2015 N13 Engine Engine Service Manual

SCR - US, Canada, Mexico
2015 N13 Engine

ENGINE SERVICE MANUAL
ENGINE SERVICE MANUAL
2015 N13 Engine
0000004741
Navistar, Inc.
Revision 4
July 2015
2701 Navistar Drive, Lisle, IL 60532 USA
© 2015 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.
ENGINE SERVICE MANUAL I
TABLE OF CONTENTS
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine-to-Vehicle Connection Points... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29
Engine Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33
Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Service and Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Engine Component Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81
Engine Disassembly Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .819
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1191
Standard Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1197
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1203
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1215
Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1227
Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1237

II ENGINE SERVICE MANUAL
ENGINE SERVICE MANUAL 1
Foreword
Navistar, Inc. is committed to continuous research and development to improve products and introduce
technological advances. Procedures, specifications, and parts defined in published technical service literature
may be altered.
NOTE: Photo illustrations identify specific parts or assemblies that support text and procedures; other areas in
a photo illustration may not be exact.
This manual includes necessary information and specifications for technicians to maintain Navistar® diesel
engines. See vehicle manuals and Technical Service Information (TSI) bulletins for additional information.
Technical Service Literature

N13 with SCR Engine Operation and Maintenance Manual
N13 with SCR Engine Service Manual
N13 with SCR Engine and Aftertreatment Wiring Schematic Form
Technical Service Literature is revised periodically. If a technical publication is ordered, the latest revision will
be supplied.
NOTE: To order technical service literature, contact your International dealer.
2 ENGINE SERVICE MANUAL
Service Diagnosis
Service diagnosis is an investigative procedure that must be followed to find and correct an engine application
problem or an engine problem.
If the problem is engine application, see specific vehicle manuals for further diagnostic information.
If the problem is the engine, see specific Engine Diagnostic Manual for further diagnostic information.
Prerequisites for Effective Diagnosis
• Availability of gauges, diagnostic test equipment, and diagnostic software.
• Availability of current information for engine application and engine systems.
• Knowledge of the principles of operation for engine application and engine systems.
• Knowledge to understand and do procedures in diagnostic and service publications.
Technical Service Literature required for Effective Diagnosis
• Engine Service Manual
• Engine Diagnostic Manual
• Diagnostics Forms
• Electronic Control Systems Diagnostics Forms
• Service Bulletins
Safety Information
This manual provides general and specific maintenance procedures essential for reliable engine operation and
your safety. Since many variations in procedures, tools, and service parts are involved, advice for all possible
safety conditions and hazards cannot be stated.
Read safety instructions before doing any service and test procedures for the engine or vehicle. See related
application manuals for more information.
Disregard for Safety Instructions, Warnings, Cautions, and Notes in this manual can lead to injury, death or
damage to the engine or vehicle.
Safety Terminology
Three terms are used to stress your safety and safe operation of the engine: Warning, Caution, and Note
Warning: A warning describes actions necessary to prevent or eliminate conditions, hazards, and unsafe
practices that can cause personal injury or death.
Caution: A caution describes actions necessary to prevent or eliminate conditions that can cause damage to
the engine or vehicle.
Note: A note describes actions necessary for correct, efficient engine operation.
Safety Instructions
Work Area
• Keep work area clean, dry, and organized.
• Keep tools and parts off the floor.
• Make sure the work area is ventilated and well lit.
• Make sure a First Aid Kit is available.
Safety Equipment
• Use correct lifting devices.
• Use safety blocks and stands.
Protective Measures
• Wear protective safety glasses and shoes.
• Wear correct hearing protection.
• Wear cotton work clothing.
• Wear sleeved heat protective gloves.
• Do not wear rings, watches or other jewelry.
• Restrain long hair.
Vehicle
• Make sure the vehicle is in neutral, the parking brake is set, and the wheels are blocked before servicing
engine.
• Clear the area before starting the engine.

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

Fluids Under Pressure
• Use extreme caution when working on systems under pressure.
• Follow approved procedures only.
Fuel
• Do not over fill the fuel tank. Over fill creates a fire hazard.
• Do not smoke in the work area.
• Do not refuel the tank when the engine is running.
Removal of Tools, Parts, and Equipment
• Reinstall all safety guards, shields, and covers after servicing the engine.
• Make sure all tools, parts, and service equipment are removed from the engine and vehicle after all work is
done.
ENGINE IDENTIFICATION 7
Table of Contents
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
Engine Accessory Labels and Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Optional Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Chassis Mounted Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Engine Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Aftertreatment Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

SCR Switchback Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
DPF Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26
SCR Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27
8 ENGINE IDENTIFICATION
Engine Serial Number
Figure 1 Engine serial number

1. Engine Serial Number (ESN) location
2. Engine emission label
3. Cylinder head
4. Flywheel housing
5. Crankcase
The Engine Serial Number (ESN) is located on the front of the crankcase (left side), below the cylinder head.
Engine Serial Number Examples

N13: 124KM2Y4400000
Engine Serial Number Codes

126 – Engine displacement
K – Diesel, turbocharged, Charge Air Cooler (CAC), and electronically controlled
M2 – Motor truck
Y – Huntsville, Alabama
7 digit suffix – Engine serial number sequence
Engine Emission Label
Figure 2 U.S. Environmental Protection Agency (EPA) exhaust emission label (example)
The U.S. Environmental Protection Agency (EPA) exhaust emission label is on top of the valve cover (front left
side). The EPA label typically includes the following:
• Model year
• Engine family, model, and displacement
• Advertised brake horsepower and torque rating
• Emission family and control systems
• Valve lash specifications
• Engine Serial Number (ESN)
• EPA, Onboard Diagnostics (OBD), EURO, and reserved fields for specific applications
Engine Accessory Labels and Identification Plates

The following engine accessories may have manufacturer's labels or identification plates:
• Aftertreatment Control Module (ACM)
• Aftertreatment Purge Air Valve (AFTPAV)
• Air compressor
• Air conditioning compressor
• Alternator
• Cooling fan clutch
• Diesel Oxidation Catalyst (DOC)
• Diesel Particulate Filter (DPF)
• Engine Control Module (ECM)
• High Pressure (HP) fuel pump
• Power steering pump
• Selective Catalyst Reduction (SCR) catalyst
• Starter motor
• Turbochargers
Engine Description
N13 Diesel Engine

Engine Configuration 4 stroke, inline six cylinder diesel
Advertised brake horsepower @ rpm
• N13 See EPA exhaust emission label
Peak torque @ rpm
• N13 See EPA exhaust emission label
Displacement
• N13 12.4 L (758 in³)
Compression ratio
• N13 17.0:1
Stroke
• N13 166 mm (6.54 in)
Bore (sleeve diameter)
• N13 126 mm (4.96 in)

Total engine weight (dry weight without trim or accessories)
• N13 1087 kgs (2392 lbs)
Firing order 1-5-3-6-2-4
Engine rotation direction (facing flywheel) Counterclockwise
Aspiration Dual turbocharged and charge air cooled
Combustion system Direct injection turbocharged
Fuel system High-pressure common rail
Lube system capacity (including filter) 40 L (42 qts)
• N13
Lube system capacity (overhaul only, with filter) 44 L (46 qts)
• N13
Engine oil pressure at operating temperature with SAE 15W-40 oil
• Low idle 69 kPa (10 psi) min.
• High idle 276 - 483 kPa (40 - 70 psi)
Idle speed (no load) 600 rpm, nominal
Thermostat operating temperature
• Primary 83°C - 95°C (181°F - 203°F)

• Secondary 71°C - 86°C (160°F - 187°F)
Engine Description
The N13 diesel engine is designed for increased durability, reliability, and ease of maintenance.
The cylinder head has four valves per cylinder for increased airflow. The overhead valve train includes rocker
arms and valve bridges to operate the four valves. The fuel injector is centrally located between the four valves,
directing fuel over the piston for improved performance and reduced emissions.
The overhead camshaft is supported by seven bearings in the cylinder head. The camshaft gear is driven from
the rear of the engine. The overhead valve train includes roller rocker arms and dual valves that open, using a
valve bridge.
N13 engines use one-piece steel pistons. All pistons use an offset piston axis and centered combustion bowls.
Crown markings show correct piston orientation in the crankcase.
The one-piece crankcase uses replaceable wet cylinder liners that are sealed by dual crevice seals.
The crankshaft has seven main bearings with fore and aft thrust controlled at the sixth bearing. One fractured
cap connecting rod is attached at each crankshaft journal. The piston pin moves freely inside the connecting
rod and piston. Piston pin retaining rings secure the piston pin in the piston. The rear oil seal carrier is part of
the flywheel housing.
A gerotor lube oil pump is mounted behind the front cover and is driven by the crankshaft. Pressurized oil is
supplied to various engine components. All N13 engines also use an engine oil cooler and a cartridge-style
engine oil filter, which are installed in the engine lube oil module.
The low-pressure fuel pump draws fuel from the fuel tank(s) through a chassis mounted filter/water separator.
The low-pressure fuel pump provides fuel for the engine mounted fuel module. Conditioned low-pressure fuel
is supplied from the engine mounted fuel module to the high-pressure fuel pump, Inlet Air Heater fuel solenoid,
and the AFT fuel doser module.
The high-pressure fuel system is a direct fuel injected common-rail system. The common-rail includes a
high-pressure fuel pump, two fuel rail supply lines, fuel rail, six fuel injectors, and pressure relief valve.
The fuel injectors are installed in the cylinder head under the valve cover and are electronically actuated by the
ECM.
N13 engines use a dual stage, fixed geometry turbocharger assembly. Each stage includes a Charge Air Cooler
(CAC). The High Pressure (HP) turbocharger includes a pneumatically operated wastegate. The Low Pressure
Charge Air Cooler (LPCAC) is mounted on the lower right side of the engine, and uses the engine cooling system
to regulate charge air temperatures. The High Pressure Charge Air Cooler (HPCAC) is mounted in front of the
engine cooling package. The HPCAC is an air-to-air type cooler, and requires no connections to the engine's
cooling system.
The Exhaust Gas Recirculation (EGR) system circulates cooled exhaust into the air inlet duct. The EGR cooler
provides regulated cooling of the EGR gases before entering the air inlet duct. This cools the combustion
process, and reduces Nitrogen Oxides (NOX) emissions.
The open crankcase breather system uses a centrifugal Crankcase Oil Separator (CCOS) to return oil mist to
the crankcase, and vent the cleaned crankcase gasses to the atmosphere. The CCOS is part of the oil module.
The breather system has been redesigned, and uses no crankcase breather filter or external piping. Blowby
gases enter the CCOS through the side of the crankcase.
The Inlet Air Heater system warms the incoming air supply during engine cranking and several minutes after
cold engine start up to help reduce emissions.
The Navistar® Engine Brake by Jacobs® is optional for N13 engine displacements. The engine brake is a
compression release system that provides additional vehicle braking performance. The operator can control
the engine brake for different operating conditions.
Optional Equipment
Optional cold climate features available are an oil pan heater and a coolant heater. Both heaters use an electric
element to warm engine fluids in cold weather.
The oil pan heater warms engine oil to ensure optimum oil flow to engine components.
The coolant heater warms the engine coolant surrounding the cylinders. Warmed engine coolant increases fuel
economy and aids start-up in cold weather.
Chassis Mounted Equipment

• The chassis mounted fuel filter/water separator removes a majority of the water and foreign particles that
may enter the fuel system from the supply tank(s). This filter works with the engine mounted fuel module to
eliminate foreign matter and moisture from the fuel before entering the fuel injection system.
• The Low Temperature Radiator (LTR) regulates the temperature of the LPCAC. The LTR is mounted in front
of the radiator cooling package, and requires connections to the engine cooling system.
• The HPCAC lowers temperature after the air is compressed by the turbochargers, and has no connections
to the engine cooling system. The HPCAC is an air-to-air cooler. The HPCAC is mounted in front of the
radiator cooling package.
• The Diesel Oxidation Catalyst (DOC) oxidizes hydrocarbons and carbon monoxide, provides heat for
exhaust system warm-up, aids in temperature management for the Diesel Particulate Filter (DPF), and
oxidizes NO into NO2 for passive DPF regeneration. The DOC is monitored by the Aftertreatment Control
Module (ACM) using one Diesel Oxidation Catalyst Inlet Temperature (DOCIT) sensor positioned at the
DOC inlet, and one Diesel Particulate Filter Inlet Temperature (DPFIT) sensor positioned at the DPF inlet.
• The DPF temporarily stores carbon-based particulates, oxidizes stored particulates, stores non-combustible
ash, and provides required exhaust back pressure for proper engine performance. The DPF is monitored by
the ACM using the DOC / DPF temperature sensor module installed on the DPF, and the Diesel Particulate
Filter Differential Pressure (DPFDP) / outlet pressure sensor installed on or near the DPF.
• The Selective Catalyst Reduction (SCR) catalyst oxidizes Nitrogen Oxides (NOx) into Nitrogen gas and
water. The SCR catalyst is monitored by the ACM using a NOx IN sensor module installed after the HP
turbocharger outlet pipe, and a NOx OUT sensor module installed after the outlet of the SCR catalyst. An
ammonia (NH3) sensor provides feedback to the ACM related to Diesel Exhaust Fluid (DEF) injection into
the SCR catalyst.
Engine Component Locator

Engine Component Table
Table below lists all components found on Engine Component Locator illustrations. Numbers in the columns to
the right provide Item Numbers for the engine view (top of column) where component can be located.
Component Description Top Front Left Left – Right Right Back

Closeup Front
Accessory Drive Pulley 13
Aftertreatment Fuel Supply 16 7
Module (AFTFSM); AFTFSM
contains Aftertreatment
fuel Shut-Off (AFTSO) and
Aftertreatment Fuel Pressure
Control (AFTFPC)
Aftertreatment Fuel Injector 1
(AFTFI)
Aftertreatment Fuel Pressure 8
1 Sensor (AFTFP1)
Aftertreatment Fuel Shutoff 9
Valve (AFTFSV)
Aftertreatment Purge Air 13
Valve (AFTPAV)
Air Compressor 15
Air Control Valve (ACV) 3 4
Assembly
Air Inlet Duct 6
Camshaft Position (CMP) 12 1
sensor
Charge-Air-Cooler Outlet 8 3
Temperature (CACOT)
sensor
Coolant Distribution Housing 14
Crankcase Oil Separator 12
(CCOS) breather tube
Crank Shaft Position (CKP) 4
sensor
EGR coolant return manifold 15
EGR cooler gas outlet 14
manifold
EGR Valve coolant return 3
EGR valve coolant supply 4

Closeup Front
Engine Coolant Inlet 13 11
Engine Coolant Outlet 10
Engine Control Module 7
(ECM) with Barometric
Pressure (BARO) internal
sensor
Engine Coolant Temperature 13 5
1 (ECT1) sensor
Engine Coolant Temperature 1 6
2 (ECT2) sensor
Engine mounted secondary 10 5
fuel filter access
Engine Oil Pressure (EOP) 10 7
sensor
Engine Oil Temperature 9 3
(EOT) sensor
Engine Throttle Valve (ETV) 4
Exhaust Back Pressure 18
Valve housing
Exhaust Back Pressure 15
Valve (EBPV)
Exhaust Gas Recirculation 2 1 5
(EGR) cooler
Exhaust Gas Recirculation 12 6
Cooler Gas Temperature
(EGRGT) sensor
Exhaust Gas Recirculation 5 2 2
(EGR) valve
Flywheel Housing 14 17
Fuel Delivery Pressure 11
(FDP) sensor
Fuel Pressure Control Valve 2
(FPCV)
Fuel primer pump assembly 10
Fuel Rail 11 6
Fuel Rail Pressure (FRP) 17 1
sensor (behind ECM, at front
of Fuel Rail)
High Pressure (HP) pump 11
pulley

Closeup Front
High Pressure (HP) 3
turbocharger
Injector harness 6
Intake Air Heater Fuel Igniter 11 9 1
(IAHFI)
Intake Air Heater Relay 6 8
(IAHR)
Intake Air Heater Fuel 7 5
Solenoid (IAHFS)
Intake Manifold Pressure 10 2 4
(IMP) sensor
Intake Manifold Temperature 9
(IMT) sensor
Intake Throttle Duct 9 18
assembly
Interstage Charge Air Cooler 13
(ISCAC)
Low Pressure Fuel Pump 12
(LPFP)
Low Pressure (LP) fuel 3
pressure test port
Low Pressure (LP) 14
turbocharger
Low Temperature 2 8 5
Thermostat (LTT)
NOx In Sensor 16
NOx In sensor module 3
Oil Filter Cap 7
Oxygen Sensor (O2S) 15
Thermostat housing 4
Turbocharger 1 Turbine 4 1
Outlet Pressure (TC1TOP)
sensor
Turbocharger 2 Compressor 2
Inlet Sensor (TC2CIS)
Vibration damper 12
Top View
Figure 3 Top View

1. Engine Coolant Temperature 2 7. Intake Air Heater Fuel Solenoid 12. Exhaust Gas Recirculation
(ECT2) sensor (IAHFS) Cooler Gas Temperature
2. Exhaust Gas Recirculation 8. Charge-Air-Cooler Outlet (EGRGT) sensor
(EGR) cooler Temperature (CACOT) sensor 13. Engine Coolant Temperature 1
3. EGR Valve coolant return 9. Intake throttle duct assembly (ECT1) sensor
4. EGR valve coolant supply 10. Intake Manifold Pressure (IMP) 14. EGR cooler gas outlet manifold
5. Exhaust Gas Recirculation sensor 15. EGR coolant return manifold
(EGR) valve 11. Intake Air Heater Fuel Igniter
6. Intake Air Heater Relay (IAHR) (IAHFI)
Front View
Figure 4 Front View

1. Exhaust Gas Recirculation 6. Exhaust Gas Recirculation 11. Accessory Drive Pulley
(EGR) cooler Cooler Gas Temperature 12. Vibration damper
2. Low Temperature Thermostat (EGRGT) sensor 13. Engine Coolant Inlet
(LTT) 7. EGR cooler gas outlet manifold 14. Coolant Distribution Housing
3. Air Control Valve (ACV) 8. Intake Manifold Pressure (IMP) 15. Exhaust Back Pressure Valve
Assembly sensor (EBPV)
4. Thermostat housing 9. Intake Air Heater Fuel Igniter
5. Engine Coolant Temperature 1 (IAHFI)
(ECT1) sensor 10. Engine Coolant Outlet
Left View
Figure 5 Left View

1. Intake Air Heater Fuel Igniter 9. Intake Manifold Temperature 16. Aftertreatment Fuel Supply
(IAHFI) (IMT) sensor Module (AFTFSM); AFTFSM
2. Intake Manifold Pressure (IMP) 10. Engine mounted secondary fuel contains Aftertreatment
sensor filter access fuel Shut-Off (AFTSO) and
3. Charge-Air-Cooler Outlet 11. Fuel Rail Aftertreatment Fuel Pressure
Temperature (CACOT) sensor 12. Camshaft Position (CMP) sensor Control (AFTFPC)
4. Engine Throttle Valve (ETV) 13. Aftertreatment Purge Air Valve 17. Fuel Rail Pressure (FRP) sensor
5. Intake Air Heater Fuel Solenoid (AFTPAV) (behind ECM, at front of Fuel
(IAHFS) 14. Flywheel Housing Rail)
6. Injector harness 15. Air Compressor 18. Intake throttle duct assembly
7. Engine Control Module (ECM)
with Barometric Pressure
(BARO) internal sensor
8. Intake Air Heater Relay (IAHR)
Left View – Closeup
Figure 6 Left View – Closeup

1. Fuel Rail Pressure (FRP) sensor 6. Fuel Rail 10. Fuel primer pump assembly
(behind ECM, at front of Fuel 7. Aftertreatment Fuel Supply 11. Fuel Delivery Pressure (FDP)
Rail) Module (AFTFSM); AFTFSM sensor
2. Fuel Pressure Control Valve contains Aftertreatment 12. Low Pressure Fuel Pump
(FPCV) fuel Shut-Off (AFTSO) and (LPFP)
3. Low Pressure (LP) fuel pressure Aftertreatment Fuel Pressure 13. High Pressure (HP) fuel pump
test port Control (AFTFPC)
4. Intake Manifold Temperature 8. Aftertreatment Fuel Pressure 1
(IMT) sensor Sensor (AFTFP1)
5. Engine mounted secondary fuel 9. Aftertreatment Fuel Shutoff
filter access Valve (AFTFSV)
Right View
Figure 7 Right View

1. Aftertreatment Fuel Injector 7. Oil Filter Cap 13. Interstage Charge Air Cooler
(AFTFI) 8. Low Temperature Thermostat (ISCAC)
2. Exhaust Gas Recirculation (LTT) 14. Low Pressure (LP) turbocharger
(EGR) valve 9. Engine Oil Temperature (EOT) 15. Oxygen Sensor (O2S)
3. High Pressure (HP) turbocharger sensor 16. NOx In Sensor
4. Turbocharger 1 Turbine Outlet 10. Engine Oil Pressure (EOP) 17. Flywheel Housing
Pressure (TC1TOP) sensor sensor 18. Exhaust Back Pressure Valve
5. Exhaust Gas Recirculation 11. Engine Coolant Inlet housing
(EGR) cooler 12. Crankcase Oil Separator
6. Air Inlet Duct (CCOS) breather tube
Right Front View
Figure 8 Right Front View

1. Turbocharger 1 Turbine Outlet 4. Air Control Valve (ACV) 7. Engine Oil Pressure (EOP)
Pressure (TC1TOP) sensor Assembly sensor
2. Turbocharger 2 Compressor 5. Low Temperature Thermostat
Inlet Sensor (TC2CIS) (LTT)
3. Engine Oil Temperature (EOT) 6. Engine Coolant Temperature 2
sensor (ECT2) sensor
Back View
Figure 9 Back View

1. Camshaft Position (CMP) sensor 3. NOx IN sensor module
2. Exhaust Gas Recirculation 4. Crank Shaft Position (CKP)
(EGR) valve sensor
Aftertreatment Component Locator
SCR Switchback Assembly
Figure 10 SCR Switchback Assembly

1. Exhaust Jumper Harness 3. Selective Catalyst Reduction 4. Diesel Particular Filter (DPF)
2. Decomposition Reactor Tube (SCR) assembly assembly
DPF Components
Figure 11 DPF Components

1. Diesel Exhaust Fluid Doser 5. Diesel Oxidation Catalyst Intake 9. Diesel Particulate Filter
(DEFD) Temperature (DOCIT) sensor Differential Pressure (DPFDP) /
2. Decomposition Reactor Tube 6. Diesel Particulate Filter (DPF) outlet pressure sensor module
3. Diesel Oxidation Catalyst (DOC) assembly 10. Low Pressure Tube
/ DPF Diesel Particulate Filter 7. Diesel Particulate Filter Inlet 11. Diesel Particulate Filter Outlet
(DPF) Temperature sensor Temperature (DPFIT) sensor Temperature (DPFOT) sensor
module 8. High Pressure Tube 12. DPF Outlet
4. DOC Intake
SCR Components
Figure 12 SCR Components

1. NOx Out sensor 4. Selective Catalyst Reduction 6. Ammonia (NH3) sensor module
2. Selective Catalyst Reduction Inlet Temperature (SCRIT) 7. Ammonia (NH3) sensor
Outlet Temperature (SCROT) sensor 8. SCR sensor jumper harness
sensor 5. Selective Catalyst Reduction 9. Selective Catalyst Reduction
3. NOx Sensor Module (SCR) temperature sensor (SCR) assembly
module
ENGINE-TO-VEHICLE CONNECTION POINTS 29
Table of Contents
Engine-to-Vehicle Connection Points... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

30 ENGINE-TO-VEHICLE CONNECTION POINTS
ENGINE-TO-VEHICLE CONNECTION POINTS 31
Engine-to-Vehicle Connection Points

Overview
The following illustrations were designed to show connection points between the engine and vehicle on a typical
(ProStar) platform. it is ONLY intended to provide a general guideline for identifying the engine-to-vehicle
connection points. There may be variations in engine-to-vehicle connection points depending on the
configuration.
Figure 13 Engine to Vehicle Connection Points

1. Auxiliary cab heater supply 4. Auxiliary cab heater return 7. Electrical ground
connection connection 8. Turbocharger down-pipe
2. Auxiliary coolant return 5. High-Pressure (HP)
3. Low-Pressure (LP) turbocharger turbocharger air outlet duct
air inlet duct 6. Front engine mounts (2)
32 ENGINE-TO-VEHICLE CONNECTION POINTS
Figure 14 Engine to Vehicle Connection Points (Continued)

1. Intake Air Heater (IAH) Igniter 5. 21-way engine-to-chassis 9. High-Pressure Fuel Pump
fuel supply line connector (HPFP) oil fill
2. Engine Throttle Valve (ETV) 6. Rear engine mounts (2) 10. Thermostat outlet
3. Engine Control Module (ECM) 7. Fuel return line connection 11. Water pump inlet
chassis-side electrical terminals 8. Fuel supply line connection 12. Block heater
4. IAH igniter relay (from tank)
ENGINE REMOVAL FROM CHASSIS 33
Table of Contents
Engine Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

34 ENGINE REMOVAL FROM CHASSIS
Engine Removal From Chassis

Overview
Engine Removal From Chassis procedure is based on a ProStar platform and is ONLY intended to provide a
general guideline for removing an engine from chassis. There may be variation in engine removal steps for other
truck chassis in comparison to engine removal steps outlined in this section.
Figure 15 Engine Removal From Chassis Manual References

1. Heat Ventilation Air Conditioning 3. Exhaust Aftertreatment System 6. Radiator/Cooling System
(HVAC) System with DPF and SCR Service Manual
2. Cab: Day Cab and Sleeper Cab 4. Hydraulic Clutch Service Manual 7. Hood, Grille, Fenders and
Service Manual 5. Electrical Circuit Diagrams Bumpers Service Manual
Special Tools
Description Tool Number
Air and Fuel Cap and Plug Kit ZTSE4891
Coolant Management Tool KL5007NAV
Lifting Device Obtain locally
Transmission Jack and Support Straps Obtain locally
1. Remove battery-box cover.

