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Figure 103
1.
2.
CCV
Coolant Mixer Valve (CMV) terminal
Coolant Flow Valve (CFV) terminal
Figure 104
1.
2. ETV
ETV
ETV harness connector
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.
© 2011 Navistar, Inc. All rights reserved
ENGINE ELECTRICAL 99
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clarity)
1. Install new 16.7 x 24 seal ring and IMT sensor.
1. Exhaust back pressure valve housing Tighten sensor to special torque (page 106).
2. O2S (with harness lead)
NOTE: It may be necessary to rotate the harness
3. Harness clip (2)
connector to ensure the alignment tabs engage
properly.
1. If removed, install new O2S. Tighten O2S to 2. Connect harness connector to IMT sensor.
special torque (page 106).
3. Turn IMT sensor harness connector locking ring
2. Attach clips to secure harness lead to coolant 90° clockwise.
tube and valve actuator bracket and at left rear of
engine.
Rail Fuel Pressure (RFP) Sensor
3. Connect harness to O2S terminal end by pushing
in on connector until a click is heard.
4. Engage release lever.
NOTE: Any time the O2S is replaced, an Oxygen
Sensor Calibration Procedure must be done. See
MaxxForce® 11 and 13 Engine Diagnostic Manual
EGES-470 for details.
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
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.
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1. CACOT sensor
2. Harness connector
3. Standoff tie strap
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
ENGINE ELECTRICAL 101
Humidity / Air Inlet Temperature (IAT) Sensor Mass Air Flow (MAF) Sensor
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2. Harness connector 2. MAF sensor
3. IAT 3. Harness connector
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
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
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.
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Figure 112 FPCV (on high-pressure fuel pump)
1. FPCV
2. Harness connector
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
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2. EOP sensor 2. Oil module flange
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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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
104 ENGINE ELECTRICAL
Engine Coolant Temperature 2 (ECT2) Sensor Engine Coolant Temperature 1 (ECT1) Sensor
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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
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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
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Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lbf·ft)
Exhaust Gas Recirculation Temperature (EGRT)
37 N·m (27 lbf·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lbf·ft)
Humidity / Air Inlet Temperature (AIT) sensor, M6
9 N·m (80 lbf·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lbf·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lbf·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lbf·in)
Oxygen Sensor (O2S) 50 N·m (37 lbf·ft)
Rail Fuel Pressure (RFP) sensor 140 N·m (103 lbf·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lbf·in)
M6 x 16 bolt
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
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
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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
108 COLD START ASSIST
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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
COLD START ASSIST 109
Exploded View
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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
110 COLD START ASSIST
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parking brake, and block wheels before doing
diagnostic or service procedures.
Figure 122 Relay assembly
WARNING: To prevent personal injury or
1. Engine Control Module (ECM) support bracket
death, make sure the engine has cooled before
2. M6 x 20 bolt (2)
removing components.
3. Relay assembly
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
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)
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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.
© 2011 Navistar, Inc. All rights reserved
112 COLD START ASSIST
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3. M6 x 20 bolt (2)
3. Fuel supply solenoid hose (tube)
4. Fuel supply solenoid hose (tube)
4. Clip on fuel HP pump drain hose
5. Banjo 6 bolt (M10 x 1)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
COLD START ASSIST 113
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Figure 127 Glow plug
1. Glow plug
2. Air intake throttle duct (horizontal shown)
3. Glow plug locking nut
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
114 COLD START ASSIST
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1. Solenoid valve
1. Glow plug
2. Seal 10.7 x 16 ring (12)
2. Air intake throttle duct (horizontal shown)
3. M6 x 20 bolt (2)
3. Glow plug locking nut
4. Fuel supply solenoid hose (tube)
5. Banjo 6 bolt (M10 x 1)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
COLD START ASSIST 115
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3. Banjo 8 bolt (M12 x 1.5) Figure 131 Fuel supply solenoid hose clips
4. Fuel supply solenoid hose (tube)
1. Clips on electrical harness (2)
2. Clip on fuel filter bracket
3. Fuel supply solenoid hose
4. Position fuel supply solenoid hose banjo fitting on
4. Clip on fuel HP pump drain hose
port at bottom of fuel filter housing. Install two new
seal 12.7 x 18 rings and banjo 8 bolt into fuel filter
housing. 6. Install fuel supply solenoid hose to four clips.
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
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1. Glow plug Figure 133 Relay assembly
2. Fuel supply cold start hose
3. Solenoid valve 1. ECM support
4. M8 x 1 banjo bolt 2. M6 x 20 bolt (2)
5. Washer (seal ring) (2) 3. 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
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
COLD START ASSIST 117
Special Torque
Fuel supply cold start hose fitting nut 10 N·m (11 lbf·ft)
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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
118 COLD START ASSIST
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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
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
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HCI Coolant Return Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
HCI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
HCI Fuel Tube Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
120 AFTERTREATMENT SYSTEM
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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
AFTERTREATMENT SYSTEM 121
Illustrations
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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
122 AFTERTREATMENT SYSTEM
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Figure 135 Aftertreatment system fuel supply
1. Metering unit valve assembly 7. HCI fuel tube bracket assembly 12. Supply fuel after filter hose
2. M8 x 35 bolt (3) 8. HCI fuel 2 tube assembly 13. HCI fuel 1 tube assembly
3. Cushioned 1/4 inch diameter 9. Fitting (quick-connect adapter) 14. Metering unit bracket
clamp (contains port O-ring seal) 15. M8 x 16 bolt (4)
4. M10 x 16 bolt 10. Fitting (straight union orifice)
5. P 6 x 15 clamp (2) (contains port and fitting O-rings)
6. M6 x 16 bolt (2) 11. Clamp (to fuel drain tube)
EGES-465-1
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Follow all warnings, cautions, and notes.
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AFTERTREATMENT SYSTEM 123
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parking brake, and block wheels before doing
diagnostic or service procedures. Figure 136 Supply fuel after filter hose
connection
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
124 AFTERTREATMENT SYSTEM
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2. Metering unit valve assembly
Figure 137 Fuel Line Disconnect Tool 11.8 mm
3. P-clamp (2)
on fuel supply hose
4. HCI fuel 2 tube assembly fitting (brazed to tube)
1. Fuel Line Disconnect Tool 11.8 mm 5. HCI fuel 1 tube assembly nut
2. Supply fuel after filter hose quick-connect fitting 6. M6 x 16 bolt (2)
7. M10 x 16 bolt
8. Cushioned 1/4 inch diameter clamp
2. Using Fuel Line Disconnect Tool 11.8 mm (page
136), disconnect supply fuel after filter hose from
metering unit valve assembly. 3. Loosen HCI fuel 1 tube assembly nut and
disconnect tube from fitting assembly at metering
unit valve assembly.
4. Remove M6 x 16 bolt, M10 x 16 bolt, P-clamp and
cushioned 1/4 inch diameter clamp from HCI fuel
1 tube assembly.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AFTERTREATMENT SYSTEM 125
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1. 6.6 x 15 x 23 spacer (2)
5. Loosen HCI fuel 1 tube assembly nut and 2. M6 x 40 bolt (2)
disconnect fuel tube from HCI fuel 2 tube 3. HCI fuel 2 tube assembly nut
assembly. 4. P 6 x 15 clamp (2)
5. HCI fuel 2 tube assembly
6. Remove M6 x 16 bolt, P-clamp and HCI fuel 1 tube 6. Hydrocarbon injector assembly
assembly.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
126 AFTERTREATMENT SYSTEM
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2. Metering unit valve assembly
3. O-ring seal (orifice fitting)
Figure 141 Metering unit valve assembly 4. Fitting (straight union orifice)
1. Metering unit valve assembly 5. O-ring (# 011)
2. M8 x 35 bolt (3) 6. O-ring seal (adapter)
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AFTERTREATMENT SYSTEM 127
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Figure 143 HCI coolant supply tube assembly 1. Hydrocarbon injector
1. Straight fitting 2. Tube M10 elbow fitting
2. HCI coolant supply tube nut (at coolant manifold)
3. HCI coolant supply tube assembly
4. Tube M10 elbow fitting NOTE: Perform step 4 only if tube M10 elbow fitting is
leaking or if hydrocarbon injector is being replaced.
4. Remove tube M10 elbow fitting from hydrocarbon
1. Loosen the HCI coolant supply tube assembly nut injector.
and disconnect tube from tube M10 elbow fitting.
2. Loosen coolant supply tube nut and disconnect
tube from straight fitting at coolant manifold.
Remove HCI coolant supply tube.
3. If necessary, remove straight fitting from coolant
manifold.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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Figure 145
1.
2.
3.
4.
5.
HCI coolant return tube assembly
HCI coolant return tube nut
Tube M10 elbow fitting
Pipe single cushion clamp
M8 x 16 bolt
HCI coolant return tube assembly
Figure 146 Hydrocarbon injector tube M10
elbow fitting
1. Hydrocarbon injector
6. Tube clamp (2) 2. Tube M10 elbow fitting
7. Open breather tube
8. Hose clamp (spring type)
NOTE: Perform step 5 only if tube M10 elbow fitting is
leaking or if hydrocarbon injector is being replaced.
1. Loosen HCI coolant return tube assembly nut and
5. Remove tube M10 elbow fitting from hydrocarbon
disconnect tube from tube M10 elbow fitting.
injector.
2. Remove M8 x 16 bolt from pipe single cushion
clamp. Separate clamp from tube as necessary.
EGES-465-1
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Follow all warnings, cautions, and notes.
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AFTERTREATMENT SYSTEM 129
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Figure 147 Hydrocarbon injector
Figure 148 Hydrocarbon injector
1. M8 x 45 bolt (2)
2. Hydrocarbon injector gasket 1. Hydrocarbon injector
3. Thermal management valve housing 2. Injector nozzle tip
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
130 AFTERTREATMENT SYSTEM
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Figure 149 Metering unit valve assembly
(adapter/unions)
1. Fitting (quick-connect adapter)
2. Metering unit valve assembly
3. O-ring seal
4. Fitting (straight union orifice)
5. O-ring (# 011)
6. O-ring seal
EGES-465-1
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Follow all warnings, cautions, and notes.
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AFTERTREATMENT SYSTEM 131
Hydrocarbon Injector
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2. Electrical connections (4)
3. Metering unit valve assembly Figure 152 Hydrocarbon injector
1. M8 x 45 bolt (2)
2. Hydrocarbon injector gasket
6. Position supply fuel after filter hose onto fitting 3. Thermal management valve housing
(quick-connect adapter) and push on until click is
heard or felt.
7. Reconnect wiring harness to four electrical 1. Position hydrocarbon injector and gasket onto the
connections. thermal management valve housing. Install two
new M8 x 45 bolts and tighten as follows.
a. Pre-tighten bolts to 11 N·m (97 lbf·in).
Hydrocarbon Injector Flow Test
b. Final-tighten bolts to 25 N·m (18 lbf·ft). Do not
Before installing hydrocarbon injector onto engine, over tighten.
perform a flow test using Hydrocarbon Injector Flow
Test Kit ZTSE6069. See EGES-470 MaxxForce® 11 NOTE: Do steps 2 and 3 only if fittings were removed
and 13 Engine Diagnostic Manual for Hydrocarbon or if hydrocarbon injector was replaced.
Flow Test setup and procedure.
EGES-465-1
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Follow all warnings, cautions, and notes.
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132 AFTERTREATMENT SYSTEM
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1. Hydrocarbon injector
2. Tube M10 elbow fitting (coolant out)
3. Tube M10 elbow fitting (coolant in) Figure 154 HCI coolant return tube assembly
1. HCI coolant return tube nut
2. Install tube M10 elbow fitting (coolant in) into 2. Tube M10 elbow fitting
hydrocarbon injector and finger-tighten. 3. Pipe single cushion clamp
4. M8 x 16 bolt
3. Install tube M10 elbow fitting (coolant out) into 5. HCI coolant return tube assembly
hydrocarbon injector and finger-tighten. 6. Tube clamp (2)
7. Open breather tube
8. Hose clamp (spring type)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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Figure 155 HCI coolant supply tube assembly
1. Straight fitting
2. HCI coolant supply tube nut (at coolant manifold)
3. HCI coolant supply tube assembly
4. Tube M10 elbow fitting
EGES-465-1
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Follow all warnings, cautions, and notes.
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134 AFTERTREATMENT SYSTEM
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2. Metering unit valve assembly
Figure 156 HCI fuel 2 tube assembly 3. P 6 x 15 clamp (2)
1. 6.6 x 15 x 23 spacer (2) 4. HCI fuel 2 tube assembly fitting (brazed to tube)
2. M6 x 40 bolt (2) 5. M6 x 16 bolt (2)
3. HCI fuel 2 tube assembly nut 6. M10 x 16 bolt
4. P 6 x 15 clamp (2) 7. Cushioned 1/4 inch diameter clamp
5. HCI fuel 2 tube assembly
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.
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AFTERTREATMENT SYSTEM 135
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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
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)
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Hydrocarbon injector body to assembly (if accidentally 20 N·m (15 lbf·ft)
loosened during fuel tube nut service)
Tube M10 elbow fittings at hydrocarbon injector 17.5 N·m (13 lbf·ft)
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.
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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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Follow all warnings, cautions, and notes.
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138 EXHAUST BACK PRESSURE CONTROL
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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.
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EXHAUST BACK PRESSURE CONTROL 139
Exploded Views
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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.
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140 EXHAUST BACK PRESSURE CONTROL
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parking brake, and block wheels before doing Figure 160 Air control valve tubes and hoses
diagnostic or service procedures.
1. M8 x 85 bolts (2)
2. Air control valve
WARNING: To prevent personal injury or 3. Low-pressure wastegate actuator hose
death, make sure the engine has cooled before 4. High-pressure wastegate actuator hose
removing components. 5. Air supply tube connection
6. Exhaust back pressure valve tube
WARNING: To prevent personal injury or 7. TC1 turbine outlet pressure (TC1TOP) sensor tube
death, do not let engine fluids stay on your skin. 8. Crimp clamp (2)
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids. 1. Cut two crimp clamps securing high-pressure and
low-pressure wastegate actuator hoses. Discard
two crimp clamps and separate hoses from air
WARNING: To prevent personal injury or
control valve.
death, wear safety glasses with side shields.
2. Loosen TC1TOP sensor tube nut and exhaust
NOTE: Refer to the following service sections for
back pressure tube nut. Disconnect tubes from
information on removal of components prior to this
control valve.
section:
CAUTION: Relieve system pressure before loosening
• Engine Electrical
air supply tube valve.
• Aftertreatment System
3. Loosen air supply tube nut from air control valve.
Disconnect air supply tube from control valve.
4. Disconnect air supply tube nut from bulkhead
fitting. Cut any tie straps and remove tube if
necessary.
5. Remove two M8 x 85 bolts and control valve.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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Figure 161 Exhaust back pressure valve
actuator and TC1 turbine outlet pressure
(TC1TOP) sensor tubes
1.
2.
Exhaust back pressure valve tube nut
Exhaust back pressure valve actuator
Figure 162 TC1TOP sensor and exhaust back
pressure valve tubes
1.
2.
3.
4.
TC1TOP sensor tube bracket
M6 x 40 bolt (2)
Exhaust back pressure valve tube bracket (2)
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
142 EXHAUST BACK PRESSURE CONTROL
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assembly
Figure 164 Exhaust back pressure valve
1. M8 x 45 bolt (7) assembly
2. Spacer (7)
1. M8 x 45 bolt (7)
3. Exhaust back pressure valve assembly
2. Spacer (7)
3. Exhaust back pressure valve assembly
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 BACK PRESSURE CONTROL 143
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actuator lubrication points
EGES-465-1
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Follow all warnings, cautions, and notes.
