 bolt to attach harness clip to EGR TC2CIS, EOP, ACV, ECT2, CCOSS, CCV and
cooler low-temperature housing. Tighten bolt to EOT terminals.
standard torque (page 471).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 93
Engine Injector (Wiring) Harness 1. Check that 32.92 x 3.53 O-ring is in position on
collar of harness mounting flange and in good
condition. Replace as necessary.
2. Carefully route injector harness through valve
cover base opening and along valve cover base
to injectors.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
94 ENGINE ELECTRICAL
3. Install four M6 x 16 bolts to attach injector harness 5. Install tie straps at six locations to secure injector
mounting flange to valve cover base. Tighten harness to valve cover base.
bolts to standard torque (page 471).
6. Install 12 harness nuts to connect harness leads
4. Install tie strap to secure injector at center of to injector terminals.
cylinder head.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 95
EGES-465-1
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Follow all warnings, cautions, and notes.
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96 ENGINE ELECTRICAL
Figure 99 TC2CIS
1. M6 x 16 bolt (2)
2. TC2CIS
EGES-465-1
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ENGINE ELECTRICAL 97
EGES-465-1
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98 ENGINE ELECTRICAL
3. Engage release tab and secure CMV and CFV 4. See (Intake Manifold Pressure (IMP) Sensor,
terminals to wiring harness. page 100) and (Charger Air Cooler Outlet
Temperature (CACOT) Sensor, page 100) for
installation of ETV-mounted sensors.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 99
EGES-465-1
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Follow all warnings, cautions, and notes.
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100 ENGINE ELECTRICAL
1. Remove Disposable Air and Fuel Cap from fuel Charger Air Cooler Outlet Temperature (CACOT)
rail port and install RFP sensor. Sensor
2. Tighten sensor to special torque (page 106).
3. Connect harness to RFP sensor terminal by
pushing in on connector until a click is heard.
4. Push in yellow tab to lock sensor connector.
EGES-465-1
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Follow all warnings, cautions, and notes.
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ENGINE ELECTRICAL 101
Humidity / Air Inlet Temperature (IAT) Sensor Mass Air Flow (MAF) Sensor
1. Insert new O-ring and place IAT in position on air 1. Install new 2.62 x 26.64 ID O-ring and place MAF
inlet duct. sensor in position on air inlet duct.
2. Install two M6 x 16 bolts. Tighten bolts to special 2. Install two M4 x 0.7 cap screws. Tighten cap
torque (page 106). screws to special torque (page 106).
3. Connect harness to IAT terminal by pushing in on 3. Connect harness to MAF sensor terminal by
connector until a click is heard. pushing in on connector until a click is heard.
4. Push in yellow tab to lock sensor connector. 4. Push in yellow tab to lock sensor connector.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
102 ENGINE ELECTRICAL
Fuel Pressure Control Valve (FPCV) 1. Install FDP sensor and new 18.7 x 26 seal ring.
Tighten sensor to special torque (page 106).
1. See (High-pressure Fuel Pump (HPFP) and
Drive Housing, page 210) in the “FUEL SYSTEM” NOTE: It may be necessary to rotate the harness
section for installation of high-pressure fuel pump. connector to ensure the alignment tabs engage
properly.
2. Connect harness to FDP sensor.
3. Turn sensor harness connector locking ring 90°
clockwise.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 103
Engine Oil Pressure (EOP) Sensor Engine Oil Temperature (EOT) Sensor
1. Install EOP sensor and new 18.7 x 26 seal ring 1. Install EOT sensor and new 16.7 x 24 seal ring
in oil module assembly. Tighten sensor to special in oil module flange. Tighten sensor to special
torque (page 106). torque (page 106).
NOTE: It may be necessary to rotate the harness NOTE: It may be necessary to rotate the harness
connector to ensure the alignment tabs engage connector to ensure the alignment tabs engage
properly. properly.
2. Connect harness to EOP sensor. 2. Connect harness to EOT sensor.
3. Turn sensor connector locking ring 90° clockwise. 3. Turn sensor connector locking ring 90° clockwise.
EGES-465-1
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104 ENGINE ELECTRICAL
Engine Coolant Temperature 2 (ECT2) Sensor Engine Coolant Temperature 1 (ECT1) Sensor
1. Install ECT2 sensor and new 16.7 x 24 seal ring 1. Install ECT1 sensor with new 16.7 x 24 seal ring in
in EGR module low-temperature housing. Tighten EGR coolant manifold at rear of engine. Tighten
sensor to special torque (page 106). sensor to special torque (page 106).
NOTE: It may be necessary to rotate the harness NOTE: It may be necessary to rotate the harness
connector to ensure the alignment tabs engage connector to ensure the alignment tabs engage
properly. properly.
2. Connect harness to ECT2 sensor. 2. Connect harness connector to ECT1 sensor.
3. Turn sensor connector locking ring 90° clockwise. 3. Turn sensor harness connector locking ring 90°
clockwise.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 105
Figure 119 CMP sensor (typical) Figure 120 CKP sensor (typical)
1. Locking tab
2. M6 x 16 bolt
1. Lubricate new O-ring with oil-based grease and
3. CKP sensor
install on CMP sensor.
4. CKP harness connector
2. Insert CMP sensor in port at left rear of cylinder
head.
1. Lubricate new O-ring with oil-based grease and
3. Install M6 x 12 bolt to attach CMP sensor to head.
install on CKP sensor.
Tighten bolt to special torque (page 106).
2. Insert CKP sensor in port at top left of flywheel
4. Connect harness to CMP sensor terminal by
housing.
pushing in on connector until a click is heard.
3. Install M6 x 16 bolt to CKP sensor. Tighten bolt to
5. Push in yellow tab to lock sensor connector in
special torque (page 106).
place.
4. Connect harness to CKP sensor terminal by
pushing in on connector until a click is heard.
5. Push in yellow tab to lock connector in place.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
106 ENGINE ELECTRICAL
Special Torque
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
COLD START ASSIST 107
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Glow Plug and Fuel Supply Cold Start Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Glow Plug and Fuel Supply Cold Start Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
EGES-465-1
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Follow all warnings, cautions, and notes.
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108 COLD START ASSIST
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Follow all warnings, cautions, and notes.
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COLD START ASSIST 109
Exploded View
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
110 COLD START ASSIST
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Follow all warnings, cautions, and notes.
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COLD START ASSIST 111
Glow Plug and Fuel Supply Cold Start Hose Fuel Supply Solenoid Hose
Figure 123 Glow plug and fuel supply cold start Figure 124 Fuel supply solenoid hose (at fuel
hose filter housing)
1. Glow plug 1. Fuel filter housing
2. Fuel supply cold start hose 2. Seal 12.7 x 18 ring (2)
3. Solenoid valve 3. Banjo 8 bolt (M12 x 1.5)
4. M8 x 1 banjo bolt 4. Fuel supply solenoid hose
5. Washer (seal ring) (2)
EGES-465-1
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Follow all warnings, cautions, and notes.
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112 COLD START ASSIST
EGES-465-1
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Follow all warnings, cautions, and notes.
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COLD START ASSIST 113
EGES-465-1
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Follow all warnings, cautions, and notes.
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114 COLD START ASSIST
EGES-465-1
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Follow all warnings, cautions, and notes.
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COLD START ASSIST 115
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
116 COLD START ASSIST
Glow Plug and Fuel Supply Cold Start Hose Relay Assembly
1. Position fuel supply cold start hose onto solenoid 1. Position relay assembly on mounting pad at rear
valve port. of ECM support.
2. Install two new washers (seal rings) and M8 x 1 2. Install two M6 x 20 bolts. Tighten bolts to special
banjo bolt. Tighten banjo bolt to special torque torque (page 117).
(page 117). 3. Refer to Engine Electrical (page 61) for wiring
3. Install fuel supply cold start hose onto glow plug harness connection.
fitting. Tighten fitting nut to special torque (page
117).
4. Refer to Engine Electrical section (page 61) for
wiring harness connection.
EGES-465-1
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Follow all warnings, cautions, and notes.
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COLD START ASSIST 117
Special Torque
Fuel supply cold start hose fitting nut 10 N·m (11 lbf·ft)
EGES-465-1
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Follow all warnings, cautions, and notes.
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118 COLD START ASSIST
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AFTERTREATMENT SYSTEM 119
Table of Contents
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Supply Fuel After Filter Hose and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Metering Unit Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
HCI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
HCI Coolant Return Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Hydrocarbon Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Metering Unit Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Hydrocarbon Injector Flow Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Hydrocarbon Injector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
HCI Coolant Return Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
HCI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
HCI Fuel Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
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120 AFTERTREATMENT SYSTEM
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AFTERTREATMENT SYSTEM 121
Illustrations
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Follow all warnings, cautions, and notes.
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122 AFTERTREATMENT SYSTEM
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AFTERTREATMENT SYSTEM 123
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Follow all warnings, cautions, and notes.
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124 AFTERTREATMENT SYSTEM
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Follow all warnings, cautions, and notes.
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AFTERTREATMENT SYSTEM 125
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Follow all warnings, cautions, and notes.
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126 AFTERTREATMENT SYSTEM
CAUTION: To prevent component damage, keep NOTE: Do steps 3 and 4 only if metering unit valve
metering unit valve assembly and related components assembly adapter or union fitting are leaking or if
clean and protected from damage until ready to install. unit is being replaced. Use adapter and fitting on
Do not let dirt or other debris, lubricants or water get replacement unit.
into fuel passages. Do not blow compressed air
CAUTION: To prevent engine damage, all fuel
into fuel passages. If protection caps are used, they
exposed O-rings and O-ring seals must be replaced
should be new, or ultrasonically cleaned before using.
with biodiesel compatible O-rings and O-ring seals.
CAUTION: To prevent component damage, do not The specific Navistar P/N must be used for service.
drop metering unit valve assembly onto a hard
3. Remove fitting (quick-connect adapter) from
surface. If this happens, replace the valve.
metering unit valve assembly. Remove and
1. Remove three M8 x 35 bolts and metering unit discard O-ring seal.
valve assembly.
4. Remove fitting (straight union orifice) from
2. If necessary, remove four M8 x 16 bolts and metering unit. Remove and discard O-ring (#
metering unit bracket. (Figure 135). 011) and O-ring seal.
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AFTERTREATMENT SYSTEM 127
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128 AFTERTREATMENT SYSTEM
HCI Coolant Return Tube Assembly 3. Release HCI coolant return tube from two tube
clamps at open breather tube.
4. Loosen hose clamp (spring type). Separate HCI
coolant return tube from open breather tube.
Remove from engine.
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AFTERTREATMENT SYSTEM 129
CAUTION: To prevent component damage, keep CAUTION: To prevent component damage, cleaning
hydrocarbon injector and related components clean of the hydrocarbon injector using carb and choke
and protected from damage until ready to install. cleaner, other solvents or using any brush is NOT
Make sure to protect the injector nozzle tip as well as recommended. It is not considered a regular
sealing and threaded surfaces. Do not let dirt or other maintenance procedure, nor is the injector considered
debris, lubricants or water get into fuel or coolant a serviceable item. Do not blast the injector with
passages. Do not blow compressed air into injector compressed air. Do not pull or otherwise manipulate
fuel passage. If protection caps are used, they should the injector nozzle tip. There is no acceptable
be new, or ultrasonically cleaned before using. cleaning method for the hydrocarbon injector. If in
doubt, do not clean the injector, replace it.
CAUTION: To prevent component damage, do not
drop hydrocarbon injector (especially nozzle tip) onto
a hard surface. If this happens, replace the injector.
1. Remove two M8 x 45 bolts and hydrocarbon
injector from valve housing. Discard bolts.
2. Remove hydrocarbon injector gasket and save
the used gasket for reuse during the hydrocarbon
injector flow test.
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Follow all warnings, cautions, and notes.
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130 AFTERTREATMENT SYSTEM
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AFTERTREATMENT SYSTEM 131
Hydrocarbon Injector
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132 AFTERTREATMENT SYSTEM
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AFTERTREATMENT SYSTEM 133
5. Snap HCI coolant return tube into two tube clamps 1. If previously removed, install straight fitting into
and install hose clamp (spring type) to secure tube coolant manifold and tighten to special torque
to open breather tube. (page 136).
6. Tighten HCI coolant return tube assembly nut 2. Loosely install HCI coolant supply tube nut onto
onto tube M10 elbow fitting (orient fitting as straight fitting at coolant manifold.
needed to reduce tube stress and to not contact
NOTE: Do steps 3 and 4 if tube M10 elbow fitting
other components) and tighten tube nut and
was removed or if hydrocarbon injector was replaced.
elbow fitting each to special torque (page 136).
Otherwise, skip to step 5.
3. Install tube M10 elbow fitting onto hydrocarbon
HCI Coolant Supply Tube Assembly injector and tighten fitting to maintain orientation
and clearance for HCI coolant supply tube
assembly. Tighten tube M10 elbow fitting to
special torque (page 136).
4. Loosely install HCI coolant supply tube nut onto
tube M10 elbow fitting (orient fitting as needed)
on hydrocarbon injector.
5. Tighten two HCI coolant supply tube nuts to
special torque (page 136).
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134 AFTERTREATMENT SYSTEM
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Follow all warnings, cautions, and notes.
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AFTERTREATMENT SYSTEM 135
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Follow all warnings, cautions, and notes.
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136 AFTERTREATMENT SYSTEM
Special Torque
Fitting (straight union orifice) at metering unit valve assembly 35 N·m (26 lbf·ft)
HCI coolant supply and return tube nut at tube M10 elbow 15 N·m (11 lbf·ft)
fittings
HCI coolant supply tube nut at coolant manifold 25 N·m (18 lbf·ft)
HCI fuel 1 tube assembly nut at HCI fuel 2 tube fitting (brazed) 25 N·m (18 lbf·ft)
HCI fuel 1 tube assembly nut at metering unit valve assembly 25 N·m (18 lbf·ft)
HCI fuel 2 tube assembly nut at hydrocarbon injector 18 N·m (13 lbf·ft)
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST BACK PRESSURE CONTROL 137
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Air Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .141
Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Exhaust Back Pressure Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Air Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Exhaust Back Pressure Valve Actuator and TC1 Turbine Outlet Pressure Sensor Tubes. . . . . .143
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138 EXHAUST BACK PRESSURE CONTROL
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Follow all warnings, cautions, and notes.
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EXHAUST BACK PRESSURE CONTROL 139
Exploded Views
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Follow all warnings, cautions, and notes.
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140 EXHAUST BACK PRESSURE CONTROL
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EXHAUST BACK PRESSURE CONTROL 141
Exhaust Back Pressure Valve Actuator and TC1 2. Loosen TC1TOP sensor tube nut from
Turbine Outlet Pressure Sensor Tubes low-pressure turbocharger housing flare M10 x
M12 (24 degree) fitting and disconnect tube.
3. If necessary, remove flare M10 x M12 (24 degree)
fitting.
Figure 161 Exhaust back pressure valve Figure 162 TC1TOP sensor and exhaust back
actuator and TC1 turbine outlet pressure pressure valve tubes
(TC1TOP) sensor tubes 1. TC1TOP sensor tube bracket
2. M6 x 40 bolt (2)
1. Exhaust back pressure valve tube nut
3. Exhaust back pressure valve tube bracket (2)
2. Exhaust back pressure valve actuator
4. Exhaust back pressure valve tube
3. TC1TOP sensor tube nut
5. TC1TOP sensor tube
4. Flare M10 x M12 (24 degree) fitting
1. Loosen exhaust back pressure valve tube nut 4. Remove two M6 x 40 bolts, exhaust back pressure
from exhaust back pressure valve actuator and valve tube and TC1TOP sensor tube.
disconnect tube.
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142 EXHAUST BACK PRESSURE CONTROL
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EXHAUST BACK PRESSURE CONTROL 143
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Follow all warnings, cautions, and notes.
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144 EXHAUST BACK PRESSURE CONTROL
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EXHAUST BACK PRESSURE CONTROL 145
7. Install air supply tube nut to air control valve and 9. Install crimp clamps on turbocharger high- and
tighten tube nut to special torque (page 146). low-pressure actuator hoses. Position actuator
hoses to air control valve ports. Using crimping
8. If removed, position air supply tube to engine.
pliers, tighten the clamps.
Install tube nut to bulkhead fitting and tighten to
special torque (page 146). Install tie straps to
brackets as necessary.
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146 EXHAUST BACK PRESSURE CONTROL
Special Torque
Exhaust back pressure valve tube nut (at air control 15 N·m (11 lbf·ft)
valve)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lbf·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lbf·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 15 N·m (11 lbf·ft)
degree) fitting
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Follow all warnings, cautions, and notes.