2. Disconnect battery-to-ground cable.
3. Drain air tank.
4. Remove left-side seat.
5. Remove left kick panel.
6. Remove interior panel from pedal area.
7. Remove left scuff plate.
8. Remove right-side seat.
9. Remove right scuff plate.
10. Remove right kick panel.
11. If equipped with manual transmission, remove gear shift level and air lines.
12. Remove front-cab floor mat.
13. Remove cup holder from engine housing cover.
14. Remove bracket from engine housing cover.
15. Remove engine housing cover.
16. Open hood.
17. Unlatch and flip down front bumper.
18. Close hood.
19. Disconnect fog lamp electrical connectors.
20. Remove front bumper.
21. Open hood.
22. Remove left and right torsion-bar mount plates.
23. Remove torsion bar from hood hinge.
24. Disconnect electrical harness connectors from hood.
25. Disconnect shock absorbers from hood and close hood.
26. Remove hood-hinge bolts.
27. Remove hood.
28. Remove air filter housing and tube. Install appropriate plug from Air and Fuel cap and Plug Kit ZTSE4891.
29. Remove Charge Air Cooler (CAC) outlet hose. Install appropriate plug from Air and Fuel cap and Plug Kit
ZTSE4891.
30. Remove power steering return hose from power steering reservoir. Install appropriate plug from Air and
Fuel cap and Plug Kit ZTSE4891.
31. Remove power steering return hose from steering gear. Install appropriate plug from Air and Fuel cap and
Plug Kit ZTSE4891.
32. Remove power steering pressure hose from union. Install appropriate plug from Air and Fuel cap and Plug
Kit ZTSE4891.
33. Using Coolant Management Tool KL5007NAV, drain cooling system.
34. Disconnect upper radiator hose from engine.
35. Disconnect upper surge tank heater hose.
36. Remove CAC inlet hose. Install appropriate plug from Air and Fuel cap and Plug Kit ZTSE4891.
37. Evacuate air conditioning refrigerant from air conditioning system.
38. Disconnect condenser to receiver drier hose from receiver dryer and discard O-ring and C-plate. Install
appropriate plug from Air and Fuel cap and Plug Kit ZTSE4891.
39. Disconnect evaporator to compressor hose from receiver drier and discard O-ring and C-plate. Install
40. Disconnect line to compressor suction fitting connection and discard O-ring and C-plate. Install appropriate
plug from Air and Fuel cap and Plug Kit ZTSE4891.
41. Disconnect evaporator to compressor hose from compressor and discard O-ring and C-plate. Install
42. Disconnect lower radiator hose from radiator.
43. Disconnect engine harness connectors from Engine Coolant Level (ECL) sensor and Air Conditioning (A/C)
pressure transducer.
44. Disconnect coolant surge tank coolant hose from Exhaust Gas Recirculation (EGR) cooler.
45. Disconnect lower heater hose from surge tank.
46. Disconnect lower Low-Temperature Radiator (LTR) heater hose from EGR cooler.
47. Disconnect transmission oil cooler hose from radiator. Install appropriate plug from Air and Fuel cap and
Plug Kit ZTSE4891.
48. Re-position power steering cooler tube.
49. Remove hood-hinge bracket from truck body.
50. Disconnect chassis harness headlight and ground wires from lower radiator support frame.
51. Position rubber boot onto fan shroud ring.
52. Remove left and right radiator stay rods.
53. Install lifting device onto radiator.
54. Remove 2 lower radiator core support nuts.
55. Remove radiator assembly.
56. Clean any excess coolant from floor.
57. Remove fan from fan clutch.

58. Remove fan shroud ring.
59. Remove right front fender assembly and bracket.
60. Remove left front fender assembly and bracket.
61. Remove floor pan and shifter boot.
62. Remove transmission shift tower and discard gasket.
63. Remove drive shaft.
64. Remove both fuel-tank tie bars.
65. Remove transmission harness connectors from Vehicle Speed Sensor (VSS), Transmission Temperature
Sensor (TTS), and reverse switch.
66. Disconnect transmission oil cooler hose from transmission. Install appropriate plug from Air and Fuel cap
and Plug Kit ZTSE4891.
67. Disconnect air supply line from transmission.
68. Reposition clutch slave cylinder.
69. Remove clutch inspection cover.
70. Remove clutch-release bearing grease-tube fitting
71. Remove all but 2 transmission to engine mounting bolts.
72. Raise front of truck until both front wheels are off the ground.
73. Install transmission jack and support straps to stabilize transmission for removal.
74. Remove remaining 2 transmission mounting bolts and remove transmission from truck.
75. Lower front of truck down to ground.
76. Remove Pre-Diesel Oxidation Catalyst (PDOC) and discard gasket.
77. Disconnect engine harness connectors from Engine Coolant Temperature 1 (ECT1) sensor, EGR valve, and
Oxygen Sensor (O2S).
78. Remove lower battery cable guide bolts.
79. Disconnect battery ground cable from Low Pressure Charge Air Cooler (LPCAC) ground stud.
80. Disconnect battery to starter cable from starter ground stud.
81. Disconnect battery to starter cable from starter positive stud.
82. Disconnect starter solenoid connector.
83. Disconnect oil centrifuge supply hose from crankcase return tube. Install appropriate plug from Air and Fuel
cap and Plug Kit ZTSE4891.
84. Remove oil-supply hose O-ring seal.
85. Remove oil centrifuge return hose from crankcase return tube. Install appropriate plug from Air and Fuel
cap and Plug Kit ZTSE4891.
86. Remove oil-return hose O-ring seal.
87. Disconnect coolant filter inlet and outlet hoses.
88. Secure steering wheel to prevent rotation.

89. Remove steering shaft.
90. Disconnect fuel return tube from engine. Install appropriate plug from Air and Fuel cap and Plug Kit
ZTSE4891.
91. Disconnect fuel supply tube from engine. Install appropriate plug from Air and Fuel cap and Plug Kit
ZTSE4891.
92. Disconnect engine-harness 42-way connector.
93. Disconnect battery positive at junction block on air cleaner mounting bracket.
94. Remove air cleaner housing bracket.
95. Cut tie straps from, and disconnect 10-pin chassis harness connector at exhaust stack.
96. Position chassis harness on engine.
97. Disconnect engine block heater at cab.
98. Disconnect inlet and outlet heater hoses for heater core.
99. Remove heater-hose tube from top of EGR cooler.
100. Disconnect compressor-to-line connection discharge fitting.
101. Disconnect front air compressor supply line from air compressor.
102. Remove 3 bolts and P-clamps securing transmission oil cooler hoses to oil pan brackets.
103. Remove lower radiator hose from engine.
104. Re-position hydraulic clutch reservoir.
105. Remove CB radio antenna mast.
106. Remove both wiper arms.
107. Remove cowl panel.
108. Remove wiper-motor drive shaft and lever assembly.
109. Remove 2 engine mounting bolts and 4 engine mounting nuts.
110. Remove drain plug from oil pan and drain engine oil.
111. Install drain plug into oil pan.
112. For front sump engine applications, remove front cross member.
113. Install lifting device and chains onto engine.
114. Remove engine assembly from truck.
115. Remove right side engine mounting bracket from engine.
116. Clean floor and prep area.
117. Lower engine assembly onto jack stands.
MOUNTING ENGINE ON STAND 41
Table of Contents
Mounting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Engine Cleaning................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
42 MOUNTING ENGINE ON STAND
Mounting Engine
GOVERNMENT REGULATION: Engine fluids (oil, fuel, and coolant) may be a hazard to human
health and the environment. Handle all fluids and other contaminated materials (e.g. filters, rags)
in accordance with applicable regulations. Recycle or dispose of engine fluids, filters, and other
contaminated materials according to applicable regulations.
WARNING: To prevent personal injury or death, read all safety instructions in the “Safety
Information” section of this manual.
WARNING: To prevent personal injury or death, make sure the engine has cooled before removing
components.
WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin. Clean
skin and nails using hand cleaner and wash with soap and water. Wash or discard clothing and rags
contaminated with engine fluids.
WARNING: To prevent personal injury or death, make sure the engine is supported before removing
mounting hardware.
Special Tools
Disposable Air and Fuel Caps ZTSE4891
Engine Lifting Tool Kit 12-000-01-01 – 12-000-01-07
Engine Stand Adapter Plate 12-051-01
Engine Stand Adapter Plate Mounting Bolts 12-051-01-02
Engine Roll-Over Stand OTC1750A
Special Torques
Oil drain plug 75 N·m (55 lb·ft)
Engine front mount support 225 N·m (166 lb·ft).
Small engine stand adapter plate mounting bolts 12-051-01-02 107 N·m (79 lb·ft)
Large engine stand adapter plate mounting bolts 12-051-01-02 216 N·m (159 lb·ft)
5/8 x 1.5 inch grade 8 mounting bolts 266 N·m (196 lb·ft)
Engine Cleaning
1. Using Disposable Air and Fuel Caps, cover all engine openings to prevent water, de-greasing agents, or
detergents from entering engine.
2. Cover exposed electrical connectors and the Engine Control Module (ECM) using plastic and duct tape.
3. Using an appropriate detergent mixed in the correct ratio as described on the detergent directions, apply to
engine using a hot pressure washer or similar cleaning equipment.
Mounting Engine on Stand

NOTE: Before mounting engine on engine stand, do the following.
1. Drain any remaining coolant from individual components as necessary into a suitable container.
2. Remove oil drain plug and drain oil into a suitable container.
3. Inspect oil drain plug O-ring. Discard and replace if damaged.
4. After oil is drained, lubricate oil drain plug O-ring with clean engine oil and install oil drain plug.
5. Tighten oil drain plug to 75 N·m (55 lb·ft).
6. Remove Low-Pressure Charge Air Cooler (LPCAC). See Low-Pressure Charge Air Cooler (LPCAC)
Removal (page 848).
Figure 16 Heater Return Tube

1. Heater return tube 2. Heater return tube nut 3. Water distribution housing
See Heater Return Tube (Figure 16) to perform steps 7 and 8.

7. Loosen heater return tube nut (2) that secures heater tube return tube (1) to water distribution housing (3)
and remove heater return tube.
8. Remove starter motor assembly. See Starter Motor Assembly Removal.
Figure 17 Rear Coolant Manifold

1. Rear coolant manifold
2. NH3 sensor module
3. Engine harness mounting bracket bolts (3)
4. Engine harness mounting bracket
5. NH3 sensor module bolts (2)
6. Chassis harness mounting bracket bolts (2)
7. Chassis harness mounting bracket
See Rear Coolant Manifold (Figure 17) to perform steps 9 through 12.
9. Remove 3 engine harness mounting bracket bolts (3) that secure engine harness mounting bracket (4) to
rear coolant manifold (1).
10. Disconnect wire clips.
11. Remove 2 NH3 sensor module bolts (5) that secure NH3 sensor module (2) to rear coolant manifold (1).
Move NH3 sensor module out of way.
12. Remove 2 chassis harness mounting bracket bolts (6) that secure chassis harness mounting bracket (7) to
rear coolant manifold (1). Remove chassis harness mounting bracket from engine.
WARNING: To prevent personal injury or death, use a chain hoist rated for the weight of the engine,
follow manufacturer's installation and safety instructions, and attach safety latch lifting hooks to lifting
eyes on the engine.
Figure 18 Lifting Chain Assembly Connected to Main Engine Lift Bracket

1. Engine lift
2. Lifting chain assembly 12-000-01-07
3. Front lifting ring 12-000-01-04
4. Rear lifting ring 12-000-01-05
5. Main engine lift bracket 12-000-01-01
See Lifting Chain Assembly Connected to Main Engine Lift Bracket (Figure 18) to perform steps 13 and 14.
13. Connect lifting chain assembly (2) to engine lift (1).
14. Connect lifting chain assembly (2) onto main engine lift bracket (5) using front lifting ring (3). Connect at
rear lifting ring (4) if lifting engine and transmission as an assembly.
Figure 19 Main Engine Lift Bracket Secured to Front Engine Lifting Eyelet
1. Front engine lifting eyelet
3. Lynch pin 12-000-01-03
See Main Engine Lift Bracket Secured to Front Engine Lifting Eyelet (Figure 19) to perform step 15.
15. Slide main engine lift bracket (2) into front engine lifting eyelet (1). Secure main engine lift bracket in place
with lynch pin (3).
Figure 20 Adapter Bracket Installed

1. Adapter bracket 12-000-01-02
2. Nut, bolt, and washer combination (4)
4. Rear lifting eyelets (2)
See Adapter Bracket Installed (Figure 20) to perform steps 16 through 19.
16. Remove engine cover (dog house).
17. Using 2 nut, bolt, and washer combinations (2), loosely install adapter bracket (1) to front side of both rear
lifting eyelets (4) on flywheel housing.
18. Using 2 nut, bolt, and washer combinations (2), loosely install adapter bracket (1) onto main engine lift
bracket (3).
19. Tighten 4 nut, bolt, and washer combinations (2), but allow for adapter bracket (1) movement.
Figure 21 Cab Shim Assembly Installed

1. Cab shim assembly 12-000-01-06
2. Cab mount
See Cab Shim Assembly Installed (Figure 21) to perform step 20.
NOTE: Installation of Cab Shim Assembly 12-000-01-06 is not required for all models, although it may provide
additional access for some models.
20. To install cab shim assembly (1):
a. Remove steel strap securing cab mount (2) to cab bushing.
b. Safely raise passenger side of cab.
c. Install cab shim assembly (1).
d. Lower cab mount (2) down onto cab shim assembly (1).
21. Raise and remove engine from vehicle using engine lift.
Figure 22 Engine Front Mount Support (right side)

1. Engine front-mount-support bolts (4)
2. Engine front-mount support
See Engine front mount support (right side) (Figure 22) to perform step 22.
NOTE: For reinstallation of engine front mount support, torque bolts to 225 N·m (166 lb·ft).
22. Remove 4 engine front-mount-support bolts (1) and remove engine front-mount support (2).
Figure 23 Engine Stand Adapter Plate (mounting bracket) 12-051-01
WARNING: To prevent personal injury or death, use metric class 10.9 or SAE grade 8 bolts when
mounting Engine Stand Adapter Plate to engine and engine stand. See instructions included with engine
stand and Engine Stand Adapter Plate.
Figure 24 Engine Stand Adapter Plate (mounting bracket) Mounted to Engine

1. Small engine stand adapter plate mounting bolts 12-051-01-02 (2)
2. Engine stand adapter plate 12-051-01
3. Large engine stand adapter plate mounting bolts 12-051-01-02 (4)
See Engine Stand Adapter Plate (mounting bracket) 12-051-01 (Figure 23) and Engine Stand Adapter Plate
(mounting bracket) Mounted to Engine (Figure 24) to perform steps 23 and 24.
23. Position engine stand adapter plate (2) on right side of engine. Secure engine stand adapter plate with 4
large engine stand adapter plate mounting bolts (3). Torque bolts to 216 N·m (159 lb·ft).
24. Install 2 small engine stand adapter plate mounting bolts (1) to secure engine stand adapter plate (2) to
engine. Torque bolts to 107 N·m (79 lb·ft).
Figure 25 Engine Stand Adapter Plate Attached to Engine Roll-Over Stand

1. Engine Roll-Over Stand 2. Engine Stand Adapter Plate
OTC1750A 12-051-01
See Engine Stand Adapter Plate Attached to Engine Roll-Over Stand (Figure 25) to perform step 25.
25. Attach engine stand adapter plate (2) to engine roll-over stand (1) using four 5/8 x 1.5 inch grade 8 mounting
bolts. Tighten bolts to 266 N·m (196 lb·ft).
SERVICE AND TEST PROCEDURES 57
Table of Contents
Service Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Crankshaft Rotation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Cylinder No. 1 TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Valve Overlap. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Valve Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Hand Primer Pump Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Engine Run-in Procedure........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77

Exhaust Gas Recirculation (EGR) Cooler Bench Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
58 SERVICE AND TEST PROCEDURES
Service Procedures
Crankshaft Rotation
Figure 26 High-pressure Pump Pulley

1. High-pressure pump pulley
2. M16 x 40 LH bolt (left-hand thread)
NOTE: The crankshaft can be rotated using the M16 x 40 LH bolt (left-hand thread) on the high-pressure pump
pulley. Care must be used to ensure the bolt is not loosened while the crankshaft is rotated.
1. Adjust a torque wrench to 162 N·m (120 lb-ft).
2. Place a 19 mm socket on the torque wrench.
3. Slowly rotate the M16 x 40 LH bolt (left-hand thread) bolt clockwise. Stop pulling if the torque wrench clicks.
Torque in excess of 162 N·m (120 lb-ft) may cause the bolt to loosen. Continue rotating to desired position
when compression leaks down and less force is needed to rotate the crankshaft.
Cylinder No. 1 TDC

1. Remove the upper valve cover and base. See Upper Valve Cover and Base .
Figure 27 Camshaft Gear Timing Mark

1. Valve cover surface
2. Camshaft gear
3. Timing mark
2. Rotate crankshaft in direction of engine rotation until the camshaft timing gear mark aligns with the valve
cover surface on the intake side of the engine. See Crankshaft Rotation Procedure (Crankshaft Rotation,
page 59).
Figure 28 Flywheel Housing Timing Index (Typical)

1. Flywheel housing timing index
2. Flywheel timing mark
3. Remove timing hole cover from lower side of flywheel housing.

4. Rotate crankshaft in direction needed to align the flywheel timing mark with flywheel housing timing index.
5. Recheck that the timing mark on camshaft gear is aligned with the valve cover gasket surface (on intake side
of cylinder head). If flywheel and camshaft gear marks are in agreement, the engine is at TDC for cylinder
1. Skip step 6 and proceed to Valve Overlap Procedure (Valve Overlap, page 62).
CAUTION: To prevent engine damage, a new large idler gear must be installed if the large idler gear has slipped.
6. If flywheel and camshaft gear marks are not in agreement, the large idler gear has slipped. See Rear Timing
Gears (page 480) for procedure to install a new large idler gear.
Valve Overlap
NOTE: Valve lash adjustments are done in firing order sequence (1, 5, 3, 6, 2, 4), using the valve overlap
method. Valve overlap happens on the companion cylinder near the end of the exhaust stroke and the beginning
of the intake stroke, when both valves are open for a short period of time.
NOTE: Valve lash must be set with engine cold and cylinder head assembled to crankcase.
1. Starting with cylinder 1 at TDC compression, set valve lash for cylinder 1, according to Valve Lash Adjustment
Procedure (Valve Lash Adjustment, page 63).
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 (Valve Lash Adjustment, page 63).
3. Repeat Valve Overlap Procedure, in order for remaining cylinders 3, 6, 2, and 4.
Valve Lash Adjustment

Figure 29 Valve Lash Adjustment (Typical)

1. Exhaust rocker arm
2. Intake rocker arm
3. Adjusting screw
4. Valve lash adjustment M10 nut
5. Valve bridge (intake/exhaust)
NOTE: Adjust engine valve lash and engine brake lash at 120,000 miles (190,000 km), 300,000 miles (480,000
km), then every 300,000 miles (480,000 km) thereafter.
1. Perform Valve Overlap Procedure (Valve Overlap, page 62).
2. Loosen valve lash adjustment M10 nut (Figure 29) (Item 4) on intake rocker arm (Figure 565) (item 2).
3. Insert Lash Gauge ZTSE6076–5A 0.5 mm (0.020 in) between intake valve bridge (Figure 29) (Item 5) and
adjusting screw (Figure 29) (Item 3), and tighten adjusting screw until a slight drag on Lash Gauge 0.5 mm
(0.020 in) is felt.
4. Hold adjusting screw in position and tighten valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
NOTE: If equipped with N13 engine brake, go to step 6 to adjust exhaust valve lash and engine brake lash. If
no engine brake, continue to step 5.
5. For engines without brake, adjust exhaust valve lash as follows:
a. Loosen valve lash adjustment M10 nut on exhaust rocker arm.
b. Insert Lash Gauge ZTSE6976–7A 0.8 mm (0.031 in) between exhaust valve bridge and adjusting
screw until a slight drag on Lash Gauge is felt.
c. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to 33 lb-ft (45
N•m).
d. Go to Step 6.
Figure 30 Brake Lash Adjustment (Equipped with N13 Engine Brake)

1. Slave piston adjusting screw
2. Brake lash adjustment M10 (jam) nut
3. Engine brake housing assembly
4. Actuator pin (in exhaust valve bridge)
5. Slave piston
6. For engines with N13 engine brake, adjust exhaust valve lash and engine brake lash as follows:
a. Loosen brake lash adjustment M10 (jam) nut (Figure 30) (Item 2) on engine brake housing assembly
(Figure 30) (Item 3), and back out slave piston adjusting screw (Figure 30) (Item 1) so slave piston
no longer contacts valve bridge.
b. Loosen valve lash adjustment M10 nut on exhaust rocker arm (Figure 565) (item 1).
c. Insert Lash Gauge 0.8 mm (0.031 in) on exhaust rocker arm between exhaust valve bridge (Figure
29) (Item 5) and adjusting screw, and tighten adjusting screw until a slight drag on Lash Gauge is
felt.
d. Hold adjusting screw position and tighten exhaust valve lash adjustment M10 nut to 33 lb-ft (45
N•m).
e. Insert Lash Gauge 0.8 mm (0.031 in) on engine brake housing assembly between slave piston
(Figure 30) (Item 5) and bridge actuator pin (Figure 30) (Item 4).
f. Turn adjusting screw in until slave piston contacts Lash Gauge 0.8 mm (0.031 in) and a slight drag
on Lash Gauge 0.8 mm (0.031 in) is felt.
g. Using a 5 mm Allen wrench, hold slave piston adjusting screw to prevent from turning and tighten
jam nut to 33 lb·ft (45 N·m).
Cylinder at TDC compression Companion cylinder in valve overlap

1 6
5 2
3 4
6 1
4 5
2 3
7. Turn crankshaft in direction of engine rotation to position next cylinder in firing order at TDC compression
(one at a time) and adjust lash for the respective cylinder. See (Crankshaft Rotation Procedure, page 405).
For each cylinder positioned at TDC compression, the companion cylinder will be in valve overlap as shown
in following table.
Fuel System Priming

CAUTION: To prevent damage to the high-pressure fuel pump, do not start the engine until the fuel system is
properly primed. The Fuel System Priming Tool should be used to prime the fuel system. If the Fuel System
Priming Tool is not available, prime the fuel system using the hand primer pump method.
1. Obtain Fuel System Priming Tool.
NOTE: Fuel System Priming Tool ball valves should be in the closed position, unless suction and pressure hoses
are connected to the vehicle fuel system.
Figure 31 Fuel System Priming Tool

1. Pressure hose
2. Pressure regulator selector lever
3. Suction hose
4. Sight glass
5. Ball valve (2)
6. Filler cap (filter housing)
CAUTION: To prevent damage to fuel system components, make sure pressure regulator handle is in the 50
psi (345 kPa) position (as shown) when servicing N13 engines.
2. Fill Fuel System Priming Tool fuel filter housing with clean diesel fuel, the first time the tool is used and any
time there is no diesel fuel in the filter housing.
3. Put a fuel drain pan under the chassis mounted primary fuel filter / water separator.
4. If necessary, fill the chassis mounted fuel filter with clean diesel fuel. Fill the cartridge type filter from the top
or pump the hand primer button for the spin-on type filter.
NOTE: For different vehicles the chassis mounted primary fuel filter / water separator is mounted in different
locations than what is shown in (Figure 33) and (Figure 34).
NOTE: The Fuel System Priming Tool will work with either of the primary fuel filter / water separators shown in
(Figure 32) or (Figure 33).
Figure 32 Chassis-Mounted Primary Fuel Filter / Water Separator (Optional)

1. Fuel output to engine 2. Chassis mounted primary fuel 3. Fuel input from tank
filter / water separator
Figure 33 Chassis-Mounted Primary Fuel Filter / Water Separator (Typical)

1. Chassis mounted primary fuel 2. Fuel input from tank
filter / water separator 3. Fuel output to engine
5. Disconnect fuel supply line to engine (fuel output to engine) by pushing red release tab and pulling line off
the primary fuel filter housing (Figure 34).
Figure 34 Chassis-Mounted Primary Fuel Filter / Water Separator (Typical)

1. Fuel supply line to engine 2. Red release tab
6. Connect Fuel System Priming Tool suction hose to the primary fuel filter output (Figure 35).
Figure 35 Fuel Priming Tool Suction Hose Connected to Primary Fuel Filter Output
1. Fuel supply line to engine 2. Fuel System Priming Tool 3. Ball valve (closed)
suction hose
7. Connect Fuel System Priming Tool pressure hose to fuel supply line to engine (Figure 36).
Figure 36 Connecting Fuel System Priming Tool Pressure Hose to Fuel Supply Line to Engine
1. Fuel supply line to engine
2. Fuel System Priming Tool
pressure hose
Figure 37 Ball Valves Closed

1. Pressure Hose Ball Valve Closed 2. Suction Hose Ball Valve Closed
8. Open pressure and suction hose ball valves (Figure 38).
Figure 38 Ball Valves Open

1. Pressure hose ball valve open 2. Suction hose ball valve open
Figure 39 Pressure Regulator Selector Lever
9. Set Fuel System Priming Tool pressure regulator selector lever to 50 psi (345 kPa).
Figure 42 Fuel System Priming Tool Connected to Vehicle and Electrical Power
10. Connect electrical power and press the Fuel System Priming Tool power button (Figure 42).
11. Run Fuel System Priming Tool until no bubbles are visible in sight glass. After bubbles are clear, run Fuel
System Priming Tool for at least two more minutes.
Figure 43 Fuel System Priming Tool Sight Glass

1. Sight glass
12. Turn Fuel System Priming Tool off.

13. Close pressure and suction hose ball valves (Figure 37).
Figure 44 Ball Valves Closed

1. Pressure hose ball valve closed 2. Suction hose ball valve closed
14. Disconnect Fuel System Priming Tool pressure and suction hoses.
15. Connect fuel supply line to engine, to chassis-mounted primary fuel filter / water separator (Figure 45).
Figure 45 Chassis-Mounted Primary Fuel Filter / Water Separator

1. Fuel supply line to engine 2. Red release tab
16. Install left front fender assembly and bracket.

Hand Primer Pump Method

NOTE: Priming the fuel system by hand is not necessary if the Fuel System Priming Tool was used to prime the
fuel system.
Figure 46 Fuel Primer Pump

1. Fuel primer pump 3. Fuel filter housing
2. Fuel filter cover 4. Water drain valve (closed)
1. Prime engine at hand primer pump by performing the following:

a. Turn the fuel primer pump knob counterclockwise to unlock the pump stem.
b. Pump the fuel priming pump a minimum of 250 times (approximately 2 minutes). Continue pumping
even after higher pumping force is required. Make sure to raise and lower the knob completely on
each stroke.
c. After priming, depress the fuel primer pump knob fully and turn the fuel primer pump knob clockwise
until tight to secure the pump stem.
CAUTION: To prevent engine damage, if engine fails to start after 20 seconds of cranking, stop cranking engine
and wait two minutes to allow the starter motor to cool.
2. Start engine and check for fuel leaks. Let engine run for 2 minutes. If engine does not start after 20 seconds
of cranking, wait 2 minutes before trying to start the engine again. If the engine does not start, re-prime the
low-pressure fuel system using the above procedure.
4. Flip up and secure front bumper (if equipped).
5. Close and secure hood.
6. Remove wheel chocks.
Engine Run-in Procedure
WARNING: To prevent personal injury or death, shift transmission to park or neutral, set parking
brake, and block wheels before doing diagnostic or service procedures.
Use the following engine run-in procedure after installing new pistons, piston rings, piston pins, or cylinder
sleeves:
1. Start engine and run at low idle with no load. If engine does not exceed 138 kPa (20 psi) oil pressure within
20 to 30 seconds, shutdown engine and correct the problem.
2. Run engine at low idle with no load for 5 minutes and check for any of the following problems:
• Unusual noise
• Coolant leaks
• Oil leaks
• Fuel leaks
• Air leaks
• Excessive exhaust smoke
• Excessive vibration
• Loose turbocharger mounting
3. Turn engine off and correct any of these problems to prevent engine or turbocharger damage.
4. Wait 15 minutes for oil level to stabilize, then check engine oil level. Add oil if needed. See appropriate
Engine Operation and Maintenance Manual for correct grade and viscosity of engine oil.
5. Start engine and drive vehicle (unloaded) for 30 minutes in city mode, then drive vehicle (unloaded) for an
additional 60 minutes in highway mode. Verify no loss in power.
6. Return to idle and check for leaks.
7. Turn off engine and repair any leaks.
Test Procedures
Exhaust Gas Recirculation (EGR) Cooler Bench Test
Overview
The EGR cooler pressure test procedure was developed to determine if the EGR cooler is leaking coolant.
Equipment Conditions
EGR cooler disassembled .
Special Tools Required