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144 EXHAUST BACK PRESSURE CONTROL
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1. M8 x 85 bolts (2)
2. Air control valve
3. Low-pressure wastegate actuator hose
Figure 168 TC1TOP sensor and exhaust back
4. High-pressure wastegate actuator hose
pressure valve actuator tubes
5. Air supply tube connection
1. TC1TOP sensor tube bracket 6. Exhaust back pressure valve tube
2. M6 x 40 bolt (2) 7. TC1 turbine outlet pressure (TC1TOP) sensor tube
3. Exhaust back pressure valve tube bracket (2) 8. Crimp clamp (2)
4. Exhaust back pressure valve tube
5. TC1TOP sensor tube
5. Position TC1TOP sensor and exhaust back
pressure valve tubes. Install tube nuts and
4. Position exhaust back pressure valve tube and tighten to special torque (page 146).
TC1TOP sensor tube against EGR cooler. Using
6. Tighten exhaust back pressure valve tube nut
two M6 x 40 bolts and two spacers, secure tubes
at valve actuator and TC1TOP sensor tube nut
to EGR cooler. Tighten bolts to standard torque
at flare M10 x M12 (24 degree) fitting to special
(page 471).
torque (page 146).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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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
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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Description Tool Number
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
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
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Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Turbochargers and Related Parts Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Turbocharger Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Low-pressure Charge Air Cooler (LPCAC) Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
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
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
148 TURBOCHARGERS
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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
TURBOCHARGERS 149
Exploded Views
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Figure 170 Turbochargers and charge air cooler assembly
1. Rear exhaust manifold 8. O-ring 15. Low-pressure turbocharger
2. Wastegate high-pressure 9. M6 x 20 bolt assembly
actuator 10. M10 x 20 x 35 stud bolt 16. Turbocharger oil supply tube
3. High-pressure turbocharger 11. High-pressure compressor out assembly
assembly duct 17. Wastegate low-pressure
4. Air inlet duct 12. Inlet (and outlet) high-pressure actuator
5. M8 x 16 bolt compressor seal
6. Cab heater return tube assembly 13. M10 x 40 bolt
7. Air supply high-pressure 14. Low-pressure charge air cooler
turbocharger duct
EGES-465-1
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Follow all warnings, cautions, and notes.
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150 TURBOCHARGERS
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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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Figure 172 Turbocharger oil supply tube and support bracket
1. High-pressure turbocharger 5. Male stud connector (on 9. M8 x 40 x 15 stud bolt
assembly crankcase) 10. 19 x 20 spacer (2)
2. M6 x 16 bolt (2) 6. Low-pressure turbocharger 11. Turbocharger support bracket
3. Turbocharger supply seal (2) assembly
4. Turbocharger oil supply tube 7. M8 x 40 bolt
assembly 8. M8 x 16 bolt
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152 TURBOCHARGERS
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Figure 173 Turbocharger oil return tubes
1. High-pressure turbocharger 4. Oil return high-pressure 7. Oil return low-pressure
assembly turbocharger tube turbocharger tube
2. Turbocharger oil drain gasket (2) 5. Metric bonded seal washer 8. Low-pressure turbocharger
3. M8 x 20 bolt (4) 6. 24.7 x 32 seal ring assembly
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TURBOCHARGERS 153
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Figure 174 Air inlets, actuators and air control valve
1. High-pressure wastegate hose 7. Air supply high-pressure 11. Cable lock strap (6)
2. Cable lock strap (3) turbocharger duct 12. Wrap insulator
3. Air control valve assembly 8. Low-pressure wastegate hose 13. Wastegate low-pressure
4. 12.3 x 7 crimp clamp (4) 9. Inlet low-pressure compressor actuator
5. Inlet high-pressure compressor seal 14. M8 x 14 bolt (6)
seal 10. Wastegate high-pressure 15. Seal ring (2)
6. Air inlet duct actuator 16. M24 threaded fitting (2)
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154 TURBOCHARGERS
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Figure 175 Turbochargers
1. M8 x 16 bolt (3) 6. M10 x 45 stud 12. Wastegate low-pressure
2. High-pressure turbocharger heat 7. M10 nut (3) actuator
shield 8. M8 x 14 bolt (6) 13. M10 x 55 bolt (5)
3. 10.5 x 20 x 15 sleeve (2) 9. Wastegate high-pressure 14. Low-pressure turbocharger
4. High-pressure turbocharger actuator assembly
assembly 10. Turbocharger heat shield
5. Dowel pin (2) 11. M8 x 16 bolt (2)
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TURBOCHARGERS 155
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parking brake, and block wheels before doing
diagnostic or service procedures.
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Follow all warnings, cautions, and notes.
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156 TURBOCHARGERS
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connections
3. 72.2 x 60 (DMR) tube seal (extension tube)
1. Coolant hose (supply) 4. LPCAC air outlet
2. M10 x 100 bolt 5. Low-pressure charge air cooler
3. Low-pressure charge air cooler 6. Coolant return
4. Ground stud bolt (2) 7. Coolant supply
5. 3/4 inch constant torque hose clamp (2)
6. Coolant return hose
6. Remove LPCAC from engine.
CAUTION: To prevent engine damage, do not remove
NOTE: Refer to "OIL COOLER, FILTER HOUSING,
extension tube by grabbing sealing surface.
AND CRANKCASE VENTILATION" for removal
of the open breather tube assembly and related 7. Remove 72.2 x 60 (DMR) tube seal (extension
components. tube) from LPCAC. Do so by inserting pry bar
handle (or wooden dowel) into tube seal and
1. Loosen 3/4 inch hose clamp and disconnect
carefully prying side-to-side to lift tube from
coolant hose (supply) from LPCAC.
LPCAC. Inspect sealing surfaces of tube seal
2. Loosen 3/4 inch hose clamp and disconnect (extension tube) and LPCAC. Discard if damaged.
coolant return hose from LPCAC.
8. Remove O-ring seal from LPCAC and discard.
3. Remove M10 x 100 bolt from LPCAC.
4. Remove two M10 stud bolts from LPCAC.
5. Pull down to separate LPCAC from LP
turbocharger and air supply HP turbocharger
duct.
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TURBOCHARGERS 157
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3. Tube support
1. 3/4 inch constant torque hose clamp (2) 4. M8 x 20 bolt
2. Low temperature housing (EGR cooler) 5. Cab heater return tube assembly
3. Coolant return hose 6. M6 x 20 bolt
4. Coolant tube 7. 3/4 inch constant torque hose clamp
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.
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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
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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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duct
1. Air inlet duct
2. M8 x 45 bolt
3. M10 x 20 x 35 stud bolt
4. M10 x 140 bolt
5. HP compressor out (outlet) duct Figure 184 High-pressure (HP) turbocharger air
6. M10 x 40 bolt supply duct
1. HP turbocharger air supply duct
2. M10 x 200 bolt (2)
1. Remove M10 x 40 bolt and M10 x 20 x 35 stud
3. High-pressure compressor inlet seal
bolt.
4. M24 threaded fitting
2. Disconnect HP compressor out duct from HP
turbocharger compressor outlet. Remove from
engine. 1. Remove two M10 x 200 bolts and HP
turbocharger air supply duct from HP
NOTE: The high-pressure compressor inlet seal is
turbocharger.
used in two places on the high-pressure compressor
including both compressor inlet and outlet. 2. Remove HP compressor inlet seal and discard.
3. Remove high-pressure compressor inlet seal from 3. Only if required, remove M24 threaded fitting and
compressor out duct and discard. discard seal ring.
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160 TURBOCHARGERS
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1. Turbocharger oil supply tube assembly
1. High-pressure (HP) turbocharger oil return tube
2. Oil supply tube fitting
2. M8 x 20 bolt (4)
3. Male stud connector
3. Oil return tube fittings (2)
4. Low-pressure (LP) turbocharger oil return tube
5. 24.7 x 32 seal ring
6. Loosen turbocharger oil supply tube fitting at male
6. Turbocharger oil drain gasket (2)
stud connector on crankcase. Disconnect tube
fitting from crankcase connector.
1. Loosen LP turbocharger oil return tube fitting nut
from HP turbocharger oil return tube.
2. Remove four M8 x 20 bolts and disconnect HP oil
return tube from HP and LP turbocharger and LP
oil return tube.
3. Remove and discard two turbocharger oil drain
gaskets.
4. Remove and discard bonded seal washer
between HP and LP turbocharger oil return
tubes.
5. Remove LP turbocharger oil return tube from
crankcase and discard 24.7 x 32 seal ring.
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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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Figure 188 Turbocharger heat shields
Figure 189
1.
2.
3.
4.
Turbocharger support bracket
Turbocharger support bracket
M8 x 16 bolt
M8 x 40 bolt
M8 x 40 x 15 stud bolt
5. 19 x 20 spacer (2)
1. M8 x 16 bolt (5)
2. HP turbocharger heat shield
3. Turbocharger heat shield
1. Remove M8 x 16 bolt at bottom of LP
turbocharger.
1. Remove three M8 x 16 bolts and HP turbocharger 2. Remove M8 x 40 bolt, M8 x 40 x 15 stud bolt, two
heat shield. spacers and support bracket.
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162 TURBOCHARGERS
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actuator
Figure 191 Low-pressure (LP) wastegate
1. M8 x 14 bolt (3) actuator
2. HP wastegate actuator
1. LP turbocharger assembly
3. C-clip
2. LP wastegate actuator linkage C-clip
3. LP wastegate actuator
4. M8 x 14 bolt (3)
NOTE: It is not necessary to remove the wastegate
actuator to remove the turbocharger. The
turbocharger and wastegate actuator can be removed
4. Remove C-clip from LP wastegate actuator
as an assembly. If the wastegate actuator is being
linkage.
replaced, proceed with the following steps.
5. Remove three M8 x 14 bolts.
1. Remove C-clip from HP actuator wastegate
linkage. 6. Remove LP wastegate actuator.
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TURBOCHARGERS 163
Turbocharger Mounting
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nut)
2. 10.5 x 20 x 15 sleeve (2)
1. HP turbocharger assembly 3. HP turbocharger mounting flange
2. M10 nut
3. M10 x 45 stud
2. Remove two M10 nuts and two 10.5 x 20 x 15
sleeves.
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164 TURBOCHARGERS
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Figure 194 High-pressure (HP) and low-pressure
(LP) turbocharger connection
1. M10 x 55 bolt (5)
2. HP turbocharger assembly
3. LP turbocharger assembly
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TURBOCHARGERS 165
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Figure 195 Free rotation of turbocharger
4. Clean all gasket and O-ring sealing surfaces.
assembly shaft (typical)
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
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Figure 196 LPCAC pressure test (typical)
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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Follow all warnings, cautions, and notes.
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TURBOCHARGERS 167
Installation
Turbocharger Mounting
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2. With help of an assistant, align three studs
and position HP turbocharger to middle exhaust
manifold. Check that turbine exhaust outlet flange
is aligned square with Turbo Alignment Bracket.
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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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2. M10 x 55 bolt (5)
1. M10 x 45 stud 3. HP turbocharger assembly
2. M10 nut
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TURBOCHARGERS 169
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1. Turbocharger support bracket 2. LP wastegate actuator linkage C-clip
2. M8 x 16 bolt 3. LP wastegate actuator
3. M8 x 40 bolt 4. M8 x 14 bolt (3)
4. M8 x 40 x 15 stud bolt
5. 19 x 20 spacer (2)
1. Position LP wastegate actuator with hose port
facing down and install three M8 x 14 bolts.
1. Position turbocharger support bracket and install
2. Tighten three bolts to special torque (page 179).
two 19 x 20 spacers, M8 x 40 x 15 stud bolt and
M8 x 40 bolt. 3. Position LP wastegate actuator linkage on
wastegate lever pin. Install actuator linkage
2. Install M8 x 16 bolt into bottom of turbocharger.
C-clip on wastegate lever pin.
Tighten three bolts to standard torque (page 471).
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170 TURBOCHARGERS
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2. HP wastegate actuator
3. C-clip
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Follow all warnings, cautions, and notes.
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TURBOCHARGERS 171
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1. Turbocharger oil supply tube assembly
1. Turbocharger oil supply tube assembly
2. Oil supply tube fitting
2. M6 x 16 bolt (2)
3. Male stud connector
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172 TURBOCHARGERS
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3. Oil return tube fittings (2)
4. Low-pressure (LP) turbocharger oil return tube
5. 24.7 x 32 seal ring
6. Turbocharger oil drain gasket (2) Figure 209 High-pressure (HP) turbocharger air
supply duct
1. HP turbocharger air supply duct
6. Install LP turbocharger oil return tube with new
2. M10 x 200 bolt (2)
24.7 x 32 seal ring into crankcase. Snug fitting
3. High-pressure compressor inlet seal
only until final tightening.
4. M24 threaded fitting
7. Connect HP turbocharger oil return tube to LP
turbocharger oil return tube with new bonded seal
washer. Snug fitting only until final tightening. 1. Lubricate new high-pressure compressor inlet
seal with P-80® rubber lubricant or equivalent
8. Position HP turbocharger oil return tube with new
(page 179) and install over HP turbocharger
oil drain gaskets to oil return outlet flanges of LP
compressor inlet groove.
turbocharger and HP turbocharger.
2. Install HP turbocharger air supply duct along with
9. Install four M8 x 20 bolts and tighten bolts to
two M10 x 200 bolts. Tighten bolts to standard
standard torque (page 471).
torque (page 471).
10. Final tighten LP turbocharger oil return tube fitting
3. If previously removed, install new seal ring and
nut at crankcase fitting as follows:
M24 threaded fitting and tighten to special torque
a. Tighten fitting nut to 10 N·m (89 lbf·in). (page 179).
b. Turn fitting nut an additional 90°.
11. Final tighten HP turbocharger oil return tube fitting
nut at LP turbocharger oil return tube as follows:
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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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duct
1. Air inlet duct
2. M8 x 45 bolt
3. M10 x 20 x 35 stud bolt
4. M10 x 140 bolt
Figure 211 Coolant return hose (air supply duct
5. HP compressor out duct
to water distribution housing)
6. M10 x 40 bolt
1. Air supply high-pressure (HP) turbocharger duct
(coolant return integral with duct)
1. Lubricate a new LP compressor inlet seal with 2. 3/4 inch worm gear hose clamp
P-80® rubber lubricant or equivalent (page 179) 3. Water distribution housing
and install seal over LP turbocharger compressor 4. 1 inch worm gear hose clamp
inlet. 5. Coolant return hose
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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
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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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TURBOCHARGERS 175
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3. Coolant return hose 1. O-ring seal
4. Coolant tube 2. LPCAC air inlet
3. 72.2 x 60 (DMR) tube seal (extension tube)
4. LPCAC air outlet
8. Install coolant hose and two 3/4 inch hose clamps 5. Low-pressure charge air cooler
between coolant tube and low-temperature 6. Coolant return
housing (EGR cooler). 7. Coolant supply
9. Tighten clamps to special torque (page 179).
1. Lubricate 72.2 x 60 (DMR) tube seal (extension
tube) with P-80® rubber lubricant or equivalent
(page 179) and install into LPCAC using
Extension Tube Installer (page 179).
2. Lubricate new O-ring seal with P-80® rubber
lubricant or equivalent (page 179) and install
O-ring at LPCAC air inlet.
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176 TURBOCHARGERS
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2. M10 x 100 bolt
3. Low-pressure charge air cooler
4. Ground stud bolt (2)
5. 3/4 inch worm gear hose clamp (2)
6. Coolant return hose
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TURBOCHARGERS 177
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Figure 217 HP and LP wastegate hoses
1. 12.3 x 7 crimp clamp (2) 5. Coolant tube (EGR cooler to 8. Turbocharger oil supply tube
2. Cable lock strap (11) LPCAC) 9. HCI coolant return tube
3. EGRV coolant supply tube 6. LP wastegate hose
4. Air control valve assembly 7. HP wastegate hose
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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)
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Special Service Tools
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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Follow all warnings, cautions, and notes.