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TURBOCHARGERS 147
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
High-pressure (HP) and Low-pressure (LP) Wastegate Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .155
Low-pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
High-pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
High-pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160
Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Turbocharger Wastegate Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .162
Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Turbocharger Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Turbocharger Support Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Turbocharger Wastegate Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Turbocharger Heat Shields. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Turbocharger Oil Return and Oil Supply Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
High-pressure Turbocharger Air Supply Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
High-pressure (HP) Compressor Out Duct and Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Low-pressure Charge Air Cooler (LPCAC) Coolant Tube and Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Low-pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
High-pressure (HP) and Low-pressure (LP) Wastegate Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .177
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148 TURBOCHARGERS
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TURBOCHARGERS 149
Exploded Views
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© 2011 Navistar, Inc. All rights reserved
150 TURBOCHARGERS
Figure 171 Coolant tube, coolant hoses and low-pressure charge air cooler (LPCAC)
1. LPCAC air inlet 8. Coolant return hose (at EGR 15. Hose clamp (1 inch worm gear)
2. Intake O-ring (low-pressure cooler) 16. 72.2 x 60 (DMR) tube seal
turbocharger to LPCAC) 9. Coolant tube (EGR cooler to (extension tube)
3. Low-pressure charge air cooler LPCAC) 17. LPCAC air outlet (to air supply
4. Coolant return hose (CAC to 10. Tube support high-pressure turbocharger
coolant return duct) 11. Air supply high-pressure duct)
5. M24 x 1.5 threaded fitting (2) turbocharger duct 18. Coolant hose (coolant tube to
6. Coolant return duct (integral with 12. M10 x 200 bolt (2) CAC water inlet)
air supply duct) 13. M8 x 20 bolt 19. M10 x 100 bolt
7. 3/4 inch constant torque hose 14. Coolant return hose (to water 20. Ground stud bolt (2)
clamp (7) distribution housing) 21. EGR cooler assembly
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TURBOCHARGERS 151
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Follow all warnings, cautions, and notes.
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152 TURBOCHARGERS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
TURBOCHARGERS 153
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
154 TURBOCHARGERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
TURBOCHARGERS 155
EGES-465-1
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Follow all warnings, cautions, and notes.
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156 TURBOCHARGERS
EGES-465-1
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TURBOCHARGERS 157
1. Loosen two 3/4 inch hose clamps. 3. Cut two cable lock straps from coolant tube.
2. Disconnect coolant return hose from low 4. Remove M8 x 20 bolt to release coolant tube
temperature housing and coolant tube. support and cab heater return tube assembly
retainer.
5. Remove M8 x 16 bolt and tube support behind air
inlet duct. Remove M6 x 20 bolt to release cab
heater return tube assembly and remove tube.
Remove and discard O-ring.
6. Loosen 3/4 inch hose clamp and disconnect
coolant tube from coolant hose. Remove coolant
tube.
EGES-465-1
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158 TURBOCHARGERS
Figure 181 Coolant return hose (at air supply Figure 182 Coolant return hose (air supply duct
high-pressure turbocharger duct) to water distribution housing)
1. 3/4 inch constant torque hose clamp 1. Air supply high-pressure turbocharger duct (coolant
2. Coolant return hose return integral with duct)
3. Air supply high-pressure turbocharger duct (coolant 2. 3/4 inch constant torque hose clamp
return integral with duct) 3. Water distribution housing
4. 1 inch worm gear hose clamp
5. Coolant return hose
7. Loosen 3/4 inch hose clamp and disconnect
coolant hose from air supply high-pressure
turbocharger duct. 8. Loosen 3/4 inch hose clamp, 1 inch hose clamp
and disconnect coolant return hose from air
supply duct and water distribution housing.
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TURBOCHARGERS 159
High-pressure (HP) Compressor Out Duct and 4. Remove M8 x 45 bolt and M10 x 140 bolt.
Air Inlet Duct Remove air inlet duct from low-pressure
turbocharger.
5. Remove LP compressor inlet seal from LP
turbocharger compressor inlet and discard.
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160 TURBOCHARGERS
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TURBOCHARGERS 161
7. Remove two M6 x 16 bolts from turbocharger 2. Remove two M8 x 16 bolts and turbocharger heat
oil supply tube at LP and HP turbochargers. shield.
Disconnect oil supply tube.
8. Remove and discard turbocharger supply seals
Turbocharger Support Bracket
from LP and HP turbocharger oil supply tube
ends. Clean and inspect sealing surfaces.
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Follow all warnings, cautions, and notes.
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162 TURBOCHARGERS
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TURBOCHARGERS 163
Turbocharger Mounting
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164 TURBOCHARGERS
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TURBOCHARGERS 165
Turbocharger Inspection
4. Turn shafts by hand and check for impeller and
CAUTION: To prevent engine damage, do not wheel rub in the housings.
damage compressor impeller or turbine wheel. If
The shaft, impeller and turbine must rotate freely.
either is damaged, a new turbocharger must be
If there is any rubbing or interference, replace
installed.
turbocharger.
1. Inspect turbochargers for cracks and leaks.
Replace if necessary.
2. Inspect compressor impellers and turbine wheels
for blade erosion, bends, breakage or deposits.
Replace turbochargers if damaged.
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166 TURBOCHARGERS
1. Attach Charge Air Cooler Test Kit (page 179) to 3. Spray a soapy water solution on LPCAC. Look
LPCAC using instructions supplied with tool and for leaks from hose connections, LPCAC or test
three inch couplers and clamps (obtain locally). components.
4. If a leak is detected on LPCAC or test gauge
WARNING: To prevent personal injury or pressure drops, replace LPCAC.
death, wear safety glasses with side shields.
5. Remove Charge Air Cooler Test kit from LPCAC.
Limit compressed air pressure to 207 kPa (30 psi).
2. Pressurize LPCAC to 30 psi (207 kPa).
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TURBOCHARGERS 167
Installation
Turbocharger Mounting
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168 TURBOCHARGERS
3. With turbocharger supported in place, install two 6. Remove Turbo Alignment Bracket (ZTSE6041)
10.5 x 20 x 15 sleeves and two new M10 nuts on from engine.
upper mounting studs. Finger-tighten nuts.
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TURBOCHARGERS 169
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170 TURBOCHARGERS
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TURBOCHARGERS 171
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172 TURBOCHARGERS
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TURBOCHARGERS 173
High-pressure (HP) Compressor Out Duct and 4. Install HP compressor out duct into HP
Air Inlet Duct turbocharger air outlet, install M10 x 40 bolt and
M10 x 20 x 35 stud bolt and tighten to standard
torque (page 471).
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174 TURBOCHARGERS
Figure 212 Coolant return hose (air supply Figure 213 Coolant and cab heater tubes
high-pressure turbocharger duct)
1. Cable lock strap (2)
1. 3/4 inch worm gear hose clamp 2. Coolant tube
2. Coolant return hose 3. Tube support
3. Air supply HP turbocharger duct (coolant return 4. M8 x 20 bolt
integral with duct) 5. Cab heater return tube assembly
6. M6 x 20 bolt
7. 3/4 inch constant torque hose clamp
2. Install coolant return hose to air supply HP
turbocharger duct. Install 3/4 inch hose clamp
and loosely tighten at this time. 3. Lubricate new cab heater return tube O-ring with
P-80® rubber lubricant or equivalent (page 179).
4. Install a new O-ring onto cab heater return tube
assembly.
5. Position cab heater return tube assembly and
install M6 x 20 bolt and M8 x 20 bolt through tube
support behind air inlet duct. Tighten bolts to
standard torque (page 471).
6. Install coolant hose onto lower end of coolant
supply tube. Install 3/4 inch hose clamp onto
hose and loosely tighten at this time.
7. Position coolant tube support and cab heater
return tube assembly retainer and install M8 x 20
bolt. Tighten bolt to standard torque (page 471).
NOTE: Two cable lock straps are installed later after
LP wastegate hose is installed to secure hose to
coolant tube.
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Follow all warnings, cautions, and notes.
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TURBOCHARGERS 175
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176 TURBOCHARGERS
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TURBOCHARGERS 177
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178 TURBOCHARGERS
NOTE: Replace HP or LP wastegate hoses (or 5. Install five cable lock straps to secure HP
insulator wrap) if damaged or deformed. wastegate hose to turbocharger oil supply tube
and EGRV coolant supply tube.
1. Route HP and LP wastegate hoses onto engine
as noted during removal. 6. Install six cable lock straps to secure LP
wastegate hose to HCI coolant return tube and
2. Connect HP wastegate hose to HP wastegate
EGR cooler to LPCAC coolant tube.
actuator fitting.
7. Connect LP and HP wastegate hoses to air control
3. Connect LP wastegate hose to LP wastegate
valve. Refer to "EXHAUST BACK PRESSURE
actuator fitting.
CONTROL" for procedure.
4. Install two new crimp clamps to secure hoses.
Using crimping pliers (page 179), tighten the
clamps.
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Follow all warnings, cautions, and notes.
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TURBOCHARGERS 179
Special Torque
Table 10 Turbochargers
3/4 inch and 1 inch worm gear hose clamps 3.5 N·m (31 lbf·in)
Turbocharger oil supply tube assembly fitting nut to male stud connector 27 N·m (20 lbf·ft)
Table 11 Turbochargers
Description Tool Number
3-inch couplers and clamps Obtain locally
Charge Air Cooler Test Kit ZTSE6042
Crimping pliers Obtain locally
Extension Tube Installer ZTSE6043
P-80® rubber lubricant or equivalent Obtain locally
Turbo Alignment Bracket ZTSE6041
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180 TURBOCHARGERS
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AIR COMPRESSOR AND POWER STEERING 181
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .185
Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .187
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
All components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .188
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
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182 AIR COMPRESSOR AND POWER STEERING
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AIR COMPRESSOR AND POWER STEERING 183
Exploded Views
Power Steering and One-Cylinder Air Compressor
Figure 218 One-cylinder air compressor and power steering system (typical)
1. Extension clip 7. Lock washer (10 mm) (2) 14. O-ring seal
2. M6 x 25 bolt 8. Return coolant tube assembly 15. 1/2” 90 degree tube elbow
3. Power steering (low-pressure) 9. Return coolant hose assembly 16. 1-1/16” 90 degree elbow
tube assembly 10. Air compressor 17. Power steering (high-pressure)
4. M6 x 1.0 nut (2) 11. M8 x 110 bolt (4) tube assembly
5. Power steering pump 12. M8 x 40 bolt (2) 18. Support bracket
6. M10 x 40 bolt (2) 13. Power steering pump adapter 19. M16 straight union (2)
Optional two-cylinder compressors are available. crankcase and chassis are similar to one-cylinder
Although compressor housings are longer, compressors.
compressor and power steering line connections to
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184 AIR COMPRESSOR AND POWER STEERING
Figure 219 Optional two-cylinder air compressor and power steering system (typical)
1. Extension clip 9. O-ring seal (3) 17. M10 x 110 bolt
2. M6 x 25 bolt 10. M16 straight fitting (3) 18. Power steering pump adapter
3. Power steering (low-pressure) 11. 21 mm constant-tension clamp 19. O-ring seal
tube assembly (4) 20. 1/2” tube 90 degree elbow
4. M6 x 1.0 nut (2) 12. Coolant return hose 21. 1-1/16”-12ST 90 degree elbow
5. Power steering pump 13. M16 45 degree fitting 22. Power steering (high-pressure)
6. M10 x 40 bolt (2) 14. Coolant supply hose tube assembly
7. Lock washer (10 mm) (2) 15. M8 x 40 bolt (2) 23. Support bracket
8. Air compressor 16. M8 x 110 bolt (4)
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AIR COMPRESSOR AND POWER STEERING 185
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186 AIR COMPRESSOR AND POWER STEERING
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AIR COMPRESSOR AND POWER STEERING 187
Figure 223 Power steering pump Figure 225 Air compressor coolant hoses
1. Power steering pump 1. Coolant return hose
2. Air compressor 2. Coolant return tube (one cylinder air compressor) or
3. M10 x 40 bolt and lock washer (2) Coolant supply hose (two cylinder air compressor)
3. Air compressor
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188 AIR COMPRESSOR AND POWER STEERING
Cleaning
All components
1. Cover coolant, fluid and air openings to ensure dirt
does not enter air compressor and power steering
pump.
2. Clean foreign material from sealing surfaces of
air compressor. Use a scraper to clean sealing
material from the sealing surfaces.
Figure 227 Air compressor (typical)
3. Use only hot water to clean all hoses and tubes.
1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)
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AIR COMPRESSOR AND POWER STEERING 189
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190 AIR COMPRESSOR AND POWER STEERING
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AIR COMPRESSOR AND POWER STEERING 191
NOTE: This procedure should be completed only if Power Steering Pressure Tubes
replacing power steering pump, or if one or both of
NOTE: If high-pressure and low-pressure tubes were
the elbows were removed.
replaced, do steps 1 and 2.
1. Check seals on elbow for damage. Replace as
1. If equipped and removed, install front support
necessary.
brackets and rubber isolator onto the high- and
2. Install 1/2” 90 degree tube elbow to power low-pressure tubes.
steering pump. Lock nuts should not be tightened
2. If removed, install rear support brackets and
until power steering lines are installed for proper
rubber isolator onto the high- and low-pressure
orientation.
tubes.
3. Install 1-1/16” 90 degree elbow to power steering
pump. Lock nuts should not be tightened until
power steering lines are installed for proper
orientation.
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192 AIR COMPRESSOR AND POWER STEERING
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AIR COMPRESSOR AND POWER STEERING 193
Special Torque
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194 AIR COMPRESSOR AND POWER STEERING
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 195
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204
Fuel Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .205
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
Fuel Filter Stand Pipe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .208
High-pressure Pump (Drive Belt) Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
High-pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . .210
High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
High-Pressure Pump (Drive Belt) Pulley Housing and Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . .223
High-Pressure Pump (Drive Belt) Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Fuel Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Filter and Fuel Strainer Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
EGES-465-1
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196 FUEL SYSTEM
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FUEL SYSTEM 197
Exploded Views
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
198 FUEL SYSTEM
EGES-465-1
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 199
EGES-465-1
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Follow all warnings, cautions, and notes.
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200 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 201
Removal
WARNING: To prevent personal injury or
death, remove ground cable from the negative
terminal of main battery before disconnecting
GOVERNMENT REGULATION: Engine or connecting electrical components. Always
fluids (oil, fuel, and coolant) may be a hazard connect ground cable last.
to human health and the environment.
Handle all fluids and other contaminated
WARNING: To prevent personal injury or
materials (e.g. filters, rags) in accordance
death, do not let engine fluids stay on your skin.
with applicable regulations. Recycle
Clean skin and nails using hand cleaner and wash
or dispose of engine fluids, filters, and
with soap and water. Wash or discard clothing
other contaminated materials according to
and rags contaminated with engine fluids.
applicable regulations.
EGES-465-1
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Follow all warnings, cautions, and notes.
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202 FUEL SYSTEM
EGES-465-1
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 203
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
204 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 205
Fuel Supply and Drain (Return) Lines Figure 250 After-filter fuel supply hose
connections
1. Quick-connect 90° fitting (at high-pressure fuel
pump)
2. Quick-connect 90° fitting (at metering unit valve)
3. M14 banjo bolt
4. Clip
5. After-filter fuel supply hose
EGES-465-1
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206 FUEL SYSTEM
Figure 251 Pre-pump fuel supply hose Figure 252 Pre-filter fuel supply hose
connections connections
1. Quick-connect 90° fitting (at high-pressure fuel 1. Quick-connect 90° fitting (at high-pressure fuel
pump) pump)
2. Quick-connect 90° fitting (at primer pump) 2. Quick-connect 90° fitting (at filter housing)
3. Pre-filter fuel supply hose 3. Pre-filter fuel supply hose
3. Disconnect pre-pump fuel supply hose assembly 4. Disconnect pre-filter fuel supply hose assembly
quick-connect 90° fittings at high-pressure fuel quick-connect 90° fittings at high-pressure fuel
pump and at primer pump. Remove hose and pump and at fuel filter housing. Remove hose
cap openings. and cap openings.
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 207
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208 FUEL SYSTEM
Fuel Filter Housing Assembly 2. Remove three M8 x 45 bolts and remove fuel filter
housing assembly.
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 209
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Follow all warnings, cautions, and notes.
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210 FUEL SYSTEM
High-pressure Pump (Drive Belt) Pulley Housing 6. Clean all RTV from sealing surfaces.
and Radial Shaft Seal
7. Remove drive belt shaft from high-pressure fuel
pump drive housing.