• EGR Cooler Pressure Test Kit 12-892-07
Special Service Message
Figure 47 Exhaust Gas Recirculation (EGR) Assembly

1. EGR Assembly 3. EGR cooler strap bolt (4)
2. EGR cooler straps (4) 4. ERG cooler bracket
See Exhaust Gas Recirculation (EGR) Assembly (Figure 47) for the following:
Do not loosen and / or remove EGR cooler strap bolts (3) or EGR cooler straps (2) from EGR cooler bracket
(4). If EGR cooler strap bolts and / or EGR cooler straps have been loosened and / or removed, or if signs
of tampering with EGR cooler strap bolts and / or EGR cooler straps are visible, EGR assembly (1) must be
replaced.
Test Procedure
components.
Figure 48 Exhaust Side Testing

1. Exhaust gas outlet plug 8. EGR cooler coolant inlet port 13. EGR valve supply port
12-892-07-01 9. Coolant inlet block-off 14. EGR valve supply adapter
2. EGR cooler exhaust outlet port 12-892-07-06 12-892-07-09
3. Block-off plugs 12-892-07-10 (3) 10. Exhaust gas inlet plug 15. Container of water (half full)
4. Sleeper cab heat block-off 12-892-07-02 16. Coolant outlet clamp
12-892-07-05 11. Regulator assembly 12-892-07-07
5. Bunk heater port 12-892-07-08 17. EGR cooler coolant return port
6. Main cab heat plug 12-892-07-03 12. EGR cooler exhaust gas inlet 18. Bubble test hose assembly
7. EGR cooler main cab heat port port 12-892-07-04
See Exhaust Side Testing (Figure 48) to perform steps 1 through 16.
1. Install exhaust gas outlet plug 12-892-07-01 (1) into EGR cooler exhaust gas outlet port (2). Tighten knurled
ring to seal.
2. Install exhaust gas inlet plug 12-892-07-02 (10) into EGR cooler exhaust gas inlet port (12). Tighten knurled
ring to seal.
3. Install coolant outlet clamp 12-892-07-07 (16) to seal EGR cooler coolant return port (17). Tighten knurled
knob to seal.
4. Install EGR valve supply adapter 12-892-07-09 (14) into EGRV supply port (13) and tighten to seal.
5. Install block-off plugs 12-892-07-10 (3) as needed.
6. Install main cab heat plug 12-892-07-03 (6) into EGR cooler main cab heat port (7). Tighten knurled knob
to seal.
7. Insert coolant inlet block-off 12-892-07-06 (9) into EGR cooler coolant inlet port (8). Tighten knurled knobs
to seal.
8. If vehicle is equipped with bunk heater, remove bunk heater port connector from bunk heater port (5). Install
sleeper cab heat block-off 12-892-07-05 (4). Tighten knurled knob to seal.
9. Install bubble test hose assembly 12-892-07-04 (18) onto exhaust gas outlet plug 12-892-07-01 (1).
10. Install regulator assembly 12-892-07-08 (11) onto exhaust gas inlet plug 12-892-07-02 (10).
11. Connect regulator assembly 12-892-07-08 (11) to shop air. Turn regulator knob counter clockwise until no
air flows from regulator.
12. Spray EGR cooler, adapters, and fittings with soapy water.
13. Gradually turn regulator adjustment knob clockwise to increase air pressure to 35 psi (241 kPa). Inspect
EGR cooler, adapters, and fittings for leaks.
14. Insert bubble test hose assembly (18) into a container of clean water filled half full (15). Keeping end of
test hose close to top of water, watch for air bubbles coming from hose end. Bubbles at hose end indicate
leaking cooler. Let EGR cooler remain pressurized for 10 minutes.
15. Relieve air pressure from regulator assembly (11).
16. Remove all adapters, plugs, clamps, and air regulator assembly from EGR cooler.
Expected Outcome
EGR cooler should have pass the exhaust-side pressure test and be free of leaks.
ENGINE COMPONENT REPLACEMENT PROCEDURES 81
Table of Contents
General Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Cleaning Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Inspection Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Engine Electrical............................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Crankshaft Position (CKP)Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Crankshaft Position (CKP)Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96
Crankshaft Position (CKP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Camshaft Position (CMP) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Camshaft Position (CMP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Engine Coolant Temperature 1 (ECT1) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100
Engine Coolant Temperature 1 (ECT1) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Engine Coolant Temperature 2 (ECT2) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Engine Coolant Temperature 2 (ECT2) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .102
Engine Coolant Temperature 2 (ECT2) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Exhaust Gas Recirculation Gas Temperature (EGRGT) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104
Exhaust Gas Recirculation Gas Temperature (EGRGT) Removal. . . . . . . . . . . . . . . . . . . . . . . . . .104
Exhaust Gas Recirculation Gas Temperature (EGRGT) Installation. . . . . . . . . . . . . . . . . . . . . . .106
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Engine Oil Temperature (EOT) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .108
Engine Oil Temperature (EOT) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Engine Oil Pressure (EOP) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Engine Oil Pressure (EOP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Engine Oil Level (EOL) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Engine Oil Level (EOL) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Engine Oil Level (EOL) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Crankcase Oil Separator Speed (CCOSS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Crankcase Oil Separator Speed (CCOSS) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114
Crankcase Oil Separator Speed (CCOSS) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fuel Delivery Pressure (FDP) Sensor Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116
Fuel Delivery Pressure (FDP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .117
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Fuel Pressure Control Valve (FPCV) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Fuel Pressure Control Valve (FPCV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119
Charger Air Cooler Outlet Temperature (CACOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Charger Air Cooler Outlet Temperature (CACOT) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . .120
Charger Air Cooler Outlet Temperature (CACOT) Sensor Installation. . . . . . . . . . . . . . . . . . . .121
Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Intake Manifold Pressure (IMP) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Intake Manifold Pressure (IMP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Fuel Rail Pressure (FRP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Fuel Rail Pressure (FRP) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
82 ENGINE COMPONENT REPLACEMENT PROCEDURES
Fuel Rail Pressure (FRP) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Intake Manifold Temperature (IMT) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .126
Intake Manifold Temperature (IMT) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Oxygen Sensor (O2S). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Oxygen Sensor (O2S) Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .128
Oxygen Sensor (O2S) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Nitrogen Oxides (NOx) IN Sensor Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Nitrogen Oxides (NOx) IN Sensor Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Nitrogen Oxides (NOx) IN Sensor Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Nitrogen Oxides (NOx) In Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Nitrogen Oxides (NOx) In Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Nitrogen Oxides (NOx) In Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Engine Throttle Valve (ETV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Engine Throttle Valve (ETV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Exhaust Gas Recirculation (EGR) Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Exhaust Gas Recirculation (EGR) Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Turbocharger 2 Compressor Inlet (TC2CIS) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Turbocharger 2 Compressor Inlet (TC2CIS) Sensor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Turbocharger 2 Compressor Inlet (TC2CIS) Sensor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .144
Wiring Harness ECM Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Wiring Harness ECM Connections Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
Wiring Harness ECM Connections Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Engine Injector (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Engine Injector (Wiring) Harness Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .148
Engine Injector (Wiring) Harness Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
Engine Sensor (Wiring) Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Engine Sensor (Wiring) Harness Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Engine Sensor (Wiring) Harness Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .156
Engine Control Module (ECM) and Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Engine Control Module (ECM) and Mounting Bracket Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Engine Control Module (ECM) and Mounting Bracket Installation. . . . . . . . . . . . . . . . . . . . . . . . .162
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Engine Injection and Engine Sensor Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .164
Sensors and Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165
Engine Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .166
Special Torques and Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167
Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168

Relay Assembly........................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Relay Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Relay Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose. . . . . . . . . . . . . . . . . . . . . . . .171
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose Removal. . .171
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose Installation. . .173
Fuel Solenoid Valve and Fuel Supply Solenoid Hose. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Fuel Solenoid Valve and Fuel Supply Solenoid Hose Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .174
Fuel Solenoid Valve and Fuel Supply Solenoid Hose Installation. . . . . . . . . . . . . . . . . . . . . . . . .177
Special torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Aftertreatment System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .181

Supply Fuel After Filter Hose and Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Supply Fuel After Filter Hose and Tubes Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .182
Supply Fuel After Filter Hose and Tubes Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Aftertreatment Purge Air Valve (AFTPAV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .189
Aftertreatment Purge Air Valve (AFTPAV) Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Aftertreatment Purge Air Valve (AFTPAV) Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . .191
Aftertreatment (AFT) Fuel Doser Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Aftertreatment (AFT) Fuel Doser Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .193
Aftertreatment (AFT) Fuel Doser Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
AFTFI Coolant Supply Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
AFTFI Coolant Supply Tube Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
AFTFI Coolant Supply Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .198
AFTFI Coolant Return Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
AFTFI Coolant Return Tube Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
AFTFI Coolant Return Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201
Aftertreatment Fuel Injector (AFTFI) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Aftertreatment Fuel Injector (AFTFI) Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Aftertreatment Fuel Injector (AFTFI) Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Aftertreatment Fuel Injector (AFTFI) Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Aftertreatment (AFT) Fuel Supply Module Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .210
Special Torques and Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .212
Exhaust Back-Pressure Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .213

Exhaust Back-Pressure Valve (EBPV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Exhaust Back-Pressure Valve (EBPV) Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .214
Exhaust Back-Pressure Valve (EBPV) Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Exhaust Back-Pressure Valve (EBPV) Actuator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Exhaust Back-Pressure Valve (EBPV) Actuator Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .228
Exhaust Back-Pressure Valve (EBPV) Actuator Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Thermal Management Valve (TMV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Thermal Management Valve (TMV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Thermal Management Valve (TMV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate Air
Supply Lines................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .234
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate
Air Supply Lines Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate
Air Supply Lines Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Thermal Management Valve (TMV) Air Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Thermal Management Valve (TMV) Air Supply Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Thermal Management Valve (TMV) Air Supply Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . .240
Exhaust Back Pressure Valve Housing Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .242
Special Torques and Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .243
Exhaust Manifold............................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .244

Exhaust Manifold Cuffs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Front Cuff Inspection... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .244
Front Cuff Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Front Cuff Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Front Cuff Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .251
Rear Cuff Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .255

Rear Cuff Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Rear Cuff Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Rear Cuff Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Exhaust Manifold Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Exhaust Manifold Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .269
Exhaust Manifold Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Intake System. ................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .284

Air Filter Housing and Air Intake Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Air Filter Housing and Air Intake Tube Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Air Filter Housing and Air Intake Tube Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .286
Low-Pressure Charge Air Cooler (LPCAC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Low-Pressure Charge Air Cooler (LPCAC) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Low-Pressure Charge Air Cooler (LPCAC) Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . .292
Low-Pressure Charge Air Cooler (LPCAC) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .293
Low-Pressure (LP) Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Low-Pressure (LP) Turbocharger Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Low-Pressure (LP) Turbocharger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
High-Pressure (HP) Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
High-Pressure (HP) Turbocharger Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .323
High-Pressure (HP) Turbocharger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .330
High-Pressure (HP) Turbocharger Center Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
High-Pressure (HP) Turbocharger Center Section Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
High-Pressure (HP) Turbocharger Center Section Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .345
Air Compressor and Power Steering System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353

Power Steering Pressure Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Power Steering Pressure Tubes Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Power Steering Pressure Tubes Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .355
Power Steering Elbows................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
Power Steering Elbows Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .357
Power Steering Elbows Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
Power Steering Pump................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Power Steering Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Power Steering Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .360
Air Compressor Coolant Hoses..... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .361
Air Compressor Coolant Hoses Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
Air Compressor Coolant Hoses Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Air Compressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
Air Compressor Removal... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .364
Air Compressor Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
Air Compressor and Power Steering System Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
All Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .366
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368

High-pressure Fuel Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .368
HPFP to Rail Supply Tube Damper Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .370
HPFP to Rail Supply Tube Damper Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .372
High-pressure Fuel Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .374

High-pressure Fuel Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377
Injector and Fuel Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .381
Injector and Fuel Drain (Return) Lines Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .381
Injector and Fuel Drain (Return) Lines Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .382
Fuel Rail Assembly................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .383
Fuel Rail Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .383
Fuel Rail Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .384
Fuel Primer Pump Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Fuel Primer Pump Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Fuel Primer Pump Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .386
Fuel Supply and Drain (Return) Lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Fuel Supply and Drain (Return) Lines Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Fuel Supply and Drain (Return) Lines Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
Fuel Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397
Fuel Filter Housing Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397
Fuel Filter Housing Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
Fuel Filter Stand Pipe Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
Radial Shaft Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
Radial Shaft Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
Fuel Pressure Control Valve (FPCV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
Fuel Pressure Control Valve (FPCV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .406
Fuel Pressure Control Valve (FPCV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
Piston Overflow Valve (KUEV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
Piston Overflow Valve (KUEV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .408
Piston Overflow Valve (KUEV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
High-pressure Fuel Pump (HPFP) and Drive Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
High-pressure Fuel Pump (HPFP) and Drive Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . .410
High-pressure Fuel Pump (HPFP) and Drive Housing Installation. . . . . . . . . . . . . . . . . . . . . . . . .417
Fuel Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Fuel Injectors Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .424
Fuel Injectors Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .431
Filter and Fuel Strainer Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .439
Fuel System Priming. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
Fuel System Priming Tool Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .440
Hand Primer Pump Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .449
Fuel System Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
Low-pressure and High-pressure Fuel System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .450
Engine Mounted Fuel Filter Assembly Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . .451
Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .452
Fuel Injector Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .453
Oil Cooler, Filter Housing, and Crankcase Ventilation System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .457

Oil Filter Cover and Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
Oil Filter Cover and Filter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .458
Oil Filter Cover and Filter Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459
Crankcase Oil Separator (CCOS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
Crankcase Oil Separator (CCOS) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .460
Crankcase Oil Separator (CCOS) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .462
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464

Oil Module Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .464
Oil Module Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .468
Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Oil Cooler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471
Oil Cooler Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .473
Oil Cooler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .474
Oil Pressure Relief Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
Oil Pressure Relief Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .476
Oil Pressure Relief Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .477
Oil Cooler, Filter Housing, and Crankcase Ventilation System Cleaning, Inspection, and
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Oil Filter and Oil Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .478
Oil Cooler Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .480
Extension Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .481
Crankcase Oil Separator (CCOS) and Breather Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .482
Exhaust Gas Recirculation (EGR) System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486

Exhaust Gas Recirculation (EGR) Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486
Exhaust Gas Recirculation (EGR) Cooler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .486
Exhaust Gas Recirculation (EGR) Cooler Bench Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .497
Exhaust Gas Recirculation (EGR) Cooler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .500
EGR Valve................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
EGR Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .514
EGR Valve Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .520
EGR Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .521
Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .527
Exhaust Gas Recirculation (EGR) Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528

Exhaust Gas Recirculation (EGR) Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .528
EGR Valve Disassembly, Cleaning, Inspection, and Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .533
Exhaust Gas Recirculation (EGR) Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .534
Engine Throttle Valve (ETV), Air Intake Throttle Duct Assembly, and Exhaust Manifold System. . . . . . .539
Engine Throttle Valve (ETV). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540
Engine Throttle Valve (ETV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .540
Engine Throttle Valve (ETV) Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .542
Engine Throttle Valve (ETV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .543
Air Intake Throttle Duct................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .545
Air Intake Throttle Duct Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .545
Air Intake Throttle Duct Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .550
Air Intake Throttle Duct Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .551
Exhaust Gas Recirculation (EGR) Outlet Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556
Exhaust Gas Recirculation (EGR) Outlet Manifold Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .556
Exhaust Gas Recirculation (EGR) Outlet Manifold Cleaning and Inspection. . . . . . . . . . . .558
Exhaust Gas Recirculation (EGR) Outlet Manifold Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . .559
Exhaust Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
Exhaust Manifold Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .561
Exhaust Manifold Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .563
Exhaust Manifold Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .567
Exhaust Manifold Cuff. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .572

Exhaust Manifold Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .573
Special Torques.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .574
Front Cover, Fan Drive, Cooling System, and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .575
Pulley (High Mount Fan)......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .576
Pulley (High Mount Fan) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .576
Pulley (High Mount Fan) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .577
Tensioner Bracket (High Mount Fan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578
Tensioner Bracket (High Mount Fan) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .578
Tensioner Bracket (High Mount Fan) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .580
High Mount Fan Drive............. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581
High Mount Fan Drive Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .581
High Mount Fan Drive Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .582
Coolant Outlet Manifold and Thermostat Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
Coolant Outlet Manifold and Thermostat Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .584
Coolant Outlet Manifold and Thermostat Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .586
Low-Temperature (LT) Coolant Manifold and LT Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .588
Low-Temperature (LT) Coolant Manifold and LT Thermostat Removal. . . . . . . . . . . . . . . . . . .588
Low-Temperature (LT) Coolant Manifold and LT Thermostat Installation. . . . . . . . . . . . . . . .592
Automatic Belt Tensioner and Idler Pulleys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596
Automatic Belt Tensioner and Idler Pulleys Remvoal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .596
Automatic Belt Tensioner and Idler Pulleys Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .597
Water Pump Assembly and Pulley. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
Water Pump Assembly and Pulley Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .598
Water Pump Assembly and Pulley Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .599
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .600
Vibration Damper Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .600
Vibration Damper Assembly Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .602
Vibration Damper Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .605
Thermostat Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
Thermostat Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .607
Thermostat Housing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .610
Water Distribution Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
Water Distribution Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .612
Water Distribution Housing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .613
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .614
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . .614
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal Installation. . . . . . . . . . . . . . . . . . . . . .615
Front Belt- or Gear-Driven Fan Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .616
Front Belt- or Gear-Driven Fan Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .616
Front Belt- or Gear-Driven Fan Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .617
Radial Shaft Seal (Fan Low Mount Drive). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
Radial Shaft Seal (Fan Low Mount Drive) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .618
Radial Shaft Seal (Fan Low Mount Drive) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .619
Fan Low Mount Drive Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
Fan Low Mount Drive Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .620
Fan Low Mount Drive Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .621
Front Cover, Fan Drive, Cooling System, and Related Components Cleaning, Inspection, and
Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
All Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .624
N13 Engine Brake by Jacobs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626

Engine Brake Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .626
Engine Brake Housing Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .628
Engine Brake Housing Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .631
Engine Brake Lash Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635
Engine Brake Lash Adjustment Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .635
Solenoid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636
Solenoid Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .636
Solenoid Assembly Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .637
Solenoid Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .639
Control Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641
Control Valve Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .641
Control Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .642
Master Piston........................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643
Master Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .643
Master Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .644
Slave Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645
Slave Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .645
Slave Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .648
Specifications, Special Torques, and Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .651
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652

Cylinder Head, Camshaft and Valve Train Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652
Crankshaft Rotation Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .652
Cylinder No. 1 TDC Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .654
Valve Overlap Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .656
Valve Lash Adjustment Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .657
Upper Valve Cover and Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660
Upper Valve Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .660
Upper Valve Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .661
Upper Valve Cover and Base Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .663
Upper Valve Cover and Base Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .665
Rocker Arm Assembly (Non-Brake Engine). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668
Rocker Arm Assembly (Non-Brake Engine) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .668
Rocker Arm Assembly (Non-Brake Engine) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .670
Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .672
Camshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .672
Camshaft Installation........ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .677
Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681
Cylinder Head Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .681
Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .684
Cylinder Head Idler Gear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689
Cylinder Head Idler Gear Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .689
Cylinder Head Idler Gear Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .690
Cylinder Head, Camshaft and Valve Train Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . .691
Cylinder Head and Crankcase Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .691
Composite Valve Cover Assembly Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .692
Camshaft Bearings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .693
Fuel Injector Bore. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .694
Valves Leak Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .695

Flywheel and Flywheel Housing......... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700

Pilot Bearing....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .700
Pilot Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .700
Pilot Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .702
Flywheel (Manual Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .703
Flywheel (Manual Transmission) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .703
Flywheel (Manual Transmission) Preliminary Checks and Measurements. . . . . . . . . . . . . . .704
Flywheel Surface Runout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .705
Flywheel and Flywheel Housing Reconditioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .706
Flywheel (Manual Transmission) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .708
Flywheel and Flexplate Assembly (Automatic Transmission). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .710
Flywheel and Flexplate Assembly (Automatic Transmission) Removal. . . . . . . . . . . . . . . . . .710
Flywheel and Flexplate Assemblies Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .711
Flywheel and Flexplate Assembly (Automatic Transmission) Installation. . . . . . . . . . . . . . .712
Radial Shaft Ring Seal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Radial Shaft Ring Seal Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .714
Radial Shaft Ring Seal Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .715
Lifting Eyes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .716
Lifting Eyes Removal... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .716
Lifting Eyes Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .717
Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718
Flywheel Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .718
Flywheel Housing Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .720
Flywheel Housing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .722
Flywheel and Flywheel Housing Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725
All Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .725
Oil Pan and Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727

Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727
Oil Pan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .727
Oil Pan Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .730
Oil Pan Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .731
Oil Pickup Tube — Front Sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
Oil Pickup Tube — Front Sump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .732
Oil Pickup Tube — Front Sump Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .734
Oil Pickup Tube — Front Sump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .735
Oil Recovery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736
Oil Recovery Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .736
Oil Recovery Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .738
Oil Pickup Tube — Rear Sump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742
Oil Pickup Tube — Rear Sump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .742
Oil Pickup Tube — Rear Sump Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .743
Oil Pickup Tube — Rear Sump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .744
Special Torques.................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .746
Oil Fill Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .747

Oil Fill Tube Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .747
Oil Fill Tube Adapter Mount Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .750

Oil Fill Tube Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .751
Oil Fill Tube Assembly Leak Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .753
Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756

Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .756
Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759
Oil Pump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .759
Oil Pump Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .761
Oil Pump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .762
Front Crank Gears..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . .764
Front Crank Gears Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .764
Front Crank Gears Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .765
Front Crank Gears Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .766
Rear Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767
Rear Timing Gears Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .767
Rear Timing Gears Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .769
Rear Timing Gears Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .770
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .774

Piston and Connecting Rod. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .776
Piston and Connecting Rod Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .776
Connecting Rod Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .778
Connecting Rod Bore Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .780
Piston and Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .781
Cylinder Sleeves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
Cylinder Sleeves Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .785
Cylinder Sleeves Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .786
Cylinder Sleeves Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .788
Piston. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .789
Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .789
Piston Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .791
Piston Ring Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .793
Piston Ring Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .794
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .795
Engine Run-in Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .797
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .800

Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .803
Crankshaft Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .803
Crankshaft Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .805
Crankshaft Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .806
Main Bearings Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .807
Crankcase Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .809
Crankshaft Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .810
Piston Cooling Jets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .815
Piston Cooling Jets Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .815
Piston Cooling Jets Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .816

Piston Cooling Jets Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .817
General Procedures
Cleaning Procedures
WARNING: To prevent personal injury or death, wear safety glasses with side shields. Limit
compressed air pressure to 30 psi (207 kPa).
NOTE: Do not use a caustic solution on turbochargers and related components.
NOTE: Do not use air tools or abrasive pads to clean aluminum parts.
1. Cover coolant, fluid, and air openings to ensure dirt does not enter air compressor and power steering pump.
3. Use a suitable solvent to remove dirt, grease, and deposits from removed parts.
4. Use only hot water to clean all hoses and tubes.
5. Clean all bolts (except head bolts) with a suitable solvent and dry thoroughly. New head bolts must be
installed.
6. Clean all bolt holes with steam and then dry with filtered compressed air.
7. Using a scraper and / or wire brush, clean coolant and oil seal mating surfaces on the crankcase, cylinder
head, water distribution housing, water pump assembly, coolant outlet manifold, thermostat housing, and
front belt- or gear-driven fan cover.
8. After removing foreign material from sealing surfaces, use a commercially available, non-caustic brake
cleaner to clean gasket surfaces of crankcase and flywheel housing.
Inspection Procedures
Engine Wiring and Sensor Inspections

1. Inspect wiring harness(es) for worn conduit, frayed insulation, and / or heat damage to wires. Repair or
replace as necessary.
2. Inspect sensors for corroded terminals; loose, bent, or broken pins; or broken sensor housing. Repair or
3. Inspect connector terminals for corrosion or damage; loose, bent, or broken pins; missing or damaged seals;
or broken connector housing. Repair or replace as necessary.
Engine Component Inspections

4. Inspect engine components for fluid leaks. Repair or replace as necessary.
5. Inspect engine components for cracks, pitting, and other notable damage. Repair or replace as necessary.
6. Inspect engine components for carbon build-up, plugging, and other notable damage. Repair or replace as
necessary.
7. Inspect engine components for signs of excessive heat, warping, kinking, and other notable damage. Repair
or replace as necessary.
8. Inspect internal engine components for spalling, galling, excessive wear, and other notable damage. Repair
Engine Electrical
Warnings and Cautions
WARNING: To prevent personal injury or death, remove ground cable from negative terminal of
main battery before disconnecting or connecting electrical components. Always connect ground cable
last.
CAUTION: To prevent engine damage, do not tug on wiring harnesses; if resistance is felt, find the problem and
free connectors or clips.
Disconnect ground cable (–) from the negative terminal of the battery.
Crankshaft Position (CKP)Sensor

Crankshaft Position (CKP)Sensor Removal
Figure 49 CKP Sensor

1. M6 x 16 bolt 3. CKP sensor harness connector 5. O-ring
2. Locking tab 4. Flywheel housing 6. CKP sensor
See CKP Sensor (Figure 49) to perform steps 1 through 4.

1. Pull out locking tab (2) on CKP sensor harness connector (3).
2. Press release lever and disconnect harness connector from CKP sensor (6) installed in top left of flywheel
housing (4).
3. Remove M6 x 16 bolt (1) from CKP sensor.
4. Remove CKP sensor and discard O-ring (5).
Crankshaft Position (CKP) Sensor Installation
Figure 50 CKP Sensor

1. M6 x 16 bolt 3. CKP sensor harness connector 5. O-ring
2. Locking tab 4. Flywheel housing 6. CKP sensor
See CKP Sensor (Figure 50) to perform steps 1 through 7.

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

Camshaft Position (CMP) Sensor Removal
Figure 51 CMP Sensor

1. O-ring
2. Cylinder head
3. CMP sensor
4. CMP sensor harness connector
5. Locking tab
6. M6 x 12 bolt
See CMP Sensor (Figure 51) to perform steps 1 through 4.

1. Pull out locking tab (5) on CMP sensor harness connector (4).
2. Press release lever and disconnect harness connector from CMP sensor (3) installed in rear left of cylinder
head (2).
3. Remove M6 x 12 bolt (6) from CMP sensor.
4. Remove CMP sensor and discard O-ring (1).
Camshaft Position (CMP) Sensor Installation
Figure 52 CMP Sensor

1. O-ring 3. CMP sensor 5. Locking tab
2. Cylinder head 4. CMP sensor harness connector 6. M6 x 12 bolt
See CMP Sensor (Figure 52) to perform steps 1 through 7.