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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
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Air Compressor Coolant Hoses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Power Steering Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Power Steering Elbows. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .190
Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
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Follow all warnings, cautions, and notes.
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182 AIR COMPRESSOR AND POWER STEERING
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Follow all warnings, cautions, and notes.
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AIR COMPRESSOR AND POWER STEERING 183
Exploded Views
Power Steering and One-Cylinder Air Compressor
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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
EGES-465-1
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Follow all warnings, cautions, and notes.
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184 AIR COMPRESSOR AND POWER STEERING
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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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Follow all warnings, cautions, and notes.
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AIR COMPRESSOR AND POWER STEERING 185
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removing components. 3. 1/2” 90 degree tube elbow
4. 1-1/6” 90 degree tube elbow
WARNING: To prevent personal injury or 5. Low-pressure tube fitting nut
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash 1. Place a drain pan under the power steering pump
with soap and water. Wash or discard clothing to catch any fluid.
and rags contaminated with engine fluids.
2. Loosen high-pressure tube fitting nut and
disconnect tube from 1/2” 90 degree tube elbow.
3. Loosen low-pressure tube fitting nut and
disconnect tube from 1-1/16” 90 degree elbow.
EGES-465-1
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Follow all warnings, cautions, and notes.
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186 AIR COMPRESSOR AND POWER STEERING
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3. M6 nut
4. M6 x 20 stud
5. Rear support bracket
6. Power steering (high-pressure) tube assembly
Figure 222 Power steering pump and 90 degree
elbows
4. Remove rear support bracket M6 nut from
1. Power steering pump
extension clip stud at the oil pan.
2. 1/2” 90 degree tube elbow
5. If equipped, remove front support bracket M6 nut 3. 1-1/16” 90 degree elbow
from support bracket.
6. Remove high-pressure and low-pressure tubes as
1. Loosen the lock nut and rotate the 1/2” 90 degree
an assembly.
tube elbow counterclockwise to remove from
NOTE: If replacing high-pressure and low-pressure power steering pump.
tubes, do steps 7 and 8.
2. Loosen the lock nut and rotate the 1-1/16” 90
7. Remove the rear support brackets and rubber degree elbow counterclockwise to remove from
isolator from the high-pressure and low-pressure power steering pump.
tubes.
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Follow all warnings, cautions, and notes.
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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)
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3. Air compressor
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Follow all warnings, cautions, and notes.
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188 AIR COMPRESSOR AND POWER STEERING
Cleaning
All components
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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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Follow all warnings, cautions, and notes.
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AIR COMPRESSOR AND POWER STEERING 189
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Figure 228 Air compressor (typical)
3. Air compressor
1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)
1. Depending on compressor model, straight and
45° coolant fittings are used. If loosened, tighten
fittings as follows:
WARNING: To prevent personal injury or
One-cylinder compressors
death, get assistance to remove and install the air
compressor and power steering pump assembly. • Tighten M16 straight fittings (at crankcase or air
compressor) to special torque (page 193).
CAUTION: To prevent engine damage, install
component within 5 minutes of sealant application to • If equipped, tighten M16 45° fitting (at crankcase)
inhibit the formation of a skin and ensure a leak-proof to special torque (page 193).
joint.
• If equipped, tighten M18 straight fittings (at air
NOTE: For two-cylinder air compressor only, an compressor) to special torque (page 193).
additional M10 x 110 bolt is located in the mounting
Two-cylinder compressors
hole next to the power steering pump.
• Tighten M16 straight fittings (at crankcase or air
1. Apply Loctite® 5900 sealant or Wacker® A-442
compressor) to special torque (page 193).
RTV (page 193) to crankcase and air compressor
mating surface. • If equipped, tighten M16 45° fitting (at crankcase
or air compressor) to special torque (page 193).
2. For one-cylinder air compressor, position air
compressor and install two M8 x 40 bolts and four 2. Check air compressor coolant supply and return
M8 x 110 bolts. Tighten bolts to special torque hose O-rings before installation. Replace O-rings
(page 193). as needed.
3. For two-cylinder air compressor, position air 3. Place coolant supply hose in position between
compressor and install two M8 x 40 bolts, four M8 crankcase and air compressor coolant fittings.
x 110 bolts and M10 x 110 bolt. Tighten bolts to
special torque (page 193).
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
190 AIR COMPRESSOR AND POWER STEERING
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2. If pump collar O-ring was removed or damaged,
install a new O-ring. Lubricate the new O-ring with
P80® rubber lubricant (page 193) or equivalent.
Figure 230 Power steering pump adapter
3. Install power steering pump and two M10 x 40
1. Power steering pump adapter bolts. Tighten bolts to special torque (page 193).
2. Air compressor
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Follow all warnings, cautions, and notes.
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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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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
192 AIR COMPRESSOR AND POWER STEERING
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3. M6 x 1.0 nut
4. M6 x 20 bolt
5. Rear support bracket NOTE: Do the following steps if fittings were removed
6. Power steering (high-pressure) tube assembly or if power steering pump was replaced.
5. Loosely install the high-pressure tube fitting nut
to the elbow. Using an appropriate size wrench to
3. Position high-pressure and low-pressure tube as
hold the elbow, tighten 1/2" 90 degree tube elbow
an assembly. Install M6 x 1.0 nut onto extension
lock nut to special torque (page 193).
clip stud to secure rear support bracket at the oil
pan. Tighten nut to standard torque (page 471). 6. Loosely install the low-pressure tube fitting nut to
the elbow. Using an appropriate size wrench to
4. If equipped, install front support bracket to
hold the elbow, tighten 1-1/16" 90 degree elbow
extension clip stud on front engine support and
lock nut to special torque (page 193).
secure with M6 x 1.0 flange nut. Tighten nut to
standard torque (page 471). 7. Tighten the high-pressure and low-pressure tube
fitting nuts to special torque (page 193).
EGES-465-1
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Follow all warnings, cautions, and notes.
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AIR COMPRESSOR AND POWER STEERING 193
Special Torque
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Power steering pump M10 x 40 bolt 67 N·m (49 lbf·ft)
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Follow all warnings, cautions, and notes.
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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
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Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
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
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
196 FUEL SYSTEM
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EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 197
Exploded Views
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Figure 235 High-pressure fuel lines
1. Thrust washer (6) 9. Fuel to rail supply clamp 14. Rail fuel pressure sensor
2. Injector hold-down clamp (6) assembly (2) 15. High-pressure rail to injector
3. Rounded washer (6) 10. High-pressure pump to rail tube tube assembly (6)
4. M8 x 50 bolt (6) assembly 2 16. High-pressure connector
5. Injector (6) 11. High-pressure pump to rail tube retaining nut (6)
6. 3 x 20.9 ID O-ring (6) assembly 1 17. 13.5 x 3 O-ring (6)
7. Combustion washer (6) 12. M8 x 40 bolt (3) 18. High-pressure connector body
8. Pressure limiting valve (fuel rail) 13. Fuel rail (6)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
198 FUEL SYSTEM
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Figure 236
1.
2.
3.
Fuel supply and drain (return) lines
After-filter fuel supply hose
(assembly)
Pre-pump fuel supply hose
assembly
Pre-filter fuel supply hose
4.
5.
6.
Fuel drain (return) hose
assembly
Fuel filter bracket assembly with
brace
M14 banjo bolt (3)
8.
9.
10.
11.
12.
Fuel drain (return) tube assembly
Closed (P) clamp and 8 x 16 bolt
Wiring clip
8 x 13 single retainer
C-clip
(assembly) 7. Seal ring, 14.7 x 22 (6)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 199
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Figure 237 Fuel filter housing assembly
1. Priming cup cap 9. Fuel filter cap 18. Fuel Delivery Pressure (FDP)
2. Priming element 10. Fuel filter cap O-ring sensor
3. Priming pump 11. Fuel filter element 19. Fuel supply adapter
4. M8 x 25 bolt (2) 12. Fuel filter housing assembly 20. Banjo fitting
5. M8 x 30 bolt (4) 13. Threaded union (3) 21. Check valve (quick connect)
6. 9 ID x 18 OD x 10.5 spacer (3) 14. Seal ring, 14.7 x 22 (12) 22. Dust cap
7. Fuel filter bracket assembly with 15. M14 x 1.5 hex socket plug 23. Fuel filter stand pipe
brace 16. Fuel filter drain plug
8. 9 ID x 17 OD x 6.5 spacer 17. M8 x 45 bolts (3)
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Follow all warnings, cautions, and notes.
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200 FUEL SYSTEM
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Figure 238 High-pressure fuel pump and drive housing
1. M24 jam nut 11. High-pressure (fuel) pump 21. 55 x 70 x 8 radial shaft seal
2. Washer, 25 x 44 x 4 support 22. High-pressure pump (drive belt)
3. High-pressure (fuel) pump gear 12. M12 x 30 bolt (2) pulley
4. High-pressure (fuel) pump drive 13. M10 x 40 bolt (4) 23. M16 x 40 LH bolt (left-hand
housing 14. M12 x 130 bolt (2) thread)
5. M12 x 90 bolt 15. M12 x 40 bolt
6. 100 x 3.349 O-ring 16. Drive belt shaft
7. High-pressure fuel pump 17. 30.2 x 3 O-ring
8. Seal ring, 16.7 x 24 (4) 18. Sleeve
9. Quick-connect M16 x 1.5 19. High-pressure pump (drive belt)
connector (4) pulley housing
10. M14 x 30 bolt (2) 20. M10 x 40 bolt (4)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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parking brake, and block wheels before doing • Engine Electrical
diagnostic or service procedures.
• Cold Start Assist
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
202 FUEL SYSTEM
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NOTE: It is necessary to remove tube clamps (step 3)
from high-pressure fuel pump to fuel rail assemblies
if only one tube (tube 1 or 2) is to be removed. Tube
clamps can remain installed if both pump to rail tubes
are removed as an assembly.
3. Remove two clamps from high-pressure fuel
pump to fuel rail tube assemblies 1 and 2.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 203
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assembly
5. Loosen line fitting nuts at fuel pump and fuel
rail and remove high-pressure pump to rail tube 1. Cylinder 1 high-pressure connector body and
assembly 2. Cap open fuel pump and fuel rail retaining nut
connections with clean Disposable Air and Fuel 2. Cylinder 1 high-pressure rail to injector tube
Caps (page 234). assembly
3. Fuel rail
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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3. M14 banjo bolt (2)
Figure 246 Cylinders 2-6 high-pressure rail to 4. Fuel drain tube
injector tubes 5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee)
9. Remove high-pressure rail to injector tube
assemblies for cylinders 2 through 6. Cap
open high-pressure connector body and fuel rail 1. Remove M8 x 16 bolt and closed (P) clamp
connections. securing fuel drain tube to crankcase.
2. Loosen fuel drain line fitting nut at the fuel return
Injector and Fuel Drain (Return) Lines hex manifold tee and disconnect tube from fuel
return line.
NOTE: It is not necessary to disassemble the fuel
drain lines unless individual components are leaking 3. Remove M14 banjo bolt and two 14.7 x 22 seal
or damaged. rings to disconnect fuel drain tube at fuel rail.
Discard seal rings.
CAUTION: To prevent engine damage, plug
component connections immediately after each 4. Remove M14 banjo bolt and 14.7 x 22 seal
fuel line is removed. rings connecting fuel drain tube at cylinder head.
Remove fuel drain tube and discard seal rings.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 205
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1. Support fuel rail to prevent it from falling during
removal.
2. Remove three M8 x 40 bolts and remove fuel rail
from cylinder head.
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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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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)
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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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 207
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2. M8 x 25 bolt (2)
5. Fuel drain hose
3. Fuel filter housing
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
208 FUEL SYSTEM
Fuel Filter Housing Assembly 2. Remove three M8 x 45 bolts and remove fuel filter
housing assembly.
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1. 9 ID x 18 OD x 10.5 spacer (3)
2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer
1. Remove three M8 x 16 bolts and remove metering
unit bracket.
3. Remove four M8 x 30 bolts and spacers; remove
fuel filter bracket from crankcase.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 209
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1. Remove fuel filter cap and O-ring
2. Using an appropriate wrench, loosen and remove Figure 260 High-pressure pump pulley
stand pipe from housing.
1. High-pressure pump pulley
3. Remove O-ring from center tube at bottom of 2. M16 x 40 LH bolt (left-hand thread)
stand pipe
4. Apply P-80® rubber lubricant or equivalent (page
234) to new O-ring and install O-ring on center 1. Remove M16 x 40 LH bolt. Clean any sealer off
tube in bore at bottom of stand pipe. of bolt threads.
5. Insert stand pipe into housing assembly and 2. Remove high-pressure pump pulley from drive
using carefully thread pipe into bore at bottom of belt shaft assembly. Clean any sealer from shaft
housing. and pulley.
6. Tighten the stand pipe to special torque (page
233).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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and seal
1. High-pressure pump pulley housing
2. M10 x 40 bolt (4)
3. 30.2 x 3 O-ring
4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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)
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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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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
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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.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 213
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5. Remove six M8 x 50 hold-down clamp bolts and 8. Install extractor on injector.
rounded washers.
6. Remove six thrust washers.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
214 FUEL SYSTEM
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10. Position two plate columns on two opposite
cylinder head bolts, and slide extractor plate over
extractor and plate columns.
11. Install and finger-tighten plate column nuts on
plate columns.
Figure 274 Injector seals (typical)
1. Injector assembly
2. 3 x 20.9 ID O-ring
3. Combustion washer
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 215
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5. Clean outside surfaces of low-pressure fuel lines,
fuel filter housing assembly and fuel primer pump
assembly with a suitable non-caustic solvent. Dry
with filtered compressed air.
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
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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CAUTION: To prevent engine damage, install new
injector O-ring and combustion washer before
installing injector.
2. Install a new combustion washer onto injector tip.
3. Lubricate a new 3 x 20.9 ID O-ring with clean
engine oil and install in recess at mid-point of
Figure 275 Thrust washer
injector.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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1. Injector hold-down clamp
2. Injector
Figure 279 Alignment of high-pressure
connector body (typical)
CAUTION: To prevent engine damage, align injector
1. Notch in cylinder head
and hold-down clamp correctly with cylinder head; do
2. Locating ball
not twist injector when inserting injector into cylinder
3. High-pressure connector body
head.
NOTE: Make sure injector bore in cylinder head is
clean and no old combustion washer remains inside 7. Align locating ball on each new high-pressure
the bore. connector body with notch in cylinder head and
install six new high-pressure connector bodies.
5. Install injector by lowering injector and hold-down
clamp as one unit into injector bore.
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)
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2. Injector hold-down clamp (6)
3. Thrust washer (6)
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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1. M8 x 50 bolt (6) and rounded washer (6)
2. High-pressure connector body (6)
2. Injector hold-down clamp (6)
3. Thrust washer (6)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
220 FUEL SYSTEM
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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
FUEL SYSTEM 221
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Figure 285 High-pressure fuel pump and drive housing assembly
1. High-pressure fuel pump 5. Drive housing 9. High-pressure pump gear
2. M10 x 40 bolts (4) 6. 25 x 44 x 4 washer 10. 100 x 3.349 O-ring
3. Key 7. M24 jam nut
4. Dowel pin 8. Sleeve
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
222 FUEL SYSTEM
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6. Check that dowel pin and sleeve are properly
seated in place in drive housing.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 223
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4. M14 x 30 bolt (2)
and seal
1. High-pressure pump pulley housing
11. Place support bracket in position below 2. M10 x 40 bolt (4)
high-pressure fuel pump and install two M12 3. 30.2 x 3 O-ring
x 30 and two M14 x 30 bolts. 4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft
• Tighten two M12 x 30 bolts to standard torque
(page 471).
• Tighten two M14 x 30 bolts to special torque 1. Lubricate drive belt shaft with clean engine oil
(page 233). and insert shaft into high-pressure pump pulley
housing bushing bore.