8. Remove and discard drive belt shaft 30.2 x 3
O-ring.
1. With an awl and hammer, punch two holes 180° Figure 262 High-pressure fuel pump support
apart in radial shaft seal. bracket
2. Thread a slide hammer (page 234) with correct 1. High-pressure fuel pump
size screw into one of the two holes. 2. M12 x 30 bolt (2)
3. Support bracket
3. Slide hammer until one side of seal begins to pull
4. M14 x 30 bolt (2)
out of housing. Move slide hammer to other hole
and repeat until radial shaft seal is removed.
4. Remove four M10 x 40 drive belt pulley housing 1. Remove two M12 x 30 and two M14 x 30 bolts and
bolts. remove support bracket from below high-pressure
5. Remove drive belt pulley housing assembly off fuel pump.
high-pressure fuel pump drive housing. Check
that (alignment) sleeve remains in place on pulley
housing mounting flange.
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FUEL SYSTEM 211
Figure 263 High-pressure fuel pump drive Figure 264 High-pressure fuel pump and drive
housing and jam nut housing
1. High-pressure pump gear 1. High-pressure fuel pump drive housing
2. High-pressure fuel pump drive housing 2. M12 x 90 bolt
3. 25 x 44 x 4 washer 3. M12 x 130 bolt (2)
4. M24 jam nut 4. High-pressure fuel pump
5. 16.7 x 24 seal ring (4)
6. Quick-connect M16 x 1.5 connector (4)
NOTE: If high-pressure fuel pump is to be removed 7. M12 x 40 bolt
from drive housing after removal of assembly from
engine, block crankshaft to prevent timing gears from
turning and loosen (but do not remove) M24 jam nut 2. Remove M12 x 40, M12 x 90 and two M12 x 130
before proceeding with next step. This will aid removal bolts and remove high-pressure fuel pump and
of pump from drive housing for later service. drive housing assembly from crankcase.
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212 FUEL SYSTEM
3. Check that dowel pin and sleeve remain seated in NOTE: The injector harness nuts are part of the
drive housing. injector harness and cannot be separated.
NOTE: If high-pressure fuel pump is to be replaced, 1. Loosen 12 injector harness nuts and position
continue with steps 4 through 6 to remove pump from injector harness aside.
drive housing.
4. Remove 25 x 44 x 4 washer and M24 jam nut
securing pump gear to pump shaft.
5. Remove four M10 x 40 bolts attaching
high-pressure fuel pump to drive housing.
6. Remove four M16 x 1.5 quick-connect connectors
and discard seal rings.
Fuel Injectors
CAUTION: To prevent engine damage, remove
injectors before removing cylinder head.
CAUTION: To prevent engine damage, do not use
power tools to remove or install fuel injector clamp
bolts. Threads will be damaged if a bolt or nut is Figure 267 High-pressure connector body
rotated too quickly. (typical)
CAUTION: To prevent engine damage, install new 1. Retaining high-pressure connector nut (6)
injector O-ring and combustion washer before 2. High-pressure connector body (6)
installing injector.
EGES-465-1
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 213
EGES-465-1
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Follow all warnings, cautions, and notes.
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214 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 215
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
216 FUEL SYSTEM
Installation
Fuel Injectors
CAUTION: To prevent engine damage, remove
protective plugs and cups only before immediate
installation of components.
CAUTION: To prevent engine damage, do not use
power tools to remove or install fuel injector clamp
bolts. Threads will be damaged if a bolt or nut is
rotated too quickly.
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FUEL SYSTEM 217
4. Slide injector into hold-down clamp with injector 6. Using Injector Installer (page 234), firmly press
fuel inlet opening on opposite side of hold-down injector and hold-down clamp and make sure
clamp. injector is fully seated into cylinder head.
CAUTION: To prevent engine damage, six new
high-pressure connector bodies must be installed and
aligned before tightening M8 x 50 bolts for six fuel
injectors.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
218 FUEL SYSTEM
Injector hold-down clamp (M8 x 50 bolts) High-pressure connector body (retaining nuts)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 219
Injector hold-down clamp (Final torque of M8 x 50 High-pressure connector body (Final torque of
bolts) retaining nuts)
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220 FUEL SYSTEM
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FUEL SYSTEM 221
1. Press key into slot on high-pressure fuel pump 4. Install four M10 x 40 bolts, hand-tight, to attach
shaft. high-pressure fuel pump to drive housing.
2. Install a new 100 x 3.349 O-ring on fuel pump 5. Install 25 x 44 x 4 washer and M24 jam nut,
mounting flange collar. hand-tight, to secure gear on high-pressure fuel
pump shaft.
3. Place high-pressure fuel pump gear into pump
drive housing and assemble drive housing to
pump. Check that key slot in gear is aligned with
key on shaft and push gear onto shaft.
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Follow all warnings, cautions, and notes.
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222 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 223
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224 FUEL SYSTEM
6. Install four M10 x 40 bolts and tighten to special Fuel Filter Housing Assembly
torque (page 233).
7. Using Fan Hub/High Pressure Drive Seal Installer
(page 234), drive new radial shaft seal into
housing. Seal is fully installed when tool bottoms
out on housing.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 225
2. Install fuel filter housing assembly and three M8 Fuel Primer Pump Assembly
x 45 bolts. Tighten bolts to special torque (page
233).
EGES-465-1
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226 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 227
Figure 298 Pre-filter fuel supply hose assembly Figure 299 Pre-pump fuel supply hose assembly
1. Quick-connect 90° fitting (at high-pressure fuel 1. Quick-connect 90° fitting (at high-pressure fuel
pump) pump)
2. Quick-connect 90° fitting (at filter housing) 2. Quick-connect 90° fitting (at primer pump)
3. Pre-filter fuel supply hose 3. Pre-pump fuel supply hose
7. Check that O-rings are in place in pre-filter 9. Check that O-rings are in place in pre-pump fuel
fuel supply quick-connect 90° fittings and not supply hose quick-connect 90° fittings and not
damaged. Replace as necessary. damaged. Replace as necessary.
8. Install pre-filter fuel supply hose. Push on 10. Install pre-pump fuel supply hose. Push on
quick-connect 90° fitting at high-pressure fuel quick-connect 90° fitting at high-pressure fuel
pump until an audible click is heard. Pull pump until an audible click is heard. Pull
quick-connect fitting to make sure it is seated. quick-connect fitting to make sure it is seated.
Repeat the procedure for the quick-connect 90° Repeat the procedure for the quick-connect 90°
fitting at fuel filter housing. fitting at primer pump.
EGES-465-1
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© 2011 Navistar, Inc. All rights reserved
228 FUEL SYSTEM
Fuel Rail
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 229
Injector and Fuel Drain (Return) Lines 4. Tighten fuel drain tube M14 banjo bolts at fuel rail
and cylinder head to special torque (page 233).
5. Install closed (P) clamp and M8 x 16 bolt to secure
drain tube to crankcase. Tighten bolt to standard
torque (page 471).
EGES-465-1
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Follow all warnings, cautions, and notes.
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230 FUEL SYSTEM
EGES-465-1
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 231
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
232 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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FUEL SYSTEM 233
Specifications
Special Torque
EGES-465-1
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Follow all warnings, cautions, and notes.
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234 FUEL SYSTEM
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 235
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .239
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
EGES-465-1
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Follow all warnings, cautions, and notes.
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236 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 237
Exploded Views
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
238 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 239
WARNING: To prevent personal injury or 1. Place absorbent material under the engine and oil
death, do not let engine fluids stay on your skin. module assembly.
Clean skin and nails using hand cleaner and wash 2. Unscrew oil filter cover from oil module using a
with soap and water. Wash or discard clothing 36mm wrench.
and rags contaminated with engine fluids.
3. Rotate oil filter element slightly and remove oil
filter from filter cover.
4. Remove and discard O-ring seal from exterior of
oil filter cover.
5. Dispose of oil filter according to local regulations.
EGES-465-1
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Follow all warnings, cautions, and notes.
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240 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
EGES-465-1
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 241
Oil Module Assembly 4. Remove hose clamp (spring type) securing heater
return tube to open breather tube assembly.
Remove open breather tube assembly.
5. Remove M6 x 16 bolt and pipe single cushioned
clamp securing heater return tube to LPCAC.
6. Loosen tube nut securing heater return tube
to straight fitting on water distribution housing.
Remove heater return tube.
CAUTION: To prevent engine damage, drain all
coolant from the engine through the radiator when
removing the oil module assembly. Coolant can enter
the oil sump and contaminate the engine oil. Engine
oil must be drained and replaced after oil module
removal and installation, before the engine is started.
7. Drain coolant from engine through radiator.
EGES-465-1
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Follow all warnings, cautions, and notes.
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242 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 243
Oil Cooler
2. Remove oil cooler from oil module assembly. 1. Remove oil pressure relief valve. Clean and
inspect oil pressure relief valve. Replace if
necessary.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
244 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
Cleaning, Inspection and Testing 1. Install Engine Oil Cooler Pressure Test Plate
(page 250) onto oil cooler.
Oil Cooler
CAUTION: To prevent engine damage, replace the oil 2. Attach an air pressure regulator (page 250) to
cooler if an engine bearing fails. Bearing debris can Engine Oil Cooler Pressure Test Plate. Connect
not be removed from the oil cooler. to compressed air supply and adjust air pressure
to approximately 172 to 207 kPa (25 to 30 psi).
1. The oil cooler can be cleaned in solvent and dried
with filtered compressed air. 3. Immerse oil cooler in large container of clean
water.
• Clean oil cooler in suitable solvent.
4. Inspect oil cooler and test plate for leaks. If test
• Flush and drain oil cooler to remove any plate fittings leak, tighten fittings and continue
residue. Dry components with filtered looking for leaks. Air bubbles at any location from
compressed air. oil cooler indicate leaks. Replace oil cooler if
leaking.
Oil Cooler Leak Test 5. Dry oil cooler using filtered compressed air.
Extension Tubes
1. Wipe extension tubes clean and inspect for
tears, cuts or other damage to sealing surfaces.
Replace as necessary.
Oil Centrifuge
1. Clean the oil centrifuge and inspect for damage.
Replace as necessary.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 245
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
246 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
Figure 329 Oil cooler installation Figure 330 Oil module assembly
1. M10 x 80 bolt (7)
3. Install oil cooler over gaskets and into oil module. 2. M10 x 170 bolt
Hand-tighten bolts. 3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes
NOTE: Ensure gaskets remain in place during 9 x 16 x 15 spacer
cooler installation.
Tighten two M8 x 45 and two M8 x 90 bolts to
special torque (page 250). CAUTION: To prevent engine damage, do not use
any silicone or other sealant when installing oil module
assembly.
Oil Module Assembly 2. Position oil module assembly and install seven
1. Position new gasket onto oil module assembly. M10 x 80 bolts, M10 x 170 bolt and three M10
x 110 bolts.
3. Tighten oil module bolts to special torque (page
250).
4. Place 9 x 16 x 15 spacer between water
distribution housing and oil module assembly.
5. Install M8 x 150 bolt through water pump
assembly, water distribution housing, spacer and
into front side of oil module assembly. Tighten
M8 x 150 bolt to special torque (page 250).
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 247
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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248 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
Oil Centrifuge
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 249
Figure 335 Oil filter cover NOTE: Three additional bolts secure the oil module
assembly. These bolts are installed along with the HP
1. Filter cover turbo air supply duct (two M10 x 200 bolts) and the
2. O-ring seal air inlet duct for the LP turbocharger (one M10 x 140
3. Oil filter bolt). See "TURBOCHARGERS" for procedures.
4. Oil module assembly
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Follow all warnings, cautions, and notes.
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250 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
Special Torque
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 251
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Coolant Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
EGR Dual Flap Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Heat Protection EGR Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
EGR Inlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
EGR Outlet Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
Heat Protection (Cylinders 4-6) Shield. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
EGR Cooler Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Coolant Elbow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Coolant Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
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Follow all warnings, cautions, and notes.
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252 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 253
Exploded Views
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
254 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Figure 337 EGR outlet tubes (cylinders 1-3 and cylinders 4-6)
1. EGR outlet gasket (4) 4. EGR outlet (cylinders 4-6) tube 6. EGR module cover
2. M8 x 30 bolt (8) 5. Air intake throttle duct
3. EGR outlet (cylinders 1-3) tube (horizontal)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 255
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
256 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 257
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
258 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 259
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
260 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Figure 345 EGR inlet (cylinders 1-3) tube Figure 346 EGR inlet (cylinders 4-6) tube
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 261
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
262 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 263
Cleaning, Inspection and Testing 3. Install test plate from EGR Cooler Pressure Test
Kit (page 270) to front of EGR cooler assembly.
EGR System Components
Tighten bolts to standard torque (page 471).
1. Using steam, clean all carbon from ends of EGR
dual flap valve, coolant manifold and coolant
elbow at rear.
CAUTION: To prevent engine damage, do not use
steam to clean EGR cooler heat exchanger cores.
2. Using steam, clean EGR cooler coolant return
manifold at front. Clean all EGR cooler assembly
coolant ports.
3. Inspect EGR system components for cracks and
damage. Replace worn or damaged parts.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
264 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
On Bench
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 265
Installation
EGR Cooler Assembly
NOTE: Install or connect exterior components to
the EGR cooler as necessary. When installing
a replacement EGR cooler assembly, transfer
necessary components from the cooler being
replaced.
1. Install EGR cooler assembly, six M10 x 45 bolts 2. Install EGR dual flap valve and nine M8 x 30
and M10 x 170 bolt. Tighten bolts to special heat-resistant bolts. Tighten bolts to special
torque (page 270). torque (page 270).
2. Connect low-temperature EGR hose assembly to 3. Attach EGR valve coolant supply tube nut to EGR
EGR cooler assembly. Position and install spring valve and tighten to special torque (page 270).
clamp to secure hose. 4. Attach EGR valve coolant return tube to EGR
valve and install spring clamp.
EGES-465-1
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Follow all warnings, cautions, and notes.
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266 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 267
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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268 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
EXHAUST GAS RECIRCULATION (EGR) SYSTEM 269
3. Tighten three coolant elbow bolts to standard 2. Install extension tube (DMR62 x 51) and
torque (page 471). extension tube (DMR44 x 35) into coolant
manifold using Extension Tube Installer Large
4. Lubricate sealing surfaces of extension tube and Extension Tube Installer Small (page 270).
(DMR62 x 51) with P-80® rubber lubricant or
equivalent (page 270). Install extension tube 3. Install coolant manifold using two M8 x 45 bolts,
(DMR62 x 51) to coolant elbow using Extension one M8 x 50 x 16 stud bolt and one M8 x 25
Tube Installer Large (page 270). heat-resistant bolt (at heat protection (cylinder
4-6) shield). Tighten M8 x 12 heat-resistant bolt
NOTE: Alternatively, install extension tube (DMR62 x to standard torque (page 471). Tighten two M8 x
51) into coolant manifold. 45 bolts and one M8 x 50 x 16 stud bolt to special
torque (page 270).
4. Install one M8 x 12 bolt and tighten to standard
torque (page 471).
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
270 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Special Torque
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 271
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .276
Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Air Intake Throttle Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
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Follow all warnings, cautions, and notes.
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272 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 273
Exploded Views
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
274 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 275
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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276 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 277
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
278 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
Cleaning, Inspection and Testing 1. Use a straightedge and feeler gauge (page 282)
to check seating surface flatness of three exhaust
Air Intake Throttle Duct and Exhaust Manifolds
manifold sections.
NOTE: Do not use air tools or abrasive pads to clean
2. Check for flatness across left, right and diagonally
aluminum parts.
of each exhaust manifold section individually. See
Air intake throttle duct and three exhaust manifold exhaust manifold maximum allowable warpage
sections are castings and may be cleaned with steam specification (page 282).
or suitable non-caustic solvents.
3. If specification is not met, replace individual
1. Clean cylinder head, air intake throttle duct and exhaust manifold section. Do not resurface.
exhaust manifold gasket sealing surfaces.
2. Clean multipiece oil (FEY) ring grooves and
sealing surfaces of the exhaust manifold sections.
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 279
Exhaust Manifold
CAUTION: To prevent engine damage, hand torque
all fasteners of the exhaust manifolds. The exhaust
manifold hardware has a special high-temperature
Figure 372 Air intake throttle horizontal duct coating which will be damaged by air tools.