1. Clean CMP sensor bore with a shop towel.
2. Lubricate new O-ring (1) with oil-based grease and install on CMP sensor (3).
CAUTION: To prevent sensor damage, do not use chemical cleaners to clean CMP sensor.
3. Clean debris build-up on CMP sensor with a shop towel.
4. Insert CMP sensor in port at left rear of cylinder head (2).
5. Install M6 x 12 bolt (6) to attach CMP sensor to cylinder head. Tighten bolt to 71 lb·in (8 N·m).
6. Connect CMP sensor harness connector (4) to CMP sensor terminal by pushing in on connector until a click
is heard.
7. Push in locking tab (5) to lock sensor connector in place.
Engine Coolant Temperature 1 (ECT1) Sensor

Engine Coolant Temperature 1 (ECT1) Sensor Removal
Figure 53 ECT1 Sensor
1. Turn ECT1 sensor harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from ECT1 sensor installed in underside of Exhaust Gas Recirculation (EGR)
coolant manifold at rear of engine.
3. Remove ECT1 sensor and discard seal ring.
Engine Coolant Temperature 1 (ECT1) Sensor Installation
1. Install ECT1 sensor with new 16.7 x 24 seal ring in EGR coolant manifold at rear of engine. Tighten sensor
to special torque (page 1239).
NOTE: It may be necessary to rotate the harness connector to ensure the alignment tabs engage properly.
2. Connect harness connector to ECT1 sensor.
3. Turn sensor harness connector locking ring 90° clockwise.
Engine Coolant Temperature 2 (ECT2) Sensor

Engine Coolant Temperature 2 (ECT2) Sensor Removal
Figure 55 ECT2 Sensor Connector
1. Turn ECT2 sensor harness connector locking ring 90 degrees counterclockwise.

2. Disconnect harness connector from ECT2 sensor installed in EGR module low-temperature housing on
upper right side of engine.
3. Remove ECT2 sensor and discard seal ring.
Engine Coolant Temperature 2 (ECT2) Sensor Installation
1. Install ECT2 sensor and new 16.7 x 24 seal ring in EGR module low-temperature housing. Tighten sensor
2. Connect harness to ECT2 sensor.
3. Turn sensor connector locking ring 90° clockwise.
Exhaust Gas Recirculation Gas Temperature (EGRGT)

Exhaust Gas Recirculation Gas Temperature (EGRGT) Removal
Figure 57 Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor Engine Harness Connector
1. Exhaust Gas Recirculation Gas 2. EGRGT sensor engine harness
Temperature (EGRGT) sensor connector
See Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor Engine Harness Connector (Figure 57) to
perform step 1.
1. Remove EGRGT sensor engine harness connector (2) from EGRGT sensor (1).
Figure 58 EGRGT Sensor

1. EGR outlet manifold 2. EGRGT sensor
See EGRGT Sensor (Figure 58) to perform step 2.

2. Loosen and remove EGRGT sensor (2) from EGR outlet manifold (1).
Exhaust Gas Recirculation Gas Temperature (EGRGT) Installation

None
Torque Specifications
EGRGT sensor 10 lb·ft (14 N·m)
Figure 59 Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor

1. EGR outlet manifold 2. EGRGT sensor
See Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor (Figure 59) to perform step 1.
1. Install EGRGT sensor (2) into EGR outlet manifold (1). Tighten EGRGT sensor. See Torque Specifications
(page 106).
Figure 60 Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor Engine Harness Connector
1. EGRGT sensor
2. EGRGT sensor engine harness
connector
See Exhaust Gas Recirculation Gas Temperature (EGRGT) Sensor Engine Harness Connector (Figure 60) to
perform step 2.
2. Install EGRGT sensor engine harness connector (2) onto EGRGT sensor (1).
Engine Oil Temperature (EOT) Sensor

Engine Oil Temperature (EOT) Sensor Removal
Figure 61 EOT Sensor

1. EOT sensor
2. Oil module flange
1. Turn EOT harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from EOT sensor and remove sensor from oil module flange. Discard seal
ring.
Engine Oil Temperature (EOT) Sensor Installation
Figure 62 EOT Sensor

1. EOT sensor
1. Install EOT sensor and new 16.7 x 24 seal ring in oil module flange. Tighten sensor to special torque (page
1239).
2. Connect harness to EOT sensor.
Engine Oil Pressure (EOP) Sensor

Engine Oil Pressure (EOP) Sensor Removal
Figure 63 EOP Sensor

1. Oil module assembly
2. EOP sensor
1. Turn EOP harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from EOP sensor and remove sensor from oil module assembly. Discard
seal ring.
Engine Oil Pressure (EOP) Sensor Installation
Figure 64 EOP Sensor

2. EOP sensor
1. Install EOP sensor and new 18.7 x 26 seal ring in oil module assembly. Tighten sensor to special torque
(page 1239).
2. Connect harness to EOP sensor.
Engine Oil Level (EOL) Sensor

Engine Oil Level (EOL) Sensor Removal
Figure 65 Engine Oil Level (EOL) Sensor

1. EOL sensor engine harness 2. EOL sensor
connector 3. Crankcase
See Engine Oil Level (EOL) Sensor (Figure 65) to perform steps 1 and 2.
1. Disconnect EOL sensor engine harness connector (1) from EOL sensor (2).
2. Loosen and remove EOL sensor (2) from crankcase (3). Discard O-ring seal.
Engine Oil Level (EOL) Sensor Installation

None
Engine Oil Level (EOL) sensor 33 lb·ft (45 N·m)
Figure 66 Engine Oil Level (EOL) Sensor

1. EOL sensor engine harness 2. EOL sensor
connector 3. Crankcase
See Engine Oil Level (EOL) Sensor (Figure 66) to perform steps 1 and 2.
1. Install new O-ring seal onto EOL sensor (2).
2. Install EOL sensor (2) into crankcase (3) and torque to 33 lb·ft (45 N·m).
3. Connect EOL sensor engine harness connector (1) to EOL sensor (2).
Crankcase Oil Separator Speed (CCOSS) Sensor

Crankcase Oil Separator Speed (CCOSS) Sensor Removal
Figure 67 CCOSS Sensor

1. CCOSS sensor
2. Crankcase Oil Separator (CCOS) (part of oil module assembly)
3. M6 x 14 bolt and nut
1. Press release tab to disconnect wiring harness connector from CCOSS sensor (1).
2. Remove M6 x 14 bolt and nut (3) and remove sensor from bracket on CCOS (2).
Crankcase Oil Separator Speed (CCOSS) Sensor Installation
Figure 68 CCOSS Sensor

1. CCOSS sensor
2. Crankcase Oil Separator (CCOS) (part of oil module assembly)
3. M6 x 14 bolt and nut
1. Place CCOSS sensor (1) in position on bracket and install M6 x 14 bolt and nut (3).
2. Tighten bolt to special torque (page 1239).
3. Connect harness to CCOSS sensor by pushing in on connector until a click is heard.
4. Push in yellow tab to lock connector in place.
Fuel Delivery Pressure (FDP) Sensor

Fuel Delivery Pressure (FDP) Sensor Removal
Figure 69 Fuel Delivery Pressure (FDP) Sensor

1. FDP sensor engine harness 2. FDP sensor 4. Fuel filter module
connector 3. Tie strap
See Fuel Delivery Pressure (FDP) Sensor (Figure 69) to perform steps 1 and 2.
1. Remove tie strap (3) and disconnect FDP sensor engine harness connector (1) from FDP sensor (2).
2. Loosen and remove FDP sensor (2) from fuel filter module (4). Discard FDP sensor O-ring seal.
Fuel Delivery Pressure (FDP) Sensor Installation

None
Torques
Fuel Delivery Pressure (FDP) sensor 33 lb·ft (45 N·m)
Figure 70 Fuel Delivery Pressure (FDP) Sensor

1. FDP sensor engine harness 2. FDP sensor 4. Fuel filter module
connector 3. Tie strap
See Fuel Delivery Pressure (FDP) Sensor (Figure 70) to perform step 1.
1. Install new O-ring seal onto FDP sensor (2).
2. Install FDP sensor (2) into fuel filter module (4). Torque FDP sensor to 33 lb·ft (45 N·m).
3. Connect FDP sensor engine harness connector (1) to FDP sensor (2) and secure with new tie strap (3).
Fuel Pressure Control Valve (FPCV)

Fuel Pressure Control Valve (FPCV) Removal
Figure 71 FPCV (on High-Pressure Fuel Pump)

1. FPCV 2. FPCV harness connector
See FPCV (on High-Pressure Fuel Pump) (Figure 71) to perform steps 1 through 3.
1. Pull out yellow locking tab on FPCV harness connector (2).
2. Press release tab and disconnect harness connector from FPCV (1) mounted at upper rear of high-pressure
fuel pump.
3. See High-pressure Fuel Pump (HPFP) and Drive Housing (page 410) for removal of high-pressure pump
with integral FPCV if the FPCV requires replacement.
Fuel Pressure Control Valve (FPCV) Installation

1. See High-pressure Fuel Pump (HPFP) and Drive Housing for installation of high-pressure fuel pump.
Figure 72 FPCV (on High-Pressure Fuel Pump)

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

3. Push in yellow tab to lock sensor connector.
Charger Air Cooler Outlet Temperature (CACOT) Sensor

Charger Air Cooler Outlet Temperature (CACOT) Sensor Removal
Figure 73 CACOT Sensor

1. CACOT sensor
2. Harness connector
3. Standoff tie strap
1. Press release tab to loosen tie strap and remove standoff bracket securing connector harness lead to
CACOT sensor.
2. Press release tab to disconnect harness from CACOT sensor.
3. Remove CACOT sensor from throttle valve housing. Discard O-ring.
Charger Air Cooler Outlet Temperature (CACOT) Sensor Installation
Figure 74 HS / IAT Sensor

1. M6 x 16 bolt (2) 2. Harness connector 3. HS / IAT sensor
See HS / IAT Sensor (Figure 74)to perform steps 1 through 4.

1. Insert new O-ring and place HS / IAT sensor (3) in position on air inlet duct.
2. Install two M6 x 16 bolts (1). Tighten bolts to 80 lb·in (9 N·m).
3. Connect harness to IAT terminal by pushing in on connector until a click is heard.
4. Push in yellow tab to lock sensor connector.
Intake Manifold Pressure (IMP) Sensor

Intake Manifold Pressure (IMP) Sensor Removal
Figure 75 IMP Sensor

1. IMP sensor
1. Press release tab to loosen tie strap and remove standoff bracket securing harness connector lead to IMP
sensor.
2. Press release tab to disconnect harness from IMP sensor.
3. Remove IMP sensor from Engine Throttle Valve (ETV) housing. Discard O-ring.
Intake Manifold Pressure (IMP) Sensor Installation
Figure 76 IMP Sensor

1. IMP sensor
1. Install new O-ring and install IMP sensor in Engine Throttle Valve (ETV) housing. Tighten sensor to special
torque (page 167).
2. Connect harness to IMP sensor terminal by pushing in on connector until a click is heard.
3. Engage release tab.
4. Attach tie strap to secure harness standoff bracket to IMP sensor.
Fuel Rail Pressure (FRP) Sensor

Fuel Rail Pressure (FRP) Sensor Removal
Figure 77 FRP Sensor (Typical)
1. Pull out yellow locking tab on FRP sensor harness connector.

2. Press release lever and disconnect harness connector from FRP sensor installed in front of fuel rail on left
side of engine.
3. Remove FRP sensor from fuel rail.
4. Install plastic protective cap from Disposable Air and Fuel Caps , to prevent dirt from entering fuel system.
Fuel Rail Pressure (FRP) Sensor Installation
Figure 78 FRP Sensor (Typical)
1. Apply a thin film of Lubricant F11V27 or equivalent to the threads and seal ring of the FRP sensor.
2. Remove plastic protective cap from the FRP sensor port.
3. Install and hand tighten FRP sensor. Tighten FRP sensor to special torque (page 167).
4. Connect engine harness connector to FRP sensor terminal by pushing in on connector until a click is heard.
5. Push in yellow tab to lock engine harness connector.
Intake Manifold Temperature (IMT) Sensor

Intake Manifold Temperature (IMT) Sensor Removal
Figure 79 IMT Sensor
1. Turn IMT sensor harness connector locking ring 90° counterclockwise.

2. Disconnect harness connector from IMT sensor.
3. Remove IMT sensor from cylinder head and discard seal ring.
Intake Manifold Temperature (IMT) Sensor Installation
Figure 80 IMT Sensor
1. Install new 16.7 x 24 seal ring and IMT sensor. Tighten sensor to special torque (page 167).
2. Connect harness connector to IMT sensor.
3. Turn IMT sensor harness connector locking ring 90° clockwise.
Oxygen Sensor (O2S)

Oxygen Sensor (O2S) Removal
NOTE: The Oxygen sensor should only be replaced after a coolant and/or oil loss into the exhaust system has
been verified based on the Engine Symptoms Diagnostics in the Engine Diagnostic Manual.
Figure 81 O2S (Valve Actuator Removed for Clarity)

1. Clip (2) 3. Exhaust back pressure valve 4. NOx IN Sensor (with harness
2. O2S (with harness lead) housing lead)
See O2S (Valve Actuator Removed for Clarity) (Figure 81) to perform steps 1 through 3.
1. Press release lever and disconnect O2S harness lead (2) from engine electrical harness at left rear of engine.
2. Disconnect clips (1) securing O2S harness lead at right rear of engine to coolant tube and to valve actuator
bracket.
3. Only if required, remove O2S from exhaust back pressure valve housing (2).
Oxygen Sensor (O2S) Installation
Figure 82 O2S (Valve Actuator Removed for Clarity)

1. Clip (2) 3. Exhaust back pressure valve 4. NOx IN Sensor (with harness
See O2S (Valve Actuator Removed for Clarity) (Figure 82) to perform steps 1 through 4.
NOTE: The O2S should be reused unless there is damage to the sealing ring and evidence of an exhaust leak.
1. If removed, install O2S (2). Tighten O2S to 37 lb·ft (50 N·m).
2. Attach clips (1) to secure harness lead to coolant tube and valve actuator bracket and at left rear of engine.
3. Connect harness to O2S terminal end by pushing in on connector until a click is heard.
4. Engage release lever.
NOTE: Any time the O2S is replaced, an Oxygen Sensor Calibration Procedure must be done. See N13 Engine
Diagnostic Manual for details.
Nitrogen Oxides (NOx) IN Sensor Module

Nitrogen Oxides (NOx) IN Sensor Module Removal
Figure 83 NOx IN Sensor Module Connector

1. NOx IN sensor module 3. NOx IN sensor harness 5. NOx IN sensor module
2. Tiedown strap 4. NOx IN sensor module nut (2) connector
See NOx IN Sensor Module Connector (Figure 83) to perform steps 1 through 3.
1. Disconnect NOx IN sensor module connector (5) from NOx IN sensor module (1).
2. Cut tiedown straps (2).
3. Remove two NOx IN sensor module nuts (4) from NOx IN sensor module.
Nitrogen Oxides (NOx) IN Sensor Module Installation
Figure 84 NOx IN Sensor Module Connector

1. NOx IN sensor module 4. NOx IN sensor module nut 6. NOx IN sensor module nut
2. Tiedown strap 5. NOx IN sensor module
3. NOx IN sensor harness connector
See NOx IN Sensor Module Connector (Figure 84) to perform steps 1 through 4.
1. Secure NOx In sensor module (1) on vehicle with two NOx In sensor module nuts (4, 6).
2. Tighten NOx In sensor module nuts to 115 lb‐in (13 N∙m).
3. Secure NOx In sensor harness (3) with tiedown straps (2) as required.
4. Connect NOx In sensor module connector (5) to NOx IN sensor module (1).
Nitrogen Oxides (NOx) In Sensor

Nitrogen Oxides (NOx) In Sensor Removal
Figure 85 NOx In Sensor (valve actuator removed for clarity)

1. Clip (2) 3. Exhaust back pressure valve 4. NOx IN sensor (with harness
See NOx In Sensor (valve actuator removed for clarity) (Figure 85)to perform steps 1 through 3.
1. Press release lever and disconnect NOx IN sensor (4) harness lead from engine electrical harness at left
rear of engine.
2. Disconnect clips (1) securing NOx IN sensor harness lead at right rear of engine to coolant tube and to valve
actuator bracket.
3. Only if required, remove NOx IN sensor from exhaust back pressure valve housing (3).
Nitrogen Oxides (NOx) In Sensor Installation
Figure 86 NOx In Sensor (valve actuator removed for clarity)

1. Clip (2) 3. Exhaust back pressure valve 4. NOx IN sensor (with harness
See NOx In Sensor (Figure 86) to perform steps 1 and 2.

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

Engine Throttle Valve (ETV) Removal
CAUTION: To prevent engine damage, make sure gasket debris and dirt do not enter cylinder head opening.
1. Remove ETV inlet duct from ETV.
Figure 87 ETV Assembly

1. Intake Air Heater (IAH) igniter 5. Charge Air Cooler Outlet 8. ETV inlet O-ring
supply line Temperature (CACOT) sensor 9. Intake Air Heater (IAH) igniter
2. ETV 6. CACOT sensor engine harness 10. IAH igniter supply line tube nut
3. Bolts (3) connector
4. Air intake throttle duct 7. ETV engine harness connector
See ETV Assembly (Figure 87) to perform steps 1 through 5.

2. Disconnect engine harness connectors (5, 6, and 7) from CACOT sensor (5) and ETV (2).
3. Remove tie straps as necessary.
4. Loosen IAH igniter fuel supply line tube nut (10) and remove IAH igniter supply line (1) from IAH Igniter (9).
5. Remove and ETV inlet O-ring (8) from ETV (2) and discard.
6. Remove 3 bolts (3) securing ETV (2) to air intake throttle duct (4) and remove ETV from engine.
Engine Throttle Valve (ETV) Installation

Exhaust Gas Recirculation (EGR) Valve

Exhaust Gas Recirculation (EGR) Valve Removal
1. Using Coolant Management Tool KL5007NAV, drain coolant.
Figure 89 EGR Heat Shield

1. EGR heat shield 3. EGR valve heat shield bolts (5)
2. EGR valve 4. EGR cooler
See EGR Heat Shield (Figure 89) to perform step 2.

2. Remove 5 EGR valve heat shield bolts (3) from EGR valve (2) and EGR cooler (4). Remove EGR valve
heat shield (1).
Figure 90 EGR Valve Coolant Lines

1. EGR valve 3. EGR valve coolant supply line 5. EGR valve coolant return line
2. EGR valve coolant supply line 4. EGR valve coolant return line tube nut
tube nut
See EGR Valve Coolant Lines (Figure 90) to perform steps 3 and 4.
3. Loosen EGR valve coolant supply line tube nut (2) and remove EGR valve coolant supply line (3) from EGR
valve (1).
4. Loosen EGR valve coolant return line tube nut (5) and remove EGR valve coolant return line (4) from EGR
valve (1).
Figure 91 EGR Valve Coolant Return Line

1. EGR cooler 3. EGR valve coolant supply line
2. EGR valve coolant return line stud bolts (2)
See EGR Valve Coolant Return Line (Figure 91) to perform step 5.
5. Remove 2 EGR valve coolant return line stud bolts (3) that secure EGR valve coolant return line (2) to EGR
cooler (1).
Figure 92 EGR Valve Jumper Harness Connector

1. EGR valve 2. EGR valve jumper harness 3. EGR valve coolant return line
connector 4. EGR valve coolant supply line
See EGR Valve Jumper Harness Connector (Figure 92) to perform steps 6 and 7.
6. Remove EGR valve jumper harness connector (2) from EGR valve (1). Cut tie straps as necessary.
7. Move both EGR valve coolant lines (3 and 4) out of way. Do not bend or kink EGR valve coolant lines.
Figure 93 EGR Valve Bellows

1. Rear exhaust manifold 4. EGR valve to rear exhaust 6. EGR valve to EGR cooler
2. EGR valve bellows V-band manifold bellows tube bellows tube
clamps (4) 5. EGR valve 7. EGR cooler
3. EGR valve bellows gaskets (4)
See EGR Valve Bellows (Figure 93) to perform steps 8 through 11.
8. Remove 2 EGR valve bellows V-band clamps (2) from EGR valve to EGR cooler bellows tube (6). Discard
both EGR valve bellows V-band clamps.
9. Remove EGR valve to EGR cooler bellows tube (6) from EGR valve (5) and EGR cooler (7). Discard 2 EGR
valve bellows gaskets (3).
10. Remove 2 EGR valve bellows V-band clamps (2) from EGR valve to rear exhaust manifold bellows tube (4).
Discard EGR valve bellows V-band clamps.
11. Remove EGR valve to rear exhaust manifold bellows tube (4) from EGR valve (5) and rear exhaust manifold
(1). Discard 2 EGR valve bellows gaskets (3).
Figure 94 EGR Valve

1. EGR valve 2. EGR valve bolts (4) 3. EGR valve mounting bracket
See EGR Valve (Figure 94) to perform step 12.

12. Remove 4 EGR valve bolts (2) that secure EGR valve (1) to EGR valve mounting bracket (3). Remove EGR
valve.
Exhaust Gas Recirculation (EGR) Valve Installation

Turbocharger 2 Compressor Inlet (TC2CIS) Sensor

Turbocharger 2 Compressor Inlet (TC2CIS) Sensor Removal
Figure 96 TC2CIS
1. M6 x 16 bolt (2)
2. TC2CIS
1. Pull out yellow lock tab on TC2CIS harness connector.

2. Press release tab and disconnect harness lead from TC2CIS.
3. Remove two M6 x 16 bolts and sensor from high-pressure turbocharger air supply duct. Discard O-ring seal.
Turbocharger 2 Compressor Inlet (TC2CIS) Sensor Installation
Figure 97 TC2CIS
1. M6 x 16 bolt (2)
2. TC2CIS
1. Place TC2CIS sensor in position on air supply duct and install two M6 x 16 bolts. Tighten bolts to special
torque (page 1239).
2. Connect harness to TC2CIS terminal by pushing in on connector until a click is heard.
3. Push in yellow tab to lock connector.
Wiring Harness ECM Connections

Wiring Harness ECM Connections Removal
last.
1. If not done, disconnect ground (–) cable from the negative terminal of the battery.
2. Note location of wire ties for reinstallation. Cut wire ties securing engine injector, engine sensor and chassis
harness connector lock levers at ECM.
Figure 98 ECM harness connectors

1. ECM
2. Engine injector harness connector (to ECM 16-pin E2 terminal)
3. ECM 58-pin C2 chassis terminal
5. Engine sensor harness connector (to ECM 96-pin E1 terminal)
3. If not already done, disconnect chassis wiring harness connectors from ECM 58-pin C1 and C2 terminals.
4. Remove connector clip and lift lock lever to release engine injector harness connector. Pull straight out to
remove connector from ECM terminal E2.
5. Lift lock lever to release engine sensor harness connector. Pull straight out to remove connector from ECM
terminal E1.
Wiring Harness ECM Connections Installation
Figure 99 ECM harness connectors

1. ECM
2. Engine injector harness connector (to ECM 16-pin E2 terminal)
5. Engine sensor harness connector (to ECM 96-pin E1 terminal)
1. Check that ECM E1 and E2 terminal pins are straight and undamaged.
2. Align engine sensor harness connector with ECM E1 terminal and push connector straight in to engage pins.
Push down on lock lever to draw in and secure connector.
Figure 100 Injector harness connector

1. Lock lever
2. Connector clip
3. Align engine injector harness connector with ECM E2 terminal and push connector straight in to engage
pins. Push down on lock lever to draw in and secure connector. Install connector clip.
4. Connect chassis harness connectors to ECM 58–pin C1 and C2 terminals. Lock connectors in place.
Engine Injector (Wiring) Harness

Engine Injector (Wiring) Harness Removal
Figure 101 Injector harness attachment points at ECM

1. Injector harness
2. M6 x 30 bolt (2)
1. Remove two M6 x 30 bolts and remove injector harness retainer clips from ECM.
2. Remove upper valve cover from valve cover base. See Upper Valve Cover and Base(page 663) .
Figure 102 Injector harness attachment points at cylinder head

1. Injector harness nut (12)
2. Tie strap (7)
3. M6 x 16 bolt (4)
3. Loosen 12 harness nuts (two at each injector) and disconnect harness leads from injector terminals.
4. Cut tie straps at six locations securing injector harness to valve cover base.
5. Cut tie strap securing harness at center of cylinder head.
6. Remove four M6 x 16 bolts from injector harness mounting flange.
7. Carefully pull harness through valve cover base opening and remove harness from engine.
Engine Injector (Wiring) Harness Installation
Figure 103 Engine injector (wiring) harness O-ring location

1. Engine injector (wiring) harness
2. Harness mounting flange
3. 32.92 x 3.53 O-ring
4. Harness flange collar
1. Check that 32.92 x 3.53 O-ring is in position on collar of harness mounting flange and in good condition.
Replace as necessary.
CAUTION: To prevent engine damage, verify injector harness wires are not pinched or rubbing against the
engine brake housing or rocker arm assembly.
2. Carefully route injector harness through valve cover base opening and along valve cover base to injectors.
Figure 104 Injector harness attachment points at cylinder head

1. Tie strap (7) 2. Injector harness nut (12) 3. M6 x 16 bolt (4)
3. Install four M6 x 16 bolts to attach injector harness mounting flange to valve cover base. Tighten bolts to
standard torque (page 1201).
4. Install tie strap to secure injector at center of cylinder head.
5. Install tie straps at six locations to secure injector harness to valve cover base.
6. Install 12 harness nuts to connect harness leads to injector terminals.
Figure 105 Injector harness attachment points at ECM

1. Injector harness
2. M6 x 30 bolt (2)
7. Install two M6 x 30 bolts to attach engine injector harness retainer clips to ECM. Tighten bolts to special
torque (page 1239).
Engine Sensor (Wiring) Harness

Engine Sensor (Wiring) Harness Removal
1. Remove all sensor and component engine harness connectors from their respective sensors or components.
Figure 106 Engine Wiring Harness (Front of Cylinder Head)

1. Bolt 2. Engine wiring harness 3. Cylinder head
See Wiring Harness (Front of Cylinder Head) (Figure 106) to perform step 1.
2. Remove bolt securing engine wiring harness to left front of cylinder head.
Figure 107 Engine Wiring Harness (Rear of Cylinder Head)

1. Bolt 2. Cylinder head 3. Engine wiring harness
See Engine Wiring Harness (Rear of Cylinder Head) (Figure 107) to perform step 2.
3. Remove bolt securing engine wiring harness to rear of cylinder head.
Figure 108 Engine Wiring Harness (Engine Block)

1. Bolts (2) 2. Engine wiring harness 3. Crankcase
See Engine Wiring Harness (Engine Block) (Figure 108) to perform step 3.
4. Remove 2 bolts securing engine wiring harness to crankcase.
5. Remove tie straps as necessary and completely remove engine wiring harness from engine.
Engine Sensor (Wiring) Harness Installation
Figure 109 96-pin E1 Engine Wiring Harness (Engine Block)

1. Bolts (2) 2. 96-pin E1 engine harness 3. Crankcase
1. Install 96-pin E1 engine harness (2) to crankcase (3) and secure with 2 bolts (1). Torque bolts to 35 N·m
(26 lb·ft).
Figure 110 96-pin E1 Engine Harness (Rear of Cylinder Head)

1. Bolt 2. Cylinder head 3. 96-pin E1 engine harness
See 96-pin E1 Engine Harness (Rear of Cylinder Head) (Figure 110) to perform step 2.
2. Secure 96-pin E1 engine harness (3) to rear of cylinder head (2) with bolt (1). Torque bolt to 35 N·m (26
lb·ft).
Figure 111 96-pin E1 Engine Harness (Front of Cylinder Head)

1. Bolt 2. 96-pin E1 engine harness 3. Cylinder head
See 96-pin E1 Engine Harness (Front of Cylinder Head) (Figure 111) to perform step 3.
3. Secure 96-pin E1 engine harness to left front of cylinder head with bolt. Torque bolt to 31 N·m (23 lb·ft).
4. Connect all sensor and component engine harness connectors to their respective sensors or components.
Engine Control Module (ECM) and Support

Engine Control Module (ECM) and Mounting Bracket Removal
Overview
This section provides instructions for the removal of the Engine Control Module (ECM).
Component Locator
Figure 112 Component Locator

1. Intake Air Heater Fuel Solenoid 6. High-pressure rail to injector 10. Engine wiring harness
(IAHFS) tube assembly (6) 11. 96-pin E1 engine harness
2. Engine Control Module (ECM) 7. Harness 21-way connector connector
3. Intake Air Heater (IAH) relay bracket 12. 16-pin E2 engine harness
4. Air Control Valve (ACV) supply 8. HPFP to rail supply tube damper connector
line assembly
5. Upper valve cover 9. Engine injector harness
None.
Equipment Condition
The following steps must be completed before removing ECM and mounting bracket:
1. Disconnect batteries.
Removal Procedure
Figure 113 Engine Control Module (ECM)

1. Intake Air Heater Fuel Solenoid 6. IAH relay connector 11. Engine wiring harness
(IAHFS) 7. Air Control Valve (ACV) supply 12. 96-pin E1 engine harness
2. IAHFS bolts (2) line connector
3. Engine Control Module (ECM) 8. ECM mounting bolt (2) 13. 16-pin E2 engine injector
4. ECM mounting bolt (6) 9. Chassis connector sockets harness connector
5. ECM mounting bracket 10. Engine injector harness
See Engine Control Module (ECM) (Figure 116) to perform steps 2 through 8.
2. Disconnect harness at chassis harness connectors (9) and IAH relay connector (6).
3. Remove two ECM mounting bolts (8) securing engine injector harness (10) to ECM mounting bracket (5).
4. Disconnect 16-pin E2 engine injector harness connector (13) from ECM (3).
5. Disconnect 96-pin E1 engine harness connector (12) from ECM.
6. Remove two IAHFS bolts (2) securing IAHFS (1) to ECM mounting bracket (5).
7. Remove remaining six ECM mounting bolts (4) securing ECM (3) to ECM mounting bracket (5) and remove
ECM.
8. Remove any clips or tie straps securing engine wiring harness (11) to ECM mounting bracket (5).
Figure 114 ECM Mounting Bracket

1. ECM mounting bracket bolt (3) 4. Cylinder head 6. Harness 21-way connector
2. Rubber insulator (6) 5. Air Control Valve (ACV) supply
3. ECM mounting bracket line
See ECM Mounting Bracket (Figure 114) to perform step 9.