NOTE: If high-pressure fuel pump was replaced or
fittings were previously removed, continue with step 2. Install new 30.2 x 3 O-ring in groove on drive belt
shaft.
12. Install four M16 x 1.5 quick-connect connectors
with new 16.7 x 24 seal rings to high-pressure fuel 3. Check that (alignment) sleeve is in place on pulley
pump. Tighten connectors to special torque (page housing mounting flange.
233). CAUTION: To prevent engine damage, install
component within 5 minutes of sealant application to
inhibit the formation of a skin and ensure a leak proof
joint.
4. Apply Wacker® A-442 RTV sealant (page 234)
or equivalent to joining surfaces of pulley housing
and high-pressure fuel pump drive housing.
5. Place pulley housing assembly with drive belt
shaft in position on high-pressure fuel pump drive
housing, using care to mesh drive belt shaft gear
with idler gear in crankcase.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer
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).
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1. M8 x 16 bolts (3) 3. 14.7 x 22 seal ring (3)
2. Metering unit (valve) bracket 4. Fuel primer pump
5. M8 x 25 bolt (2)
6. Fuel filter housing
3. Position metering unit bracket on filter housing 7. Banjo fitting
and install three M8 x 16 bolts. Tighten bolts to 8. Fuel supply adapter
standard torque (page 471).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
226 FUEL SYSTEM
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5. Fuel drain hose
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
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
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7. Check that O-rings are in place in pre-filter
fuel supply quick-connect 90° fittings and not
damaged. Replace as necessary.
8. Install pre-filter fuel supply hose.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
228 FUEL SYSTEM
Fuel Rail
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pump)
2. Quick-connect 90° fitting (at metering unit)
3. M 14 banjo bolt with two 14.7 x 22 seal rings
4. C-clip
5. After-filter fuel supply hose
Figure 301 Fuel rail assembly
1. M8 x 40 bolt (3)
11. Install after-filter fuel supply hose as follows:
2. Fuel rail
a. Check that O-rings are in place in after-filter
fuel supply hose quick-connect 90° fittings
and not damaged. Replace as necessary. 1. Support fuel rail in position against underside of
cylinder head.
b. Position banjo fitting with two new 14.7 x 22
seal rings at filter housing and install M14 2. Install and hand tighten three M8 x 40 bolts to
banjo bolt. Tighten banjo bolt to special attach rail to cylinder head.
torque (page 233).
c. Push on quick-connect 90° fitting at
high-pressure pump until an audible click
is heard. Pull quick-connect fitting to make
sure it is seated.
EGES-465-1
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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).
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1. Fuel rail
2. 14.7 x 22 seal ring (4)
3. M14 banjo bolt (2)
4. Fuel drain tube Figure 303 Crowfoot wrench (typical)
5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee) 1. Obtain a crowfoot wrench (page 234) to connect
all high pressure fuel line fittings. When using a
crowfoot wrench to tighten fittings, calculate the
1. Install M14 banjo bolt with two new 14.7 x 22 seal torque compensation to match specific wrench
rings to connect fuel drain tube to cylinder head. configuration. See Using a Torque Wrench
Do not tighten at this time. Extension (page 472)
2. Install M14 banjo bolt with two new 14.7 x 22 seal
rings to connect fuel drain tube to fuel rail. Do not WARNING: To prevent personal injury or
tighten at this time. death, whenever any fuel line (tubing) in the
high-pressure fuel system is removed, it must be
NOTE: Use a backup wrench when tightening fitting
replaced with new.
nut on hex manifold tee.
3. Connect fuel drain tube to fuel return hex manifold
tee at fuel filter bracket. Tighten drain line fitting
nut to special torque (page 233).
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
230 FUEL SYSTEM
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assembly 2. Fuel rail
3. Fuel rail
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 231
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1. Fuel to rail supply clamp assembly (2)
7. Install new high-pressure pump to rail tube 2. High-pressure pump to rail tube assembly 1
assembly 1 between high-pressure fuel pump 3. High-pressure pump to rail tube assembly 2
and fuel rail. Hand tighten line fitting nuts.
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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three M8 x 16 bolts. Tighten bolts to standard
torque (page 471)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FUEL SYSTEM 233
Specifications
Special Torque
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Fuel primer pump M8 x 25 bolt 30 N·m (22 lbf·ft)
Fuel rail M8 x 40 bolt 35 N·m (26 lbf·ft)
Fuel strainer cover 10 N·m (89 lbf·in)
Fuel supply adapter 30 N·m (22 lbf·ft)
High-pressure connector (body) retaining nut See tightening steps in procedure
High-pressure fuel pump drive housing M12 x 40, M12 x 90,
105 N·m (77 lbf·ft)
M12 x 130 bolt
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lbf·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lbf·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lbf·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lbf·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lbf·ft)
Injector harness nut 1.5 N·m (13 lbf·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Quick-connect M16 x 1.5 connector 30 N·m (22 lbf·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lbf·ft)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
234 FUEL SYSTEM
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Slide hammer Obtain locally
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 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
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Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .245
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Oil Centrifuge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
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Follow all warnings, cautions, and notes.
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236 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 237
Exploded Views
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Figure 311 Oil module assembly
1. Clamp (spring) 7. Extension tube 13. M6 x 16 bolt (2)
2. Oil centrifuge (DMR37 x DN29) 14. Tube clamp (2)
3. Filter cover 8. Seal (formed) 15. Open breather tube assembly
4. M8 x 45 bolt (3) 9. Oil module assembly
5. Oil module flange 10. Heater return tube assembly
6. Extension tube 11. Hose clamp (spring)
(DMR20 x DN14) 12. Tube clamp (2)
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Follow all warnings, cautions, and notes.
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238 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
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Figure 312 Oil module
1. Oil centrifuge 8. Extension tube 15. M10 x 170 bolt
2. Open breather tube connection (DMR37 x DN29) 16. M10 x 200 bolt (2)
3. Filter cover 9. Oil module flange 17. M10 x 80 bolt (7)
4. O-ring seal 10. Seal (formed) 18. M8 x 90 bolt (2)
5. Oil filter 11. Oil module assembly 19. M10 x 110 bolt (3)
6. M8 x 45 bolt (3) 12. Oil module gasket 20. M10 x 140 bolt
7. Extension tube 13. Oil cooler 21. M8 x 45 bolt (2)
(DMR20 x DN14) 14. Oil cooler gasket (2) 22. M6 socket head bolt (4)
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 239
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set the parking brake, and block the wheels before
doing diagnostic or service procedures.
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.
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Follow all warnings, cautions, and notes.
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240 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
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1. Open breather tube assembly
2. Clamp (spring)
3. Oil centrifuge outlet
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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.
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return tube
1. Open breather tube assembly
2. M6 x 16 bolt (3)
3. Tube clamp (2)
4. Tube clamp (2) (for hydrocarbon injector (HCI)
coolant return tube assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
7. Pipe single cushioned clamp
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Follow all warnings, cautions, and notes.
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242 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
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2. Extension tube (DMR37 x DN29) Figure 320 Oil module assembly
3. Oil module flange
4. M8 x 45 bolt (3) 1. M10 x 80 bolt (7)
5. Engine oil temperature sensor 2. M10 x 170 bolt
3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes
8. If not previously done, disconnect engine oil 9 x 16 x 15 spacer
temperature sensor connector. Remove engine
oil temperature sensor from oil module flange
if needed. See "ENGINE ELECTRICAL" for 11. Remove seven M10 x 80 bolts, three M10 x 110
procedure. bolts, M10 x 170 bolt, M8 x 150 bolt (from water
pump into front side of oil module assembly) and
9. Remove three M8 x 45 bolts then remove oil 9 x 16 x 15 spacer (between oil module assembly
module flange by pulling away from cylinder head and water distribution housing).
to disengage extension tubes. Discard the oil
module flange seal (formed). 12. Remove oil module assembly and gasket from
engine. Discard oil module assembly gasket.
CAUTION: To prevent engine damage, do not remove
extension tubes by grabbing sealing surfaces.
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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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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 243
Oil Cooler
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1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2) Oil Pressure Relief Valve
3. Oil module assembly
NOTE: Perform this procedure if replacing oil pressure
relief valve for oil pressure-related issues.
1. Remove two M8 x 45 and two M8 x 90 bolts.
2. Remove oil cooler from oil module assembly. 1. Remove oil pressure relief valve. Clean and
inspect oil pressure relief valve. Replace if
necessary.
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Follow all warnings, cautions, and notes.
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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.
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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.
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 245
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1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2)
3. Oil module assembly
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Follow all warnings, cautions, and notes.
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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
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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).
EGES-465-1
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Follow all warnings, cautions, and notes.
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OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION 247
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2. Extension tube (DMR37 x DN29) 2. M6 x 16 bolt (3)
3. Oil module flange 3. Tube clamp (2)
4. M8 x 45 bolt (3) 4. Tube clamp (2) (for HCI coolant return tube
5. Engine oil temperature sensor assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
6. Lubricate sealing surfaces of DMR20 x DN14 and 7. Pipe single cushioned clamp
DMR37 x DN29 extension tubes with P-80® rubber
lubricant or equivalent (page 250) and insert into
oil module flange. 10. Install two tube clamps onto open breather tube.
Position open breather tube assembly to LPCAC
7. Install extension tubes into oil module flange using
and install two M6 x 16 bolts. Tighten bolts to
Extension Tube Installer Large and Extension
special torque (page 250).
Tube Installer Small (page 250).
11. If not previously done, snap two tube clamps over
8. Position oil module with new formed seal onto oil
open breather tube assembly and HCI coolant
module while gently pushing extension tubes into
return tube assembly.
cylinder head. Install three M8 x 45 bolts. Tighten
bolts to special torque (page 250). 12. If not previously done, install HCI coolant
return tube onto open breather tube assembly
9. If not previously done, install engine oil
and install hose clamp (spring type). See
temperature sensor into oil module flange
"AFTERTREATMENT SYSTEM" for procedure.
if needed. See "ENGINE ELECTRICAL"
for procedure. Connect temperature sensor 13. Position heater return tube assembly to straight
electrical connector. fitting on water distribution housing and loosely
tighten tube nut.
14. Install pipe single cushioned clamp onto heater
return tube assembly and install M6 x 16 bolt into
LPCAC and tighten to special torque (page 250).
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Follow all warnings, cautions, and notes.
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248 OIL COOLER, FILTER HOUSING AND CRANKCASE VENTILATION
Oil Centrifuge
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3. Oil centrifuge outlet
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Follow all warnings, cautions, and notes.
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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
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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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Description Tool Number
Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
P-80® rubber lubricant or equivalent Obtain locally
EGES-465-1
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Follow all warnings, cautions, and notes.
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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
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In-vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
On Bench. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
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
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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.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 253
Exploded Views
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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.
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254 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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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.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 255
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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.
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256 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Figure 339 EGR system components
1. EGR dual flap valve 6. M10 x 170 bolt 13. M8 x 65 heat-resistant bolt (2)
2. EGR valve coolant return tube 7. M8 x 25 heat-resistant bolt (2) 14. M8 x 12 bolt (3)
assembly 8. EGR cooler bracket 15. Tube EGR gasket (4)
3. M8 x 30 heat-resistant bolt (two 9. M8 x 25 heat-resistant bolt (2) 16. M8 x 30 heat-resistant bolt (7)
at front of EGR valve) 10. Low-temperature EGR hose 17. Inlet EGR (cylinders 1-3) tube
4. EGR cooler assembly assembly 18. Heat protection EGR shield
5. EGR valve coolant supply tube 11. M10 x 45 bolt (6) 19. Inlet EGR (cylinders 4-6) tube
assembly 12. EGR dual flap valve gasket 20. M8 x 25 heat-resistant bolt (6)
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 257
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parking brake, and block wheels before doing 1. Extension tube (DMR44 x 35)
diagnostic or service procedures. 2. M8 x 45 bolt (2)
3. M8 x 12 bolt
4. Extension tube (DMR62 x 51)
WARNING: To prevent personal injury or
5. M8 x 25 heat-resistant bolt
death, make sure the engine has cooled before
6. M8 x 50 x 16 stud bolt
removing components.
7. Extension tube (DMR62 x 51)
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Follow all warnings, cautions, and notes.
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258 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Figure 341 Coolant elbow Figure 342 EGR cooler bracket
1. M8 x 25 bolt (3) 1. Heat protection shield (at front exhaust manifold)
2. Coolant elbow 2. EGR cooler bracket
3. Extension tube (DMR62 x 51) 3. M8 x 25 heat-resistant bolt (2)
4. Hydrocarbon injector fuel supply (tube) bracket
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 259
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Figure 343 Heat protection (cylinders 4-6) shield 2. EGR outlet (cylinders 1-3) tube
1. Heat protection (cylinders 4-6) shield 3. EGR outlet (cylinders 4-6) tube
2. M8 x 12 bolt (3)
3. M8 x 25 heat-resistant bolt
1. Remove four M8 x 30 bolts securing the EGR
outlet (cylinders 4-6) tube.
1. Remove M8 x 25 heat-resistant bolt. 2. Remove EGR outlet (cylinders 4-6) tube and
2. Remove three M8 x 12 bolts and heat protection discard tube gaskets.
shield. 3. Remove four M8 x 30 bolts securing the EGR
outlet (cylinders 1-3) tube.
4. Remove EGR outlet (cylinders 1-3) tube and
discard tube gaskets.
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Follow all warnings, cautions, and notes.
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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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2. EGR inlet (cylinders 1-3) tube 2. EGR inlet (cylinders 4-6) tube
3. Rear exhaust manifold 3. Rear exhaust manifold
4. M8 x 65 heat-resistant bolt (2)
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 261
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Figure 347 Heat protection EGR shield 1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (9)
1. Heat protection EGR shield
3. EGR coolant supply tube nut
2. M8 x 12 bolt (2)
4. Spring clamp
5. Coolant return tube
1. Remove two M8 x 12 bolts at rear exhaust
manifold.
NOTE: Drain coolant from EGR cooler assembly
2. Remove heat protection EGR shield. before removal.
1. Disconnect coolant return tube spring clamp and
tube from EGR dual flap valve.
EGR Dual Flap Valve
2. Loosen tube nut and disconnect EGR dual flap
NOTE: If removing complete EGR cooler assembly
valve coolant supply tube from bottom of EGR
for disassembly of engine, removal of EGR dual flap
dual flap valve.
valve is not required.
3. Remove nine M8 x 30 heat-resistant bolts (two
NOTE: The EGR dual flap valve can be removed as
bolts go through cooler into valve) and EGR dual
an in-vehicle service.
flap valve.
4. Remove and discard EGR dual flap valve gasket.
EGES-465-1
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Follow all warnings, cautions, and notes.
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262 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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6. Y-fitting (to deaeration port hoses)
7. EGR cooler bracket
EGES-465-1
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Follow all warnings, cautions, and notes.
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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.
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2. Remove EGR outlet tubes (page 259) from EGR
cooler assembly.
Figure 351 EGR cooler pressure test plate
installed (EGR valve removed)
1. Pressure test plate
2. M8 bolt (9)
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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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1. M8 bolt (4)
2. Pressure test plate
EGES-465-1
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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.
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Figure 354 EGR cooler assembly 1. EGR dual flap valve
2. M8 x 30 heat-resistant bolt (9)
1. EGR cooler assembly 3. EGR coolant supply tube nut
2. M10 x 45 bolt (6) 4. Spring clamp
3. M10 x 170 bolt 5. Coolant return tube
4. Spring clamp
5. Low-temperature EGR hose assembly
1. Install a new gasket.
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.