1. M8 x 50 bolt CAUTION: To prevent engine damage, do not reuse
2. M8 x 100 bolt (2) sleeve spacers or exhaust manifold bolts.
3. Air intake throttle horizontal duct
NOTE: Do not apply anti-seize compound to threads.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
280 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
1. Install four new multipiece oil (FEY) rings, two NOTE: Ensure that raised part of exhaust manifold
to the front exhaust manifold and two to the rear gasket is facing out towards exhaust manifold.
exhaust manifold, using FEY Rings Installation
3. Position six new exhaust manifold gaskets and
Tools (page 282). Refer to the tool kit installation
install exhaust manifold assembly.
instructions. Each multipiece oil ring (four
individual rings) must be positioned with the
four individual ring gaps alternating at 6 and 12
o’clock positions within each exhaust manifold
ring groove.
2. Install the front and rear exhaust manifolds into
the middle exhaust manifold.
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 281
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
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282 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
Specifications
Special Torque
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 283
COMPONENTS
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Automatic Belt Tensioner and Idler Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297
Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .301
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .303
Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Coolant Control Valve (CCV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .306
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
Automatic Belt Tensioner and Idler Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .308
Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
High Mount Fan Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
Pulley (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
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Follow all warnings, cautions, and notes.
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284 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 285
COMPONENTS
Exploded Views
Figure 378 High mount fan drive system and vibration damper
1. Fan drive clutch assembly 7. Fan drive pulley (high mount fan 13. Shoulder bolt
2. Tensioner bracket only) 14. Pulley assembly
3. M8 x 30 bolt (3) 8. M16 x 85 socket-head screw (8)
4. M10 x 35 bolt (9) 9. Fan drive tensioner assembly
5. Vibration damper 10. M10 x 70 countersunk screw
6. Damper hub (low mount fan 11. M10 x 150 bolt - 12.9 (5)
only) 12. M10 x 65 bolt
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
286 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 287
COMPONENTS
Figure 380 Thermostat assembly and coolant outlet manifold (low mount fan)
1. M8 x 70 bolt 3. Coolant outlet manifold 5. Bushing (2)
2. Fan coupling bracket assembly 4. Thermostat assembly (2) 6. M8 x 130 bolt (2)
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Follow all warnings, cautions, and notes.
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288 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Figure 381 Thermostat assembly and coolant outlet manifold (high mount fan)
1. M8 x 70 bolt (3) 2. Coolant outlet manifold (to 3. Thermostat assembly (2)
radiator)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 289
COMPONENTS
Figure 382 Water pump assembly, Coolant Control Valve (CCV), water distribution housing,
thermostat housing and EGR cooler return manifold
1. Extension tube (DMR40 / 10. Gasket 19. Engine water inlet
DN32F) (2) 11. Water distribution housing 20. CCV assembly
2. Extension tube (DMR62 / 51) 12. Dowel (2) 21. M8 x 60 stud bolt (2)
3. M8 x 30 bolt 13. Water pump assembly 22. Lock washer (2)
4. M8 x 75 bolt 14. M8 x 40 bolt (7) 23. Housing coolant distribution
5. EGR cooler return manifold 15. M8 x 130 bolt gasket
6. M8 x 145 bolt (4) 16. M8 x 150 bolt (2) 24. O-ring
7. Housing thermostat gasket 17. M8 x 150 bolt (tightens into oil
8. M8 x 60 bolt module assembly)
9. Thermostat housing 18. Water pump gasket
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
290 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 291
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
292 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 293
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
294 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
1. Remove M10 x 70 countersunk screw and fan 1. Disconnect air line from back of fan drive clutch
drive tensioner. assembly.
2. Remove five M10 x 150 - 12.9 bolts and M10 x 65
bolt. Remove fan drive clutch.
3. Discard six M10 bolts.
2. Remove three M8 x 30 bolts and tensioner Figure 390 Coolant outlet manifold (low mount
bracket. fan)
1. M8 x 70 bolt
High Mount Fan Drive 2. M8 x 130 bolt (2)
3. Fan coupling bracket
4. Coolant outlet manifold
5. Bushing (2)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 295
COMPONENTS
1. Remove coolant outlet manifold bolts as follows. 3. Remove two thermostat assemblies from
thermostat housing.
a. If equipped with low mount fan, remove M8 x
70 bolt, two M8 x 130 bolts, bracket and two
bushings. Automatic Belt Tensioner and Idler Pulleys
b. If equipped with high mount fan, remove three
M8 x 70 bolts.
2. Remove coolant outlet manifold.
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
296 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
1. Remove two M12 x 55 bolts and idler pulleys. 2. Remove M8 x 130, M8 x 150 and seven M8 x 40
bolts.
CAUTION: To prevent engine damage, do not twist
the belt tensioner; damage to the locating pin may CAUTION: To prevent engine damage, do not drop
occur, resulting in improper alignment of the belt water pump impeller or hit impeller with hard objects.
tensioner.
3. Remove water pump assembly and discard water
2. Remove M10 x 70 countersunk screw and pump gasket.
automatic belt tensioner.
Vibration Damper
Water Pump Assembly and Pulley
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 297
COMPONENTS
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
298 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Thermostat Housing
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 299
COMPONENTS
6. Remove two extension tubes (DMR40 / DN32F) 2. Remove water distribution housing and discard
from thermostat housing using a wood-handled gasket.
tool. Gently pry the extension tubes out until
3. Remove two M10 x 30 bolts and separate engine
removed. Inspect extension tubes for damage,
water inlet from water distribution housing.
replace as needed.
Remove and discard gasket.
4. Remove coolant heater from engine water inlet as
Water Distribution Housing needed.
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
300 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal (Fan Low Mount Drive)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 301
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
302 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Cleaning, Inspection and Testing 5. Inspect belt automatic tensioners and pulleys
to make sure tensioner arms and pulleys are
properly in line with the fan drive belt and
WARNING: To prevent personal injury or
accessory drive belt and not coming apart. Make
death, wear safety glasses with side shields.
sure tensioner arms are not binding and pulley
Limit compressed air pressure to 207 kPa (30 psi).
bearings are not loose. Replace belt tensioners
1. Clean water distribution housing, water pump, if required.
coolant outlet manifold, thermostat housing and
6. Inspect idler pulleys to make sure pulleys are
front belt- or gear-driven fan cover with a suitable
properly in line with the fan drive belt and
non-caustic solvent.
accessory drive belt and not coming apart.
2. Blow parts dry using filtered compressed air. Replace idler pulleys if required.
3. Clean coolant and oil seal mating surfaces on 7. Inspect thermostat assemblies. If thermostat
the crankcase, cylinder head, water distribution assembly elements are stuck open, damaged,
housing, water pump assembly, coolant outlet cracked or not opening properly, replace
manifold, thermostat housing and front belt- or thermostat assemblies.
gear-driven fan cover.
8. Inspect water pump assembly. Wiggle water
4. Inspect water distribution housing, coolant outlet pump assembly hub and shaft. If water pump
manifold, vibration damper and front belt- or assembly bearing has excess play, replace
gear-driven fan cover for damage, contamination water pump assembly. Inspect water distribution
or excessive wear. Replace parts if required. housing and water pump assembly for coolant
leaks. Replace if leaking.
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 303
COMPONENTS
1. Install fan low mount drive, M8 x 40 bolt and four Figure 409 Radial shaft seal installation
M8 x 25 bolts. Tighten bolts to standard torque
(page 471). 1. Fan Seal Installer
2. Fan low mount drive assembly
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
304 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Front Belt- or Gear-Driven Fan Cover Front Belt- or Gear-Driven Fan Cover Radial Shaft
Seal
Figure 410 Front belt- or gear-driven fan cover 1. Front belt- or gear-driven fan cover
bolts (typical) 2. Front Crankshaft Seal Installer
1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3) CAUTION: To avoid damage to the radial shaft seal,
3. M8 x 40 bolt (2) do not touch inner seal lip, allow oil or grease on any
4. M12 x 30 bolt (2) part of the seal during installation.
1. Using Front Crankshaft Seal Installer (page 313),
install a new radial shaft seal into the front cover.
WARNING: To prevent personal injury or a. Install inner hub of tool to crankshaft flange.
death, use a suitable lifting device and get help Use two bolts provided to secure tool.
when removing, lowering and installing the front
cover. b. Install radial shaft seal to inner hub of tool.
1. Position a new front cover gasket on crankcase c. Install pressing hub and nut and tighten to
dowels. install radial shaft seal. When tool bottoms
out, seal is fully installed.
2. Install front cover on crankcase dowels.
3. Install two M8 x 40 bolts, two M12 x 30 bolts, three
M12 x 75 bolts and 13 M8 x 25 bolts in locations
shown. Tighten M8 bolts to standard torque (page
471). Tighten M12 bolts to special torque (page
312).
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 305
COMPONENTS
Thermostat Housing
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Follow all warnings, cautions, and notes.
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306 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 307
COMPONENTS
Vibration Damper
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
308 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Water Pump Assembly and Pulley Automatic Belt Tensioner and Idler Pulley
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 309
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
310 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
High Mount Fan Drive 2. Install fan drive clutch assembly and five new M10
x 150 - 12.9 and one new M10 x 65 bolt with
engine oil lightly applied to threads.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 311
COMPONENTS
Tensioner Bracket (High Mount Fan) 2. Install fan drive tensioner and M10 x 70
countersunk screw. Make sure locating pin is
placed into locating hole. Tighten countersunk
screw to special torque (page 312).
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Follow all warnings, cautions, and notes.
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312 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Special Torque
Table 24 Front Cover, Fan Drive, Cooling System and Related Components
Automatic belt tensioner countersunk screw,
47 N·m (35 lbf·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lbf·ft)
M8 x 60
Coolant heater 41 N·m (30 lbf·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lbf·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lbf·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lbf·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lbf·ft)
Front belt- or gear-driven fan cover bolts,
• M12 x 75 115 N·m (85 lbf·ft)
• M12 x 30 115 N·m (85 lbf·ft)
High mount fan drive clutch assembly bolts,
See tightening steps in procedure
M10
High mount fan drive tensioner countersunk
47 N·m (35 lbf·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lbf·ft)
Low mount fan drive bolt, M10 x 110 37 N·m (27 lbf·ft)
Thermostat housing bolts, M8 35 N·m (26 lbf·ft)
Vibration damper socket-head cap screws,
See tightening steps in procedure
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lbf·ft)
Water pump assembly bolts, M8 35 N·m (26 lbf·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lbf·ft)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 313
COMPONENTS
Table 25 Front Cover, Fan Drive, Cooling System and Related Components
Description Tool Number
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
314 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
MAXXFORCE® ENGINE BRAKE BY JACOBS 315
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .325
Master Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Engine Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
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316 MAXXFORCE® ENGINE BRAKE BY JACOBS
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Follow all warnings, cautions, and notes.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 317
Exploded Views
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Follow all warnings, cautions, and notes.
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318 MAXXFORCE® ENGINE BRAKE BY JACOBS
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MAXXFORCE® ENGINE BRAKE BY JACOBS 319
Figure 431 Engine injector wiring harness with engine brake solenoid leads
1. Solenoid assembly (2) 3. Engine brake assembly (2) 5. Engine injector harness
2. Solenoid connector nut (part of 4. Engine brake solenoid harness assembly
harness connector) (4) connector lead (2) 6. Tie strap (3)
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320 MAXXFORCE® ENGINE BRAKE BY JACOBS
Removal
Engine Brake Housing Assembly
Disassembly
NOTE: When disassembling the engine brake
housing, keep all component parts together in sets
and if reused, reinstall each set back in its original
location.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 321
4. Remove upper and lower seal rings from solenoid NOTE: Use same procedure to remove all control
stem. Discard seal rings. valves from engine.
5. Remove and discard solenoid screen. 1. Push down on control valve cover and hold
to remove spring pressure from control valve
retaining ring. Using suitable snap-ring pliers,
remove control valve retaining ring from housing
control valve bore. Slowly release control valve
cover to relieve spring pressure.
2. Remove control valve cover from valve bore.
3. Using a pick, carefully remove inner and outer
springs from bore.
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Follow all warnings, cautions, and notes.
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322 MAXXFORCE® ENGINE BRAKE BY JACOBS
Master Piston
The master piston group currently is not a serviceable Figure 436 Slave piston
part. If a fault condition is traced to a malfunctioning 1. M10 (jam) nut
master piston, replace brake housing assembly. 2. Slave piston adjusting screw
3. Slave piston
4. Slave piston spring
5. Slave piston washer
6. Slave piston retaining ring
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MAXXFORCE® ENGINE BRAKE BY JACOBS 323
Figure 437 Slave Piston Removal Tool Figure 438 Slave piston retaining ring
1. Clamp screw collar 1. Slave piston retaining ring
2. Slave Piston Removal Tool 2. Slave Piston Removal Tool
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324 MAXXFORCE® ENGINE BRAKE BY JACOBS
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MAXXFORCE® ENGINE BRAKE BY JACOBS 325
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326 MAXXFORCE® ENGINE BRAKE BY JACOBS
Master Piston
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MAXXFORCE® ENGINE BRAKE BY JACOBS 327
Solenoid
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328 MAXXFORCE® ENGINE BRAKE BY JACOBS
Installation
Engine Brake Housing Assembly
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MAXXFORCE® ENGINE BRAKE BY JACOBS 329
CAUTION: To prevent engine damage, do not over Engine Brake Lash Adjustment
torque nuts on wiring harness connector leads. Too
much torque will damage solenoid terminals.
4. Connect brake wiring harness connector leads
to solenoid on front and rear engine brake
housing assemblies. Make sure harness terminal
connectors are in straight alignment with harness.
Hold terminal connectors stationary to avoid
twisting and tighten connector nuts to special
torque (page 330).
5. Install two tie straps to secure solenoid harness
connector lead on front brake housing and one tie
strap to secure harness connector lead on rear
brake housing.
6. Adjust engine brake lash. See (Engine Brake
Lash Adjustment, page 329) for procedure.
Figure 448 Engine brake lash adjustment
7. Install upper valve cover. See Upper Valve Cover
and Base in the “CYLINDER HEAD, CAMSHAFT 1. Slave piston adjusting screw
AND VALVE TRAIN” section (Upper Valve Cover 2. M10 (jam) nut
and Base, page 359) for procedure. 3. Actuator pin (in exhaust valve bridge)
4. Slave piston
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330 MAXXFORCE® ENGINE BRAKE BY JACOBS
Specifications
Solenoid resistance:
Special Torque
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 331
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .342
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .343
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .345
Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .352
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .356
Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
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332 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 333
Exploded Views
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Follow all warnings, cautions, and notes.
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334 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 335
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Follow all warnings, cautions, and notes.
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336 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 337
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338 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
1. Flywheel housing timing index NOTE: Valve lash adjustments are done in firing order
2. Flywheel timing mark sequence (1, 5, 3, 6, 2, 4), using the valve overlap
method. Valve overlap happens on the companion
cylinder near the end of the exhaust stroke and the
3. Remove timing hole cover from lower side of beginning of the intake stroke, when both valves are
flywheel housing. open for a short period of time.
4. Use a pry bar to rotate crankshaft in direction 1. Starting with cylinder 1 at TDC compression, set
needed to align the flywheel timing mark with valve lash for cylinder 1, according to Valve Lash
flywheel housing timing index. Adjustment Procedure below.
2. After valves for cylinder 1 have been adjusted,
rotate crankshaft slowly and watch valves for
cylinder 2; watch the exhaust valve as it closes,
and watch for intake valve to start opening. When
cylinder 2 intake and exhaust valves are open
equally, adjust valves on cylinder 5 according to
the Valve Lash Adjustment Procedure below.
3. Repeat Valve Overlap Procedure, in order for
remaining cylinders 3,6,2, and 4. See Table 29
(page 340).
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 339
Valve Lash Adjustment Procedure c. Hold adjusting screw in position and tighten
exhaust valve lash adjustment M10 nut to
special torque (page 361).
d. Go to step 6 to complete adjustments.
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340 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 341
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342 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
Figure 460 Rocker arm assembly (typical) 4. Mark rocker bearing blocks 1 through 6 so each
block can be installed in its original cylinder
1. M12 x 60 (socket-head) screw (12) location.
2. Rocker arm assembly (6)
5. Remove six rocker bearing blocks.
6. Mark valve bridges so each bridge can be
1. Mark rocker arm assemblies 1 through 6 so each
installed in its original location and orientation.
assembly can be installed in its original cylinder
location. 7. Remove 12 valve bridges.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 343
Camshaft
CAUTION: To prevent engine damage, use
permanent marker to identify internal engine
components and their orientation. Do not use paint
or temporary markers.
Figure 462 Camshaft end play check (typical) 2. Turn engine crankshaft in direction of engine
rotation, until timing mark on camshaft gear is
aligned with cylinder head surface.