Remove ECM Mounting Bracket if removing and replacing fuel injectors for cylinders 1, 2, 3.
9. Remove three ECM mounting bracket bolts (1) and six rubber insulators (2) securing ECM mounting bracket
(3) to cylinder head (4) and remove ECM mounting bracket.
Follow-on Maintenance
None.
Engine Control Module (ECM) and Mounting Bracket Installation

None.
ECM Bracket Mounting Bolts with Rubber Insulators. 23 lb-ft 31 N·m)
96-Pin E1 Engine Harness to ECM Mounting Bracket Bolt 89 lb-in (10 N·m)
ECM Mounting Bolts 89 lb-in (10 N·m)
IAHFS Bolts 53 lb-in (6 N·m)
Installation Procedure

1. ECM mounting bracket bolt (3) 4. Cylinder head 6. Harness 21-way connector
2. Rubber insulator (6) 5. Air Control Valve (ACV) supply
3. ECM mounting bracket line

1. Install ECM mounting bracket (3) to cylinder head (4) with three ECM mounting bracket bolts (1) and six
rubber insulators (2). Torque ECM mounting bracket bolts to 115 lb-in (13 N·m).

1. Intake Air Heater Fuel Solenoid 6. IAH relay connector 11. Engine wiring harness
(IAHFS) 7. Air Control Valve (ACV) supply 12. 96-pin E1 engine harness
2. IAHFS bolts (2) line connector
3. Engine Control Module (ECM) 8. ECM mounting bolt (2) 13. 16-pin E2 engine injector
4. ECM mounting bolt (6) 9. Chassis connector sockets harness connector
5. ECM mounting bracket 10. Engine injector harness
See Engine Control Module (ECM) to perform steps 2 through 7.

2. Install ECM (3) to ECM mounting bracket (5) and secure with six ECM mounting bolts (4).
3. Install IAHFS (1) to ECM mounting bracket (5) secure with two IAHFS bolts (2).
4. Connect 96-pin E1 engine harness connector (12) to ECM (3).
5. Connect 16-pin E2 engine injector harness connector (13) to ECM.
6. Securing engine injector harness (10) to ECM mounting bracket (5) with two remaining ECM mounting bolts
(8). Torque ECM mounting bolts to 89 lb-in (10 N·m).
7. Connect harness at chassis harness connectors (9) and IAH relay connector (6).
8. Connect batteries.
Cleaning and Inspection

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

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

1. Inspect rubber seal on harness connector and in ECM pin recesses.
2. Check for bent pins in ECM connections.
Special Torques and Special Tools
Special Torques
Camshaft Position (CMP) sensor, M6 x 12 bolt 8 N·m (71 lb·in)
Charger Air Cooler Outlet Temperature (CACOT)
11 N·m (97 lb·in)
sensor
Crankcase Oil Separator Speed (CCOSS) sensor,
10 N·m (89 lb·in)
M6 x 14 bolt
Crankshaft Position (CKP) sensor, M6 x 16 bolt 8 N·m (71 lb·in)
10 N·m (89 lb·in)
Engine Control Module (ECM), M6 x 30 bolt
See procedure for tightening sequence
Engine Control Module (ECM) support, M8 x 40 bolt 13 N·m (115 lb·in)
Engine Coolant Temperature 1 (ECT1) sensor 45 N·m (33 lb·ft)
Engine injector harness retainer clip, M6 x 30 bolt 10 N·m (89 lb·in)
Engine Oil Level (EOL) sensor 45 N·m (33 lb·ft)
Engine Oil Pressure (EOP) sensor 45 N·m (33 lb·ft)
Engine Oil Temperature (EOT) sensor 45 N·m (33 lb·ft)
Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT)
14 N·m (10 lb·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lb·ft)
Humidity / Inlet Air Temperature (IAT) sensor, M6
9 N·m (80 lb·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lb·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lb·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lb·in)
Oxygen Sensor (O2S) 50 N·m (37 lb·ft)
NOx IN Sensor 50 N∙m (37 lb∙ft)
Fuel Rail Pressure (FRP) sensor 70 N·m (52 lb·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lb·in)
M6 x 16 bolt
Special Tools
Inlet Air Heater System
components.
Relay Assembly
Relay Assembly Removal
Figure 117 Relay Assembly

1. Engine Control Module (ECM) support bracket
2. M6 x 20 bolt (2)
3. Relay assembly
1. Disconnect wiring harness connector from relay assembly (Figure 117) (Item 3), if not already done.
2. Remove two M6 x 20 bolts (Figure 117) (Item 2) and remove relay assembly from ECM support bracket
(Figure 117) (Item 1).
Relay Assembly Installation
Figure 118 Relay Assembly

1. ECM support
2. Relay assembly M6 x 20 bolt (2)
3. Relay assembly
1. Position relay assembly (Figure 118) (Item 3) on mounting pad at rear of ECM support (Figure 118) (Item 1).
2. Install two relay assembly M6 x 20 bolts (Figure 118) (Item 2).
3. Tighten bolts to 89 lb·in (10 N·m).
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose Removal
Figure 119 IAHFI and Fuel Supply Inlet Air Heater Hose
1. Inlet Air Heater Fuel Igniter (IAHFI)
2. Fuel supply inlet air heater hose fitting nut
3. Fuel supply inlet air heater hose
4. M8 x 1 banjo bolt
5. Washer (seal ring) (2)
6. Solenoid valve
WARNING: To prevent personal injury or death, store diesel fuel properly in an approved container
designed for and clearly marked diesel fuel.
WARNING: To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
1. Place suitable container clearly marked DIESEL FUEL under fuel supply inlet air heater hose (Figure 119)
(Item 3).
2. Loosen hose fitting nut (Figure 119) (Item 2) that attaches to IAHFI (Figure 119) (Item 1) fitting. Drain fuel
into container.
3. Loosen and remove M8 x 1 banjo bolt (Figure 119) (Item 4) securing fuel supply inlet air heater hose to
solenoid valve (Figure 119) (Item 6).
4. Remove fuel supply inlet air heater hose and discard two washers (seal rings) (Figure 119) (Item 5).
Figure 120 Inlet Air Heater Fuel Igniter (IAHFI)

1. Wiring harness
2. Inlet Air Heater Fuel Igniter (IAHFI)
3. Fuel line port
4. IAHFI locking nut
5. Fuel supply inlet air heater hose
6. Air intake throttle duct
7. IAHFI wiring harness nut
5. If not already done, remove IAHFI wiring harness nut (Figure 120) (Item 7) and remove wiring harness
(Figure 120) (Item 1) from the IAHFI (Figure 120) (Item 2).
6. Loosen IAHFI locking nut (Figure 120) (Item 4).
7. Remove IAHFI from air intake throttle duct (Figure 120) (Item 6) by rotating counterclockwise.
Inlet Air Heater Fuel Igniter (IAHFI) and Fuel Supply Inlet Air Heater Hose Installation
Figure 121 Fuel Supply Solenoid Hose (at Fuel Filter Housing)
1. Fuel filter housing
2. Seal 12.7 x 18 ring (2)
3. Banjo 8 bolt (M12 x 1.5)
4. Fuel supply solenoid hose (tube)
1. Install two new seal 12.7 x 18 rings (Figure 127) (Item 2) and banjo 8 bolt (Figure 127) (Item 3) into fuel filter
housing finger tight.
2. Install fuel supply solenoid hose (Figure 126) (Item 3) to clips on electrical harness (Figure 126) (Item 1),
fuel filter bracket (Figure 126) (Item 2), and fuel drain hose (Figure 126) (Item 4).
3. Tighten banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts to 11 lb·ft (15 N·m).
Fuel Solenoid Valve and Fuel Supply Solenoid Hose

Fuel Solenoid Valve and Fuel Supply Solenoid Hose Removal
2. Seal 12.7 x 18 ring (2)
4. Fuel supply solenoid hose
designed for and clearly marked diesel fuel.
WARNING: To prevent personal injury or death, do not smoke and keep fuel away from flames and
sparks.
1. Place suitable container clearly marked DIESEL FUEL under lower end of fuel supply solenoid hose (Figure
122) (Item 4).
2. Remove banjo 8 bolt (M12 x 1.5) (Figure 122) (Item 3) from fuel filter housing (Figure 122) (Item 1) and drain
fuel into container.
3. Remove and discard two seal 12.7 x 18 rings (Figure 122) (Item 2).
Figure 123 Fuel Supply Solenoid Hose (at Solenoid Valve)

1. Solenoid valve
2. Seal 10.7 x 16 ring (2)
3. M6 x 20 bolt (2)
4. ECM support bracket
5. Banjo 6 bolt (M10 x 1)
4. Remove banjo 6 bolt (M10 x 1) (Figure 123) (Item 5) from solenoid valve (Figure 123) (Item 1).
5. Remove and discard two seal 10.7 x 16 rings (Figure 123) (Item 2).
6. Remove two M6 x 20 bolts (Figure 123) (Item 3) securing the solenoid valve to the ECM support bracket
(Figure 123) (Item 4). Remove valve.
Figure 124 Fuel Supply Solenoid Hose Clips

1. Clips on electrical harness (2) 3. Fuel supply solenoid hose (tube)
2. Clip on fuel filter bracket 4. Clip on fuel drain hose
7. Remove fuel supply solenoid hose from clips on electrical harness (Figure 124) (Item 1), fuel filter bracket
(Figure 124) (Item 2), and fuel drain hose (Figure 124) (Item 4) and remove hose from engine.
Fuel Solenoid Valve and Fuel Supply Solenoid Hose Installation
Figure 125 Fuel Supply Solenoid Hose (at Solenoid Valve)

1. Solenoid valve
2. Seal 10.7 x 16 ring (2)
3. M6 x 20 bolt (2)
4. ECM support bracket
5. Banjo 6 bolt (M10 x 1)
1. Install solenoid valve (Figure 125) (Item 1) to ECM support bracket (Figure 125) (Item 4) using two M6 x 20
bolts (Figure 125) (Item 3). Finger-tighten bolts.
2. Tighten two M6 x 20 bolts to 53 lb·in (6 N·m).
Figure 126 Fuel supply solenoid hose

1. Clips on electrical harness (2)
2. Clip on fuel filter bracket
4. Clip on fuel drain hose
3. Position fuel supply solenoid hose (Figure 126) (Item 3) on engine.

4. Install two new seal 10.7 x 16 rings (Figure 125) (Item 2), and install banjo 6 bolt (M10 x 1) (Figure 125)
(Item 5) into solenoid valve finger tight.
2. Seal 12.7 x 18 ring (2)
5. Install two new seal 12.7 x 18 rings (Figure 127) (Item 2) and banjo 8 bolt (Figure 127) (Item 3) into fuel filter
housing finger tight.
6. Install fuel supply solenoid hose (Figure 126) (Item 3) to clips on electrical harness (Figure 126) (Item 1),
fuel filter bracket (Figure 126) (Item 2), and fuel drain hose (Figure 126) (Item 4).
7. Tighten banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts to 11 lb·ft (15 N·m).
Special torques
Special Torques
Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts 15 N·m (132 lb·in)
Banjo M8 x 1 bolt 8 N·m (71 lb·in)
Fuel supply inlet air heater hose fitting nut 10 N·m (89 lb·in)
IAHFI locking nut 23 N·m (17 lb·ft)
IAHFI wiring harness nut 4 N·m (35 lb·in)
Relay assembly M6 x 20 bolts 10 N·m (89 lb·in)
Solenoid valve M6 x 20 bolts 6 N·m (53 lb·in)
Aftertreatment System
components.
last.
Supply Fuel After Filter Hose and Tubes

Supply Fuel After Filter Hose and Tubes Removal
Figure 128 Supply Fuel After Filter Hose Connection

1. Aftertreatment (AFT) fuel doser module
2. Fitting (quick-connect adapter)
3. Supply fuel after-filter hose
designed for and clearly marked DIESEL FUEL.
CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel
compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service.
1. Place suitable container clearly marked DIESEL FUEL under AFT doser module.
Figure 129 AFTFI Fuel 1 and 2 Tube Assemblies

1. AFTFI fuel 1 tube assembly nut
4. AFTFI fuel 2 tube assembly fitting (brazed to tube)
5. P-clamp (2)
6. M6 x 16 bolt (2)
2. Loosen AFTFI fuel 1 tube assembly nut (Figure 129) (Item 1) and disconnect tube from fitting assembly at
AFT fuel doser module (Figure 129) (Item 2).
3. Remove two M6 x 16 bolts (Figure 129) (Item 6) and two P-clamps (Figure 129) (Item 5) from AFT fuel 1
tube assembly.
Figure 130 AFTFI Fuel 1 Tube Assembly Connection

1. AFTFI fuel 1 tube assembly
4. M6 x 16 bolt
4. Loosen AFTFI fuel 1 tube assembly nut and disconnect fuel tube from AFTFI fuel 2 tube assembly.
5. Remove M6 x 16 bolt, P-clamp and AFTFI fuel 1 tube assembly.
Figure 131 AFTFI Fuel 2 Tube Assembly

1. 6.6 x 15 x 23 spacer (2)
2. M6 x 40 bolt (2)
4. P 6 x 15 clamp (2)
6. Aftertreatment Fuel Injector (AFTFI) Assembly
6. Loosen AFTFI fuel 2 tube assembly nut and disconnect tube from hydrocarbon injector assembly.
7. Remove two M6 x 40 bolts, two 6.6 x 15 x 23 spacers and remove AFTFI assembly.
Supply Fuel After Filter Hose and Tubes Installation
Figure 132 AFTFI Fuel 2 Tube Assembly

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

2. Connect AFTFI fuel 2 tube assembly onto hydrocarbon injector assembly.
3. Install two M6 x 40 bolts, 2 clamps and two 6.6 x 15 x 23 spacers. Tighten bolts to standard torque (page
1201).
4. Using a wrench, hold the hydrocarbon injector assembly hex to keep it from rotating. Tighten AFTFI fuel 2
tube nut to special torque (page 1240), while holding the injector body hex.
Figure 133 AFTFI fuel 1 and 2 tube assemblies

2. Downstream Injection (DSI) unit
3. AFT fuel doser module
5. AFTFI fuel 2 tube assembly fitting (brazed to tube)
6. P-clamp (2)
7. M6 x 16 bolt (2)
5. Position AFTFI fuel 1 tube assembly to engine. Loosely connect fuel 1 tube with fuel 2 tube and DSI unit.
6. Install two M6 x 16 bolts, one M10 x 16 bolt, two P 6 x 15 clamps and cushioned 1/4 inch diameter clamp.
Tighten bolts to standard torque (page 1201).
Figure 134 Fuel Supply Assembly Connection

4. M6 x 16 bolt
7. Tighten AFTFI fuel 1 tube assembly nut at AFTFI fuel 2 tube nut (brazed) to special torque (page 1240).
8. Tighten AFTFI fuel 1 tube assembly nut at AFTFI to special torque (page 1240).
9. Connect clamp from fuel drain tube to AFTFI fuel 1 tube assembly.
Aftertreatment Purge Air Valve (AFTPAV) Assembly

Aftertreatment Purge Air Valve (AFTPAV) Assembly Removal
Figure 135 Aftertreatment Purge Air Valve (AFTPAV) Assembly

1. Harness retainer
2. AFTPAV connector
3. Quick connect fitting
4. Aftertreatment Purge Air Valve (AFTPAV) assembly
5. M8 x 60 hex flange bolt (2)
6. AFTPAV Air supply line quick‐connect fitting
7. M8 x 60 Stud bolt
CAUTION: Ensure that air system has been drained before removing air supply line from AFTPAV quick‐connect
fitting.
1. Remove AFTPAV connector (Figure 135) (Item 2) together with harness retainer (Figure 135) (Item 1) from
M8 x 60 Stud bolt (Figure 135) (Item 7).
2. Remove formed air tube (0.25”) from quick connect fitting (Figure 135) (Item 3).
3. Remove two M8 x 60 hex flange bolts (Figure 135) (Item 5) and AFTPAV assembly (Figure 135) (Item 4).
Figure 136 AFTPAV support bracket

1. M10 x 16 bolt
2. AFTPAV support bracket
3. M8 nut
4. M8 x 16 bolt
4. If necessary, remove M10 x 16 bolt (Figure 136) (Item 1), M8 x 16 bolt (Figure 136) (Item 4), and M8 nut
5. Remove AFTPAV support bracket (Figure 136) (Item 2) from engine.
Aftertreatment Purge Air Valve (AFTPAV) Assembly Installation
Figure 137 AFTPAV support bracket

1. M10 x 16 bolt
2. AFTPAV support bracket
3. M8 nut
4. M8 x 16 bolt
1. Install AFTPAV support bracket (Figure 137) (Item 2).

2. Install M10 x 16 bolt (Figure 137) (Item 1), M8 x 16 bolt (Figure 137) (Item 4), and M8 nut (Figure 137) (Item
3) and tighten to 23 lbf•ft (31 N•m).
Figure 138 AFTPAV Assembly

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

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

Aftertreatment (AFT) Fuel Doser Module Removal
Figure 139 AFT Fuel Doser Module

2. Aftertreatment Purge Air Valve (AFTPAV) supply tube connector
4. Aftertreatment Purge Air Valve (AFTPAV) supply tube
5. M8 x 65 hex flange bolt
6. Harness support bracket
7. Aftertreatment Fuel Doser Module (AFTFSV) fuel shutoff valve connector
8. Aftertreatment Fuel Pressure Sensor 1 (AFTFP1) connector
CAUTION: To prevent component damage, keep AFT fuel doser module and related components clean and
protected from damage until ready to install. Do not let dirt or other debris, lubricants, or water get into fuel
passages. Do not blow compressed air into fuel passages. If protection caps are used, they should be new, or
ultrasonically cleaned before using.
CAUTION: To prevent component damage, do not drop AFT fuel doser module onto a hard surface. If this
happens, replace the valve.
1. If not already done, remove the harness connectors from AFTFP1 (Figure 139) (Item 8) and AFTFSV (Figure
139) (Item 7).
2. Push 90 degree connector locking tab to release AFTPAV supply tube (Figure 139) (Item 4) from AFT fuel
doser module (Figure 139) (Item 1) and cap off the end of tube.
3. Remove M8 x 60 stud bolt (Figure 139) (Item 3), M8 x 65 hex flange bolt (Figure 139) (Item 5), harness
support bracket (Figure 139) (Item 6), and AFT fuel doser module.
Figure 140 AFT Fuel Doser Module, AFTFP1, and AFTFSV1

1. Aftertreatment Fuel Pressure 1 (AFTFP1) sensor
2. O-ring
3. AFT doser module
4. O-ring
5. Aftertreatment Fuel Shutoff Valve (AFTFSV)
NOTE: Do steps 4 and 5 only if AFTFP1 or AFTFSV are leaking or if AFT sensor is being replaced.
CAUTION: To prevent engine damage, all fuel exposed O‐rings and O‐ring seals must be replaced with biodiesel
compatible O‐rings and O‐ring seals. The specific Navistar P/N must be used for service.
4. Loosen and remove AFTFP1 (Figure 140) (Item 1) from AFT doser module (Figure 140) (Item 3) and discard
O‐ring (Figure 140) (Item 2).
5. Loosen and remove AFTFSV (Figure 140) (Item 5) and discard O‐ring (Figure 140) (Item 4).
Aftertreatment (AFT) Fuel Doser Module Installation
Figure 141 AFT Fuel Doser Module, AFTFP1, and AFTFSV1

1. Aftertreatment Fuel Pressure 1 (AFTFP1) sensor
2. O-ring
4. Aftertreatment Fuel Shutoff Valve (AFTFSV)
5. O-ring (# 011)
6. O-ring seal
NOTE: Do steps 1 through 4 only if AFTFP1 or AFTFSV are leaking or if AFT sensor is being replaced.
CAUTION: To prevent engine damage, all fuel exposed O-rings and O-ring seals must be replaced with biodiesel
compatible O-rings and O-ring seals. The specific Navistar P/N must be used for service.
1. Lubricate new O-ring (Figure 141) (Item 2) and install onto AFTFP1 (Figure 141) (Item 1).
2. Install and tighten AFTFP1 into AFT fuel doser module (Figure 141) (Item 3).
3. Lubricate new O-ring (Figure 141) (Item 4) and install onto AFTFSV (Figure 141) (Item 5).
4. Install and tighten AFTFSV (Item 5) into AFT fuel doser module.
Figure 142 AFT Fuel Doser Module

2. Aftertreatment Purge Air Valve (AFTPAV) supply tube connector
3. 8 x 60 stud bolt
4. Aftertreatment Purge Air Valve (AFTPAV) supply tube
5. M8 x 65 bolt
6. Harness support bracket
7. Aftertreatment Fuel Doser Module (AFTFSV) fuel shutoff valve connector
8. Aftertreatment Fuel Pressure Sensor 1 (AFTFP1) connector
5. Install harness support bracket (Item 6) and AFT fuel doser module (Item 1) and secure with M8 x 60 stud
bolt (Item 3) and M8 x 65 hex flange bolt (Item 5).
6. Tighten bolts to 23 lbf•ft (31 N•m).
7. Connect AFTPAV supply tube (Item 4) to 90 degree connector (Item 2) on AFT fuel doser module.
8. Connect harness connectors to AFTFP1 (Item 8) and AFTFSV (Item 7).
AFTFI Coolant Supply Tube Assembly

AFTFI Coolant Supply Tube Assembly Removal
Figure 143 AFTFI Coolant Supply Tube Assembly

1. Coolant Manifold
2. 90 degree adjustable fitting
3. AFTFI coolant supply tube nut
4. AFTFI coolant supply tube assembly
1. Loosen the AFTFI coolant supply tube nut (Figure 143) (Item 6) and disconnect AFTFI coolant supply tube
assembly (Figure 143) (Item 4) from tube 90 degree adjustable fitting (Figure 143) (Item 5).
2. Loosen AFTFI coolant supply tube nut (Figure 143) (Item 3) and disconnect AFTFI coolant supply tube
assembly from 90 degree adjustable fitting (Figure 143) (Item 2) at coolant manifold (Figure 143) (Item 1).
3. Remove AFTFI coolant supply tube assembly.
NOTE: Perform following steps only if 90 degree adjustable fittings are leaking.
4. Remove 90 degree adjustable fitting (Figure 143) (Item 6) from AFTFI assembly (Figure 143) (Item 7).
5. Remove 90 degree adjustable fitting(Figure 143) (Item 2) from coolant manifold (Figure 143) (Item 1).
AFTFI Coolant Supply Tube Assembly Installation
Figure 144 AFTFI Coolant Supply Tube Assembly

1. Coolant Manifold
4. AFTFI coolant supply tube assembly
1. If previously removed, loosely install 90 degree adjustable fitting (Figure 144) (Item 2) into coolant manifold
2. Loosely install AFTFI coolant supply tube nut (Figure 144) (Item 3 onto 90 degree adjustable fitting at coolant
manifold.
NOTE: Do step 3 if tube M10 elbow fitting was removed. Otherwise, skip to step 5.
3. Loosely install 90 degree adjustable fitting (Figure 144) (Item 5) onto AFTFI assembly (Figure 144) (Item 7)
and adjust to maintain alignment and clearance for AFTFI coolant supply tube assembly.
4. Loosely install AFTFI coolant supply tube nut (Figure 144) (Item 6) onto 90 degree adjustable fitting (Figure
144) (Item 5) (align fitting as needed) on AFTFI assembly.
5. Tighten AFTFI coolant supply tube nut s and 90 degree adjustable fittings to 13 lb·ft (17.5 N·m).
AFTFI Coolant Return Tube Assembly

AFTFI Coolant Return Tube Assembly Removal
Figure 145 AFTFI Coolant Return Tube Assembly