© 2011 Navistar, Inc. All rights reserved
266 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Figure 356 Heat protection EGR shield
1. M8 x 25 heat-resistant bolt (2)
1. Heat protection EGR shield 2. EGR inlet (cylinders 4-6) tube
2. M8 x 12 bolt (2) 3. Rear exhaust manifold
4. M8 x 65 heat-resistant bolt (2)
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 267
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2. EGR outlet (cylinders 1-3) tube
3. EGR outlet (cylinders 4-6) tube
3. Position two new EGR inlet (cylinders 1-3) tube
gaskets, one to EGR valve and one to middle
exhaust manifold. 1. Install EGR outlet (cylinders 4-6) tube, two new
tube gaskets and four M8 x 30 bolts. Tighten bolts
4. Install EGR inlet (cylinders 1-3) tube and four M8
to standard torque (page 471).
x 25 heat-resistant bolts. Tighten bolts to special
torque (page 270). 2. Install EGR outlet (cylinders 1-3) tube, two new
tube gaskets and four M8 x 30 bolts. Tighten bolts
to standard torque (page 471).
3. Check EGR outlet tube hose clamps for
looseness. Tighten tube hose clamps to special
torque (page 270).
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Follow all warnings, cautions, and notes.
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268 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
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Figure 360 Heat protection (cylinders 4-6) shield
Figure 361 EGR cooler bracket
1. Heat protection (cylinders 4-6) shield
1. Heat protection shield (at front exhaust manifold)
2. M8 x 12 bolt (3)
2. EGR cooler bracket
3. M8 x 25 heat-resistant bolt
3. M8 x 25 heat-resistant bolt (2)
EGES-465-1
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Follow all warnings, cautions, and notes.
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EXHAUST GAS RECIRCULATION (EGR) SYSTEM 269
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Figure 362 Coolant elbow 1. Extension tube (DMR44 x 35)
2. M8 x 45 bolt (2)
1. M8 x 25 bolt (3) 3. M8 x 12 bolt
2. Coolant elbow 4. Extension tube (DMR62 x 51)
3. Extension tube (DMR62 x 51) 5. M8 x 25 heat-resistant bolt
4. Hydrocarbon injector fuel supply (tube) bracket 6. M8 x 50 x 16 stud bolt
7. Extension tube (DMR62 x 51)
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
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
270 EXHAUST GAS RECIRCULATION (EGR) SYSTEM
Special Torque
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EGR Cooler Pressure Test Kit KL 20060 NAV
Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
P-80® rubber lubricant or equivalent Obtain locally
EGES-465-1
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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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Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .282
EGES-465-1
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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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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 273
Exploded Views
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1. Sleeve spacer (18) 5. Front exhaust manifold 9. Exhaust gas recirculation tube
2. M10 x 57 Torx® bolt (18) 6. M8 x 12 bolt gasket (2)
3. Multipiece oil (FEY) ring (4) 7. Heat protection shield 10. Rear exhaust manifold
4. Middle exhaust manifold 8. M10 x 45 stud 11. Exhaust manifold gasket (6)
EGES-465-1
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Follow all warnings, cautions, and notes.
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274 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
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Figure 365 Air intake throttle horizontal duct
1. Air intake throttle horizontal duct 4. Charge air cooler outlet 6. Cold start fuel ignitor (glow plug)
2. Sensor O-ring temperature sensor 7. M8 x 100 bolt (2)
3. Intake manifold pressure sensor 5. O-ring 8. M8 x 50 bolt
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 275
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Figure 366 Air intake throttle vertical duct
1. Cold start fuel ignitor (glow plug) 4. Charge air cooler outlet 6. Air intake throttle vertical duct
2. Intake manifold pressure sensor temperature sensor 7. M8 x 100 bolt (2)
3. O-ring 5. Sensor O-ring 8. M8 x 50 bolt
EGES-465-1
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Follow all warnings, cautions, and notes.
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276 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
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parking brake, and block wheels before doing
Figure 367 Exhaust manifold (typical)
diagnostic or service procedures.
1. Rear exhaust manifold
2. Middle exhaust manifold
WARNING: To prevent personal injury or
3. M10 x 57 Torx® bolt and sleeve spacer (18)
death, make sure the engine has cooled before
4. Front exhaust manifold
removing components.
5. Exhaust manifold gasket (6)
6. M8 x 12 bolt
WARNING: To prevent personal injury or 7. Heat protection shield
death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner and wash
with soap and water. Wash or discard clothing 2. Remove 18 M10 x 57 Torx® bolts and 18 sleeve
and rags contaminated with engine fluids. spacers. Discard bolts and spacers after removal.
NOTE: Refer to the following service sections for 3. Remove exhaust manifold assembly and discard
information on removal of components prior to this six exhaust manifold gaskets.
section.
• Engine Electrical
• Cold Start Assist
• Aftertreatment System
• Exhaust Back Pressure Control
• Turbochargers
• Oil Cooler, Filter Housing and Crankcase
Ventilation
• Exhaust Gas Recirculating (EGR) System
• Front Cover, Fan Drive, Cooling System and
Related Components
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 277
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5. Remove and discard multipiece oil (FEY) rings
from front and rear exhaust manifolds.
EGES-465-1
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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.
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Figure 371 Exhaust manifold section warp test
1. Left
2. Right
3. Diagonally
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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.
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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.
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sequence
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD 281
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1. Heat protection shield (at front exhaust manifold)
2. M8 x 12 bolt
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
282 AIR INTAKE THROTTLE DUCT AND EXHAUST MANIFOLD
Specifications
Special Torque
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Wacker® A-442 RTV sealant or equivalent Obtain locally
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
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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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284 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
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Follow all warnings, cautions, and notes.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 285
COMPONENTS
Exploded Views
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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.
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286 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
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Follow all warnings, cautions, and notes.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 287
COMPONENTS
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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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288 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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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)
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Follow all warnings, cautions, and notes.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 289
COMPONENTS
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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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290 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
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Figure 383 Front belt-driven fan cover (high mount fan)
1. Front belt driven fan cover 4. M12 x 75 bolt (3) 7. M8 x 40 bolt (2)
2. Front cover gasket 5. Radial shaft seal 8. M12 x 30 bolt (2)
3. Dowel pin (2) 6. M8 x 25 bolt (13)
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 291
COMPONENTS
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Figure 384 Front gear-driven fan cover (low mount fan)
1. Front gear driven fan cover 4. Dowel pin (2) 7. M8 x 25 bolt (13)
2. Front cover gasket 5. M12 x 75 bolt (3) 8. M8 x 40 bolt (2)
3. O-ring 108 x 3 6. Radial shaft seal 9. M12 x 30 bolt (2)
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Follow all warnings, cautions, and notes.
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292 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
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Figure 385 Fan low mount drive (typical)
1. M8 x 25 bolt (4) 3. O-ring 108 x 3 5. M8 x 40 bolt
2. Radial shaft seal 4. Fan low mount drive assembly
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Follow all warnings, cautions, and notes.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 293
COMPONENTS
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parking brake, and block wheels before doing
diagnostic or service procedures. 1. Remove shoulder bolt and pulley assembly.
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Follow all warnings, cautions, and notes.
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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.
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1. M8 x 30 bolt (3)
2. Tensioner bracket
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.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 295
COMPONENTS
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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.
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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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Figure 394
1.
2.
3.
Water pump assembly and pulley
Water pump assembly
Water pump pulley
M8 x 16 bolt (4) Figure 395 Vibration damper (low mount fan
4. M8 x 130 bolt with damper hub)
5. M8 x 150 bolt
6. M8 x 40 bolt (7) 1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Damper hub
1. Remove four M8 x 16 bolts and water pump pulley. 4. M10 x 35 bolt (9)
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 297
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1. M16 x 85 socket-head cap screw (8) 1. Low temperature hose assembly
2. Vibration damper 2. Hose clamp (spring type)
3. Fan drive pulley 3. Coolant Mixer Valve (CMV)
4. M10 x 35 bolt (9) 4. Coolant Flow Valve (CFV)
5. Lock washer (2)
6. M8 x 60 stud bolt (2)
7. CCV assembly
WARNING: To prevent personal injury
or death, support the vibration damper when
removing bolts. The damper can easily slide off 1. Release hose clamp (spring type) and remove low
the crankshaft. temperature hose assembly from CCV assembly.
NOTE: If equipped with high mount fan, remove 2. Remove two M8 x 60 stud bolts, two lock washers,
fan drive pulley and vibration damper together. If CCV assembly and O-ring. Discard O-ring.
equipped with low mount fan, remove damper hub
and vibration damper together.
1. Remove eight M16 x 85 socket-head cap screws.
2. Remove vibration damper with damper hub or fan
drive pulley as an assembly.
3. For vibration damper replacement only, remove
damper hub or fan drive pulley by removing nine
M10 x 35 bolts.
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298 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
COMPONENTS
Thermostat Housing
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3. M8 x 30 bolt 4. Remove M8 x 75 bolt and M8 x 60 bolt.
4. Extension tube (DMR62 / 51)
5. Remove thermostat housing and discard gasket.
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FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED 299
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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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Figure 401 Water distribution housing
Figure 402
1.
Radial shaft seal removal
Radial shaft seal
1. Water distribution housing 2. Slide hammer
2. M10 x 110 bolt with low mount fan drive or M10 x
150 - 12.9 bolt with high mount fan drive (5)
3. M8 x 150 bolt (2)
WARNING: To prevent personal injury or
4. Engine water inlet (94°)
death, wear safety glasses with side shields when
5. Coolant heater
doing the following procedure.
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan) 1. With an awl and hammer, punch two holes 180°
apart in front oil seal.
2. Thread a slide hammer (page 313) with correct
1. Remove two M8 x 150 bolts. size screw in one of the two holes.
• If equipped with low mount fan drive, five M10 3. Slide hammer until one side of seal begins to pull
x 110 bolts. out of cover. Move slide hammer to other hole and
• If equipped with high mount fan drive, five repeat until front oil seal is removed.
M10 x 150 - 12.9 bolts and one M10 x 65 bolt.
(These bolts are removed with high mount fan
drive clutch assembly removal.)
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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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1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3) Figure 404 Radial shaft seal removal
3. M8 x 40 bolt (2)
4. M12 x 30 bolt (2)
2. Thread a slide hammer (page 313) with correct
size screw in one of the two holes.
3. Slide hammer until one side of seal begins to pull
WARNING: To prevent personal injury or out of fan drive. Move slide hammer to other
death, use a suitable lifting device and get help hole and repeat until radial shaft seal is removed.
when removing, lowering and installing the front Discard radial shaft seal.
cover.
1. Remove two M8 x 40 bolts, two M12 x 30 bolts,
three M12 x 75 bolts and 13 M8 x 25 bolts.
2. Remove front belt- or gear-driven fan cover
and front cover gasket from crankcase dowels.
Discard front cover gasket.
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2. Remove four M8 x 25 bolts, one M8 x 40 bolt and
fan low mount drive assembly.
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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
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leaks. Replace if leaking.
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2. Fan low mount drive assembly
3. M8 x 40 bolt
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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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
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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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Thermostat Housing
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Figure 412 Water distribution housing
1. Water distribution housing
2. M10 x 110 bolt with low mount fan drive or M10 x
150 bolt - 12.9 with high mount fan drive (5)
3. M8 x 150 bolt (2)
4. Engine water inlet (94°)
5. Coolant heater
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan) Figure 413 Thermostat housing
1. Extension tube (DMR40 / DN32F) (2)
2. Thermostat housing
1. Install coolant heater into engine water inlet as
needed. Tighten to special torque (page 312).
2. Install new gasket and install engine water inlet 1. Lubricate sealing surfaces of two extension tubes
and two M10 x 30 bolts to water distribution (DMR40 / DN32F) with P-80® rubber lubricant or
housing. Tighten bolts to special torque (page equivalent (page 313) and install into thermostat
312). housing using Extension Tube Installer Small
(page 313).
3. Lubricate a new water distribution housing
gasket with clean coolant and install into water
distribution housing.
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306 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
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2. Install new gasket and thermostat housing.
3. Install M8 x 75 bolt and M8 x 60 bolt. Do not
tighten bolts until EGR cooler return manifold is
installed.
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COMPONENTS
Vibration Damper
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with damper hub) 1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
1. M16 x 85 socket-head cap screw (8)
3. Fan drive pulley
2. Vibration damper
4. M10 x 35 bolt (9)
3. Damper hub
4. M10 x 35 bolt (9)
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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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6. M8 x 40 bolt (7) 3. M10 x 70 countersunk screw
4. Automatic belt tensioner
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3. Thermostat assembly (2)
4. Ball valves (part of thermostat assembly)
2. Install coolant outlet manifold.
3. If equipped with low mount fan, install bracket and
1. Install two thermostat assemblies into thermostat two bushings.
housing with ball valves at 12 o’clock position. 4. Install coolant outlet manifold bolts as follows.
a. If equipped with low mount fan, install one M8
x 70 bolt and two M8 x 130 bolts. Tighten bolts
to special torque (page 312).
b. If equipped with high mount fan, install three
M8 x 70 bolts. Tighten bolts to special torque
(page 312).
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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.
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3. Tighten M10 bolts using sequence indicated
CAUTION: To prevent engine damage, clean
above as follows.
and blow dry crankcase bolt holes with filtered
compressed air. Debris or fluids in bolt holes may a. Tighten six M10 bolts to 37 N·m (27 lbf·ft).
cause binding and incorrect bolt torque.
b. Re-tighten six bolts to 37 N·m (27 lbf·ft).
c. Angle-tighten five M10 x 150 - 12.9 bolts an
WARNING: To prevent personal injury or
additional 90° in sequence.
death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi). d. Tighten M10 x 65 bolt to 62 N·m (46 lbf·ft).
1. Using filtered compressed air, clean thread holes 4. Connect air line to back of fan drive clutch
of fan drive clutch assembly. assembly.
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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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1. M8 x 30 bolt (3)
2. Tensioner bracket
Figure 428 Pulley assembly
1. Shoulder bolt
1. Install tensioner bracket and three M8 x 30 bolts. 2. Pulley assembly
Tighten bolts to standard torque (page 471).
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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,
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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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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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314 FRONT COVER, FAN DRIVE, COOLING SYSTEM AND RELATED
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EGES-465-1
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Follow all warnings, cautions, and notes.
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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
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Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .328
Engine Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
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Follow all warnings, cautions, and notes.
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316 MAXXFORCE® ENGINE BRAKE BY JACOBS
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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.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 317
Exploded Views
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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.
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318 MAXXFORCE® ENGINE BRAKE BY JACOBS
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Figure 430 MaxxForce® engine brake housing assembly
1. Master piston roller assembly 8. Control valve retaining ring 15. Slave piston
2. Master piston roller spring 9. Control valve cover 16. Slave piston spring
3. Master piston spring guide 10. Outer spring 17. Slave piston washer
4. Solenoid assembly 11. Inner spring 18. Slave piston retaining ring
5. M6 x 10 socket-head cap screw 12. Control valve assembly 19. M6 x 30 master piston guide bolt
6. Solenoid cover 13. M10 (jam) nut 20. Master piston guide sleeve
7. Solenoid screen 14. Slave piston adjusting screw
EGES-465-1
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Follow all warnings, cautions, and notes.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 319
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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)
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.
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320 MAXXFORCE® ENGINE BRAKE BY JACOBS
Removal
Engine Brake Housing Assembly
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death, shift transmission to park or neutral, set 1. Remove upper valve cover. See Upper Valve
parking brake, and block wheels before doing Cover and Base in the “CYLINDER HEAD,
diagnostic or service procedures. CAMSHAFT AND VALVE TRAIN” section (Upper
Valve Cover and Base, page 341).
WARNING: To prevent personal injury or 2. Disconnect brake wiring harness connector leads
death, make sure that the engine has cooled from solenoid by disengaging two connector nuts
before removing components. on each front and rear engine brake housing
assemblies. The connector nuts are retained by
WARNING: To prevent personal injury or the harness connectors.
death, do not let engine fluids stay on your skin. 3. Cut tie straps securing solenoid harness
Clean skin and nails using hand cleaner and wash connector leads on front and rear brake housings.
with soap and water. Wash or discard clothing Position leads out of the way.
and rags contaminated with engine fluids.