1. Check camshaft end play as follows:
a. Mount dial indicator with magnetic base (page
362) on cylinder head with indicator tip on end
of camshaft as shown.
b. Move camshaft toward rear of engine and
zero the dial indicator.
c. Move camshaft back and forth while reading
dial indicator. Compare dial indicator reading
with camshaft end play specification (page
361).
d. If end play exceeds specified limits, install a
new camshaft.
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344 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
3. Remove timing hole cover from lower side of 5. Remove seven camshaft bearing caps from
flywheel housing and verify timing mark on the cylinder head. Mark each bearing cap with
flywheel is aligned with flywheel housing timing location number and orientation.
index.
• If timing mark on flywheel is out of alignment,
then the timing has slipped due to large idler
gear slippage. Install a new large idler gear.
See “OIL PUMP AND TIMING GEARS” (page
398) section of this manual for procedures to
replace large idler gear.
• If timing mark on flywheel is aligned with
flywheel housing timing index, continue to
next step.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 345
Cylinder Head
CAUTION: To prevent engine damage, remove fuel
injectors before removing cylinder head.
1. Remove six fuel injectors. See Fuel Injectors in
the “FUEL SYSTEM” section (page 213) of this
manual for procedure to remove fuel injectors.
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346 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
4. Use Head Bolt Torx® Socket (page 362) and discard 26 M18 x 246 Torx® bolts. Begin with the
working in a circular pattern, loosen, remove and outer bolts and move inward.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 347
Figure 470 Cylinder head removal Figure 471 8 mm dowel pin (2)
5. Lift cylinder head using a suitable lifting device. 9. If damaged, remove two 8 mm dowel pins.
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348 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 349
Cleaning, Inspection, and Testing 5. Clean cylinder head bolt holes in crankcase with
Head Bolt Bottoming Tap (page 362).
Cylinder Head and Crankcase Components
6. Clean out debris with filtered compressed air.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Camshaft Bearings
Limit compressed air pressure to 207 kPa (30 psi).
1. With camshaft removed, install previously marked
CAUTION: Do not use chlorinated solvents on
bearings and camshaft bearing caps. Tighten M8
cylinder head bolts. If parts are not cleaned
x 35 bolts to special torque (page 361).
thoroughly, parts will corrode over time. Be sure
parts are clean, dry and free of chemicals other than
engine oil.
CAUTION: To prevent engine damage, do not scratch
gasket surface of cylinder head.
1. Use a scraper and wire brush to remove deposits
and gasket material from valve heads and gasket
surface.
2. Use a suitable solvent to remove dirt, grease and
deposits from removed parts.
3. Clean all bolt holes. Make sure gasket surfaces
are clean. Clean all surfaces and ports with
steam, and then dry with filtered compressed air.
4. Clean all bolts (except head bolts) with a suitable
solvent and dry thoroughly. New head bolts must
Figure 475 Camshaft bearing check (typical)
be installed.
CAUTION: To prevent engine damage, clean and
dry threads in crankcase bolt holes with filtered 2. Use a telescoping gauge set (page 362) and a
compressed air. Dirt or oil in holes may cause binding 1 - 2 inch micrometer (page 362) to measure
and incorrect torque readings. camshaft bearing inside diameter. If inside
diameter does not meet specification (page 361),
install new camshaft bearings.
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350 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 351
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352 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
Installation
Cylinder Head Idler Gear
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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 353
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354 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
CAUTION: To prevent engine damage, install new 7. Install 26 new lightly lubricated M18 x 246 Torx®
cylinder head bolts when installing cylinder head. bolts. Do not tighten bolts at this time.
Apply a light coat of clean engine oil to new bolt
8. Remove four M8 x 20 class 10.9 bolts and
threads and under bolt head. Too much oil will cause
Cylinder Head Lifting Bracket (page 362).
hydrostatic lock and give incorrect torque reading. Do
not use anti-seize compound, grease, or any other
lubricant on cylinder head bolt threads.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 355
CAUTION: To prevent engine damage, use only 3. Tighten Torx® bolts numbered 1 through
permanent ink markers to identify bolt torque 26 to 150 N·m (111 lbf·ft) in numerical
orientation. sequence.
CAUTION: To prevent engine damage, use a torque 4. Tighten Torx® bolts numbered 1 through
wrench to tighten cylinder head bolts; do not use an 26 to 300 N·m (221 lbf·ft) in numerical
impact wrench. sequence.
NOTE: For proper cylinder head surface seating and 5. Rotate Torx® bolts numbered 1 through
sealing, follow the correct tightening sequence. 26 an additional 90° (1/4 turn) clockwise
in numerical sequence.
9. Use Head Bolt Torx® Socket (page 362) to tighten
the M18 x 246 Torx® bolts in sequence indicated 6. Rotate Torx® bolts numbered 1 through
above as follows: 26 an additional 90° (1/4 turn) clockwise
in numerical sequence for second time.
1. Hand-tighten Torx® bolts.
7. Rotate Torx® bolts numbered 1 through
2. Tighten Torx® bolts numbered 1 through
26 an additional 90° (1/4 turn) clockwise
26 to 10 N·m (89 lbf·in) in numerical
in numerical sequence for third time.
sequence as shown.
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356 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
Camshaft
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 357
7. Verify timing mark on flywheel is aligned with NOTE: Make sure that each bearing cap has the two
flywheel housing timing index at bottom of dowel pins installed.
flywheel housing.
9. If previously removed, install 14 – 4H x 8 x 10
dowel pins into seven camshaft bearing caps.
NOTE: If original bearings are installed, make sure
each is placed as previously marked in its original
location and orientation.
10. Install seven new or previously marked bearing
shells on camshaft bearing caps.
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358 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 359
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360 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 361
Specifications
Special Torque
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362 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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FLYWHEEL AND FLYWHEEL HOUSING 363
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Preliminary Checks and Measurements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
Pilot Bearing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
Flywheel (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .369
Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
Recondition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374
Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .375
Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
Flywheel Assembly (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .376
Pilot Bearing (Flywheel). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
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Follow all warnings, cautions, and notes.
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364 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 365
Exploded Views
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Follow all warnings, cautions, and notes.
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366 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 367
EGES-465-1
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Follow all warnings, cautions, and notes.
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368 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 369
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Follow all warnings, cautions, and notes.
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370 FLYWHEEL AND FLYWHEEL HOUSING
1. Remove transmission and torque converter 1. With an awl and hammer, punch two holes 180°
assembly. (See transmission manufacturer’s apart in radial shaft ring seal.
service publications.)
2. Thread a slide hammer (page 379) with correct
2. Remove and discard two 12PT flange bolts, 180 size screw into one of the two holes.
degrees from each other (approximately 3 o’clock
3. Slide hammer until one side of seal begins to
and 9 o’clock positions).
pull out of flywheel housing. Move slide hammer
3. Install two guide pins (made locally) in place of two to other hole and repeat until seal is completely
removed 12PT flange bolts. removed.
4. Remove and discard the remaining eight 12PT
flange bolts.
Lifting Eyes
NOTE: The individual components of the flexplate
assembly are non-servicable. Replace the flexplate
as an assembly.
5. Slide wear plate (reinforcement ring) and four
flexplates off guide pins.
6. Slide flywheel assembly off guide pins and out of
flywheel housing.
7. Remove guide pins from crankshaft flange.
Flywheel Housing
1. Slide hammer
2. Radial shaft ring seal WARNING: To prevent personal injury or
death, get help when removing or installing the
flywheel housing.
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FLYWHEEL AND FLYWHEEL HOUSING 371
2. Remove 3/4" x 2” bolts with washers, extension 4. Use a thin gasket scraper to separate sealant
bracket and engine mounting support from the left between flywheel housing and crankcase.
side of flywheel housing.
WARNING: To prevent personal injury or
death, get help when removing or installing the
flywheel housing.
5. Remove flywheel housing with aid of an assistant.
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Follow all warnings, cautions, and notes.
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372 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 373
1. Check flywheel for cracks and damage. Replace 4. Check flywheel for cracks and damage after
flywheel if required. resurfacing. Replace flywheel if required.
2. Using 1-2 inch micrometer (page 379), measure 5. Measure flywheel thickness after resurfacing
flywheel thickness and compare to minimum and compare to minimum required thickness
required thickness specification (dimension “A”) specification. Discard flywheel if below minimum
(page 379). Discard flywheel if below minimum thickness specification.
thickness specification or if flywheel will be below
minimum thickness after resurfacing.
3. Resurface flywheel. See Flywheel Resurfacing
Machine operators manual for instructions on
flywheel resurfacing procedure.
EGES-465-1
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Follow all warnings, cautions, and notes.
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374 FLYWHEEL AND FLYWHEEL HOUSING
Installation
Flywheel Housing
CAUTION: To prevent engine damage, apply Liquid
Gasket and component within 5 minutes of application
to inhibit the formation of a skin and ensure a leak
proof joint.
EGES-465-1
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 375
Lifting Eyes
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Follow all warnings, cautions, and notes.
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376 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 377
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Follow all warnings, cautions, and notes.
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378 FLYWHEEL AND FLYWHEEL HOUSING
3. Slide flexplate assembly over guide pins. NOTE: For proper flywheel installation, follow the
correct tightening sequence while keeping the
4. Slide wear plate (reinforcement plate) over guide
crankshaft from turning.
pins with logo and part number visible towards
rear and install eight new 12PT flange bolts hand 6. Tighten 12PT flange bolts using sequence above
tight. as follows:
5. Remove guide pins and install remaining two a. Tighten bolts to 110 N•m (81 lbf·ft).
12PT flange bolts.
b. Angle tighten bolts 90°
c. Angle tighten bolts an additional 90°.
EGES-465-1
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 379
Specifications
Special Torque
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Follow all warnings, cautions, and notes.
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380 FLYWHEEL AND FLYWHEEL HOUSING
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Follow all warnings, cautions, and notes.
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OIL PAN AND OIL PICKUP TUBE 381
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Oil Pickup Tube — Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Oil Pickup Tube — Front Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .390
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382 OIL PAN AND OIL PICKUP TUBE
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Follow all warnings, cautions, and notes.
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OIL PAN AND OIL PICKUP TUBE 383
Exploded Views
Figure 521 Oil pan (front sump shown, rear sump similar, typical)
1. Oil pan gasket 5. Oil pan clamp (concave groove) 8. M8 x 40 bolt (22)
2. Oil pan (front sump) (6) 9. Extension bracket support
3. O-ring (heater, optional 6. Oil pan clamp (convex groove) (T-bracket)
equipment) (16) 10. Oil drain M27 x 2 plug
4. Oil pan heater element (optional 7. Cooling tube bracket (2) (right 11. O-ring (32.92 x 3.53)
equipment) angle)
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Follow all warnings, cautions, and notes.
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384 OIL PAN AND OIL PICKUP TUBE
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Follow all warnings, cautions, and notes.
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OIL PAN AND OIL PICKUP TUBE 385
WARNING: To prevent personal injury or Figure 523 Oil pan (front sump shown)
death, shift the transmission to park or neutral, 1. M8 x 40 bolt (22)
set the parking brake, and block the wheels before 2. Cooling tube bracket (right angle) (2)
doing diagnostic or service procedures. 3. Extension bracket support (T-bracket)
EGES-465-1
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386 OIL PAN AND OIL PICKUP TUBE
6. Remove 16 oil pan clamps (convex groove). 1. Remove two M8 x 16 bolts and pickup tube with
supports as an assembly.
7. Remove oil pan and oil pan gasket as an
assembly. 2. Only if required, remove the two M8 x 25 bolts,
prevailing torque nuts, D9/19/4 washers and oil
8. Clean and inspect the oil pan gasket. Discard
pickup tube supports.
gasket if damaged.
EGES-465-1
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Follow all warnings, cautions, and notes.
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OIL PAN AND OIL PICKUP TUBE 387
Oil Pickup Tube — Rear Sump 2. Remove oil pickup tube and supports as an
assembly.
3. Only if required, remove M8 x 25 bolts, prevailing
torque nuts and D9/19/4 washers and supports.
EGES-465-1
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388 OIL PAN AND OIL PICKUP TUBE
Cleaning and Inspection 4. Inspect oil pan for warping, dents and cracks.
Replace the oil pan if necessary.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
Oil Pickup Tube
Limit compressed air pressure to 207 kPa (30 psi).
1. Clean oil pickup tube and supports with a suitable
Oil Pan
solvent.
1. Inspect bottom of oil pan for metallic debris or
2. Dry with filtered compressed air.
other evidence of engine damage. Investigate
any abnormalities as required. 3. Inspect oil pickup tube and supports for cracks,
damage or pickup screen blockage. Replace if
2. Clean oil pan with a suitable solvent.
necessary.
3. Dry with filtered compressed air.
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Follow all warnings, cautions, and notes.
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OIL PAN AND OIL PICKUP TUBE 389
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390 OIL PAN AND OIL PICKUP TUBE
Figure 532 Oil pickup tube 1. Oil pan clamp (concave groove) (6)
2. Oil pan clamp (convex groove) (16)
1. M8 x 16 bolts (4)
2. M8 x 25 bolts (3)
3. Oil pickup tube 3. Install an oil pan clamp (concave groove) and
4. Tube support a M8 x 40 bolt in each corner of the oil pan.
Finger-tighten each bolt.
Oil Pan
1. Install oil pan gasket on oil pan.
2. Position oil pan and oil pan gasket as an assembly
on the crankcase.
Figure 534 Oil pan (front sump, typical)
1. M8 x 40 bolt (22)
2. Cooling tube bracket (right angle bracket) (2)
3. Extension bracket support (T-bracket)
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OIL PAN AND OIL PICKUP TUBE 391
6. Follow the torque sequence and tighten 22 M8 x lubricated with clean engine oil. Tighten plug to
40 bolts to special torque (page 392). special torque (page 392).
7. Re-torque 22 M8 x 40 bolts to special torque (page 9. Lubricate a new oil pan drain plug O-ring with
392). clean engine oil and put O-ring on the M27 x 2
drain plug.
8. If equipped with oil pan heater element, lubricate
a new O-ring with clean engine oil and install 10. Install M27 x 2 drain plug and tighten to special
element and lubricated O-ring into the oil pan. torque (page 392).
Tighten element to special torque (page 392).
On vehicles not equipped with an oil pan heater
element, install drain plug with a new O-ring
EGES-465-1
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Follow all warnings, cautions, and notes.
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392 OIL PAN AND OIL PICKUP TUBE
Special Torque
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 393
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .398
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
Front Crank Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
Front Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
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394 OIL PUMP AND TIMING GEARS
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OIL PUMP AND TIMING GEARS 395
Exploded Views
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Follow all warnings, cautions, and notes.
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396 OIL PUMP AND TIMING GEARS
EGES-465-1
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 397
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Follow all warnings, cautions, and notes.
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398 OIL PUMP AND TIMING GEARS
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 399
Oil Pump
Figure 540 (Rear) large idler gear backlash
measurement (typical)
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Follow all warnings, cautions, and notes.
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400 OIL PUMP AND TIMING GEARS
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 401
Figure 547 Idler gear assembly and timing Figure 549 Rear crank gear assembly (typical)
marks
1. Rear crank gear
1. M14 x 80 bolt (4) 2. Pin 8 x 60-ST
2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear) 3. Using a gear puller (page 408), remove rear crank
5. Timing mark (rear crank gear) gear assembly.
EGES-465-1
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Follow all warnings, cautions, and notes.
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402 OIL PUMP AND TIMING GEARS
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL PUMP AND TIMING GEARS 403
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
404 OIL PUMP AND TIMING GEARS
Installation
Rear Timing Gears
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL PUMP AND TIMING GEARS 405
Figure 555 Crankcase idler gear (typical) Figure 556 Large Idler gear assembly and timing
marks
1. M8 x 30 socket-head cap screw (3)
2. Small gear stud 1. M14 x 80 bolt (4)
3. Crankcase idler gear 2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear)
CAUTION: To prevent engine damage, insert the 5. Timing mark (rear crank gear)
crankcase idler gear into the crankcase with the
flatter contact surface facing outwards.
NOTE: Large idler gear has two timing marks 180°
5. Install crankcase idler gear and small gear stud.
apart; either may be used.
6. Install three crankcase idler gear M8 x 30
7. Install big gear stud and large idler gear, aligning
socket-head cap screws. Tighten cap screws
timing mark with timing mark on rear crank gear
to special torque (page 408).
(flywheel side).