1. Straight fitting 3. AFTFI coolant return tube 6. Hose clamp (spring type)
2. Aftertreatment Fuel Injector assembly 7. M8 x 16 bolt
(AFTFI) assembly 4. Tube clamp (2) 8. Pipe single cushion clamp
5. Open breather tube 9. AFTFI coolant return tube nut
1. Loosen AFTFI coolant return tube nut (Figure 145) (Item 9) and disconnect AFTFI coolant return tube
assembly (Figure 145) (Item 3) from straight fitting (Figure 145) (Item 1).
2. Remove M8 x 16 bolt (Figure 145) (Item 7) from pipe single cushion clamp (Figure 145) (Item 8). Separate
clamp from AFTFI coolant return tube assembly as necessary.
3. Release AFTFI coolant return tube assembly (Figure 145) (Item 3) from two tube clamps (Figure 145) (Item
4) at open breather tube (Figure 145) (Item 5).
4. Loosen hose clamp (spring type) (Figure 145) (Item 6). Separate AFTFI coolant return tube assembly from
open breather tube. Remove from engine.
NOTE: Do step 5 only if straight fitting is leaking.
5. Remove straight fitting (Figure 145) (Item 1) from AFTFI assembly (Figure 145) (Item 2).
AFTFI Coolant Return Tube Assembly Installation
Figure 146 AFTFI Coolant Return Tube Assembly

1. AFTFI coolant return tube nut 5. Hose clamp (spring type) 6. Open breather tube
2. Aftertreatment Fuel Injector 7. AFTFI coolant return tube
(AFTFI) assembly assembly
3. Straight fitting 8. Pipe single cushion clamp
4. Tube clamp (2) 9. M8 x 16 bolt
NOTE: Do steps 1 and 2 if straight fitting was removed. Otherwise, skip to step 3.
1. Install straight fitting (Figure 146) (Item 2) onto AFTFI (Figure 146) (Item 3) and tighten fitting to maintain
alignment and clearance for AFTFI coolant return tube assembly (Figure 146) (Item 7).
2. Tighten straight fitting to 11 lb·ft (15 N·m).
3. Position AFTFI coolant return tube assembly onto open breather tube (Figure 146) (Item 6) nipple, two tube
clamps (Figure 146) (Item 4) on open breather tube and pipe single cushion clamp (Item 8).
4. Install M8 x 16 bolt (Figure 146) (Item 9) through pipe single cushion clamp (Figure 146) (Item 8) and tighten
to 23 lb·ft (31 N·m).
5. Snap AFTFI coolant return tube assembly into two tube clamps (Figure 146) (Item 4) and install hose clamp
(spring type) (Figure 146) (Item 5) to secure tube to open breather tube.
6. Tighten AFTFI coolant return tube nut onto straight fitting. Align fitting as needed to reduce tube stress and
to not contact other components. Tighten tube nut and straight fitting each to 13 lb·ft (17.5 N·m).
Aftertreatment Fuel Injector (AFTFI) Assembly

Aftertreatment Fuel Injector (AFTFI) Assembly Removal
Figure 147 AFTFI Harness and Connections

1. Aftertreatment Fuel Injector (AFTFI) connector
2. AFTFI connector mounting bracket
3. AFTFI harness fasteners (3)
NOTE: This Engine Service Manual is written for complete engine teardown. If removing AFTFI only, do not
drain cooling system and do not remove engine cover (dog house). Access AFTFI from under vehicle.
1. Press release tab to disconnect wiring harness lead from AFTFI connector (Figure 147) (Item 1).
2. Disconnect AFTFI connector from AFTFI connector mounting bracket (Figure 147) (Item 2).
3. Disconnect three AFTFI harness fasteners (Figure 147) (Item 3).
Figure 148 AFTFI Connections (Disconnected)

1. Fuel supply line
2. AFTFI M6 mounting bolts (2)
3. Aftertreatment Fuel Injector (AFTFI)
4. Coolant supply line
5. AFTFI Coolant Line Plugs (2)
6. Coolant return line
4. Disconnect fuel supply line (Figure 148) (Item 1), and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap
line. Discard O-rings.
5. Disconnect coolant supply line(Figure 148) (Item 4) and coolant return line (Figure 148) (Item 6). Discard
O-rings.
6. Install two AFTFI Coolant Line Plugs (Figure 148) (Item 5) onto coolant supply and return line.
7. Open the BLUE vent valve on the Vacuum Module.
CAUTION: To prevent component damage, keep AFTFI and related components clean and protected from
damage until ready to install. Protect the injector nozzle tip, sealing surfaces, and threaded surfaces. Do not let
dirt, debris, lubricants, or water get into fuel or coolant passages. Do not blow compressed air into injector fuel
passage. If protection caps are used, they should be new, or ultrasonically cleaned before using.
CAUTION: To prevent component damage, do not drop AFTFI (especially nozzle tip) onto a hard surface. If this
happens, replace the injector.
8. Remove two AFTFI M6 mounting bolts (Item 2).
9. Remove AFTFI as an assembly from turbocharger exhaust outlet pipe. Discard metal gasket and fibrous
insulator.
Figure 149 AFTFI Block Off Plate and Bolts

1. AFTFI block off plate bolt (2)
2. AFTFI block off plate
10. Install AFTFI Block Off Plate 12-559-01-05 (Figure 149) (Item 2) onto turbocharger exhaust outlet pipe using
two AFTFI Block Off Plate Bolts 12-55-01-04 (Figure 149) (Item 1).
Aftertreatment Fuel Injector (AFTFI) Cleaning
Figure 150 Aftertreatment Fuel Injector (AFTFI) Assembly

1. AFTFI assembly
2. Injector nozzle tip
3. AFTFI Gasket
4. Raised sealing lip
CAUTION: To prevent component damage, cleaning of the AFTFI assembly using cleaner or solvents is
NOT recommended. Do not blast the injector with compressed air. Do not pull or otherwise manipulate
the injector nozzle tip.
1. Inspect AFTFI assembly (Figure 150) (Item 1) and injector nozzle tip (Figure 150) (Item 2) for cracks and
other damage. If damage is present, replace AFTFI assembly.
2. Use Fuel Injector Tip Cleaning Brush ZTSE4301 to clean any carbon buildup that may be present on the
injector nozzle tip.
Aftertreatment Fuel Injector (AFTFI) Assembly Installation
Figure 151 AFTFI Block Off Plate and Bolts

1. AFTFI Block Off Plate Bolt (2)
2. AFTFI Block Off Plate
NOTE: When installing the AFTFI gasket , the raised seal lip must face down toward the exhaust back pressure
valve housing.
1. Remove two AFTFI Block Off Plate Bolts 12‐55‐01‐04 (Item 1) and AFTFI Block Off Plate ( Item 2) from
turbocharger exhaust outlet pipe.
Figure 152 AFTFI Connections (Disconnected)

1. Fuel supply line
2. AFTFI M6 mounting bolts (2)
3. Aftertreatment Fuel Injector (AFTFI)
4. Coolant supply line
5. AFTFI Coolant Line Plugs (2)
6. Coolant return line
2. Install AFTFI (Figure 152) (Item 3), metal gasket, and fibrous insulator as an assembly onto turbocharger
exhaust outlet pipe.
3. Install two AFTFI M6 mounting bolts (Figure 152) (Item 2).
4. Close BLUE vent valve on Vacuum Module.
5. Remove two AFTFI Coolant Line Plugs (Figure 152) (Item 5) onto coolant supply and return line.
6. Install new O‐ring on coolant supply line (Figure 152) (Item 4) and install coolant supply line onto AFTI.
7. Install new O‐ring on coolant return line (Figure 152) (Item 6) and install coolant return line onto AFTI.
8. Remove air and fuel cap from fuel supply line (Figure 152) (Item 1).
9. Install new O‐ring onto fuel supply line and connect onto AFTFI.
Figure 153 AFTFI Harness and Connections

1. Aftertreatment Fuel Injector (AFTFI) connector
2. AFTFI connector mounting bracket
3. AFTFI harness fasteners (3)
10. Connect three AFTFI harness fasteners (Figure 153) (Item 3).
11. Connect AFTFI connector (Figure 153) (Item 1) to AFTFI connector mounting bracket (Figure 153)(Item 2).
12. Connect wiring harness lead from AFTFI connector (Figure 153) (Figure 50) (Item 1).
Aftertreatment (AFT) Fuel Supply Module Cleaning and Inspection
compressed air pressure to 207 kPa (30 psi).
CAUTION: To prevent component damage, keep Aftertreatment (AFT) fuel supply module and related
components clean and protected from damage until ready to install. Do not let dirt or other debris, lubricants,
or water get into fuel passages. Do not blow compressed air into fuel passages. If protection caps are used,
they should be new or ultrasonically cleaned before using.
CAUTION: To prevent component damage, do not drop AFT fuel supply module onto a hard surface. If this
happens, replace the module.
CAUTION: To prevent engine damage, all fuel-exposed O‐rings and O‐ring seals must be replaced with
biodiesel-compatible O‐rings and O‐ring seals. The specific Navistar P/N must be used for service.
Figure 154 AFT Fuel Supply Module

A. Aftertreatment (AFT) fuel supply C. Air line fitting F. AFT Fuel Pressure 1 (AFTFP1)
module D. Fuel supply line fitting sensor
B. AFT Fuel Injector (AFTFI) fuel E. AFT Fuel Shut-off Valve
supply tube fitting (AFTFSV)
See AFT Fuel Supply Module (Figure 154) to perform steps 1 through 5.
1. Using a non-caustic brake cleaner, clean AFT fuel supply module (A) and then dry with filtered, compressed
air.
2. Inspect AFT fuel supply module (A) for cracks, pitting, and other notable damage. Repair or replace as
necessary.
3. Inspect AFTFI fuel supply tube fitting, fuel supply line fitting, AFTFSV, and AFTFP1 sensor (B, D, E, and F)
for signs of fuel leaks. Repair or replace as necessary.
4. Inspect air line fitting (C) for cracks, pitting, poor sealing surface, and other notable damage. Repair or
5. Inspect AFTFSV and AFTFP1 sensor for (E and F) for corroded terminals; loose, bent, or broken pins; or
broken sensor housings. Repair or replace as necessary.
Special Torques
Coolant supply (straight) fitting at coolant manifold 35 N·m (26 lb·ft)
Fitting (quick-connect adapter) at DSI unit 35 N·m (26 lb·ft)
Fitting (straight union orifice) at DSI unit 35 N·m (26 lb·ft)
AFTI coolant supply and return tube nut at tube M10 elbow 15 N·m (11 lb·ft)
fittings
AFTI coolant supply tube nut at coolant manifold 25 N·m (18 lb·ft)
AFTI fuel 1 tube assembly nut at AFTI fuel 2 tube fitting 25 N·m (18 lb·ft)
(brazed)
AFTI fuel 1 tube assembly nut at DSI unit 25 N·m (18 lb·ft)
AFTI fuel 2 tube assembly nut at hydrocarbon injector 18 N·m (13 lb·ft)
assembly
Hydrocarbon injector assembly M8 x 45 bolt See tightening steps in procedure.
Hydrocarbon injector assembly body to assembly 20 N·m (15 lb·ft)
PDOC V-band clamp 7 N·m (62 lb·in)
PDOC M10 x 50 bolts 36 N·m (27 lb·ft)
M10 x 25 bolts 31 N·m (23 lb·ft)
Tube M10 elbow fittings at hydrocarbon injector assembly 17.5 N·m (13 lb·ft)
Special Tools
Coolant Block Off Plug 12–559–02–01
Fuel Line Disconnect Tool 11.8 mm ZTSE4773
P-80® rubber lubricant or equivalent Obtain locally
Fuel Injector Tip Cleaning Brush ZTSE4301
Exhaust Back-Pressure Control System
components.
WARNING: To prevent personal injury or death, wear safety glasses with side shields.
NOTE: When performing specific component removal, only remove components necessary for access.
For complete engine tear down, refer to the following service sections for information on removal of components
prior to this section:
• Engine Electrical
• Aftertreatment System
Exhaust Back-Pressure Valve (EBPV) Assembly

Exhaust Back-Pressure Valve (EBPV) Assembly Removal
Figure 155 EBPV Heat Shield

1. Bolt 3. Nut
2. Heat shield with spacer 4. EBPV assembly
See EBPV Heat Shield (Figure 155) to perform steps 1 and 2.

1. Remove nut and bolt that secure heat shield to the EBPV assembly.
2. Remove heat shield with spacer from engine.
Figure 156 Electrical Component Connections

1. O2 sensor harness connector 4. Bolt 6. NOxin sensor module
2. Rear coolant manifold 5. NOxin sensor module engine 7. NOxin sensor module bolts (2)
3. Tie straps harness connector
See Electrical Component Connections (Figure 156) to perform steps 3 through 8.

3. Remove necessary tie straps securing Nitrogen Oxides In (NOxin) sensor module wiring and Oxygen (O2)
sensor wiring to rear coolant manifold.
4. Disconnect O2 sensor harness connector.
5. Remove O2 sensor harness connector from rear coolant manifold.
6. Disconnect engine harness connector from NOxin sensor module.
7. Remove 2 bolts securing NOxin module to rear coolant manifold
8. Remove bolt securing O2 sensor harness to rear coolant manifold.
Figure 157 Air Supply Line

1. EBPV actuator 2. EBPV air supply line
See Air Supply Line (Figure 157) to perform steps 9 and 10.
9. Remove EBPV air supply line from EBPV actuator.
10. Position supply line out of way.
Figure 158 EBPV Assembly Support Bracket Bolts

1. EBPV assembly support bracket 2. Bolts (2) 3. EBPV assembly
See EBPV Assembly Support Bracket Bolts (Figure 158) to perform step 11.
11. Remove 2 bolts securing EBPV assembly support bracket to EBPV assembly
Figure 159 EBPV Assembly Support Bracket

1. Down-pipe support bracket 2. Stud bolts (2) 3. Engine bell housing
See EBPV Assembly Support Bracket (Figure 159) to perform step 12.
12. Remove 2 stud bolts securing down-pipe support bracket to engine bell housing and remove down-pipe
support bracket from engine.
Figure 160 Lower Bolt and Spacer

1. EBPV assembly 2. Low-Pressure (LP) turbocharger 3. Bolts with spacers (3)
See Lower Bolt and Spacer (Figure 160) to perform step 13.
13. Remove 3 lower bolts with spacers securing EBPV assembly to LP turbocharger.
Figure 161 EBPV Assembly

1. Bolts with spacers (3) 2. LP turbocharger 3. EBPV assembly
See EBPV Assembly (Figure 161) to perform step 14.

14. Remove 3 upper bolts with spacers securing EBPV assembly to LP turbocharger and remove EBPV
assembly and gasket. Discard gasket.
Exhaust Back-Pressure Valve (EBPV) Assembly Installation

None
Torques
Bolts with spacers 25 N·m (18 lb·ft)

Stud bolts 31 N·m (23 lb·ft)
EBPV assembly support bracket bolts 31 N·m (23 lb·ft)
EBPV actuator air supply line tube nut 15 N·m (11 lb·ft)
2
O sensor harness bolt 13 N·m (10 lb·ft)
NOxin sensor module bolts 4 N·m (3 lb·ft)
EBPV heat shield bolt and nut 31 N·m (23 lb·ft)


1. Using 3 upper bolts with spacers (1) install EBPV assembly (3) with new gasket onto LP turbocharger (2).
Torque bolts with spacers to 25 N·m (18 lb·ft).


2. Using 3 lower bolts with spacers (3) secure EBPV assembly (1) to LP turbocharger (2). Torque lower bolts
with spacers to 25 N·m (18 lb·ft).


3. Remove 2 stud bolts (2) securing down-pipe support bracket (1) to engine bell housing (3). Torque stud
bolts to 31 N·m (23 lb·ft).

1. EBPV assembly support bracket 2. EBPV assembly support bracket 3. EBPV assembly
bolts (2)
4. Using 2 EBPV assembly support bracket bolts (2), install EBPV assembly support bracket (1) onto EBPV
assembly (3). Torque EBPV assembly support bracket bolts to 31 N·m (23 lb·ft).

1. EBPV actuator 2. EBPV actuator air supply line
See Air Supply Line (Figure 166) to perform step 5.

5. Install EBPV actuator air supply line (2) onto EBPV actuator (1). Torque EBPV actuator air supply line tube
nut to 15 N·m (11 lb·ft).

1. O2 sensor harness connector 4. O2 sensor harness bolt 6. NOxin sensor module
6. Using O2 sensor harness bolt (4), secure O2 sensor harness to rear coolant manifold (2). Torque O2 sensor
harness bolt to 13 N·m (10 lb·ft).
7. Using 2 NOxin sensor module bolts (7), install NOxin module (6) onto rear coolant manifold (2). Torque NOxin
sensor module bolts to 4 N·m (3 lb·ft).
8. Connect NOxin sensor module engine harness connector (5) to NOxin sensor module (6).
9. Connect O2 sensor harness connector (1) to engine wiring harness.
10. Install necessary tie straps (3) to secure Nitrogen Oxides In (NOxin) sensor module wiring and Oxygen (O2)
sensor wiring to rear coolant manifold (1).

1. EBPV heat shield bolt 3. EBPV heat shield nut
2. EBPV heat shield with spacer 4. EBPV assembly
See EBPV Heat Shield (Figure 168) to perform step 11.

11. Using EBPV heat shield bolt and nut (1 and 3), install EBPV heat shield with spacer (2) onto EBPV assembly
(4). Torque EBPV heat shield bolt and nut to 31 N·m (23 lb·ft).
Exhaust Back-Pressure Valve (EBPV) Actuator

Exhaust Back-Pressure Valve (EBPV) Actuator Removal
Figure 169 Exhaust Back-Pressure Valve (EBPV) Actuator

1. EBPV actuator 4. EBPV actuator air supply line 6. EBPV actuator rod
2. C-clip (2) tube nut
3. EBPV actuator mounting pin (2) 5. EBPV actuator air supply line
See Exhaust Back-Pressure Valve (EBPV) Actuator (Figure 169) to perform steps 1 through 3.
1. Loosen EBPV actuator air supply line tube nut (4) that secures EBPV actuator air supply line (5) to EBPV
actuator (1) and remove EBPV actuator air supply line.
2. Mark EBPV actuator rod (6) to ensure EBPV actuator (1) adjustment is not lost.
3. Remove 2 C-clips (2) that secure EBPV actuator (1) to EBPV actuator mounting pins (3) and remove EBPV
actuator from engine.
Exhaust Back-Pressure Valve (EBPV) Actuator Installation

None
Torques
Figure 170 Exhaust Back-Pressure Valve (EBPV) Actuator

1. EBPV actuator 4. EBPV actuator air supply line 6. EBPV actuator rod
2. C-clip (2) tube nut
3. EBPV actuator mounting pin (2) 5. EBPV actuator air supply line
See Exhaust Back-Pressure Valve (EBPV) Actuator (Figure 170) to perform steps 1 through 4.
1. Apply Superlub™ synthetic high heat lubricant to both EBPV actuator mounting pins (3).
2. Using 2 C-clips (2), install EBPV actuator (1) onto EBPV actuator mounting pins (3).
3. Using marks made on EBPV actuator rod (6), ensure EBPV actuator (1) is properly adjusted.
4. Using EBPV actuator air supply line tube nut (4) install EBPV actuator air supply line (5) onto EBPV actuator
(1). Torque EBPV actuator air supply line tube nut to 15 N·m (11 lb·ft).
Thermal Management Valve (TMV)

Thermal Management Valve (TMV) Removal
Figure 171 Thermal Management Valve (TMV) Air Lines

1. High-Pressure (HP) 3. Exhaust Back-Pressure Valve 5. TMV air supply line
Turbocharger wastegate (EBPV) actuator air supply line 6. TMV air supply line tube nut
actuator air supply hose 4. EBPV actuator air supply line 7. TMV
2. Crimp clamp tube nut
See Thermal Management Valve (TMV) Air Lines (Figure 171) to perform steps 1 through 4.
1. Remove and discard crimp clamp (2) that secures HP turbocharger wastegate actuator air supply hose (1)
to TMV (7).
2. Remove HP turbocharger wastegate actuator air supply hose (1) from TMV (7).
3. Loosen EBPV actuator air supply line tube nut (4) that secures EBPV actuator air supply line (3) to TMV (7)
and remove EBPV actuator air supply line.
4. Loosen TMV air supply line tube nut (6) that secures TMV air supply line (5) to TMV (7) and remove TMV
air supply line from TMV.
Figure 172 TMV

1. TMV 3. TMV engine harness connector 5. Middle TMV mounting bolt
2. TMV pigtail connector 4. Outer TMV mounting bolt (2) 6. Water distribution housing
See TMV (Figure 172) to perform steps 5 through 7.

5. Disconnect TMV pigtail connector (2) from TMV engine harness connector (3).
6. Remove 2 outer TMV mounting bolts (4) that secure TMV (1) to water distribution housing (6).
7. Remove middle TMV mounting bolt (5) that secures TMV (1) to waster distribution housing (6) and remove
TMV from engine.
Thermal Management Valve (TMV) Installation

None
Torques
Thermal Management Valve (TMV) mounting bolts 45 N·m (33 lb·ft)

TMV air supply line tube nut 15 N·m (11 lb·ft)
Figure 173 TMV

1. TMV 3. TMV engine harness connector 5. Middle TMV mounting bolt
2. TMV pigtail connector 4. Outer TMV mounting bolt (2) 6. Water distribution housing
See TMV (Figure 173) to perform steps 1 through 3.

1. Using 2 outer TMV mounting bolts (4) install TMV (1) onto water distribution housing (6). Torque outer TMV
mounting bolts to 31 N·m (23 lb·ft).
2. Install middle TMV mounting bolt (5) that secures TMV (1) to waster distribution housing (6) and toque to
31 N·m (23 lb·ft).
3. Connect TMV pigtail connector (2) to TMV engine harness connector (3).
Figure 174 Thermal Management Valve (TMV) Air Lines

1. High-Pressure (HP) 3. Exhaust Back-Pressure Valve 5. TMV air supply line
Turbocharger wastegate (EBPV) actuator air supply line 6. TMV air supply line tube nut
actuator air supply hose 4. EBPV actuator air supply line 7. TMV
See Thermal Management Valve (TMV) Air Lines (Figure 174) to perform steps 1 through 4.
4. Using TMV air supply line tube nut (6), install TMV air supply line (5) onto TMV (7). Torque TMV air supply
line tube nut to 15 N·m (11 lb·ft).
5. Using EBPV actuator air supply line tube nut (4), install EBPV actuator air supply line (3) onto TMV (7).
Torque EBPV actuator air supply line tube nut to 15 N·m (11 lb·ft).
6. Using new crimp clamp (2), install HP turbocharger wastegate actuator air supply hose (1) onto TMV (7).
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate Air Supply Lines
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate Air Supply
Lines Removal
NOTE: Remove Exhaust Back-Pressure Valve (EBPV) actuator air supply line and High-Pressure (HP)
turbocharger wastegate actuator air supply line as an assembly.
Figure 175 Connections at Thermal Management Valve (TMV)

1. High-Pressure (HP) 3. Exhaust Back-Pressure Valve 5. Thermal Management Valve
turbocharger wastegate actuator (EBPV) actuator air supply line (TMV)
air supply line 4. EBPV actuator air supply line
See Connections at Thermal Management Valve (TMV) (Figure 175) to perform steps 1 through 3.
1. Remove crimp clamp (2) that secures HP turbocharger wastegate actuator air supply line (1) to TMV (5).
2. Remove HP turbocharger wastegate actuator air supply line (1) from TMV (5).
3. Loosen EBPV actuator air supply line tube nut (4) that secures EBPV actuator air supply line (3) to TMV (5)
and remove EBPV actuator air supply line from TMV.
Figure 176 Engine Connections

1. EBPV actuator 4. Air supply line mounting bolts (3) 6. HP turbocharger wastegate
2. EBPV actuator air supply line 5. HP turbocharger wastegate actuator
tube nut actuator air supply line 7. Crimp clamp
3. EBPV actuator air supply line
See Engine Connections (Figure 176) to perform steps 4 through 9.

4. Loosen EBPV actuator air supply line tube nut (2) that secures EBPV actuator air supply line (3) to EBPV
actuator (1).
5. Remove EBPV actuator air supply line (3) from EBPV actuator (1).
6. Remove crimp clamp (7) that secures HP turbocharger wastegate actuator air supply line (5) to HP
turbocharger wastegate actuator (6).
7. Remove HP turbocharger wastegate actuator air supply line (5) from HP turbocharger wastegate actuator
(6).
8. Remove 3 air supply line mounting bolts (4) that secure HP turbocharger wastegate actuator air supply line
(5) and EBPV actuator air supply line (3) to engine.
9. Remove HP turbocharger wastegate actuator air supply line (5) and EBPV actuator air supply line (3) from
engine as an assembly.
Exhaust Back-Pressure Valve (EBPV) and High-Pressure (HP) Turbocharger Wastegate Air Supply
Lines Installation

None
Torques
Air supply line mounting bolts 13 N·m (10 lb·ft)

EBPV actuator air supply line tube nut (both ends) 15 N·m (11 lb·ft)
NOTE: Install Exhaust Back-Pressure Valve (EBPV) actuator air supply line and High-Pressure (HP)
turbocharger wastegate actuator air supply line as an assembly, already installed within tube clamps.
Figure 177 Engine Connections

1. EBPV actuator 4. Air supply line mounting bolts (3) 6. HP turbocharger wastegate
2. EBPV actuator air supply line 5. HP turbocharger wastegate actuator
tube nut actuator air supply line 7. Crimp clamp
3. EBPV actuator air supply line
See Engine Connections (Figure 177) to perform steps 1 through 3.