4. Mark housings to indicate front and rear to insure
they are reinstalled later in the correct locations.
WARNING: To prevent personal injury or
death, disconnect the main battery negative 5. Remove three M12 x 100 socket-head screws and
terminal before disconnecting or connecting three M10 x 90 bolts and remove front engine
electrical components. brake housing assembly from cylinder head.
6. Repeat step 5 to remove rear 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.
EGES-465-1
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Follow all warnings, cautions, and notes.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 321
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Figure 433 Solenoid
1. Solenoid assembly
2. M6 x 10 socket-head cap screw
3. Solenoid cover
4. Solenoid screen
Figure 434 Control valve
1. Control valve retaining ring
1. If not already done, loosen connector nuts
2. Control valve cover
and disconnect harness connector leads from
3. Outer spring
solenoid.
4. Inner spring
2. Remove M6 x 10 socket-head cap screw. 5. Control valve assembly
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
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322 MAXXFORCE® ENGINE BRAKE BY JACOBS
Master Piston
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1. Master piston spring guide
2. Master piston roller spring
3. Master piston roller assembly
4. M6 x 30 master piston guide bolt
5. Master piston guide sleeve
The master piston group currently is not a serviceable 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
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
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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2. Place Jacobs® Slave Piston Removal Tool in
position with hole in tool clamp bracket over slave
piston adjusting screw and clamp screw collar
over slave piston stem.
3. Slowly tighten clamp screw until collar contacts
slave piston washer. Continue tightening clamp
WARNING: To prevent personal injury or
death, wear safety glasses with side shields.
4. Using snap-ring pliers, remove slave piston
retaining ring from piston bore.
5. Slowly loosen tool clamp screw to release slave
screw to compress slave piston spring and relieve piston spring pressure and remove tool.
spring pressure against slave piston retaining
ring. 6. Grasp piston stem and remove slave piston,
spring and washer.
7. Remove slave piston adjusting screw.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
324 MAXXFORCE® ENGINE BRAKE BY JACOBS
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engine brake have excessive wear, spalling or 1. Solenoid screen (removed for check)
galling, replace camshaft. See “CYLINDER 2. Pin
HEAD, CAMSHAFT AND VALVE TRAIN” 3. Button of armature
section of this manual for camshaft replacement
procedures.
9. Hold solenoid assembly upside down in hand
6. Inspect slave pistons, springs and control valve so you can look into the end where the solenoid
assembly for worn or damaged parts. Replace screen was removed. Move button of armature
parts that are broken or deformed. with finger while looking into the open end to verify
7. Inspect slave piston bores in brake housing. pin moves freely within the solenoid assembly. If
Insert slave pistons in respective bores and pin does not move freely, replace solenoid.
check for free movement without binding. If there 10. Using an ohmmeter, check solenoid assembly
is binding, replace brake housing assembly. resistance per the following steps:
8. Inspect control valve assembly bores in brake • Check resistance across the two terminals. If
housing. Insert control valve assemblies in resistance is out of specification (page 330),
respective bores and check for free movement replace solenoid assembly.
without binding. If there is binding, replace brake
housing assembly. • Check resistance from each terminal to the
solenoid can. This should be an “open
circuit.” If a resistance is measured, replace
solenoid assembly.
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
MAXXFORCE® ENGINE BRAKE BY JACOBS 325
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Figure 440 Slave piston
1. M10 (jam) nut Figure 441 Slave Piston Removal Tool
2. Slave piston adjusting screw
1. Clamp screw collar
3. Slave piston
2. Slave Piston Removal Tool
4. Slave piston spring
5. Slave piston washer
6. Slave piston retaining ring
5. Place slave piston retaining ring, oriented with
sharp side up (away from washer), in position over
slave piston stem. Install Jacobs® Slave Piston
1. Check that housing slave piston bore is clean, free
Removal Tool with clamp screw collar on slave
of any residue and debris.
piston stem.
2. Lubricate slave piston, spring and washer with
6. Slowly tighten clamp screw until screw collar
clean engine oil.
contacts slave piston washer. Continue tightening
3. Assemble slave piston spring, washer and clamp screw to compress piston spring until
retaining ring on slave piston stem. washer is approximately 1/32 inch below retaining
ring groove.
4. Insert slave piston, spring and washer assembly
into housing bore.
EGES-465-1
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Follow all warnings, cautions, and notes.
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326 MAXXFORCE® ENGINE BRAKE BY JACOBS
Master Piston
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5. Master piston guide sleeve
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Follow all warnings, cautions, and notes.
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MAXXFORCE® ENGINE BRAKE BY JACOBS 327
Solenoid
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Figure 444
1.
2.
Control valve
Control valve retaining ring
Control valve cover
3. Outer spring
4. Inner spring
5. Control valve assembly
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Follow all warnings, cautions, and notes.
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328 MAXXFORCE® ENGINE BRAKE BY JACOBS
Installation
Engine Brake Housing Assembly
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2. M10 x 90 bolt (6)
2. M6 x 10 socket-head cap screw 3. Solenoid connector nut (4)
3. Solenoid cover 4. Tie strap (3)
4. Solenoid screen
EGES-465-1
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Follow all warnings, cautions, and notes.
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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.
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3. Actuator pin (in exhaust valve bridge)
4. Slave piston
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Follow all warnings, cautions, and notes.
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330 MAXXFORCE® ENGINE BRAKE BY JACOBS
Specifications
Solenoid resistance:
Special Torque
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Special Service Tools
EGES-465-1
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Follow all warnings, cautions, and notes.
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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
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Camshaft Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .349
Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
Valves Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .350
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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Follow all warnings, cautions, and notes.
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332 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 333
Exploded Views
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Figure 449 Valve cover and base
1. Screw with damper (18) 3. M8 x 30 bolt (17) 5. Valve cover base
2. Upper valve (cover) gasket 4. Upper valve cover 6. Valve cover (base) gasket
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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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Figure 450 Non-brake rocker arm assembly and valve bridges
1. Intake and exhaust rocker arm 2. M12 x 60 (socket-head) screw 4. Valve bridge (intake and
assembly (6) (12) exhaust) (12)
3. Rocker bearing block (6)
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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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Figure 451
1.
Camshaft and cylinder head idler gear
M8 x 30 bolt (3) 5. M8 x 35 bolt (14) 10. Cylinder head idler gear
2. Camshaft timing disc (pulse 6. (Camshaft) bearing cap (7) 11. Small gear shaft
wheel) 7. 4H x 8 x 10 dowel pin (14) 12. M8 x 30 socket-head cap screw
3. Camshaft gear 8. Camshaft (3)
4. Timing (M6 x 20 dowel) pin 9. Bearing shell (14) 13. DMR 63.10 cup plug
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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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set parking brake, and block wheels before doing
diagnostic or service procedures.
Figure 453 Camshaft gear timing mark
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Follow all warnings, cautions, and notes.
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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
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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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2. Intake rocker arm
3. Adjusting screw 1. Slave piston adjusting screw
4. M10 nut 2. M10 (jam) nut
5. Valve bridge (intake/exhaust) 3. Actuator pin (in exhaust valve bridge)
4. Slave piston
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340 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 341
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Figure 458 Upper valve cover and base
Figure 459 Valve cover gaskets
1. Screw with damper (18)
1. Valve cover base
2. M8 x 30 bolt (17)
2. Screw with damper (18)
3. Upper valve cover
3. Upper valve cover gasket
4. Valve cover base
4. (Lower) valve cover gasket
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Follow all warnings, cautions, and notes.
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342 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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1. Rocker bearing block (6)
2. Valve bridge (12)
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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Follow all warnings, cautions, and notes.
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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.
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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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Follow all warnings, cautions, and notes.
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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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shell (typical)
1. Camshaft bearing cap
2. 4H x 8 x 10 dowel pin (2)
3. Bearing shell
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Follow all warnings, cautions, and notes.
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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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Figure 468 Cylinder Head Lifting Bracket
10. Remove three M8 x 30 bolts.
1. Cylinder Head Lifting Bracket
11. Remove camshaft timing disc and camshaft gear.
2. M8 x 20 class 10.9 bolt (4)
12. If damaged, remove timing pin from camshaft.
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Follow all warnings, cautions, and notes.
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346 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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Figure 469 Cylinder head bolts
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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Follow all warnings, cautions, and notes.
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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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Cylinder Head Idler Gear
death, use a hoist rated for the weight of the
cylinder head and follow the manufacturer’s
operative and safety instructions. Attach safety
lifting hooks to the cylinder head lifting bracket
and lifting eye.
CAUTION: To prevent engine damage, do not scratch
gasket surface of cylinder head.
CAUTION: To prevent engine damage, carefully set
cylinder head on wooden blocks to protect the cylinder
head idler gear.
6. Place cylinder head on a clean, non-metallic
surface.
7. Remove four M8 x 20 class 10.9 bolts and
Cylinder Head Lifting Bracket (page 362).
8. Remove and discard cylinder head gasket.
Figure 472 DMR 63.10 cup plug removal
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Follow all warnings, cautions, and notes.
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348 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 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.
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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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Follow all warnings, cautions, and notes.
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350 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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Figure 477 Leak inspection
1. Inspection mirror
2. Reflection of valve
3. Flashlight
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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 351
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Follow all warnings, cautions, and notes.
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352 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
Installation
Cylinder Head Idler Gear
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2. Cylinder head idler gear
6. Recess cup plug 2.3 mm (0.9 in) below the
3. M8 x 30 socket-head cap screw (3)
machined surface.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 353
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CAUTION: To prevent engine damage, install a new
cylinder head gasket with part number facing up.
2. Install a new cylinder head gasket on crankcase, WARNING: To prevent personal injuries
over dowel pins. or death, use a hoist rated for the weight of
the cylinder head and follow the manufacturer’s
operation and safety instructions. Attach safety
lifting hooks to the cylinder head lifting bracket
and lifting eye.
CAUTION: To prevent engine damage, do not drop or
slide cylinder head on cylinder head gasket. This can
damage the cylinder head gasket, dowel pins and the
cylinder head idler gear.
5. Attach an appropriate hoist and lifting hooks to
cylinder head lifting bracket and lifting eye.
6. Lower cylinder head onto crankcase and align
cylinder head alignment dowels in the crankcase
with dowel holes in the cylinder head.
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354 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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Figure 484 Cylinder head bolts
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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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 355
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Figure 485 Cylinder head bolt tightening sequence
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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3. Camshaft timing disc (pulse wheel) their original location and orientation.
4. M8 x 30 bolt (3) 5. Install seven new or previously marked camshaft
lower bearings on cylinder head. Make sure oil
holes in bearings are aligned with oil holes in
1. If previously removed, install timing (M6 x 20 cylinder head bearing support.
dowel) pin into camshaft.
6. Rotate crankshaft so that cylinder number 1 is
2. Align camshaft gear with timing pin and install on positioned at TDC.
camshaft.
3. Align camshaft timing disc with timing pin and
install on camshaft.
4. Install and finger-tighten three M8 x 30 bolts.
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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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2. Timing mark
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358 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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2. Exhaust manifold side
14. Tighten three M8 x 30 bolts an additional 90° (1/4
turn).
1. Place 12 new or previously marked valve bridges
on intake and exhaust valves with milled end
Rocker Arm Assembly (Non-Brake Engine) oriented toward camshaft.
NOTE: If original rocker bearing blocks are installed,
make sure each is placed as previously marked in its
original location.
2. Install six new or previously marked rocker
bearing blocks.
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Follow all warnings, cautions, and notes.
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 359
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3. Upper valve cover gasket
make sure each is placed as previously marked in its 4. (Lower) valve cover gasket
original location.
3. Install six new or previously marked rocker arm
assemblies. 1. If necessary, install a new upper and/or lower
valve cover gasket.
4. Install 12 M12 x 60 socket-head screws. Tighten
screws to special torque (page 361). 2. If previously removed, install 18 screws with
dampers in valve cover base and through valve
5. Adjust valve lash. See procedure (Valve Lash cover base gasket.
Adjustment, page 337) in this section.
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360 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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4. Valve cover base
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CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN 361
Specifications
Special Torque
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(Camshaft) bearing cap M8 x 35 bolt 25 N·m (18 lbf·ft)
Cylinder head idler gear M8 x 30 socket-head cap screw 30 N·m (22 lbf·ft)
Cylinder head M18 x 246 Torx® bolt See tightening steps in procedure
Rocker arm assembly M12 x 60 (socket-head) screw 105 N·m (77 lbf·ft)
Upper valve cover M8 x 30 bolt 10 N·m (89 lbf·in)
Valve cover base screw with damper 11 N·m (97 lbf·in)
Valve lash adjustment M10 nut 45 N·m (33 lbf·ft)
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362 CYLINDER HEAD, CAMSHAFT AND VALVE TRAIN
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M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally
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Follow all warnings, cautions, and notes.
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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
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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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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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Figure 498 Flywheel housing and flywheel (manual transmission)
1. Radial shaft ring seal 6. Dowel pin (2) 12. 12PT flange bolt (10)
2. M10 x 30 bolt (12) 7. Timing hole cover 13. M16 x 150 bolt (4)
3. M10 x 40 bolt (3) 8. Tapping screw (2) 14. Lifting eye (2)
4. Flywheel housing 9. Plug
5. 56/48 x 19 plug (converter bolt 10. Flywheel assembly
access) 11. Pilot bearing
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366 FLYWHEEL AND FLYWHEEL HOUSING
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Figure 499
1.
2.
Flywheel and flexplate assembly (automatic transmission)
12PT flange bolt (10)
Wear plate (reinforcement ring)
3.
4.
Flexplate assembly
Flywheel assembly
5. 8 x 60-ST pin
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 367
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Figure 500 Rear engine mounts
1. Left offset engine mounting 4. 3/4” x 2” bolt (12) 7. 3/4” washer (12)
support 5. Right offset engine mounting
2. Extension assembly support
3. PDO base bracket 6. Flywheel housing
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Follow all warnings, cautions, and notes.
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368 FLYWHEEL AND FLYWHEEL HOUSING
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parking brake, and block wheels before doing
diagnostic or service procedures.
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Follow all warnings, cautions, and notes.
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FLYWHEEL AND FLYWHEEL HOUSING 369
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1. Using a slide hammer (page 379), install blind
hole puller (page 379), into pilot bearing.
2. Tap slide hammer and remove pilot bearing.
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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.
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Radial Shaft Ring Seal
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.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FLYWHEEL AND FLYWHEEL HOUSING 371
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2. PDO base bracket
3. Flywheel housing WARNING: To prevent personal injury or
4. 3/4" x 2” bolt with 3/4” washer (6) death, support the flywheel housing before
removing bolts and breaking sealant bond
between housing and crankcase.
1. Remove six 3/4" x 2” bolts with washers, PDO
base bracket and engine mounting support from 3. Remove 12 M10 x 30 and three M10 x 40 bolts
right side of flywheel housing. from flywheel housing.
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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suitable solvent. Dry all with filtered compressed
air.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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Figure 510 Flywheel housing to crankcase
alignment dowel pins
1. Flywheel housing to crankcase mating surface
2. Apply Loctite 5900 or Wacker® A–442 RTV
sealant (page 379) to mating surfaces of flywheel
housing and crankcase.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FLYWHEEL AND FLYWHEEL HOUSING 375
Lifting Eyes
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4. Install 12 M10 x 30 and three M10 x 40 flywheel
housing bolts. Tighten bolts to special torque
(page 379).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
376 FLYWHEEL AND FLYWHEEL HOUSING
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2. Flywheel assembly
3. 8 x 60-ST pin
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FLYWHEEL AND FLYWHEEL HOUSING 377
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5. Tighten 12PT flange bolts using sequence
indicated above as follows:
a. Tighten bolts to 110 N·m (81 lbf·ft).
b. Angle tighten bolts 90°.
c. Angle tighten bolts an additional 90°.