8. Install four M14 x 80 bolts. Tighten bolts to special
torque (page 408).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
406 OIL PUMP AND TIMING GEARS
Front Timing Gears 3. Install two suitable alignment bolts 180° apart
through front crank gear into front of crankshaft.
Oil Pump
1. Lubricate new O-ring 22 x 2 with clean engine oil
and install oil pump pinion axle.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL PUMP AND TIMING GEARS 407
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
408 OIL PUMP AND TIMING GEARS
Specifications
Special Torque
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 409
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413
Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .414
Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .416
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425
EGES-465-1
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© 2011 Navistar, Inc. All rights reserved
410 POWER CYLINDERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 411
Exploded Views
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
412 POWER CYLINDERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 413
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
414 POWER CYLINDERS
b. Zero dial indicator with magnetic base (page CAUTION: To prevent engine damage, install
427) on crankcase deck surface. connecting rod cap and connecting rod with matching
serial numbers on the same side. If the rod cap is
c. Position dial indicator tip over piston head at
reversed or not installed on its matching connecting
3 o’clock position.
rod, the fractured mating surfaces will be damaged.
d. Rotate crankshaft in direction of normal A new connecting rod assembly must be installed.
rotation to raise piston to its maximum Do NOT attempt to reuse a rod that has been
outward protrusion at cylinder Top Dead misassembled to its cap, assembled with the wrong
Center (TDC). Push down on piston crown cap or has been cross-threaded while attempting
before taking reading. Read this maximum assembly. Serious engine damage can result.
protrusion on dial indicator.
2. Rotate crankshaft to position journals for removal
e. Reposition dial indicator tip on piston head at of connecting rod assemblies. Mark connecting
9 o’clock position. rod locations.
f. Rotate crankshaft to raise piston to its
maximum protrusion. Push down on piston
crown before taking reading. Read maximum
protrusion on dial indicator.
g. Average the two readings. Replace piston
and connecting rod if protrusion is not within
specification (page 425).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 415
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
416 POWER CYLINDERS
NOTE: Only expand piston rings enough to fit over top CAUTION: To prevent engine damage, use
of piston. permanent markers to identify internal engine
components and their orientation. Do not use paint
NOTE: Keep piston rings organized for each cylinder.
or temporary markers.
3. Using piston ring expansion pliers (page 427),
NOTE: Care must be taken not to damage piston
remove top compression ring, taper face
cooling jets during cylinder sleeve removal.
compression ring and bevelled oil ring.
1. Remove six cylinder sleeves from crankcase as
follows:
Cylinder Sleeves
a. Insert Cylinder Sleeve Puller (page 427) into
cylinder sleeve.
b. Engage removal tool hooks under bottom
edge of cylinder sleeve.
c. Position removal tool feet diagonally on
crankcase deck surface.
d. Turn threaded shaft clockwise to extract
cylinder sleeve.
e. Mark cylinder sleeves for position and set
aside for inspection.
2. Remove and discard two cylinder sleeve O-rings
from each crankcase cylinder sleeve.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 417
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
418 POWER CYLINDERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 419
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
420 POWER CYLINDERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 421
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
422 POWER CYLINDERS
Piston and Connecting Rod CAUTION: To prevent engine damage, the arrow
stamped on top of piston must face front of engine.
1. Turn crankshaft so crank pin (connecting
rod journal) on the cylinder to receive piston CAUTION: To prevent engine damage, do not
installation is at the bottom of its stroke. damage piston cooling jet when installing connecting
rod and piston assembly. If jet is bent during piston
2. Lightly coat piston and piston rings with clean
assembly installation, replace jet.
engine oil.
CAUTION: To prevent engine damage, do not allow
3. Coat cylinder sleeve walls, crankshaft journals
fractured mating surfaces of the connecting rod or
and Piston Ring Compressor (page 427) with
connecting rod cap to contact any surface other
clean engine oil.
than its matched fractured surface. Contacting any
4. Place piston in Piston Ring Compressor (page other surface could cause misalignment of the mating
427). surface, resulting in connecting rod bearing and
engine failure.
NOTE: Upper connecting rod bearings have an oil
hole and lower connecting rod bearings do not. NOTE: Before installing piston and connecting rod
assembly, make sure all piston cooling jets are
5. Install connecting rod bearings in connecting rod
installed.
and cap. Bearings with oil hole go in the upper
position. Coat bearings with clean engine oil. 6. Carefully put piston and piston ring compressor
combination and connecting rod assembly in
Be sure that all bearing locator tabs and oil holes
cylinder sleeve with arrow mark facing towards
are in alignment with connecting rod and cap and
front of engine.
that bearings are flush to fractured mating faces
of rod and cap.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 423
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
424 POWER CYLINDERS
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 425
Specifications
Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)
EGES-465-1
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Follow all warnings, cautions, and notes.
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426 POWER CYLINDERS
Special Torque
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 427
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
428 POWER CYLINDERS
EGES-465-1
Read all safety instructions in the "Safety Information" section of this Manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 429
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .432
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .433
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .434
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .438
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441
EGES-465-1
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430 CRANKCASE AND CRANKSHAFT
EGES-465-1
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Follow all warnings, cautions, and notes.
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CRANKCASE AND CRANKSHAFT 431
Exploded View
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
432 CRANKCASE AND CRANKSHAFT
WARNING: To prevent personal injury or • Oil Pan and Oil Pickup Tube
death, do not let engine fluids stay on your skin. • Oil Pump and Timing Gears
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing • Power Cylinders
and rags contaminated with engine fluids.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 433
1. Check crankshaft end play as follows: 1. M18 x 160.5 collar bolt (14)
2. Main bearing cap (7)
a. Mount dial indicator with magnetic base (page
441) on crankcase with indicator tip on end of
crankshaft as shown. CAUTION: To prevent engine damage, do not drop
b. Move crankshaft forward with pry bar and main bearing caps. Damage to the fractured mating
zero the dial indicator. surface of a main bearing cap will require replacement
of the crankcase and mated main bearing caps.
c. Move crankshaft back and forth while reading
dial indicator. Compare dial indicator reading 3. Remove 14 M18 x 160.5 collar bolts and seven
with specification (page 441). main bearing caps. Save bolts for Main Bearing
measurement procedure (page 436).
d. If end play exceeds specified limits, replace
main bearing thrust washers. 4. Remove seven lower main bearings and two
lower thrust washers from main bearing caps by
pushing out.
Crankshaft
CAUTION: To prevent engine damage, use
1. Position engine so that bottom of main bearing permanent markers to identify internal components
caps are facing upwards. or their orientation. Do not use paint or temporary
markers.
CAUTION: To prevent engine damage, use
permanent markers to identify internal components 5. Number removed lower main bearings and lower
or their orientation. Do not use paint or temporary thrust washers on back side (not running surface)
markers. and set aside for inspection.
EGES-465-1
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Follow all warnings, cautions, and notes.
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434 CRANKCASE AND CRANKSHAFT
EGES-465-1
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© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 435
Cleaning, Inspection and Testing CAUTION: To prevent engine damage, clean and
dry threads in the crankcase bolt holes with filtered
Crankcase
compressed air. Dirt or oil in holes may cause binding
and incorrect torque readings.
WARNING: To prevent personal injury or
death, wear safety glasses with side shields. 3. Clean cylinder head bolt holes with Head Bolt
Limit compressed air pressure to 207 kPa (30 psi). Bottoming Tap (page 441).
CAUTION: To prevent engine damage, do not use 4. Clean collar bolt holes with Main Bolt Bottoming
chlorinated solvents on bolts or crankcase tapped Tap (page 441).
holes. Parts should be clean, dry and free of any 5. Clean out debris with filtered compressed air.
chemicals other than engine oil.
NOTE: Thoroughly clean and inspect crankcase
before and after reconditioning. Crankshaft Measurement
1. Clean crankcase in a chemical bath or hot tank. 1. Clean and inspect crankshaft and main bearings.
This removes all carbonized material and mineral 2. Clean crankshaft with a suitable solvent.
deposits in coolant passages.
3. Use a stiff nylon brush to clean oil passages in
CAUTION: To prevent engine damage, do not use a crankshaft. Loosen accumulated dirt, sludge and
wire brush to clean the fractured mating surface of deposits.
crankcase and main bearing caps.
4. Flush oil passages with a suitable solvent.
2. If a hot tank is not available, do the following steps:
a. Use non-metallic stiff bristle brushes and WARNING: To prevent personal injury or
scrapers to clean gasket material from death, wear safety glasses with side shields.
machined surfaces of crankcase. Limit compressed air pressure to 207 kPa (30 psi).
b. Clean crankcase in solvent. 5. Dry with filtered compressed air.
c. Dry with filtered compressed air. 6. Inspect crankshaft journals (main and connecting
rod) for scratches, grooves and scoring.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
436 CRANKCASE AND CRANKSHAFT
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© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 437
h. Turn remaining collar bolts an additional 90° measurement does not meet specification (page
clockwise. 441), replace main bearings.
10. Remove 14 M18 x 160.5 collar bolts, seven main
bearing caps, upper main bearings and lower
main bearings. Discard used collar bolts.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
438 CRANKCASE AND CRANKSHAFT
Installation
Piston Cooling Jets
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 439
CAUTION: To prevent engine damage, do not bend, locking tabs align with notches in main bearing
drop or damage crankshaft. cap.
NOTE: Use only a soft-sided lifting sling. Do not use 7. Place lower main bearings in main bearing caps.
chains or steel cables. Make sure locking tabs on bearings are snapped
into main bearing caps.
4. Attach lifting sling (page 441) to crankshaft.
Orient crankshaft with front flange (8 bolt holes) 8. Lubricate bearings with clean engine oil.
and rear flange (10 bolt holes) at crankcase front
and rear, respectively. Carefully lower crankshaft
down into crankcase.
NOTE: Make sure oil grooves on thrust washers face CAUTION: To prevent engine damage, install main
outward towards crankshaft thrust surface. bearing caps with their fractured mating surfaces in
the original orientation.
5. Install two upper thrust washers into crankcase at
No. 6 main location as follows: CAUTION: To prevent engine damage, do not drop
main bearing caps. Damage to the fractured mating
a. Set upper thrust washer on top of crankshaft surface of a main bearing cap will require replacement
at No. 6 main journal with grooves towards of the crankcase and mated main bearing caps.
crankshaft thrust surface.
9. Install seven main bearing caps and 14 new M18
b. Pivot upper thrust washer around crankshaft x 160.5 collar bolts.
and down into position.
6. Install two lower thrust washers onto No. 6 main
bearing cap. Make sure lower thrust washer
EGES-465-1
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440 CRANKCASE AND CRANKSHAFT
10. Tighten collar bolts as follows: e. Tighten remaining collar bolts to 100 N·m (74
lbf·ft).
a. Tighten two collar bolts at No. 6 (thrust
washer location) main bearing cap to 10 N·m f. Tighten two collar bolts at No. 6 (thrust
(88 lbf·in). washer location) main bearing cap to 300
N·m (221 lbf·ft).
b. Tighten remaining collar bolts to 10 N·m (88
lbf·in). g. Tighten remaining collar bolts to 300 N·m (221
lbf·ft).
c. Rotate crankshaft to verify that crankshaft
does not bind. Correct as required. h. Turn two collar bolts at No. 6 (thrust washer
location) main bearing cap bolts an additional
d. Tighten two collar bolts at No. 6 (thrust
90°.
washer location) main bearing cap to 100
N·m (74 lbf·ft). i. Turn remaining collar bolts an additional 90°.
EGES-465-1
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Follow all warnings, cautions, and notes.
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CRANKCASE AND CRANKSHAFT 441
Specifications
Special Torque
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Follow all warnings, cautions, and notes.
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442 CRANKCASE AND CRANKSHAFT
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ABBREVIATIONS AND ACRONYMS 443
Table of Contents
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444 ABBREVIATIONS AND ACRONYMS
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ABBREVIATIONS AND ACRONYMS 445
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446 ABBREVIATIONS AND ACRONYMS
DTRM – Diesel Thermo Recirculation Module ETCH – Engine Throttle Control High
EBP – Exhaust Back Pressure ETCL – Engine Throttle Control Low
EBPD – Exhaust Back Pressure Desired ETP – Engine Throttle Position
EBPV – Exhaust Back Pressure Valve ETV – Engine Throttle Valve
ECB – Engine Compression Brake EWPS – Engine Warning Protection System
ECB1 – Engine Compression Brake 1 F – Fahrenheit
ECB2 – Engine Compression Brake 2 FCV – Fuel Coolant Valve
ECBP – Engine Compression Brake Pressure FDP – Fuel Delivery Pressure
ECI – Engine Crank Inhibit FEL – Family Emissions Limit
ECL – Engine Coolant Level fhp – Friction horsepower
ECM – Engine Control Module FMI – Failure Mode Indicator
ECM GND – Engine Control Module Ground FPC – Fuel Pump Control
ECM PWR – Engine Control Module Power FPCV – Fuel Pressure Control Valve
ECS – Engine Coolant System fpm – Feet per minute
ECSR – Engine Controlled Shutdown Request FPM – Fuel Pump Monitor
ECT – Engine Coolant Temperature fps – Feet per second
ECT1 – Engine Coolant Temperature 1 FRP – Fuel Rail Pressure
ECT2 – Engine Coolant Temperature 2 ft – Feet
EFAN – Engine Fan FVCV – Fuel Volume Control Valve
EFC – Engine Fan Control GND – Ground (electrical)
EFRC – Engine Family Rating Code gal – Gallon
EFS – Engine Fan Speed gal/h – U.S. Gallons per hour
EFT – Engine Fuel Temperature gal/min – U.S. Gallons per minute
EG – Ethylene Glycol GCW – Gross Combined Weight
EGC – Electronic Gauge Cluster GCWR – Gross Combined Weight Rating
EGBP – Exhaust Gas Back Pressure GPC – Glow Plug Control
EGDP – Exhaust Gas Differential Pressure GPD – Glow Plug Diagnostic
EGR – Exhaust Gas Recirculation GPR – Glow Plug Relay
EGRC – Exhaust Gas Recirculation Control GVW – Gross Vehicle Weight
EGRH – Exhaust Gas Recirculation High control H2O – Water
EGRL – Exhaust Gas Recirculation Low control HC – Hydrocarbons
EGROT – Exhaust Gas Recirculation Outlet HEST – High Exhaust System Temperature
Temperature HFCM – Horizontal Fuel Conditioning Module
EGRP – Exhaust Gas Recirculation Position Hg – Mercury
EGRT – Exhaust Gas Recirculation Temperature hp – Horsepower
EGT – Exhaust Gas Temperature HPCAC – High-Pressure Charge Air Cooler
EGT1 – Exhaust Gas Temperature 1 HPCR – High-Pressure Common Rail
EGT2 – Exhaust Gas Temperature 2 HPFP – High-Pressure Fuel Pump
EGT3 – Exhaust Gas Temperature 3 hr – Hour
EMI – Electromagnetic Interference HS – Humidity Sensor
EMP – Exhaust Manifold Pressure Hyd – Hydraulic
EMT – Exhaust Manifold Temperature IAH – Inlet Air Heater
EOL – Engine Oil Level IAHC – Inlet Air Heater Control
EOP – Engine Oil Pressure IAHD – Inlet Air Heater Diagnostic
EOT – Engine Oil Temperature IAHR – Inlet Air heater Relay
EPA – Environmental Protection Agency IC – Integrated Circuit
EPR – Engine Pressure Regulator ICP – Injection Control Pressure
ESC – Electronic System Controller ICPR – Injection Control Pressure Regulator
ESN – Engine Serial Number ICG1 – Injector Control Group 1
EST – Electronic Service Tool ICG2 – Injector Control Group 2
ETC – Engine Throttle Control ID – Inside Diameter
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ABBREVIATIONS AND ACRONYMS 447
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448 ABBREVIATIONS AND ACRONYMS
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TERMINOLOGY 449
Table of Contents
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451
Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451
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450 TERMINOLOGY
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TERMINOLOGY 451
Terminology Air entering the radiator may or may not be the same
ambient due to possible heating from other sources
Terms
or recirculation. (SAE J1004 SEP81)
Accelerator Pedal Position (APP) sensor – A
Ampere (amp) – The standard unit for measuring the
potentiometer sensor that indicates the position of the
strength of an electrical current. The flow rate of a
throttle pedal.
charge in a conductor or conducting medium of one
Accessory work – The work per cycle required coulomb per second. (SAE J1213 NOV82)
to drive engine accessories (normally, only those
Analog – A continuously variable voltage.
essential to engine operation).
Analog to digital converter (A/D) – A device in the
Actuator – A device that performs work in response
ECM that converts an analog signal to a digital signal.
to an input signal.