1. Using 3 air supply line mounting bolts (4), install HP turbocharger wastegate actuator air supply line (5) and
EBPV actuator air supply line (3) to engine. Torque air supply line mounting bolts to 13 N·m (10 lb·ft).
2. Using new crimp clamp (7), install HP turbocharger wastegate actuator air supply line (5) onto HP
turbocharger wastegate actuator (6).
3. Using EBPV actuator air supply line tube nut (2), install EBPV actuator air supply line (3) onto EBPV actuator
(1). Torque EBPV actuator air supply line tube nut to 15 N·m (11 lb·ft).
Figure 178 Connections at Thermal Management Valve (TMV)

1. High-Pressure (HP) 3. Exhaust Back-Pressure Valve 5. Thermal Management Valve
turbocharger wastegate actuator (EBPV) actuator air supply line (TMV)
air supply line 4. EBPV actuator air supply line
See Connections at Thermal Management Valve (TMV) (Figure 178) to perform steps 4 and 5.
4. Using new crimp clamp (2), install HP turbocharger wastegate actuator air supply line (1) onto TMV (5).
5. Using EBPV actuator air supply line tube nut (4), install EBPV actuator air supply line (3) onto TMV (5).
Torque EBPV actuator air supply line tube nut to 15 N·m (11 lb·ft).
Thermal Management Valve (TMV) Air Supply Line

Thermal Management Valve (TMV) Air Supply Line Removal
Figure 179 Connection at Thermal Management Valve (TMV)

1. Thermal Management Valve 2. TMV air supply line
(TMV) 3. TMV air supply line tube nut
See Connection at Thermal Management Valve (TMV) (Figure 179) to perform step 1.
1. Loosen TMV air supply line tube nut (3) that secures TMV air supply line (2) to TMV (1) and remove TMV
air supply line from TMV.
Figure 180 Air Supply Line Elbow Fitting

1. TMV air supply line 2. TMV air supply line tube nut 3. Air supply line elbow fitting
See Air Supply Line Elbow Fitting (Figure 180) to perform step 2.
2. Loosen TMV air supply line tube nut (2) that secures TMV air supply line (1) to air supply line elbow fitting
(3) and remove TMV air supply line from engine.
Thermal Management Valve (TMV) Air Supply Line Installation

None
Torques
TMV air supply line tube nut (both ends) 15 N·m (11 lb·ft)
Figure 181 Air Supply Line Elbow Fitting

1. TMV air supply line 2. TMV air supply line tube nut 3. Air supply line elbow fitting
See Air Supply Line Elbow Fitting (Figure 181) to perform step 1.
1. Using TMV air supply line tube nut (2), install TMV air supply line (1) into air supply line elbow fitting (3).
Torque TMV air supply line tube nut to 15 N·m (11 lb·ft).
Figure 182 Connection at Thermal Management Valve (TMV)

1. Thermal Management Valve 2. TMV air supply line
(TMV) 3. TMV air supply line tube nut
See Connection at Thermal Management Valve (TMV) (Figure 182) to perform step 2.
2. Using TMV air supply line tube nut (3), install TMV air supply line (2) onto TMV (1). Torque TMV air supply
Exhaust Back Pressure Valve Housing Cleaning
Figure 183 Exhaust Back Pressure Valve Housing

1. AFTFI port
2. Exhaust back pressure valve housing
CAUTION: To prevent damage to the aftertreatment system or plugging of the PDOC / DOC / DPF, ensure
no carbon debris remains in AFTFI port upon completion of steps 1 and 2.
1. Carefully remove carbon from the AFTFI port (Figure 183) (Item 1) on the exhaust back pressure valve
housing (Figure 183) (Item 2) with a chisel or other appropriate tool. Remove debris with a shop vac.
Special Torques
2
Air supply tube (at bulkhead fitting) 17.5 N·m (13 lb·ft)
Air supply tube nut (at air control valve) 12 N·m (106 lb·in)
Exhaust back pressure valve tube nut (at air control valve) 15 N·m (11 lb·ft)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lb·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lb·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting 15 N·m (11 lb·ft)
TMV mounting bolts 31 N·m (23 lb·ft)
Special Tools
Crimping pliers Obtain locally
Superlub™ synthetic high heat lubricant Obtain locally
Exhaust Manifold
Exhaust Manifold Cuffs
Front Cuff Inspection
Overview
Inspect exhaust manifold for excessive soot buildup surrounding joint connections at cuffs.
Figure 184 Exhaust Manifold Cuff Locations

1. Exhaust manifold cuff (rear) 3. Exhaust manifold cuff (front)
2. Center exhaust manifold 4. High Pressure (HP) turbocharger
See Exhaust Manifold Cuff Locations (Figure 184) to locate exhaust manifold cuffs.
Tools Required
None
Equipment condition
Refer to Equipment Condition (page 246) in Front Cuff Removal section of this manual.
Inspection Procedure
Figure 185 Exhaust Manifold Front Cuff

A. Exhaust manifold / front cuff B. Front cuff front half / back half
mating surface mating surface (top and bottom)
See Exhaust Manifold Front Cuff (Figure 185) to perform step 1.

1. Inspect exhaust manifold around exhaust manifold / front cuff mating surface (A) for visible soot buildup.
2. If soot buildup is visible, replace exhaust manifold front cuff. See Exhaust Manifold Front Cuff Replacement
(page 269).
Expected Outcome
Exhaust manifold should be free of visible soot buildup surrounding exhaust manifold / front cuff mating surfaces
and front cuff front half / back half mating surfaces.
Front Cuff Replacement

Front Cuff Removal
Overview
This section provides the engine service procedure for the replacement of the exhaust manifold front cuff.
Equipment Condition
Following steps must be completed before front cuff removal procedure can be performed:
1. Open hood.
2. Obtain service information.
3. Obtain service parts.
4. Obtain service tools.
5. Remove air intake system.
6. Install cap on intake opening.
7. Remove open breather tube assembly from Crankcase Oil Separator (CCOS) outlet. See Crankcase
Oil Separator (CCOS) Removal (page 460).
8. Disconnect engine harness from CCOS sensor.
9. Remove CCOS. See Crankcase Oil Separator (CCOS) Removal (page 460).

None
Exhaust manifold cuff clamp 70 lb-in (8 N·m)

CCOS mounting bolt
Removal Procedure
Figure 186 Air Intake System Piping

1. Air inlet duct 2. Air intake system tube
See Air Intake System Piping (Figure 186) to perform step 1.

1. Remove air intake system tube (2).
Figure 187 Component Removal

1. CCOS vent tube connecting 2. Crankcase Centrifuge Oil 3. Crankcase Oil Separator Speed
hose Separator (CCOS) (CCOSS) sensor
See Component Removal (Figure 187) to perform steps 2 through 4.

2. Disconnect CCOS vent tube connecting hose (1) from CCOS (2).
3. Disconnect CCOSS (3) from CCOS (2).
4. Remove three CCOS mounting bolts and CCOS (2).
Figure 188 Exhaust Manifold Front Cuff Clamp Removal

1. Center exhaust manifold 3. Front exhaust manifold 5. Exhaust manifold cuff clamp
2. Exhaust manifold cuff (back half) 4. Exhaust manifold cuff (front half)
See Exhaust Manifold Front Cuff Clamp Removal (Figure 188) to perform step 5.
5. Remove exhaust manifold cuff clamp (5) securing exhaust manifold cuff (back half) (2) and exhaust manifold
cuff (front half) (4).
Figure 189 Exhaust Manifold Front Cuff Removals

1. Center exhaust manifold 3. Front exhaust manifold
See Exhaust Manifold Front Cuff Removals (Figure 189) to perform step 5.
6. Remove exhaust manifold cuff (front half) (4) and exhaust manifold cuff (back half) (2) from center exhaust
manifold (1) and front exhaust manifold (3).
Front Cuff Installation
Procedure
Figure 190 Exhaust Manifold Front Cuff Installation

1. Center exhaust manifold 3. Front exhaust manifold
See Exhaust Manifold Front Cuff Installation (Figure 190) to perform step 1.
1. Install exhaust manifold cuff (front half) (4) and exhaust manifold cuff (back half) (2) on center exhaust
manifold (1) and front exhaust manifold (3).
Figure 191 Exhaust Manifold Front Cuff Clamp Installation

1. Center exhaust manifold 3. Front exhaust manifold 5. Exhaust manifold cuff clamp
See Exhaust Manifold Front Cuff Clamp Installation to perform step 2.

2. Install exhaust manifold cuff clamp (5) securing exhaust manifold cuff (back half) (2) and exhaust manifold
3. Tighten exhaust manifold cuff clamp. See torque values (page 246).
Figure 192 Component Installations

1. CCOS vent tube connecting 2. Crankcase Centrifuge Oil 3. Crankcase Oil Separator Speed
hose Separator (CCOS) (CCOSS) sensor
See Component Installations (Figure 192) to perform steps 4 through 6.

4. Install CCOS (2) and secure with three CCOS mounting bolts. Tighten mounting bolts. See Torque
Specifications (page 246).
5. Connect CCOSS (3) to CCOS (2).
6. Connect CCOS vent tube connecting hose (1) to CCOS (2).
Figure 193 Air Intake System Piping

1. Air inlet duct 2. Air intake system tube
See Air Intake System Piping (Figure 193) to perform step 1.

7. Install air intake system tube (2).
Reinstall the following:
1. Install CCOS. See Crankcase Oil Separator (CCOS) Installation (Figure 384).
2. Connect engine harness to CCOS sensor.
3. Install open breather tube assembly to Crankcase Oil Separator (CCOS) outlet. See Crankcase Oil
Separator (CCOS) Installation (Figure 384).
4. Remove cap from intake opening.
5. Install air intake system.
6. Close hood.
Rear Cuff Inspection

Overview
Inspect exhaust manifold for excessive soot buildup surrounding joint connections at cuffs.
Figure 194 Exhaust Manifold Cuff Locations

1. Exhaust manifold cuff (rear) 3. Exhaust manifold cuff (front)
2. Center exhaust manifold 4. High Pressure (HP) turbocharger
See Exhaust Manifold Cuff Locations (Figure 194) to locate exhaust manifold cuffs.
Tools Required
None
Equipment condition
Refer to Equipment Condition (page 257) in Rear Cuff Removal section of this manual.
Figure 195 Exhaust Manifold Rear Cuff

A. Exhaust manifold / rear cuff B. Rear cuff front half / back half
mating surface mating surface (top and bottom)
See Exhaust Manifold Rear Cuff (Figure 195) to perform step 1.

1. Inspect exhaust manifold around exhaust manifold / rear cuff mating surface (A) for visible soot buildup.
2. If soot buildup is visible, replace exhaust manifold rear cuff. See Exhaust Manifold Rear Cuff Replacement
(page 257).
Expected Outcome
Exhaust manifold should be free of visible soot buildup surrounding exhaust manifold / rear cuff mating surfaces
and front cuff front half / back half mating surfaces.
Rear Cuff Replacement

Rear Cuff Removal
Overview
This section provides the engine service procedure for the replacement of the exhaust manifold rear cuff.
Equipment Condition
Following steps must be completed before rear cuff removal procedure can be performed:
1. Open hood.
5. Drain air tank.
11. Remove cup holder from engine housing cover.
14. Disconnect engine harness from Oxygen (O2) sensor, NOx sensor, and AFTI. See Exhaust
Back-Pressure Valve (EBPV) Removal (page 840).
15. Remove EGR cooler mounting bracket at coolant inlet.
16. Remove rear coolant manifold. See Rear Coolant Manifold Removal.
17. Remove EGR coolant supply tube. See Exhaust Gas Recirculation (EGR) Cooler Removal (page 821).

None
Mica Ring Assembly Tool Exhaust manifold cuff clamp 70 lb-in (8 N·m)
EGR valve bellow tube V-band clamp 11 lb-in (15 N·m)
Coolant manifold pipe support bracket bolt 6 lb-in (8 N·m)
Coolant manifold pipe to EGR cooler bolt 23 lb-in (31 N·m)
Rear exhaust manifold heat shield bolts 13 lb-in (18 N·m)
Outside EGR heat shield bolts 13 lb-in (18 N·m)
Removal Procedure
1. Disconnect engine harness from Oxygen Sensor (O2S), NOX sensor, AFTFI.
2. Remove Rear Manifold Coolant Tube (page 000).
Figure 196 Coolant Manifold Pipe Assembly

1. Coolant manifold pipe support 3. Coolant manifold pipe to EGR 5. Coolant manifold pipe support
bracket bolt (2) cooler bolt (2) bracket
2. Coolant manifold pipe nut (2) 4. Coolant manifold pipe assembly
See Coolant Manifold Pipe Assembly (Figure 196) to perform steps 3 through 5.
3. Remove two coolant manifold pipe support bracket bolts (3).
4. Remove two coolant manifold pipe to EGR cooler bolts (2) securing coolant manifold pipe assembly (4) to
EGR Cooler.
5. Remove coolant manifold pipe assembly (4) together with coolant manifold pipe support bracket (5).
Figure 197 Outside EGR Heat Shield Removal

1. Rear exhaust manifold 3. Outside EGR heat shield
2. Outside EGR heat shield bolt (5) 4. EGR Cooler
See Outside EGR Heat Shield Removal (Figure 197) to perform step 6.
6. Remove five outside EGR heat shield bolts (2) and outside EGR heat shield (3) secured to rear exhaust
manifold (1) and EGR cooler (4).
Figure 198 Rear Exhaust Manifold Heat Shield

1. Rear exhaust manifold hear 2. Rear exhaust manifold heat
shield shield bolt (5)
See Rear Exhaust Manifold Heat Shield (Figure 198) to perform step 7.
7. Remove five exhaust manifold heat shield bolts (2) and rear exhaust manifold hear shield (1) secured to
rear exhaust manifold.
Figure 199 Exhaust Manifold Rear Cuff Clamp Removal

1. Rear exhaust manifold 3. Exhaust manifold cuff (front half) 5. Exhaust manifold cuff clamp
2. Exhaust manifold cuff (back half) 4. Center exhaust manifold
See Exhaust Manifold Rear Cuff Clamp Removal (Figure 199) to perform step 8.
8. Remove exhaust manifold cuff clamp (5) securing exhaust manifold cuff (back half) (2) and exhaust manifold
Figure 200 Exhaust Manifold Rear Cuff Removal

1. Rear exhaust manifold 3. Center exhaust manifold
See Exhaust Manifold Rear Cuff Removal (Figure 199) to perform step 9.
9. Remove exhaust manifold cuff (front half) (4) and exhaust manifold cuff (back half) (2) from rear exhaust
manifold (1) and center exhaust manifold (3).
Rear Cuff Installation
Figure 201 Exhaust Manifold Rear Cuff Installation

1. Rear exhaust manifold 3. Center exhaust manifold
See Exhaust Manifold Rear Cuff Installation (Figure 201) to perform step 1.
1. Install exhaust manifold cuff (front half) (4) and exhaust manifold cuff (back half) (2) to rear exhaust manifold
(1) and center exhaust manifold (3).
Figure 202 Exhaust Manifold Rear Cuff Clamp Installation

1. Rear exhaust manifold 3. Exhaust manifold cuff (front half) 5. Exhaust manifold cuff clamp
2. Exhaust manifold cuff (back half) 4. Center exhaust manifold
See Exhaust Manifold Rear Cuff Clamp Installation (Figure 202) to perform step 2.
2. Install exhaust manifold cuff clamp (5) to secure exhaust manifold cuff (back half) (2) and exhaust manifold
3. Tighten exhaust manifold cuff clamp. See Torque Specifications .

1. Rear exhaust manifold hear 2. Rear exhaust manifold heat
shield shield bolt (5)
4. Install rear exhaust manifold heat shield (1) to rear exhaust manifold and secure with five rear exhaust
manifold heat shield bolts (2). Tighten bolts. See Torque Specifications (page 257).
Figure 204 Outside EGR Heat Shield Installation

1. Rear exhaust manifold 3. Outside EGR heat shield
2. Outside EGR heat shield bolt (5) 4. EGR Cooler
See Outside EGR Heat Shield Installation (Figure 204) to perform step 5.
5. Install outside EGR heat shield (3) and secure to EGR cooler (4) and rear exhaust manifold (1) with five
outside EGR heat shield bolts (2). Tighten bolts. See Torque Specifications (page 257).
Figure 205 Coolant Manifold Pipe Assembly

1. Coolant manifold pipe support 3. Coolant manifold pipe to EGR 5. Coolant manifold pipe support
bracket bolt (2) cooler bolt (2) bracket
2. Coolant manifold pipe nut (2) 4. Coolant manifold pipe assembly
See Coolant Manifold Pipe Assembly (Figure 205) to perform steps 6 through 10.
6. Install coolant manifold pipe assembly (4) together with coolant manifold pipe support bracket (5).
7. Install two coolant manifold pipe support bracket bolts (1) and hand tighten.
8. Install two coolant manifold pipe to EGR cooler bolts (3) and two coolant manifold pipe nuts (2) securing
coolant manifold pipe assembly (4) to EGR Cooler and hand-tighten.
9. Tighten coolant manifold pipe nuts and coolant manifold pipe support bracket mounting bolts. See Torque
Specifications (page 257).
10. Install Manifold Coolant Tube.
11. Connect engine harness to Oxygen Sensor (O2S), NOX sensor, AFTFI.
1. Install EGR coolant supply tube. See Exhaust Gas Recirculation (EGR) Cooler Installation (page 1175).
2. Install rear coolant manifold. See Rear Coolant Manifold Installation (page 1175).
3. Install EGR cooler mounting bracket at coolant inlet.

4. Connect engine harness to Oxygen (O2) sensor, NOx sensor, and AFTI. See Exhaust Back-Pressure
Valve (EBPV) Installation (page 1158).
5. Install engine housing cover.
6. Install bracket to engine housing cover.
7. Install cup holder on engine housing cover.
8. Install front-cab floor mat.
9. Install gear shift level and air lines if equipped with manual transmission.
10. Install right kick panel.
11. Install right scuff plate.
12. Install right-side seat.
13. Fill air tank.
14. Close hood.
Exhaust Manifold Assembly

Exhaust Manifold Inspection
Overview
The following procedure is intended for inspection of the exhaust manifold on the engine. Exhaust manifold
sections should be free of cracks, pitting, and other notable damage. Connections and sealing surfaces should
be free of soot buildup indicating exhaust leaks.
Equipment Condition
Refer to Equipment Condition (page 272) in Exhaust Manifold Removal section of this manual.
Tools Required
None
Figure 206 Exhaust Manifold Inspection Checkpoints

A. EGR valve sealing surface D. Center exhaust manifold cylinder G. HP Turbocharger sealing
B. Rear exhaust manifold cylinder head sealing surface surface
head sealing surface E. Front exhaust manifold cylinder H. Center exhaust manifold
C. Exhaust manifold cuff (2) head sealing surface I. Rear exhaust manifold
F. Front exhaust manifold
See Exhaust Manifold Inspection Checkpoints (Figure 206) to perform steps 1 through 14.
1. Inspect rear exhaust manifold (I) for significant damage or pitting that could cause exhaust leak.
2. If damage or pitting is evident, replace rear exhaust manifold (I).
3. Inspect for signs of exhaust leak and /or soot buildup at rear exhaust manifold cylinder head sealing surface
(B).
4. If signs of exhaust leak and /or soot buildup are present, replace rear exhaust manifold.
5. Inspect center exhaust manifold (H) and front exhaust manifold (F) for significant damage or pitting that
could cause exhaust leak.
6. If damage or pitting is evident, replace entire exhaust manifold assembly.
7. Inspect for signs of exhaust leak and / or soot buildup at center exhaust manifold cylinder head sealing
surface (D), HP turbocharger sealing surface (G) and / or front exhaust manifold cylinder head sealing
surface (E).
8. If signs of exhaust leak and /or soot buildup are present, replace entire exhaust manifold assembly.
9. Inspect for signs of exhaust leak on exhaust manifold sections connection points surrounding cuffs (C).
10. If signs of exhaust leak and /or soot buildup are present, replace cuffs.
Expected Outcome
Exhaust manifold sections should be free of cracks, pitting, and other notable damage. Connections and sealing
surfaces should be free of soot buildup indicating exhaust leaks.
Exhaust Manifold Replacement

Exhaust Manifold Removal
Overview
This section provides complete, self-contained instructions for the removal and replacement of the Exhaust
Manifold.
Equipment Condition
Following steps must be completed before actual exhaust manifold procedure can be performed:
1. Open hood.
7. Drain air tank.
8. Remove left-side seat.
9. Remove left kick panel.
10. Remove interior panel from pedal area.
11. Remove left scuff plate.

17. Remove cup holder from engine housing cover
20. Using Coolant Management Tool KL5007NAV, drain cooling system.
21. Remove right front fender assembly and bracket.
22. Disconnect coolant supply line from AFTFI, discard O-ring, and use Air and Fuel Cap and Plug Kit
ZTSE4891 to cap line. See Aftertreatment Fuel Injector (AFTFI) Removal (page 837).
23. Disconnect coolant return line from AFTFI, discard O-ring, and use Air and Fuel Cap and Plug Kit
ZTSE4891 to cap line. See Aftertreatment Fuel Injector (AFTFI) Removal (page 837).
24. Disconnect AFTFI fuel supply line and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line. See
Aftertreatment Fuel Injector (AFTFI) Removal (page 837).
25. Remove EBPV heat shield. See Exhaust Back-Pressure Valve (EBPV) Removal (page 840).
26. Disconnect EBPV air supply line from EBPV Actuator. See Exhaust Back-Pressure Valve (EBPV)
Removal (page 840).
27. Disconnect engine harness from Oxygen (O2) sensor, NOx sensor, and AFTI. See Exhaust
Back-Pressure Valve (EBPV) Removal (page 840).
28. Remove EGR cooler mounting bracket at coolant inlet.
29. Remove rear coolant manifold. See Rear Coolant Manifold Removal (page 879).
30. Remove EGR coolant supply tube. See Exhaust Gas Recirculation (EGR) Cooler Removal (page 821).
31. Remove EGR heat shield. See Exhaust Gas Recirculation (EGR) Cooler Removal (page 821).
32. Remove EBPV assembly from LP turbocharger and discard gasket. See Exhaust Back-Pressure Valve
(EBPV) Removal (page 840).
33. Disconnect HP turbocharger wastegate hose. See Low-Pressure (LP) Turbocharger Removal (page
862).
34. Remove HP turbocharger wastegate actuator.
35. Remove air filter housing and tube, connected to Low-Pressure (LP) turbocharger air inlet duct (Figure
13) (Item 3), and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line.
36. Remove HPCAC air inlet pipe, connected to High-Pressure (HP) turbocharger air outlet duct (Figure 13)
(Item 5) and HPCAC, and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line.
37. Remove HP turbocharger outlet duct and discard O-ring seal. See Low-Pressure (LP) Turbocharger
Removal (page 862).
38. Disconnect engine harness from MAP, EOP sensor, CCOS sensor, EBP sensor, and ECT2 sensor.
39. Remove air inlet duct and discard air inlet duct O-ring seal. See Low-Pressure (LP) Turbocharger
Removal (page 862).
40. Remove cab heater coolant return tube and discard O-ring. See High-Pressure (HP) Turbocharger
Removal (page 855).
41. Remove LPCAC coolant supply hose and coolant return hose. See Low-Pressure Charge Air Cooler
(LPCAC) Removal (page 848).
42. Remove heater hose return tube. See Low-Pressure Charge Air Cooler (LPCAC) Removal (page 848).
43. Position open breather tube (includes removing three P-clamp bolts and disconnecting coolant hose.
44. Disconnect battery to ground cable from LPCAC ground stud.
45. Remove LPCAC ground stud.
46. Disconnect battery to starter cable from starter ground stud.
47. Disconnect battery to starter cable from starter positive stud.
48. Disconnect engine harness from starter solenoid.
49. Reposition starter heat shield.
50. Remove LPCAC. See Low-Pressure Charge Air Cooler (LPCAC) Removal (page 848).
51. Remove LPCAC 72.2x60 DMR extension tube / inspect or discard.
52. Remove LPCAC to LP turboxharger O-ring seal and discard.
53. Remove Exhaust Back Pressure (EBP) sensor from LP Turbocharger exhaust outlet.
54. Disconnect coolant return (to water distribution housing) hose from housing.
55. Remove HP Turbocharger duct air supply duct. See High-Pressure (HP) Turbocharger Removal (page
855).
56. Remove O-ring seal from HP turbocharger compressor inlet and discard.
57. Disconnect heater return tube from open breather tube. See Low-Pressure Charge Air Cooler (LPCAC)
Removal (page 848).
58. Remove open breather tube assembly from Crankcase Oil Separator (CCOS) outlet. See Crankcase
Oil Separator (CCOS) Removal (page 460).
59. Remove turbocharger oil supply line from HP and LP turbochargers and discard O-rings. See
Low-Pressure (LP) Turbocharger Removal (page 862).
60. Remove turbocharger oil drain tube from HP and LP turbochargers and discard gaskets. See
Low-Pressure (LP) Turbocharger Removal (page 862).
61. Remove turbocharger oil drain hose from crankcase. See Low-Pressure (LP) Turbocharger Removal
(page 862).
62. Remove HP turbocharger heat shield. See Low-Pressure (LP) Turbocharger Removal (page 862).
63. Remove LP turbocharger heat shield.
64. Remove turbocharger mounting bracket. See Low-Pressure (LP) Turbocharger Removal (page 862).
65. Remove LP turbocharger. See Low-Pressure (LP) Turbocharger Removal (page 862).
66. Remove HP turbocharger. See High-Pressure (HP) Turbocharger Removal (page 855).
67. Remove HP turbocharger mounting stud from exhaust manifold (if required).
68. Clean exhaust manifold / HP turbocharger mounting flange (if required).
69. Clean LP turbocharger / HP turbocharger mounting flanges.
70. Clean turbocharger oil supply hose.
71. Remove oil filter housing cap and filter. See Oil Filter Removal (page 874).
72. Clean turbocharger oil drain hose.

73. Remove CCOS. See Crankcase Oil Separator (CCOS) Removal (page 460).
74. Remove CCOS gasket. Inspect and discard if necessary.
75. Clean CCOS passages.
76. Remove rear EGR bellow tube. See Exhaust Gas Recirculation (EGR) Cooler Removal (page 821).

None
Exhaust manifold cuff clamp 70 lb-in (8 N·m)

EGR valve bellows V-band clamp 11 lb·ft (14.5 N·m)
Procedure
Figure 207 Rear Exhaust Manifold Heat Shield Removal

1. Rear exhaust manifold heat 2. Rear exhaust manifold heat 3. Rear exhaust manifold
shield bolts (4) shield
See Rear Exhaust Manifold Heat Shield Removal (Figure 207) to perform step 1.
1. Remove four rear exhaust manifold heat shield bolts (1) that secure rear exhaust manifold heat shield (2)
to rear exhaust manifold (3).
Figure 208 Exhaust Manifold Removal

1. Exhaust-manifold bolts and 2. Exhaust manifold sections (3)
sleeve spacers (18) 3. Cylinder head
See Exhaust Manifold Removal (Figure 208) to perform steps 2 and 3.

2. Remove 18 exhaust-manifold bolts and sleeve spacers (1) securing exhaust manifold sections (2) to cylinder
head (3). Remove exhaust manifold from engine as a complete assembly.
3. Discard bolts and sleeve spacers.
Exhaust Manifold Installation
Procedure
Figure 209 Exhaust Manifold Installation

1. Cylinder head 4. Exhaust manifold assembly 7. Exhaust manifold cuff clamp (2)
2. Exhaust manifold gasket 5. Exhaust manifold sleeve spacer
3. Alignment pin (2) 6. Exhaust manifold mounting bolt
See Exhaust Manifold Installation (Figure 209) to perform steps 1 through 6.

1. Loosen clamps securing two exhaust manifold cuff clamps (7) to allow free movement.
2. Install two alignment pins (3) into cylinder head (1) as shown.
3. Install an exhaust manifold gasket (2) onto each alignment pin (3), positioning gaskets against cylinder head
(1).
4. Place exhaust manifold assembly (4) into position onto cylinder head (1), using alignment pins (3) as guide.
5. Install four exhaust manifold sleeve spacers (5) and four exhaust manifold mounting bolts (6) into manifold
and gasket, securing exhaust manifold assembly (4) to the cylinders where alignment pins are located.
Hand tighten, allowing sufficient movement of exhaust manifold assembly (4) to permit remaining exhaust
manifold gaskets (2) to be inserted in following steps.
6. Remove alignment pins (3). Replace with exhaust manifold sleeve spacer (5) and exhaust manifold
mounting bolt (6). Hand tighten, allowing sufficient movement of exhaust manifold assembly (4) to permit
exhaust manifold gaskets (2) to be inserted at remaining cylinder positions.
Figure 210 Exhaust Manifold Installation

1. Exhaust manifold assembly 3. Cylinder head 5. Exhaust manifold sleeve spacer
2. Exhaust manifold gasket 4. Exhaust manifold mounting bolt
See Exhaust Manifold Installation (Figure 210) to perform steps 7 through 9.