Figure 519 Flywheel and flexplate assembly
Pilot Bearing (Flywheel) 1. Flexplate and flywheel assembly
2. 12PT flange bolt (10)
3. Guide pin (2)
4. Wear plate (reinforcement ring)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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°.
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Figure 520 Flywheel and flexplate assembly bolt
tightening sequence (typical)
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
FLYWHEEL AND FLYWHEEL HOUSING 379
Specifications
Special Torque
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Table 35 Flywheel and Flywheel Housing
Description Tool Number
1-2 inch micrometer Obtain locally
Blind hole puller Obtain locally
Brake cleaner (non-caustic) Obtain locally
Dial indicator with magnetic base Obtain locally
Loctite 5900® Obtain locally
Wacker® A–442 RTV sealant Obtain locally
Pilot Bearing Installation Tool ZTSE4898
Rear Oil Seal Installer ZTSE4875
Slide hammer Obtain locally
EGES-465-1
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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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Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
EGES-465-1
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Follow all warnings, cautions, and notes.
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382 OIL PAN AND OIL PICKUP TUBE
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL PAN AND OIL PICKUP TUBE 383
Exploded Views
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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)
EGES-465-1
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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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Figure 522 Oil pickup tube - Front sump (typical)
1. O-ring, 32 x 5 4. Oil pickup tube support (2) 7. M8 x 16 bolt (2)
2. Prevailing torque nut (M8) (2) 5. M8 x 25 bolt (2)
3. D9/19/4 washer (2) 6. Pickup oil tube
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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)
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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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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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Figure 526 Oil pickup tube O-ring
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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.
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2. M8 x 25 bolt (3)
3. Oil pickup tube
4. Tube support 4. Remove and discard oil pickup tube O-ring.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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1. Install a new oil pickup tube O-ring. Lubricate
O-ring with clean engine oil.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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
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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)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
OIL PAN AND OIL PICKUP TUBE 391
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Figure 535 Oil pan bolt torque sequence
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
392 OIL PAN AND OIL PICKUP TUBE
Special Torque
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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 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
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Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
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Follow all warnings, cautions, and notes.
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394 OIL PUMP AND TIMING GEARS
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 395
Exploded Views
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Figure 536 Oil pump
1. M6 x 20 bolt (8) 4. (Oil pump) ring gear 7. Axle for pinion (oil pump)
2. Oil pump cover 5. M10 x 35 socket-head cap screw 8. O-ring 22 x 2
3. Pinion (gear) for oil pump 6. Spring pin 4 x 14 ST 9. O-ring 25.12 x 1.78
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Follow all warnings, cautions, and notes.
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396 OIL PUMP AND TIMING GEARS
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Figure 537 Front timing gears (typical)
1. (Front) idler gear 3. M12 x 50 socket-head cap screw 4. Front crank gear
2. Gear stud (not flywheel side) (3)
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 397
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Figure 538 Rear timing gears
1. M8 x 30 socket-head cap screw 5. Air compressor coupled idler 10. Large idler gear
(3) gear assembly 11. Gear stud big
2. Gear stud small 6. Air compressor gear stud 12. M14 x 80 bolt (4)
3. Crankcase idler gear 7. M12 x 55 bolt (3)
4. Thrust washer (for gear stud air 8. Rear crank gear assembly
compressor) 9. Small idler gear
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Follow all warnings, cautions, and notes.
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398 OIL PUMP AND TIMING GEARS
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parking brake, and block wheels before doing 1. Rotate engine and look for any damaged gear
diagnostic or service procedures. teeth. Replace damaged gears as necessary.
2. Place dial indicator with magnetic base (page
WARNING: To prevent personal injury or 408) on front of crankcase with indicator tip on
death, make sure the engine has cooled before front idler gear. Position dial indicator tangent
removing components. (90°) relative to plane of gear tooth.
3. Turn front idler gear clockwise and zero dial
WARNING: To prevent personal injury or indicator.
death, do not let engine fluids stay on your skin.
4. Turn front idler gear back and forth while reading
Clean skin and nails using hand cleaner and wash
dial indicator. Compare dial indicator reading with
with soap and water. Wash or discard clothing
Specifications (page 408).
and rags contaminated with engine fluids.
5. If front idler gear backlash exceeds specification,
NOTE: Refer to the following service sections for
replace gear.
information on removal of components prior to this
section.
• Front Cover, Fan Drive, Cooling System and
Related Components
• Cylinder Head, Camshaft and Valve Train
• Flywheel and Flywheel Housing
EGES-465-1
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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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large idler gear tooth. Position dial indicator
tangent (90°) relative to plane of gear tooth.
7. Turn large idler gear clockwise and zero dial
indicator.
8. Turn large idler gear back and forth while reading
dial indicator. Compare dial indicator reading with
Specifications (page 408).
9. If backlash exceeds specification, replace large
idler gear.
Figure 542 Oil pump cover (typical)
1. M6 x 20 bolt (8)
2. Oil pump cover
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Follow all warnings, cautions, and notes.
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400 OIL PUMP AND TIMING GEARS
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CAUTION: To prevent engine damage, use 3. O-ring 22 x 2
permanent marker to identify internal engine
components and their orientation. Do not use paint
or temporary markers. 6. Remove M10 x 35 socket-head cap screw and oil
pump pinion axle.
4. Use a permanent marker to mark the front of
oil pump pinion (gear) and ring gear for correct 7. Remove and discard O-ring 22 x 2.
assembly orientation.
5. Remove oil pump pinion gear and ring gear. Front Crank Gears
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OIL PUMP AND TIMING GEARS 401
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2. Remove three M12 x 50 cap screws, gear stud 3. Crankcase idler gear
and idler gear.
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.
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Follow all warnings, cautions, and notes.
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402 OIL PUMP AND TIMING GEARS
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OIL PUMP AND TIMING GEARS 403
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3. Inspect pinion (gear) for oil pump, oil pump NOTE: There are two oil pump assemblies. When
ring gear and oil pump cover for nicks, burrs or replacing oil pump parts, be sure you are ordering the
scoring. correct set.
4. Replace any damaged components. 7. If end play exceeds specification (page 408),
replace oil pump cover, pinion (gear) for oil pump
5. Temporarily install oil pump components (page
and ring gear as a set.
406) in crankcase without O-ring and tighten M6
x 20 bolts to standard torque (page 471). 8. Remove oil pump components for final assembly.
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Follow all warnings, cautions, and notes.
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404 OIL PUMP AND TIMING GEARS
Installation
Rear Timing Gears
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1. M12 x 55 bolt (3) Top Dead Center (TDC).
2. Air compressor gear stud
3. Air compressor idler gear assembly
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Follow all warnings, cautions, and notes.
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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)
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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).
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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.
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1. Install idler gear and gear stud.
2. Install three front idler gear M12 x 50 cap screws.
Tighten screws to special torque (page 408).
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Follow all warnings, cautions, and notes.
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OIL PUMP AND TIMING GEARS 407
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3. Lubricate pinion (gear) for oil pump and ring gear
with clean engine oil. 6. Install oil pump cover.
4. Install pinion gear and ring gear with previously 7. Install eight M6 x 20 bolts. Tighten bolts to
made index marks facing towards front. standard torque (page 471).
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
408 OIL PUMP AND TIMING GEARS
Specifications
Special Torque
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(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lbf·ft)
Larger idler gear, M14 x 80 bolts 175 N·m (129 lbf·ft)
Oil pump pinion axle, M10 x 35 socket-head cap screw 65 N·m (48 lbf·ft)
EGES-465-1
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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
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Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .421
Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .422
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .425
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
410 POWER CYLINDERS
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Follow all warnings, cautions, and notes.
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POWER CYLINDERS 411
Exploded Views
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Figure 562 Piston and connecting rod (typical)
1. Compression top ring (6) 7. Connecting rod assembly (6) 11. Connecting rod bearing, lower
2. Taper face compression ring (6) (includes items 8, 9, 10) (6)
3. Bevelled oil ring (6) 8. Connecting rod 12. Connecting rod bearing, upper
4. Piston (6) 9. Connecting rod cap (6)
5. Piston pin retainer (12) 10. Connecting rod bolt (2 each 13. Front of engine
6. Piston pin (6) assembly)
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Follow all warnings, cautions, and notes.
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412 POWER CYLINDERS
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Figure 563 Cylinder sleeve
1. Cylinder sleeve (6) 2. Cylinder sleeve O-ring (12)
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Follow all warnings, cautions, and notes.
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POWER CYLINDERS 413
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parking brake, and block wheels before doing
diagnostic or service procedures. Preliminary Checks
NOTE: Evaluate piston protrusion before removing
WARNING: To prevent personal injury or any piston and connecting rod assemblies. This helps
death, make sure the engine has cooled before identify bent or twisted connecting rods.
removing components.
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).
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Piston and Connecting Rod
CAUTION: To prevent engine damage, check for a
carbon ridge on top of cylinder sleeves. If found,
remove carbon ridge with a suitable tool before
removing rod and piston assemblies.
1. Scrape carbon ridge from top of cylinder bore, if Figure 565 Connecting rod cap
necessary. Use care not to damage sleeve bore
surface. 1. Connecting rod bolt M12 x 64 (2)
2. Connecting rod cap
CAUTION: To prevent engine damage, mark with
permanent marker or tag each connecting rod and
cap with the correct cylinder number. This engine CAUTION: To prevent engine damage, assemble
has “cracked” (fractured) type connecting rods. Do connecting rod cap and connecting rod with their
not alter or damage fractured mating surfaces of fractured mating surfaces in the original orientation.
the rod and cap. A cap from one connecting rod is Matching numbers must be next to each other.
NOT interchangeable with another connecting rod.
The matching connecting rod and cap numbers or NOTE: When removed, make sure matching
symbols indicate a matched set. connecting rod and connecting rod cap numbers
stay together as a set. A cap from one connecting rod
is not interchangeable with any other connecting rod.
3. Using Connecting Rod Bolt Torx® Socket (page
427), remove two connecting rod bolts and
connecting rod cap. Save bolts for reuse during
connecting rod bore check procedure.
CAUTION: To prevent engine damage, do not push
on fractured surface of connecting rod.
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.
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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.
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POWER CYLINDERS 417
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threads. all around ring groove to ensure ring is free in
its groove.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
418 POWER CYLINDERS
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Figure 572 Piston ring end gap clearance in
cylinder bore
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
POWER CYLINDERS 419
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If outside diameter of any piston pin is less than
minimum specification (page 425), replace piston
pin.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
420 POWER CYLINDERS
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3. Check cylinder sleeve protrusion above
crankcase deck as follows:
a. Install Sleeve Protrusion Hold Down Clamps
(page 427) using four included bolts. Torque
bolts to special torque (page 426).
b. Place dial indicator with magnetic base (page
427) on crankcase deck surface.
c. Position dial indicator tip on crankcase deck
adjacent to cylinder sleeve flange. Zero dial
indicator.
d. Carefully pivot dial indicator until tip is resting
Figure 577 Cylinder sleeve bore measurement
on cylinder sleeve flange. Record reading.
e. Measure cylinder sleeve protrusion at three
2. Using a dial bore gauge (page 427), measure the locations evenly spaced around the cylinder
cylinder sleeve inside diameter at 120° intervals, sleeve.
at four different depths of cylinder sleeve. If
f. If any of the three readings of cylinder sleeve
cylinder sleeve inside diameter is not within
protrusion are not within specification (page
specification (page 425), replace cylinder sleeve.
425), fit new cylinder sleeve and repeat steps
a through e.
g. If after trying all available new cylinder
sleeves and specification still cannot be met,
contact Tech Central at 1-800-336-4500.
h. Remove six cylinder sleeves and continue
with installation.
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POWER CYLINDERS 421
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c. Using pliers, install one piston pin retainer into
groove. Be sure that retainer is fully seated in
groove and that tang ends point up.
d. Hold connecting rod so open end faces 3
o’clock position of piston when installed.
e. Place connecting rod into piston.
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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.
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that bearings are flush to fractured mating faces
of rod and cap.
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Follow all warnings, cautions, and notes.
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POWER CYLINDERS 423
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connecting rod bolts.
CAUTION: To prevent engine damage, do not use
Figure 583 Correct connecting rod and cap joint
powered tools to install connecting rod bolts; rotating
fit
bolts too quickly can damage threads.
CAUTION: To prevent engine damage, do not
CAUTION: To prevent engine damage, install rotate crankshaft until connecting rod bolts are fully
connecting rods with correct caps in the correct tightened, as this may cause bearings to rotate in
direction. If a rod cap is reversed, an offset will be place.
seen at the mating surfaces. If a reverse assembly
10. Install two NEW connecting rod bolts.
is installed on the crankshaft, the connecting rod
must be replaced. Also, check crank pin (connecting 11. Using Connecting Rod Bolt Torx® Socket (page
rod journal) fillets for damage that would require 427), tighten connecting rod bolts evenly to an
replacement of the crankshaft. initial torque of 100 N·m (74 lbf·ft).
9. Assemble cap to connecting rod with matching 12. Rotate (tighten) connecting rod bolts an additional
identification code on same crankshaft journal 90 degrees (1/4 turn).
from which it was removed. Be certain that longer
13. Repeat installation procedure for remaining piston
leg of connecting rod is positioned towards left
and connecting rod assemblies.
side of crankcase.
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424 POWER CYLINDERS
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• Fuel leaks
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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)
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Piston pin running clearance 0.010 - 0.024 mm (0.0004 - 0.0009 in)
Pistons — 13L
Skirt diameter measured 26.9 mm from piston
bottom edge, 90° to piston pin axis in “window” 125.950 ± 0.013 mm (4.9587 ± 0.0005 in)
on skirt graphite layer, where applicable
Piston protrusion measured from crankcase
0.3 ± 0.22 mm (0.0118 ± 0.009 in)
deck to piston
Piston pin bore inside diameter, measured
52.04 - 52.05 mm (2.0490 - 2.0492 in)
horizontally 26 mm from piston center
Piston pin running clearance 0.040 - 0.058 mm (0.0016 - 0.0023 in)
Piston Pins
Outside diameter 51.992 - 52.000 mm (2.0469 - 2.0472 in)
Piston Rings — 11L
Top compression ring
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426 POWER CYLINDERS
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Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)
Special Torque
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Follow all warnings, cautions, and notes.
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POWER CYLINDERS 427
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Telescoping gauge Obtain locally
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
428 POWER CYLINDERS
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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
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Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .441
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430 CRANKCASE AND CRANKSHAFT
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
CRANKCASE AND CRANKSHAFT 431
Exploded View
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Figure 585 Crankcase and crankshaft
1. M18 x 2 x 160.5 collar bolt (14) 5. M6 x 12 bolt (6) 9. Lower thrust washer (main
2. Lower main bearing (7) 6. Crankcase bearing) (2)
3. Crankshaft 7. Piston cooling jet (6)
4. Upper main bearing (with oil 8. Upper thrust washer (main
hole) (7) bearing) (2)
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432 CRANKCASE AND CRANKSHAFT
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parking brake, and block wheels before doing
Related Components
diagnostic or service procedures.
• MaxxForce® Engine Brake by Jacobs (if
equipped)
WARNING: To prevent personal injury or
death, make sure the engine has cooled before • Cylinder Head, Camshaft and Valve Train
removing components.
• Flywheel and Flywheel Housing
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.
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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)
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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.
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434 CRANKCASE AND CRANKSHAFT
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with a safety latch on hook.
CAUTION: To prevent engine damage, do not bend,
drop or damage crankshaft.
Figure 589 Piston cooling jet
NOTE: Use only a soft-sided lifting sling. Do not use
1. M6 x 12 bolt (6)
chains or steel cables.
2. Piston cooling jet (6)
6. Attach lifting sling (page 441) to crankshaft. Lift
crankshaft up and out of crankcase and set aside
for inspection. Remove six M6 x 12 bolts and six piston cooling jets.