American Trucking Association (ATA) Datalink –
Actuator Control – The ECM controls the actuators
A serial datalink specified by the American Trucking
by applying a low-level signal (low-side driver) or a
Association and the SAE.
high-level signal (high side driver). When switched on,
both drivers complete a ground or power circuit to an Boost pressure – 1. The pressure of the charge air
actuator. leaving the turbocharger.
Aeration – The entrainment of air or combustion gas 2. Inlet manifold pressure that is greater than
in coolant, lubricant, or fuel. atmospheric pressure. Obtained by turbocharging.
Aftercooler (Charge Air Cooler) – A heat exchanger Bottom Dead Center (BDC) – The lowest position of
mounted in the charge air path between the the piston during the stroke.
turbocharger and engine intake manifold. The
Brake Horsepower (bhp) – The power output from
aftercooler reduces the charge air temperature by
an engine, not the indicated horsepower. The power
transferring heat from the charge air to a cooling
output of an engine, sometimes-called flywheel
medium (usually air).
horsepower, is less than the indicated horsepower by
Aftertreatment Fuel Doser (AFTFD) – A part of the amount of friction horsepower consumed in the
the Downstream Injection (DSI) unit that sends engine.
pressurized fuel to the Aftertreatment Fuel Injector
Brake Horsepower (bhp) net – Net brake
(AFI) to inject fuel into the exhaust pipe.
horsepower is measured with all engine components.
Aftertreatment (AFT) system – A part of the exhaust The power of an engine when configured as a fully
system that processes engine exhaust to meet equipped engine. (SAE J1349 JUN90)
emission requirements and traps particulate matter
Calibration – ECM programming strategy to solve
(soot) to prevent it from leaving the tailpipe.
engine performance equations and make decisions.
Air Control Valve (ACV) – Contains the LP Calibration values are stored in ROM and put into the
turbocharger wastegate control port, HP turbocharger processor during programming to allow the engine to
wastegate control port, the EBPV control port, and operate within certain parameters.
the TC1TOP port. Although these components are
Camshaft Position (CMP) sensor – A magnetic
integral to the ACV, each circuit is controlled by the
pickup sensor that provides the ECM with a camshaft
ECM. The ACV controls compressed air for each
speed and position signal.
control valve.
Carbon Monoxide (CO) – A colorless, odorless,
Air Inlet Temperature (AIT) sensor – A thermistor
highly poisonous gas that is formed by the incomplete
sensor that monitors intake air temperature.
combustion of carbon burning diesel engine. It is
Ambient temperature – The environmental air present in the exhaust gases of diesel engines.
temperature in which a unit is operating. In general,
Catalyst – A substance that produces a chemical
the temperature is measured in the shade (no solar
reaction without undergoing a chemical change itself.
radiation) and represents the air temperature for other
engine cooling performance measurement purposes.
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452 TERMINOLOGY
Catalytic converter – An antipollution device in the Cold Start Fuel Solenoid (CSFS) – As the engine
exhaust system that contains a catalyst for chemically is cranked, the ECM energizes the CSFS valve,
converting some pollutants in the exhaust gases introducing fuel into the CSFI, which ignites and
(carbon monoxide, unburned hydrocarbons, and warms the air being drawn into the engine.
oxides of nitrogen) into harmless compounds.
Cold Start Relay (CSR) – The CSR provides voltage
Cavitation – A dynamic condition in a fluid system that to the CSFI, and is controlled by the ECM.
forms gas-filled bubbles (cavities) in the fluid.
Controller Area Network (CAN) – A J1939 high
Cetane number – 1. The auto-ignition quality of speed communication link.
diesel fuel.
Coolant – A fluid used to transport heat from one point
2. A rating applied to diesel fuel similar to octane to another.
rating for gasoline.
Coolant level switch – A switch sensor used to
3. A measure of how readily diesel fuel starts to burn monitor coolant level.
(self-ignites) at high compression temperature.
Coolant Flow Valve (CFV) – The CFV is ECM
Diesel fuel with a high cetane number self-ignites controlled and redirects coolant through the fuel
shortly after injection into the combustion chamber. cooler, based on EFT, when directed.
Therefore, it has a short ignition delay time. Diesel
Coolant Mixer Valve (CMV) – Controls coolant flow
fuel with a low cetane number resists self-ignition.
through the low-temperature radiator.
Therefore, it has a longer ignition delay time.
Continuous Monitor Test – An ECM function that
Charge air – Dense, pressurized, heated air
continuously monitors the inputs and outputs to
discharged from the turbocharger.
ensure that readings are within set limits.
Charge Air Cooler (CAC) – See Aftercooler.
Crankcase – The housing that encloses the
Charge Air Outlet Temperature (CACOT) sensor – crankshaft, connecting rods, and allied parts.
A thermistor sensor that monitors the temperature of
Crankcase breather – A vent for the crankcase to
charge air entering the intake air duct.
release excess interior air pressure.
Closed crankcase – A crankcase ventilation that
Crankcase Oil Separator Speed (CCOSS) sensor
recycles crankcase gases through a breather, then
– The CCOSS sensor sends the ECM information
back to the clean air intake.
about the speed of the crankcase oil separator internal
Closed loop operation – A system that uses sensors components.
to provide feedback to the ECM. The ECM uses the
Crankcase pressure – The force of air inside the
sensor input to continuously monitor variables and
crankcase against the crankcase housing.
adjust actuators to match engine requirements.
Crankshaft Position (CKP) sensor – A magnetic
Cloud point – The point when wax crystals occur in
pickup sensor that determines crankshaft position and
fuel, making fuel cloudy or hazy. Usually below -12 °C
speed.
(10 °F).
Current – The flow of electrons passing through a
Cold cranking ampere rating (battery rating) – The
conductor. Measured in amperes.
sustained constant current (in amperes) needed to
produce a minimum terminal voltage under a load of Damper – A device that reduces the amplitude of
7.2 volts per battery after 30 seconds. torsional vibration. (SAE J1479 JAN85)
Cold Start Fuel Ignitor (CSFI) – The CSFI heats the Deaeration – The removal or purging of gases (air or
intake air by vaporizing and igniting fuel in the air inlet combustion gas) entrained in coolant or lubricating oil.
duct.
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TERMINOLOGY 453
Deaeration tank – A separate tank in the cooling Driver (low side) – A transistor within an electronic
system used for one or more of the following functions: module that controls the ground to an actuator circuit.
• Deaeration Dual Stage Turbocharger – An assembly of two
turbochargers (low-pressure and high-pressure) in
• Coolant reservoir (fluid expansion and afterboil)
series to provide a wide range of charge air pressures
• Coolant retention efficiently.
• Filling Duty cycle – A control signal that has a controlled
on/off time measurement from 0 to 100%. Normally
• Fluid level indication (visible)
used to control solenoids.
Diagnostic Trouble Code (DTC) – 2010 model
EGR Cooler – A cooler that allows heat to dissipate
year vehicles no longer utilize DTC identification by
from the exhaust gasses before they enter the intake
number. DTCs are now identified using the Suspect
manifold.
Parameter Number (SPN) and Failure Mode Indicator
(FMI) identifiers only. Engine Control Module (ECM) – An electronic
processor that monitors and controls the engine.
Diesel Particulate Filter (DPF) – A diesel particulate
filter, sometimes called a DPF, is a device designed Engine Back Pressure Valve (EBPV) – The ECM
to remove diesel particulate matter or soot from the commands the EBPV to control the Exhaust Brake.
exhaust gas of a diesel engine.
Engine Compression Brake (ECB) valve – The
Diesel Oxidation Catalyst (DOC) – A DOC is part of ECB valve controls pressure entering the brake oil
the diesel exhaust Aftertreatment system. DOCs are gallery from the high-pressure oil rail gallery. This
devices that use a chemical process to break down activates the brake actuator pistons and opens the
pollutants in the exhaust stream into less harmful exhaust valves.
components. More specifically, DOCs utilize rare
Engine Compression Brake 1 (ECB1) solenoid –
metals such as palladium and platinum to reduce
The ECB1 solenoid controls pressure entering the
hydrocarbon based Soluble Organic Fraction (SOF)
brake oil gallery from the high-pressure oil rail gallery.
and carbon monoxide content of diesel exhaust by
simple oxidation. The DOC can be used during Engine Compression Brake 2 (ECB2) solenoid –
an active regeneration to create higher exhaust The ECB2 solenoid controls pressure entering the
temperatures, thereby reducing soot in the DPF. brake oil gallery from the high-pressure oil rail gallery.
Digital Multimeter (DMM) – An electronic meter that Engine Compression Brake Pressure (ECBP)
uses a digital display to indicate a measured value. sensor – A high-pressure sensor that provides a
Preferred for use on microprocessor systems because feedback signal to the ECM indicating brake control
it has a very high internal impedance and will not load pressure.
down the circuit being measured.
Engine Coolant Level (ECL) sensor – A switch
Disable – A computer decision that deactivates a sensor that monitors coolant level.
system and prevents operation of the system.
Engine Coolant Temperature 1 (ECT1) sensor
Displacement – The stroke of the piston multiplied by – A thermistor sensor that detects engine coolant
the area of the cylinder bore multiplied by the number temperature.
of cylinders in the engine.
Engine Coolant Temperature 2 (ECT2) sensor
Down Stream Injection (DSI) – The DSI system – A thermistor sensor that detects engine coolant
injects fuel into the exhaust system to increase temperature.
temperature of the exhaust gases, and is necessary
Engine Fuel Temperature (EFT) sensor – A
for DPF regeneration.
thermistor sensor that measures fuel temperature.
Driver (high side) – A transistor within an electronic
Engine lamp – An instrument panel lamp that comes
module that controls the power to an actuator circuit.
on when DTCs are set. DTCs can be read as flash
codes (red and amber instrument panel lamps).
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454 TERMINOLOGY
Engine OFF tests – Tests that are done with the Exhaust Manifold Pressure (EMP) sensor – A
ignition switch ON and the engine OFF. variable capacitance sensor used to indicate air
pressure in the exhaust manifold.
Engine Oil Pressure (EOP) sensor – A variable
capacitance sensor that measures oil pressure. Exhaust Manifold Temperature (EMT) sensor
– A thermistor style sensor used to indicate air
Engine Oil Temperature (EOT) sensor – A
temperature in the exhaust manifold.
thermistor sensor that measures oil temperature.
Fault detection/management – An alternate control
Engine rating – Engine rating includes Rated hp and
strategy that reduces adverse effects that can be
Rated rpm.
caused by a system failure. If a sensor fails, the ECM
Engine RUNNING tests – Tests done with the engine substitutes a good sensor signal or assumed sensor
running. value in its place. A lit amber instrument panel lamp
signals that the vehicle needs service.
Engine Throttle Valve (ETV) and Engine Throttle
Position Sensor – The ETV valve is used to Failure Mode Indicator (FMI) – Identifies the fault or
control airflow during a regeneration process of the condition effecting the individual component.
aftertreatment system. The ETV valve is also used
Filter restriction – A blockage, usually from
to ensure a smooth engine shut down by restricting
contaminants, that prevents the flow of fluid through
airflow to the engine at shut down.
a filter.
Engine Warning Protection System (EWPS) –
Flash code – See Diagnostic Trouble Code (DTC).
Safeguards the engine from undesirable operating
conditions to prevent engine damage and to prolong Fuel Delivery Pressure (FDP) sensor – A variable
engine life. capacitance sensor that monitors fuel pressure
coming from the fuel tank and sends a signal to the
Exhaust Back Pressure (EBP) – The pressure
ECM.
present in the exhaust system during the exhaust
period. Fuel inlet restriction – A blockage, usually from
contaminants, that prevents the flow of fluid through
Exhaust Back Pressure Valve (EBPV) – A valve that
the fuel inlet line.
regulates the amount of air pressure applied to the
EBPV pneumatic actuator. Fuel pressure – The force fuel exerts on the fuel
system as it is pumped through the fuel system.
Exhaust brake – A brake device using engine
exhaust back pressure as a retarding medium. Fuel Pressure Control Valve (FPCV) – The FPCV
controls the fuel pressure to the fuel rails and is
Exhaust Gas Recirculation (EGR) – A system used
controlled by the ECM. FPCV control depends on fuel
to recirculate a portion of the exhaust gases into the
pressure and fuel temperature.
power cylinder in order to reduce oxides of nitrogen.
Fuel Rail Pressure (FRP) – The amount of pressure
Exhaust Gas Temperature (EGT) – The temperature
in the fuel rail.
of exhaust gases.
Fuel Rail Pressure (FRP) sensor – A variable
Exhaust Gas Recirculation Temperature (EGRT)
capacitance sensor that monitors fuel pressure in the
sensor – A thermistor sensor that detects the exhaust
fuel rail and sends a signal to the ECM.
gas temperature entering the EGR cooler.
Fuel strainer – A pre-filter in the fuel system that
Exhaust Gas Recirculation (EGR) valve – The
keeps larger contaminants from entering the fuel
EGRV controls the flow of exhaust gases to the intake
system.
manifold. The EGRV is integrated with an EGR
Position (EGRP) sensor.
Exhaust manifold – Exhaust gases flow through the
exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.
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TERMINOLOGY 455
Fuel Volume Control Valve (FVCV) – The FVCV High Pressure Fuel Pump (HPFP) assembly – The
regulates the volume of flow sent to the HPFP. HPFP is a volumetric pump that supplies fuel at high
The FVCV allows a sufficient quantity of fuel to be pressure. The HPFP is mounted in the rear valley on
delivered to the HPFP depending on engine load, the top of the engine and is driven by the camshaft.
speed, injector quantity, fuel temperature, and number
High-pressure Piezo Common Rail (HPCR) – The
of injections per cycle.
HPFP pumps fuel through separate tubes to each
Fully equipped engine – A fully equipped engine fuel rail. Each fuel rail has four fuel tubes, one for
is an engine equipped with only those accessories each injector, that maintain constant pressure from the
necessary to perform its intended service. A fully high-pressure pump to each injector.
equipped engine does not include components
High speed digital inputs – Inputs to the ECM from
that are used to power auxiliary systems. If these
a sensor that generates varying frequencies (engine
components are integral with the engine or, for any
speed and vehicle speed sensors).
reason are included on the test engine, the power
absorbed may be determined and added to the net Horsepower (hp) – Horsepower is the unit of work
brake power. (SAE J1995 JUN90) done in a given period of time, equal to 33,000 pounds
multiplied by one foot per minute. 1hp = 33,000 lb x 1
Fusible link (fuse link) – A fusible link is a special
ft /1 min.
section of low tension cable designed to open the
circuit when subjected to an extreme current overload. Humidity Sensor (HS) – A sensor that measures
(SAE J1156 APR86) the moisture content of filtered air entering the intake
system.
Gradeability – The maximum percent grade, which
the vehicle can transverse for a specified time at a Hydrocarbons – Organic compounds consisting of
specified speed. The gradeability limit is the grade hydrogen and carbon (fuel and oil).
upon which the vehicle can just move forward. (SAE
Hydrocarbon Injector – Injects fuel into the exhaust
J227a)
system to increase temperature of the exhaust gases.
Gross Combined Weight Rating (GCWR) –
Injection Pressure Regulator (IPR) valve – A valve
Maximum combined weight of towing vehicle
that is used to maintain desired injection control
(including passengers and cargo) and the trailer.
pressure.
The GCWR indicates the maximum loaded weight
that the vehicle is allowed to tow. Injection Control Pressure (ICP) sensor – Provides
a feedback signal to the ECM indicating injection
Gross brake horsepower – The power of a complete
control pressure.
basic engine, with air cleaner, without fan, and
alternator, and air compressor not charging. Inlet Air Heater (IAH) – The IAH is primarily used to
assist in starting the engine during cold weather. In
H-Bridge Circuit – An H-Bridge (bipolar) circuit
addition, it helps to reduce white smoke emissions by
operates like putting a power source on one side of a
heating the incoming air.
motor and connecting the other side of the motor to a
ground. This turns the motor. By shifting the leads on Intake manifold – Engine component that evenly
the motor, it will turn in the opposite direction. supplies air to each intake port in the cylinder head(s).
Hall effect – The development of a transverse electric Intake Manifold Pressure (IMP) sensor – A variable
potential gradient in a current-carrying conductor or capacitance sensor used to indicate air pressure in the
semiconductor when a magnetic field is applied. intake manifold.
Hall effect sensor – Transducer that varies its output Intake Manifold Temperature (IMT) sensor – A
voltage in response to changes in a magnetic field. thermistor sensor used to indicate air temperature in
Commonly used to time the speed of wheels and the intake manifold.
shafts.
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456 TERMINOLOGY
Internal Transfer Pump (ITP) – The ITP is part of The ECM monitors the MAF signal so that the ECM
the HPFP assembly and driven off the same shaft can control the EGR and intake throttle systems.
as the HPFP assembly. The ITP supplies fuel at a
MasterDiagnostics® (MD) – Diagnostics software for
slightly higher pressure and flow to the HPFP though
engine related components and systems.
the Fuel Volume Control Valve (FVCV). The ITP
also provides fuel for cooling and lubrication of the Magnehelic Gauge – A gauge that measures
HPFP. Fuel is rerouted as pump return flow through pressure in inches of water.
the HPFP cooling and lubrication valve. Pressure is
Magnetic Pickup Sensor – A magnetic pickup
maintained at the inlet of the HPFP piston pump by
sensor generates an alternating frequency that
an ITP regulator.
indicates speed. Magnetic pickups have a two-wire
International NGV Tool Utilized for Next connection for signal and ground. This sensor has a
Generation Electronics (INTUNE) – The permanent magnetic core surrounded by a wire coil.
diagnostics software for chassis related components The signal frequency is generated by the rotation of
and systems. the gear teeth that disturb the magnetic field.
Interstage Cooler (ISC) – Uses cooled coolant to Metering unit valve assembly – The Metering unit
lower the charged air temperature that exits from the valve assembly provides a metered amount of fuel to
turbocharger low-pressure compressor and enters the the Aftertreatment Fuel Injector (AFI).
turbocharger high-pressure compressor.
Microprocessor – An integrated circuit in a
Low speed digital inputs – Switched sensor inputs microcomputer that controls information flow.
that generate an on/off (high/low) signal to the ECM.
Micro Strain Gauge (MSG) Sensor – A MSG sensor
The input to the ECM from the sensor could be from
measures pressure. Pressure exerts force on a
a high input source switch (usually 5 or 12 volts) or
pressure vessel that stretches and compresses to
from a grounding switch that grounds the signal from
change resistance of strain gauges bonded to the
a current limiting resistor in the ECM that creates a low
surface of the pressure vessel. Internal sensor
signal (0 volts).
electronics convert the changes in resistance to a
Low temperature radiator thermostat – Coolant ratiometric voltage output.
flow to the low temperature radiator is regulated by
Nitrogen Oxides (NOx) – Nitrogen oxides form by
the low temperature radiator thermostat.
a reaction between nitrogen and oxygen at high
Lubricity – Lubricity is the ability of a substance temperatures and pressures in the combustion
to reduce friction between solid surfaces in relative chamber.
motion under loaded conditions.
Normally closed – Refers to a switch that remains
Lug (engine) – A condition when the engine is run at closed when no control force is acting on it.
an overly low RPM for the load being applied.
Normally open – Refers to a switch that remains open
Manifold Absolute Pressure (MAP) – Boost when no control force is acting on it.
pressure in the manifold that is a result of the
Ohm (Ω) – The unit of electrical resistance. One ohm
turbocharger.
is the value of resistance through which a potential of
Manifold Absolute Pressure (MAP) sensor – A one volt will maintain a current of one ampere. (SAE
variable capacitance sensor that measures boost J1213 NOV82)
pressure.
On demand test – A self-test the technician initiates
Manometer – A double-leg liquid-column gauge, or a using the EST that is run from a program in the
single inclined gauge, used to measure the difference software.
between two fluid pressures. Typically, a manometer
Output Circuit Check (OCC) – An on-demand test
records in inches of water.
done during an Engine OFF self-test to check the
Mass Air Flow – The intake airflow in an engine. continuity of selected actuators.
Mass Air Flow (MAF) sensor – The MAF sensor is
used for closed loop control of the EGR valve and ITV.
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TERMINOLOGY 457
Oxides of Nitrogen (NOx) – Nitrogen oxides formed Ratiometric Voltage – In a Micro Strain Gauge
by a reaction between nitrogen and oxygen at high (MSG) sensor, pressure to be measured exerts force
temperatures. on a pressure vessel that stretches and compresses
to change resistance of strain gauges bonded to
Oxygen Sensor (O2S) – A sensor that monitors
the surface of the pressure vessel. Internal sensor
oxygen levels in the exhaust.
electronics convert the changes in resistance to a
pH – A measure of the acidity or alkalinity of a solution. ratiometric voltage output.
Particulate matter – Particulate matter includes Reference voltage (VREF) – A 5 volt reference supplied
mostly burned particles of fuel and engine oil. by the ECM to operate the engine sensors.
Piezometer – An instrument for measuring fluid Reserve capacity – Time in minutes that a fully
pressure. charged battery can be discharged to 10.5 volts at 25
amperes.
Power – Power is a measure of the rate at which
work (force x distance) is done during a specific time. Return Fuel System – The return fuel system moves
Compare with Torque. unused fuel from the fuel injectors to the fuel cooler.
Excess fuel out of the FVCV and the FPCV mix with
Power TakeOff (PTO) – Accessory output, usually
fuel from the fuel injectors on the way to the fuel cooler.
from the transmission, used to power a hydraulic
pump for a special auxiliary feature (garbage packing, ServiceMaxx™ software – Diagnostics software for
lift equipment, etc). engine related components and systems.
Pulse Width Modulation (PWM) – Succession of Signal Conditioner – The signal conditioner in the
digital electrical pulses, rather than an analog signal. internal microprocessor converts analog signals to
Efficient method of providing power between fully on digital signals, squares up sine wave signals, or
and fully off. amplifies low-intensity signals to a level that the ECM
microprocessor can process.
Random Access Memory (RAM) – Computer
memory that stores information. Information can Signal ground – The common ground wire to the
be written to and read from RAM. Input information ECM for the sensors.
(current engine speed or temperature) can be stored
Speed Control Command Switches (SCCS) – A set
in RAM to be compared to values stored in Read Only
of switches used for cruise control, Power TakeOff
Memory (ROM). All memory in RAM is lost when the
(PTO), and remote hand throttle system.
ignition switch is turned off.
Steady state condition – An engine operating
Rated gross horsepower – Engine gross
at a constant speed and load and at stabilized
horsepower at rated speed as declared by the
temperatures and pressures. (SAE J215 JAN80)
manufacturer. (SAE J1995 JUN90)
Strategy – A plan or set of operating instructions
Rated horsepower – Maximum brake horsepower
that the microprocessor follows for a desired goal.
output of an engine as certified by the engine
Strategy is the computer program itself, including
manufacturer. The power of an engine when
all equations and decision making logic. Strategy is
configured as a basic engine. (SAE J1995 JUN90)
always stored in ROM and cannot be changed during
Rated net horsepower – Engine net horsepower at calibration.
rated speed as declared by the manufacturer. (SAE
Stroke – The movement of the piston from Top Dead
J1349 JUN90)
Center (TDC) to Bottom Dead Center (BDC).
Rated speed – The speed, as determined by the
Substrate – Material that supports the wash coating
manufacturer, at which the engine is rated. (SAE
or catalytic materials.
J1995 JUN90)
Rated torque – Maximum torque produced by an
engine as certified by the manufacturer.
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458 TERMINOLOGY
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TERMINOLOGY 459
Vehicle Speed Sensor (VSS) – Normally a magnetic Voltage – Electrical potential expressed in volts.
pickup sensor mounted in the tailshaft housing of the
Voltage drop – Reduction in applied voltage from the
transmission, used to indicate ground speed.
current flowing through a circuit or portion of the circuit
Viscosity – The internal resistance to the flow of any current multiplied by resistance.
fluid.
Voltage ignition – Voltage supplied by the ignition
Viscous fan – A fan drive that is activated when a switch when the key is ON.
thermostat, sensing high air temperature, forces fluid
Washcoat – A layer of alumina applied to the
through a special coupling. The fluid activates the fan.
substrate in a monolith-type converter.
Volt (v) – A unit of electromotive force that will move
Water In Fuel (WIF) sensor – A switch sensor that
a current of one ampere through a resistance of one
measures the amount of water in the fuel.
Ohm.
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460 TERMINOLOGY
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APPENDIX A – SPECIFICATIONS 461
Table of Contents
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462 APPENDIX A – SPECIFICATIONS
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APPENDIX A – SPECIFICATIONS 463
Fuel System
Engine Brake
Solenoid resistance:
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464 APPENDIX A – SPECIFICATIONS
Table 51 Oil Pump, Low Mount Fan Drive, and Timing Gears
Power Cylinders
Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)
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APPENDIX A – SPECIFICATIONS 465
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466 APPENDIX A – SPECIFICATIONS
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APPENDIX B – TORQUES 467
Table of Contents
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468 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 469
General Torque
Bolt Identification
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470 APPENDIX B – TORQUES
General Torque Guidelines coated) do require oil lubrication to threads and under
head area for correct torque application.
CAUTION: To prevent engine damage, do not
substitute fasteners. All original equipment fasteners Threads that are dry, excessively rough, battered,
are hardened and phosphate coated. or filled with dirt require considerable effort just to
rotate. Then when the clamping load is developed or
NOTE: Inspect parts for cleanliness and defects
the bolt tension is applied, the torque reading mounts
before assembly.
rapidly (due to thread friction) to the specified torque
Many conditions affect torque and the results of value. However, the desired bolt tension and correct
torque applications. The major purpose in tightening clamping load is not achieved. This condition can
a fastener to a specified torque is to obtain a clamping lead to failure of the fastener to maintain component
load which exceeds any possible loading imposed on integrity. The correct bolt tension and clamping effect
parts. can never be attained if the fastener is dry. Fastener
threads must be new condition phosphate coated
New phosphate coated fasteners do not require oil
or have a film of clean lubricant (engine oil) to be
lubrication during assembly and torque application.
considered lubricated.
Reused fasteners (even if originally phosphate
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APPENDIX B – TORQUES 471
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs
Thread Diameter (mm) Thread Pitch (mm) Torque
6 1 13 N·m (115 lbf·in)
8 1.25 31 N·m (23 lbf·ft)
10 1.5 62 N·m (45 lbf·ft)
12 1.75 107 N·m (79 lbf·ft)
14 2 172 N·m (127 lbf·ft)
15 2 216 N·m (159 lbf·ft)
16 2 266 N·m (196 lbf·ft)
18 2.5 368 N·m (272 lbf·ft)
20 2.5 520 N·m (384 lbf·ft)
Example: Tighten four M6 x 12 pulley bolts to standard To find the standard torque for a M6 x 12 bolt look at
torque. What is the size and standard torque for these the torque chart above. We see the standard torque
four bolts? for a 6 mm thread diameter class 10.9 bolt should be
13 N·m (115 lbf·in).
M6 x 12 refers to the bolts thread diameter and length.
These bolts have a thread diameter of 6 mm and are
12 mm long.
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472 APPENDIX B – TORQUES
• F - Force applied by technician reach it. What should the torque wrench setting (TS)
be to compensate for the extension?
• L - Total length through which force is applied to
fastener • Torque specified at fastener (TE) = 65 lbf·ft
• TW - Torque applied at end of torque wrench • Length of torque wrench (LW) = 12 inches
TS = TE (LW / (LW + LE)) • Length of extension (LE) = 6 inches
• TS - Torque wrench setting TS = TE (LW / (LW + LE))
• TE - Torque specified at fastener TS = 65 lbf·ft (12 inches / (12 inches + 6 inches)
• LW - Length of torque wrench TS = 65 lbf·ft (12 inches / (18 inches)
• LE - Length of extension TS = 65 lbf·ft (0.666)
Example: A component requires a specified torque TS = 43.33 lbf·ft
value of 65 lbf·ft and a 6 inch extension is required to
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APPENDIX B – TORQUES 473
Special Torques
Mounting Engine on Stand
Engine Electrical
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474 APPENDIX B – TORQUES
Fuel supply cold start hose fitting nut 10 N·m (11 lbf·ft)
Aftertreatment System
Fitting (straight union orifice) at metering unit valve assembly 35 N·m (26 lbf·ft)
HCI coolant supply and return tube nut at tube M10 elbow 15 N·m (11 lbf·ft)
fittings
HCI coolant supply tube nut at coolant manifold 25 N·m (18 lbf·ft)
HCI fuel 1 tube assembly nut at HCI fuel 2 tube fitting (brazed) 25 N·m (18 lbf·ft)
HCI fuel 1 tube assembly nut at metering unit valve assembly 25 N·m (18 lbf·ft)
HCI fuel 2 tube assembly nut at hydrocarbon injector 18 N·m (13 lbf·ft)
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APPENDIX B – TORQUES 475
Exhaust back pressure valve tube nut (at air control 15 N·m (11 lbf·ft)
valve)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lbf·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lbf·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 15 N·m (11 lbf·ft)
degree) fitting
Turbochargers
Table 59 Turbochargers
3/4 inch and 1 inch worm gear hose clamps 3.5 N·m (31 lbf·in)
Turbocharger oil supply tube assembly fitting nut to male stud connector 27 N·m (20 lbf·ft)
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476 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 477
Fuel System
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478 APPENDIX B – TORQUES
EGR cooler assembly mounting bolts, M10 x 45 and 62 N·m (46 lbf·ft)
M10 x 70
EGR dual flap valve, M8 x 30 heat-resistant bolt 24 N·m (18 lbf·ft)
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APPENDIX B – TORQUES 479
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480 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 481
Table 65 Front Cover, Fan Drive, Cooling System and Related Components
Automatic belt tensioner countersunk screw,
47 N·m (35 lbf·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lbf·ft)
M8 x 60
Coolant heater 41 N·m (30 lbf·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lbf·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lbf·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lbf·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lbf·ft)
Front belt- or gear-driven fan cover bolts,
• M8 31 N·m (23 lbf·ft)
• M12 x 75 115 N·m (85 lbf·ft)
• M12 x 30 115 N·m (85 lbf·ft)
High mount fan drive clutch assembly bolts,
See tightening steps in procedure
M10
High mount fan drive tensioner countersunk
47 N·m (35 lbf·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lbf·ft)
Low mount fan drive bolt, M10 x 110 37 N·m (27 lbf·ft)
Thermostat housing bolts, M8 35 N·m (26 lbf·ft)
Vibration damper socket-head cap screws,
See tightening steps in procedure
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lbf·ft)
Water pump assembly bolts, M8 35 N·m (26 lbf·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lbf·ft)
Engine Brake
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482 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 483
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484 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 485
(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lbf·ft)
Power Cylinders
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486 APPENDIX B – TORQUES
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APPENDIX C – SPECIAL SERVICE TOOLS 487
Table of Contents
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488 APPENDIX C – SPECIAL SERVICE TOOLS
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APPENDIX C – SPECIAL SERVICE TOOLS 489
Special Tools
Special tools for the MaxxForce® 11 and 13 engines
with ZTSE numbers can be ordered from the SPX
Corporation, 1-800-520-2584.
Engine Electrical
Aftertreatment System
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490 APPENDIX C – SPECIAL SERVICE TOOLS
Turbochargers
Table 78 Turbochargers
Description Tool Number
3-inch couplers and clamps Obtain locally
Charge Air Cooler Test Kit ZTSE6042
Crimping pliers Obtain locally
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APPENDIX C – SPECIAL SERVICE TOOLS 491
Fuel System
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492 APPENDIX C – SPECIAL SERVICE TOOLS
Table 84 Front Cover, Fan Drive, Cooling System and Related Components
Description Tool Number
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APPENDIX C – SPECIAL SERVICE TOOLS 493
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494 APPENDIX C – SPECIAL SERVICE TOOLS
Power Cylinders
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APPENDIX C – SPECIAL SERVICE TOOLS 495
Special Tools
Essential Tools
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496 APPENDIX C – SPECIAL SERVICE TOOLS
Figure 617 ZTSE4778 coolant line release tool Figure 620 ZTSE4835 Head Bolt Torx Socket
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APPENDIX C – SPECIAL SERVICE TOOLS 497
Figure 622 ZTSE4854 Main Bolt Bottoming Tap Figure 624 ZTSE4869 Cylinder Head Lifting
Bracket
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498 APPENDIX C – SPECIAL SERVICE TOOLS
Figure 626 ZTSE4891 Disposable Air and Fuel Figure 628 ZTSE4898 Pilot Bearing Installation
Caps Tool
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APPENDIX C – SPECIAL SERVICE TOOLS 499
Figure 632 ZTSE6046 Extension Tube Installer Figure 635 ZTSE6051–2 Extension Tube Installer
Large Small
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500 APPENDIX C – SPECIAL SERVICE TOOLS
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Printed in the United States of America