7. Remove upper main bearings and upper thrust
washers from crankcase by pushing out.
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Follow all warnings, cautions, and notes.
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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.
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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.
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436 CRANKCASE AND CRANKSHAFT
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the original orientation.
7. Use a 3 - 4 inch micrometer (page 441) to
6. Lightly coat used collar bolt threads and under bolt
measure diameter of each connecting rod
heads with clean engine oil. Do not use new bolts
journal, and a 4 - 5 inch micrometer (page
for this inspection procedure.
441) to measure diameter of each main journal.
Measure each journal at both sides next to 7. With crankshaft still removed, install seven main
fillet radius at two directions 90° apart. Move bearing caps and 14 previously removed M18 x
micrometer over entire width of journal. If journal 160.5 collar bolts.
wear exceeds specification (page 441), have
8. Tighten M18 x 160.5 collar bolts in main bearings
crankshaft machined, or replace crankshaft.
caps as follows:
a. Tighten collar bolts at No. 6 main bearing cap
Main Bearings Measurement
to 10 N·m (88 lbf·in).
b. Tighten remaining collar bolts to 10 N·m (88
lbf·in).
c. Tighten collar bolts at No. 6 main bearing cap
to 100 N·m (74 lbf·ft).
d. Tighten remaining collar bolts to 100 N·m (74
lbf·ft).
e. Tighten collar bolts at No. 6 main bearing cap
to 300 N·m (221 lbf·ft).
f. Tighten remaining collar bolts to 300 N·m (221
lbf·ft).
Figure 593 Main bearing uninstalled outside g. Turn collar No. 6 main bearing cap an
diameter (free spread) measurement additional 90° clockwise.
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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.
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9. Using a dial bore gauge (page 441), measure
main bearing installed inside diameter. If
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438 CRANKCASE AND CRANKSHAFT
Installation
Piston Cooling Jets
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2. Piston cooling jet (6)
2. Place upper main bearings in crankcase. Make
sure locking tabs on bearings are snapped into
saddle and oil holes in bearings line up with oil
1. Install six piston cooling jets and six M6 x 12 bolts.
holes in crankcase.
2. Tighten bolts to special torque (page 441).
3. Lubricate running surface of bearings with clean
engine oil.
Crankshaft
NOTE: Make sure crankshaft and bearings have
been inspected per instructions in this section before
proceeding.
1. Use a lint-free cloth to wipe crankcase bearing
saddles free of oil.
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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.
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Figure 599 Main bearing caps
1. Collar M18 x 160.5 bolt (14)
Figure 598 Thrust washer installation 2. Main bearing cap (7)
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
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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°.
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CRANKCASE AND CRANKSHAFT 441
Specifications
Special Torque
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Collar bolts (main bearing cap), M18 x 160.5 See tightening procedure and sequence
Piston cooling jet bolts, M6 x 12 13 N·m (115 lbf·in)
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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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AFTFP – Aftertreatment Fuel Pressure CMPO – Camshaft Position Out
AFTFP1 – Aftertreatment Fuel Pressure 1 CMV – Coolant Mixer Valve
AFTFP2 – Aftertreatment Fuel Pressure 2 CO – Carbon Monoxide
AFTFSH – Aftertreatment Fuel Shutoff High COO – Cruise On / Off switch
AFTFSL – Aftertreatment Fuel Shutoff Low CPU – Central Processing Unit
AFTFSV – Aftertreatment Fuel Shutoff Valve CSFI – Cold Start Fuel Igniter
AIT – Air Inlet Temperature CSFS – Cold Start Fuel Solenoid
Amb – Ambient CSR – Cold Start Relay
amp or A – Ampere CTC – Coolant Temperature Compensation
AMS – Air Management System Cyl – Cylinder
API – American Petroleum Institute DB – Decibel
APP – Accelerator Pedal Position DCA – Diesel Coolant Additive
APP1 – Accelerator Pedal Position 1 DDI – Digital Direct Fuel Injection
APP2 – Accelerator Pedal Position 2 DDS – Driveline Disengagement Switch
ASTM – American Society for Testing and Materials DLC – Data Link Connector
ATA – American Trucking Association DME – Dimethyl Ether
ATAH – American Trucking Association Link High DMM – Digital Multi-meter
ATAL – American Trucking Association Link Low DOC – Diesel Oxidation Catalyst
ATDC – After Top Dead Center DOCIT – Diesel Oxidation Catalyst Inlet Temperature
AWG – American Wire Gauge DOCOT – Diesel Oxidation Catalyst Outlet
B+ or VBAT – Battery Voltage Temperature
BARO – Barometric Absolute Pressure DPF – Diesel Particulate Filter
BBDC – Before Bottom Dead Center DPFDP – Diesel Particulate Filter Differential
BDC – Bottom Dead Center Pressure
bhp – Brake Horsepower DPFIT – Diesel Particulate Filter Inlet Temperature
BOO – Brake On / Off DPFOT – Diesel Particulate Filter Outlet Temperature
BPP – Brake Pedal Position DSI – Down Stream Injection
BPS – Brake Pressure Switch DT – Diesel Turbocharged
BTDC – Before Top Dead Center DTC – Diagnostic Trouble Code
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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
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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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KOER – Key-On Engine-Running ppm – Parts per million
kPa – Kilopascal PROM – Programmable Read Only Memory
L – Liter psi – Pounds per square inch
L/h – Liters per hour psia – Pounds per square inch absolute
L/m – Liters per minute psig – Pounds per square inch gauge
L/s – Liters per second pt – Pint
lb – Pound PTO – Power Takeoff
lbf – Pounds of force PWM – Pulse Width Modulate
lb/s – Pounds per second PWR – Power (voltage)
lbf ft – Pounds of force per foot qt – Quart
lbf in – Pounds of force per inch RAM – Random Access Memory
lbm – Pounds of mass RAPP – Remote Accelerator Pedal Position
LSD – Low Sulfur Diesel RAS – Resume / Accelerate Switch (speed control)
m – Meter REPTO – Rear Engine Power Takeoff
m/s – Meters per second RFI – Radio Frequency Interference
MAF – Mass Air Flow rev – Revolution
MAF GND – Mass Air Flow Ground rpm – Revolutions per minute
MAG – Magnetic RPRE – Remote Preset Power Take Off
MAP – Manifold Absolute Pressure RSE – Radiator Shutter Enable
MAT – Manifold Air Temperature RVAR – Remote Variable
mep – Mean effective pressure SAE – Society of Automotive Engineers®
mi – Mile SCA – Supplemental Cooling Additive
MIL – Malfunction Indicator Lamp SCCS – Speed Control Command Switches
mm – Millimeter SCS – Speed Control Switch
mpg – Miles per gallon SHD – Shield (electrical)
mph – Miles per hour SID – Subsystem Identifier
MPR – Main Power Relay SIG GND – Signal Ground
MSDS – Material Safety Data Sheet SIG GNDB – Signal Ground Body
MSG – Micro Strain Gauge SIG GNDC – Signal Ground Chassis
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448 ABBREVIATIONS AND ACRONYMS
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TTS – Transmission Tailshaft Speed XCS – Transfercase
ULSD – Ultra Low Sulfur Diesel XMSN – Transmission
UVC – Under Valve Cover
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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
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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
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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
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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
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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
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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
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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
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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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Tachometer output signal – Engine speed signal for solenoid – Controls the TC1WC actuator by
remote tachometers. regulating the amount of charge air pressure supplied
to the TC1WC actuator. The TC1WC solenoid is
Thermistor – A semiconductor device. A sensing
controlled by signals from the ECM in response to
element that changes resistance as the temperature
engine speed, required fuel quantity, boost, exhaust
changes.
back-pressure, and altitude. The TC1WC actuator is
Thermistor Sensor – Changes electrical resistance part of the turbocharger assembly.
with changes in temperature. Resistance in the
Turbocharger 2 Wastegate Control (TC2WC)
thermistor decreases as temperature increases, and
solenoid – Controls the TC2WC actuator by
increases as temperature decreases. Thermistors
regulating the amount of charge air pressure supplied
work with a resistor that limits current to form a voltage
to the wastegate actuator. The TC2WC solenoid is
signal matched with a temperature value.
controlled by signals from the ECM in response to
Thrust load – A thrust load pushes or reacts through engine speed, required fuel quantity, boost, exhaust
a bearing in a direction parallel to the shaft. back-pressure, and altitude. The TC2WC actuator is
part of the turbocharger assembly.
Top Dead Center (TDC) – The uppermost position of
the piston during the stroke. Variable capacitance sensor – A variable
capacitance sensor measures pressure. The
Torque – A force having a twisting or turning effect.
pressure forces a ceramic material closer to a thin
For a single force, the cross product of a vector from
metal disc in the sensor, changing the capacitance of
some reference point to the point of application of the
the sensor.
force within the force itself. Also known as moment of
force or rotation moment. Torque is a measure of the Vehicle Electronic System Programming System –
ability of an engine to do work. The computer system used to program electronically
controlled vehicles.
Truck Computer Analysis of Performance and
Economy (TCAPE) – A computer program that Vehicle Retarder Enable/Engage – Output from the
simulates the performance and fuel economy of ECM to a vehicle retarder.
trucks.
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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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Cold — 25° C (77° F) 8.7–10 ohms
Hot — 121° C (250° F) 12–15.5 ohms
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464 APPENDIX A – SPECIFICATIONS
Table 51 Oil Pump, Low Mount Fan Drive, and Timing Gears
Power Cylinders
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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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Piston Rings — 13L
Top compression ring
Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Taper face compression ring
Ring gap 1.00 - 1.20 mm (0.0394 - 0.0472 in)
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466 APPENDIX A – SPECIFICATIONS
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APPENDIX B – TORQUES 467
Table of Contents
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Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .479
Front Cover, High Mount Fan Drive, Cooling System, Related Components. . . . . . . . . . . . . . . . . . . . . .480
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .483
Oil Pan and Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .484
Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .485
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468 APPENDIX B – TORQUES
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APPENDIX B – TORQUES 469
General Torque
Bolt Identification
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Figure 600 Metric fasteners – Classification and 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)
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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
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Figure 602 Torque wrench and extension
• 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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10 N·m (89 lbf·in)
Engine Control Module (ECM), M6 x 30 bolt
See procedure for tightening sequence
Engine Control Module (ECM) support, M8 x 40 bolt 35 N·m (26 lbf·ft)
Engine Coolant Temperature 1 (ECT1) sensor 45 N·m (33 lbf·ft)
Engine Coolant Temperature 2 (ECT2) sensor 45 N·m (33 lbf·ft)
Engine injector harness retainer clip, M6 x 30 bolt 10 N·m (89 lbf·in)
Engine Oil Pressure (EOP) sensor 45 N·m (33 lbf·ft)
Engine Oil Temperature (EOT) sensor 45 N·m (33 lbf·ft)
Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lbf·ft)
Exhaust Gas Recirculation Temperature (EGRT)
37 N·m (27 lbf·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lbf·ft)
Humidity / Air Inlet Temperature (AIT) sensor, M6
9 N·m (80 lbf·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lbf·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lbf·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lbf·in)
Oxygen Sensor (O2S) 50 N·m (37 lbf·ft)
Rail Fuel Pressure (RFP) sensor 140 N·m (103 lbf·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lbf·in)
M6 x 16 bolt
EGES-465-1
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Follow all warnings, cautions, and notes.
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474 APPENDIX B – TORQUES
Fuel supply cold start hose fitting nut 10 N·m (11 lbf·ft)
Aftertreatment System
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Fitting (quick-connect adapter) at metering unit valve assembly 35 N·m (26 lbf·ft)
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.
© 2011 Navistar, Inc. All rights reserved
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
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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)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
476 APPENDIX B – TORQUES
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Power steering pump M10 x 40 bolt 67 N·m (49 lbf·ft)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
APPENDIX B – TORQUES 477
Fuel System
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105 N·m (77 lbf·ft)
M12 x 130 bolt
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lbf·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lbf·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lbf·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lbf·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lbf·ft)
Injector harness nut 1.5 N·m (13 lbf·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Quick-connect M16 x 1.5 connector 30 N·m (22 lbf·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lbf·ft)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
478 APPENDIX B – TORQUES
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Table 63 EGR System
Coolant manifold, M8 x 45 bolt and M8 x 50 x 16 35 N·m (26 lbf·ft)
stud bolt
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)
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
APPENDIX B – TORQUES 479
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Air intake throttle duct bolts, M8 31 N·m (23 lbf·ft)
Exhaust manifold Torx® bolts, M10 x 57 See tightening procedure and sequence in steps
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
480 APPENDIX B – TORQUES
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EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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
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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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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
482 APPENDIX B – TORQUES
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Figure 605
Table 67
Cylinder head bolts tightening sequence
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Follow all warnings, cautions, and notes.
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APPENDIX B – TORQUES 483
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12PT flange bolts See tightening steps in procedure.
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
484 APPENDIX B – TORQUES
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Figure 607 Torque sequence
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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Sleeve Protrusion Hold Down Clamp bolts 80 N·m (59 lbf·ft)
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
486 APPENDIX B – TORQUES
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EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
APPENDIX C – SPECIAL SERVICE TOOLS 487
Table of Contents
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Oil Pump, Fan Drive and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .494
EGES-465-1
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Follow all warnings, cautions, and notes.
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488 APPENDIX C – SPECIAL SERVICE TOOLS
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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
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
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Disposable Air and Fuel Caps ZTSE4891
Aftertreatment System
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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Extension Tube Installer ZTSE6043
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
APPENDIX C – SPECIAL SERVICE TOOLS 491
Fuel System
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Oil Cooler, Filter Housing and Crankcase
Ventilation
Table 81
Description
Oil Cooler, Filter Housing and Crankcase Ventilation
Tool Number
Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
P-80® rubber lubricant or equivalent Obtain locally
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
492 APPENDIX C – SPECIAL SERVICE TOOLS
Table 84 Front Cover, Fan Drive, Cooling System and Related Components
Description Tool Number
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Extension Tube Installer Small ZTSE6047
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
APPENDIX C – SPECIAL SERVICE TOOLS 493
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M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
494 APPENDIX C – SPECIAL SERVICE TOOLS
Power Cylinders
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Cylinder Sleeve Puller ZTSE2536
Dial bore gauge Obtain locally
Dial indicator with magnetic base Obtain locally
Feeler gauge Obtain locally
Piston ring compressor Obtain locally
Piston ring expansion pliers Obtain locally
Sleeve Protrusion Hold Down Clamps ZTSE4825
Telescoping gauge Obtain locally
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
APPENDIX C – SPECIAL SERVICE TOOLS 495
Special Tools
Essential Tools
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Figure 613 ZTSE4751 Injector Sleeve Brushes
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
496 APPENDIX C – SPECIAL SERVICE TOOLS
Figure 617 ZTSE4778 coolant line release tool Figure 620 ZTSE4835 Head Bolt Torx Socket
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Figure 621 ZTSE4843 Connecting Rod Bolt Torx
Socket
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
APPENDIX C – SPECIAL SERVICE TOOLS 497
Figure 622 ZTSE4854 Main Bolt Bottoming Tap Figure 624 ZTSE4869 Cylinder Head Lifting
Bracket
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Figure 623 ZTSE4855 Head Bolt Bottoming Tap
Figure 625 ZTSE4873 Front Crankshaft Seal
Installer
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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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Figure 627 ZTSE4892 Fuel Injector Caps (6)
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
APPENDIX C – SPECIAL SERVICE TOOLS 499
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Figure 632 ZTSE6046 Extension Tube Installer Figure 635 ZTSE6051–2 Extension Tube Installer
Large Small
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
500 APPENDIX C – SPECIAL SERVICE TOOLS
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Flow Test Kit
EGES-465-1
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Follow all warnings, cautions, and notes.
© 2011 Navistar, Inc. All rights reserved
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