7. Starting at rear cylinder, insert exhaust manifold gasket (2) between exhaust manifold assembly (1) and
cylinder head (3); position gasket so mounting holes are aligned with manifold / cylinder mounting holes.
8. Install three exhaust manifold sleeve spacers (5) and three exhaust manifold mounting bolts (4) into manifold
and gasket, securing to cylinder head (3). Hand tighten, allowing sufficient movement of exhaust manifold
assembly (1) to permit exhaust manifold gaskets (2) to be inserted at remaining cylinder positions.
9. Repeat steps 7and 8 for remaining cylinders.
Figure 211 EGR Exhaust Manifold Tightening Sequence
See Exhaust Manifold Tightening Sequence (Figure 211) to perform step 10.
10. Tighten all bolts using the tightening sequence shown in three rounds as follows:
A. Round 1: 15 ft-lb (20 N·m)
B. Round 2: 30 ft-lb (40 N·m)
C. Round 3: additional 90⁰
11. Tighten two clamps securing two exhaust manifold cuffs (Figure 209) (Item 7). See Torque Specifications
(page 275).
Figure 212 EGR Valve Bellows Tube V-band Clamp

1. Rear exhaust manifold 3. EGR valve bellows tube V-band 5. Front EGR valve bellows tube
2. Rear EGR valve bellows tube clamps (2) 6. EGR Tube
4. EGR valve
See EGR Valve Bellows Tube (Figure 212) to perform steps 12 and 13.
12. Install rear EGR valve bellows tube (2) with two V-band clamps (3) and new gaskets.
13. Tighten V-band clamps. See Torque Specifications (page 275).
1. Install rear EGR bellow tube. See Exhaust Gas Recirculation (EGR) Cooler Installation (page 1175).
2. Clean oil cooler centrifuge passages.
3. Install CCOS gasket.
4. Install CCOS. See Crankcase Oil Separator (CCOS) Installation (Figure 384).
5. Clean turbocharger oil drain hose.
6. Install oil filter housing cap and filter. See Oil Module Installation (page 1126).
7. Clean turbocharger oil supply hose.
8. Clean LP turbocharger / HP turbocharger mounting flanges.
9. Clean exhaust manifold / HP turbocharger mounting flange (if required).

10. Install HP turbocharger mounting stud from exhaust manifold (if required).
11. Install HP turbocharger. See High-Pressure (HP) Turbocharger Installation (page 1129).
12. Install LP turbocharger. See Low-Pressure (LP) Turbocharger Installation (page 1138).
13. Install turbocharger mounting bracket. See Low-Pressure (LP) Turbocharger Installation (page 1138).
14. Install LP turbocharger heat shield.
15. Install HP turbocharger heat shield. See Low-Pressure (LP) Turbocharger Installation (page 1138).
16. Install turbocharger oil drain hose from crankcase. See Low-Pressure (LP) Turbocharger Installation
(page 1138).
17. Install turbocharger oil drain tube from HP and LP turbochargers and discard gaskets. SeeSee
Low-Pressure (LP) Turbocharger Installation (page 1138).
18. Install turbocharger oil supply line from HP and LP turbochargers and discard O-rings. See
Low-Pressure (LP) Turbocharger Installation (page 1138).
19. Install open breather tube assembly from centrifuge outlet. See Crankcase Oil Separator (CCOS)
Installation (Figure 384).
20. Connect heater return tube from open breather tube. See Low-Pressure Charge Air Cooler (LPCAC)
Installation.
21. Install O-ring seal from HP turbocharger compressor inlet and discard.
22. Install HP Turbocharger duct air supply duct. See High-Pressure (HP) Turbocharger Installation.
23. Connect coolant return (to water distribution housing) hose from housing.
24. Install Exhaust Back Pressure (EBP) sensor from LP Turbocharger exhaust outlet.
25. Install LPCAC to LP turboxharger O-ring seal and discard.
26. Install LPCAC 72.2x60 DMR extension tube / inspect or discard.
27. Install LPCAC. See Low-Pressure Charge Air Cooler (LPCAC) Installation (page 1138).
28. Reposition starter heat shield.
29. Connect engine harness to starter solenoid.
30. Connect battery to starter cable to starter positive stud.
31. Connect battery to starter cable to starter ground stud.
32. Install LPCAC ground stud.
33. Connect battery to ground cable to LPCAC ground stud.
34. Reposition open breather tube (includes connecting coolant hose and installing three P-clamp bolts).
35. Install heater hose return tube. See Low-Pressure Charge Air Cooler (LPCAC) Installation.
36. Install LPCAC coolant supply hose and coolant return hose. See Low-Pressure Charge Air Cooler
(LPCAC) Installation (page 1138).
37. Install cab heater coolant return tube and discard O-ring. See High-Pressure (HP) Turbocharger
Installation (page 1129).
38. Install air inlet duct and discard air inlet duct O-ring seal. See Low-Pressure (LP) Turbocharger
39. Install three P-clamp bolts engine harness from MAP, EOP sensor, CCOS sensor, EBP sensor, and
ECT2 sensor.
40. Install HP turbocharger outlet duct and discard O-ring seal. See Low-Pressure (LP) Turbocharger
41. Install HPCAC air inlet pipe, connected to High-Pressure (HP) turbocharger air outlet duct (Item 5) and
HPCAC, and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line.
42. Install air filter housing and tube, connected to Low-Pressure (LP) turbocharger air inlet duct (Item 3),
and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line.
43. Install HP turbocharger wastegate actuator.
44. Install HP turbocharger wastegate hose. See Low-Pressure (LP) Turbocharger Installation (page 1138).
45. Install EBPV assembly from LP turbocharger and discard gasket. See Exhaust Back-Pressure Valve
(EBPV) Installation (page 1158).
46. Install EGR heat shield. See Exhaust Gas Recirculation (EGR) Cooler Installation (page 1175).
47. Install EGR coolant supply tube. See Exhaust Gas Recirculation (EGR) Cooler Installation (page 1175).
48. Install rear coolant manifold. See Rear Coolant Manifold Installation (page 1122).
49. Install EGR cooler mounting bracket at coolant inlet.
50. Install engine harness from Oxygen(O2) sensor, NOx sensor, and AFTI. See Exhaust Back-Pressure
Valve (EBPV) Installation (page 1158).
51. Install EBPV air supply line from EBPV Actuator. See Exhaust Back-Pressure Valve (EBPV) Installation
(page 1158).
52. Install EBPV heat shield. See Exhaust Back-Pressure Valve (EBPV) Installation (page 1158).
53. Install AFTFI fuel supply line and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap line. See
Aftertreatment Fuel Injector (AFTFI) Installation (page 1170).
54. Install coolant return line from AFTFI, discard O-ring, and use Air and Fuel Cap and Plug Kit ZTSE4891
to cap line. See Aftertreatment Fuel Injector (AFTFI) Installation (page 1170).
55. Install coolant supply line from AFTFI, discard O-ring, and use Air and Fuel Cap and Plug Kit ZTSE4891
to cap line. See Aftertreatment Fuel Injector (AFTFI) Installation (page 1170).
56. Install right front fender assembly and bracket.
57. Using Coolant Management Tool KL5007NAV, fill cooling system to appropriate level.
58. Install engine housing cover.
59. Install bracket from engine housing cover.
60. Install cup holder from engine housing cover.
61. Install front-cab floor mat.
62. If equipped with manual transmission, install gear shift level and air lines.
63. Install right kick panel.
64. Install right scuff plate.
65. Install right-side seat.

66. Install left scuff plate.
67. Install interior panel from pedal area.
68. Install left kick panel.
69. Install left-side seat.
70. Fill air tank.
71. Install battery-to-ground cable.
72. Install battery-box cover.
73. Close hood.
Intake System
components.
last.
Air Filter Housing and Air Intake Tube

Air Filter Housing and Air Intake Tube Removal
Overview
This section provides instructions for removal of the air filter housing and air intake tube.

None.
Equipment Condition
None.
Removal Procedure
Figure 213 Air Filter Housing and Air Intake Tube

1. Air intake tube 2. Air filter housing
See Air Filter Housing and Air Intake Tube (Figure 213) to perform steps 1 and 2.
1. Loosen clamp, remove two mounting nuts and remove air filter housing (2).
2. Remove clamp and air intake tube (1).
None.
Air Filter Housing and Air Intake Tube Installation
Overview
This section provides instructions for installation of the air filter housing and air intake tube.

None.
Equipment Condition
None.
Figure 214 Air Filter Housing and Air Intake Tube

1. Air intake tube 2. Air filter housing
See Air Filter Housing and Air Intake Tube (Figure 214) to perform steps 1 and 2.
1. Install air intake tube (1). Tighten clamp.
2. Install air filter housing (2). Tighten clamp and two mounting nuts to secure.
None.
Low-Pressure Charge Air Cooler (LPCAC)

Low-Pressure Charge Air Cooler (LPCAC) Removal
Figure 215 AFTFI Coolant Return Tube

1. Bolt
2. Aftertreatment Fuel Injector (AFTFI) coolant return tube
3. Crankcase
See AFTFI Coolant Return Tube (Figure 215) to perform step 1.

1. Remove bolt securing AFTFI coolant return tube to crankcase.
Figure 216 AFTFI Coolant Return Tube Hold-Down Clips

1. AFTFI coolant return tube 3. Spring clamp
2. Hold-down clips 4. Open breather tube assembly
See AFTFI Coolant Return Tube Hold-Down Clips (Figure 216) to perform steps 2 through 4.
2. Remove AFTFI coolant return tube from hold-down clips.
3. Remove spring clamp securing AFTFI coolant return tube to open breather tube assembly.
4. Remove AFTFI coolant return tube from open breather tube assembly.
Figure 217 Heater Hose Return Tube

1. LPCAC 3. Heater hose return tube 5. Open breather tube assembly
2. Bolt 4. Spring clamp
See Heater Hose Return Tube (Figure 217) to perform steps 5 and 6.
5. Remove spring clamp securing heater hose return tube to open breather tube assembly.
6. Remove bolt securing heater hose return tube to LPCAC.
Figure 218 Open Breather Tube Assembly

1. Stud bolts (2) 2. Open breather tube assembly 3. LPCAC
See Open Breather Tube Assembly (Figure 218) to perform step 7.

7. Remove two stud bolts securing open breather tube assembly to LPCAC.
Figure 219 Crankcase Oil Separator (CCOS) Assembly

1. Open breather tube assembly 2. Spring clamp 3. CCOS assembly
See Crankcase Oil Separator (CCOS) Assembly (Figure 219) to perform step 8.
8. Remove spring clamp that secures open breather tube assembly to the CCOS assembly and remove open
breather tube from engine.
Figure 220 LPCAC

1. LPCAC 4. Coolant supply hose 7. Stud bolts (2)
2. Spring clamp 5. Spring clamp
3. Coolant return hose 6. Bolt
See LPCAC (Figure 220) to perform steps 9 through 11.

9. Remove spring clamp securing coolant supply hose to LPCAC and remove supply hose from LPCAC.
10. Remove spring clamp securing coolant return hose to LPCAC and remove return hose from LPCAC.
11. Remove 1 bolt and 2 stud bolts securing LPCAC to engine block and remove LPCAC from engine.
Low-Pressure Charge Air Cooler (LPCAC) Cleaning and Inspection
Figure 221 Low-Pressure Charge Air Cooler (LPCAC)

A. LPCAC
B. Low-Pressure (LP) turbocharger outlet sealing surface
C. Coolant return hose port
D. Coolant supply hose port
E. High-Pressure (HP) turbocharger air supply duct sealing surface

1. Using a non-caustic brake cleaner, clean LPCAC (A) and dry with filtered, compressed air.
2. Inspect LPCAC (A) for cracks, pitting, signs of leaks, and other notable damage. Repair or replace as
necessary.
3. Inspect LP turbocharger sealing surface, coolant return hose port, coolant supply hose port, and HP
turbocharger air supply duct sealing surface (B, C, D, and E) for cracks, pitting, and other notable damage.
Repair or replace as necessary.
Low-Pressure Charge Air Cooler (LPCAC) Installation

• Extension Tube Installer ZTSE6043
Torques
LPCAC mounting bolt 62 N·m (46 lb·ft)

LPCAC stud bolts 62 N·m (46 lb·ft)
Hose clamp 3.5 N·m (31 lb·in)
Open breather tube assembly stud bolts 31 N·m (23 lb·ft).
AFTFI coolant return tube mounting bolt 31 N·m (23 lb·ft)
Figure 222 Low-Pressure Charge Air Cooler (LPCAC) Tube Seal and O-ring
1. LPCAC air inlet O-ring seal 3. Tube seal (extension tube) 5. LPCAC
2. LPCAC air inlet 4. LPCAC air outlet
See LPCAC (Figure 222) to perform steps 1 and 2.

1. Lubricate new tube seal (3) with P-80® lubricant or equivalent and install into LPCAC (5) using Extension
Tube Installer ZTSE6043.
2. Install new LPCAC air inlet O-ring seal (1) onto LPCAC air outlet (4) and lubricate with P-80® lubricant or
equivalent.
Figure 223 LPCAC

1. LPCAC 3. Coolant return hose 5. LPCAC mounting bolt
2. Hose clamp 4. Coolant supply hose 6. LPCAC stud bolts (2)

3. Install LPCAC (1) into LP turbocharger and High-Pressure (HP) turbocharger air supply duct.
4. Using LPCAC mounting bolt (5) and 2 LPCAC stud bolts (6), install LPCAC onto engine. Torque LPCAC
mounting bolt and 2 LPCAC stud bolts to 62 N·m (46 lb·ft).
5. Using hose clamp (2), install coolant return hose (3) onto LPCAC (1). Torque hose clamp to 3.5 N·m (31
lb·in).
6. Using hose clamp (2), install coolant supply hose (4) onto LPCAC (1). Torque hose clamp to 3.5 N·m (31
lb·in).

1. Open breather tube assembly 2. Open breather tube assembly 3. CCOS assembly
spring clamp
7. Using open breather tube assembly spring clamp (2), install open breather tube assembly (1) to the CCOS
assembly (3).

1. Open breather tube assembly 2. Open breather tube assembly
stud bolts (2) 3. LPCAC

8. Using 2 open breather tube assembly stud bolts (1) install open breather tube assembly (2) onto LPCAC
(3). Torque open breather tube assembly stud bolts to 31 N·m (23 lb·ft).

1. LPCAC 3. Heater hose return tube
2. Heater hose return tube 4. Spring clamp
mounting bolt 5. Open breather tube assembly
9. Using heater hose return tube mounting bolt (2), install heater hose return tube (3) onto LPCAC (1).
10. Using spring clamp (4), install heater hose return tube (3) onto open breather tube assembly (5).
Figure 227 Aftertreatment Fuel Injector (AFTFI) Coolant Return Tube Hold-Down Clips
See AFTFI Coolant Return Tube Hold-Down Clips (Figure 227) to perform steps 11 and 12.
11. Using spring clamp (3), install AFTFI coolant return tube (1) onto open breather tube assembly (4).
12. Install AFTFI coolant return tube (1) into hold-down clips (2).
Figure 228 Aftertreatment Fuel Injector (AFTFI) Coolant Return Tube

1. AFTFI coolant return tube mounting bolt
2. AFTFI coolant return tube
3. Crankcase
See Aftertreatment Fuel Injector (AFTFI) Coolant Return Tube (Figure 228) to perform step 13.
13. Using AFTFI coolant return tube mounting bolt (1) secure AFTFI coolant return tube (2) to crankcase (3).
Torque AFTFI coolant return tube mounting bolt to 31 N·m (23 lb·ft).
Low-Pressure (LP) Turbocharger

Low-Pressure (LP) Turbocharger Removal
Figure 229 High-Pressure (HP) Turbocharger Outlet Duct

1. Crimp clamp 3. HP turbocharger
2. HP Turbocharger wastegate 4. HP turbocharger outlet duct
hose 5. Stud bolts (2)
See High-Pressure (HP) Turbocharger Outlet Duct (Figure 229) to perform steps 1 through 4.
1. Cut and remove crimp clamp (1) on HP turbocharger wastegate hose (2) and discard crimp clamp.
2. Cut and discard necessary tie straps and tie strap clips.
3. Note routing of HP turbocharger wastegate hose (2) and re-position for disassembly.
4. Remove 2 stud bolts (5) from HP turbocharger outlet duct (4) and remove HP turbocharger outlet duct from
HP turbocharger (3). Remove and discard HP turbocharger outlet duct O-ring seal.
Figure 230 Exhaust Back-Pressure (EBP) Sensor

1. Engine harness connector 4. Stud bolt 7. High-Pressure (HP)
2. Air inlet duct 5. EBP sensor line Turbocharger heat shield
3. EBP sensor 6. Nut stud bolt
See Exhaust Back-Pressure (EBP) Sensor (Figure 230) to perform steps 5 through 9.
5. Disconnect engine harness connector (1) from EBP sensor (3).
7. Remove engine harness connector (1) from air inlet duct (2) and re-position for disassembly.
8. Remove stud bolt (4) securing EBP sensor line to air inlet duct (2).
9. Remove nut (6) securing EBP sensor line (5) to HP turbocharger heat shield stud bolt (7).
Figure 231 EBP Sensor Line

1. LP turbocharger 2. Tube nut 3. EBP sensor line
See EBP Sensor Line (Figure 231) to perform step 10.

10. Loosen tube nut (2) securing EBP sensor line (3) to LP turbocharger (1) and Remove EBP sensor line from
engine.
Figure 232 HP Heat Shield

1. HP turbocharger heat shield 3. Stud bolt
2. Bolt 4. HP turbocharger
See HP Heat Shield (Figure 232) to perform step 11.

11. Remove one bolt (2) and one stud bolt (3) securing HP turbocharger heat shield (1) to HP turbocharger (4)
and remove HP turbocharger heat shield.
Figure 233 Air Inlet Duct

1. Air inlet duct 2. Air inlet duct bolts (2) 3. LP turbocharger
See Air Inlet Duct (Figure 233) to perform step 12.

12. Remove 2 air inlet duct bolts (2) securing air inlet duct (1) to engine and remove air inlet duct from LP
turbocharger (3). Remove and discard air inlet duct O-ring seal.
Figure 234 Oil Supply T-fitting

1. Oil supply line 3. Engine Oil Pressure (EOP) 5. Oil supply t-fitting
2. Tube nut sensor 6. Nut
4. Engine harness connector 7. Stud bolt
See Oil Supply T-fitting (Figure 234) to perform steps 13 through 17.
13. Loosen tube nut (2) securing oil supply line to oil supply t-fitting (5).
14. Remove oil supply line (1) from oil supply t-fitting (5).
15. Disconnect engine harness connector (4) from EOP sensor (3).
16. Remove nut (6) securing oil supply T-fitting (5) to stud bolt (7).
CAUTION: To prevent damage to Engine Oil Pressure (EOP) sensor (3), do not grip sensor by connector
housing.
17. Firmly grasp oil supply T-fitting (5) and pull oil supply T-fitting away from the engine until it slides past both
O-ring seals. Remove oil supply T-fitting from engine and discard O-rings.
Figure 235 Low Pressure Charge Air Cooler (LPCAC) Coolant Supply Line
1. LPCAC coolant supply line 3. High-Pressure (HP)
2. Bolts (2) turbocharger air supply duct
See Low Pressure Charge Air Cooler (LPCAC) Coolant Supply Line (Figure 235) to perform step 18.
18. Remove 2 bolts (2) securing LPCAC coolant supply line (1) to HP turbocharger air supply duct (3).
Figure 236 Turbocharger Oil Supply Line

1. Turbocharger oil supply line 3. HP turbocharger
2. Bolts (2) 4. LP turbocharger
See Turbocharger Oil Supply Line (Figure 236) to perform steps 19 and 20.
19. Remove 2 bolts (2) securing turbocharger oil supply line (1) to HP and LP turbochargers (3 and 4).
20. Remove turbocharger oil supply line (1) from HP and LP turbochargers (3 and 4) and discard.
Figure 237 Turbocharger Oil Drain Tube

1. Bolts (4) 3. Turbocharger oil drain tube
2. HP turbocharger 4. LP turbocharger
See Turbocharger Oil Drain Tube (Figure 237) to perform steps 21 and 22.
21. Remove 4 bolts (1) securing turbocharger oil drain tube (3) to HP and LP turbochargers (2 and 4) and
remove turbocharger oil drain tube from turbochargers.
22. Pull turbocharger oil drain tube (3) up and out of crankcase. Discard turbocharger oil drain tube and O-rings.
Figure 238 Turbocharger Mounting Bracket

1. Bolt 3. Stud bolts with spacers (2) 5. Crankcase
2. LP turbocharger 4. Turbocharger mounting bracket
See Turbocharger Mounting Bracket (Figure 238) to perform steps 23 and 24.
23. Remove bolt (1) securing turbocharger mounting bracket (4) to LP turbocharger (2).
24. Remove 2 stud bolts with spacers (3) securing turbocharger mounting bracket (4) to crankcase (5), and
remove turbocharger mounting bracket from engine.
Figure 239 LP Turbocharger

1. LP turbocharger 2. Bolts (5) 3. HP turbocharger
See LP Turbocharger (Figure 239) to perform steps 25 and 26.

25. Get help from assistant to support turbocharger assembly during removal.
26. Remove and discard 5 bolts (2) securing LP turbocharger (1) to HP turbocharger (3) and remove LP
turbocharger from engine.
27. Using Disposable Air and Fuel Caps ZTSE4891, plug all LP turbocharger inlet and outlet ports after removal.
Low-Pressure (LP) Turbocharger Installation

• P-80® lubricant - Obtain Locally
Torques
LP turbocharger to HP turbocharger mounting bolts 47 N·m (35 lb·ft)

LP turbocharger mounting bracket bolt 31 N·m (23 lb·ft)
LP turbocharger mounting bracket stud bolts with spacers 31 N·m (23 lb·ft)
Turbocharger oil drain tube bolts 31 N·m (23 lb·ft)
Turbocharger oil supply line bolts 26 N·m (19 lb·ft)
LPCAC coolant supply line bolts 31 N·m (23 lb·ft)
Oil supply t-fitting nut 13 N·m (10 lb·ft)
Oil supply line tube nut 26 N·m (19 lb·ft)
Upper air inlet duct bolt 31 N·m (23 lb·ft)
Lower air inlet duct bolt 62 N·m (45 lb·ft)
HP turbocharger heat-shield stud bolt 31 N·m (23 lb·ft)
HP turbocharger heat-shield bolt 31 N·m (23 lb·ft)
EBP sensor line nut 31 N·m (23 lb·ft)
EBP sensor line stud bolt 13 N·m (20 lb·ft).
HP turbocharger outlet duct stud bolts 62 N·m (45 lb·ft).

1. LP turbocharger 2. LP turbocharger to HP 3. HP turbocharger
turbocharger mounting bolts (5)
See LP Turbocharger (Figure 240) to perform steps 1 through 3.

1. Remove all disposable air and fuel caps ZTSE4891 from LP turbocharger inlet and outlet ports prior to
installation.
2. With help from an assistant, move LP turbocharger into place for installation. Ensure alignment dowels are
properly aligned.
3. Using 5 new LP turbocharger to HP turbocharger mounting bolts (2), install LP turbocharger (1) onto HP
turbocharger (3). Torque LP turbocharger to HP turbocharger mounting bolts to 47 N·m (35 lb·ft).

1. LP turbocharger mounting 3. LP turbocharger mounting 4. LP turbocharger mounting
bracket bolt bracket stud bolts with spacers bracket
2. LP turbocharger (2) 5. Crankcase
See Turbocharger Mounting Bracket (Figure 241) to perform steps 4 through 6.

4. Using 2 LP turbocharger mounting bracket stud bolts with spacers (3), install turbocharger mounting bracket
(4) to crankcase (5). Torque bolts to finger tight.
5. Using LP turbocharger mounting bracket bolt (1), secure turbocharger mounting bracket (4) to LP
turbocharger (2). Torque bolt to finger tight.
6. Torque 2 LP turbocharger mounting bracket stud bolts with spacers and LP turbocharger mounting bracket
bolt to 31 N·m (23 lb·ft).

1. Turbocharger oil drain tube bolts 2. HP turbocharger 4. LP turbocharger
(4) 3. Turbocharger oil drain tube
See Turbocharger Oil Drain Tube (Figure 242) to perform steps 7 through 9.
7. Install new O-rings onto new turbocharger oil drain tube and lubricate O-rings with P-80® lubricant.
8. Install bottom of new oil drain tube (3) into crankcase.
9. Using 4 turbocharger oil drain tube bolts (1), install turbocharger oil drain tube (3) into HP and LP
turbochargers (2 and 4). Torque turbocharger oil drain tube bolts to 31 N·m (23 lb·ft).

1. Turbocharger oil supply line 2. Turbocharger oil supply line 3. HP turbocharger
bolts (2) 4. LP turbocharger
10. Lubricate O-rings on new turbocharger oil supply line with P-80® lubricant.
11. Using 2 turbocharger oil supply line bolts (2), install turbocharger oil supply line (1) into HP and LP
turbochargers (3 and 4). Torque turbocharger oil supply line bolts to 26 N·m (19 lb·ft).
1. LPCAC coolant supply line 2. LPCAC coolant supply line bolts 3. High-Pressure (HP)
(2) turbocharger air supply duct
12. Using 2 LPCAC coolant supply line bolts (2), install LPCAC coolant supply line (1) to HP turbocharger air
supply duct (3). Torque LPCAC coolant supply line bolts to 31 N·m (23 lb·ft).

1. Oil supply line 4. EOP sensor engine harness 7. Oil supply t-fitting stud bolt
2. Oil supply line tube nut connector
3. Engine Oil Pressure (EOP) 5. Oil supply t-fitting
sensor 6. Oil supply t-fitting nut
housing.
13. Install new O-rings onto oil supply t-fitting (5) lubricate with P-80® lubricant.
14. Using oil supply t-fitting nut (6), install oil supply t-fitting (5) into engine. Torque oil supply t-fitting nut onto
oil supply t-fitting stud bolt (7) to 13 N·m (10 lb·ft).
15. Using oil supply line tube nut (2), install oil supply line (1) onto oil supply t-fitting (5). Torque oil supply line
tube nut to 26 N·m (19 lb·ft).
16. Connect EOP sensor engine harness connector (4) to EOP sensor (3).

1. Air inlet duct 3. Lower air inlet duct bolt
2. Upper air inlet duct bolt 4. LP turbocharger
See Air Inlet Duct (Figure 246) to perform steps 17 through 20.
17. Install new O-ring seal onto LP turbocharger (3) and lubricate with P-80® lubricant.
18. Slide end of air inlet duct (1) onto LP turbocharger (3).
19. Using upper inlet duct bolt (2), secure air inlet duct (1) to engine. Torque upper air inlet duct bolt to 31 N·m
(23 lb·ft).
20. Using lower inlet duct bolt (3), secure air inlet duct (1) to engine. Torque lower air inlet duct bolt to 62 N·m
(45 lb·ft).

1. HP turbocharger heat shield 3. HP turbocharger heat-shield 4. HP turbocharger
2. HP turbocharger heat-shield bolt stud bolt

21. Using one HP turbocharger heat-shield bolt (2) and one HP turbocharger heat-shield stud bolt (3), install HP
turbocharger heat shield (1) onto HP turbocharger (4). Torque HP turbocharger heat-shield stud bolt and
HP turbocharger heat-shield bolt to 31 N·m (23 lb·ft).
Figure 248 Exhaust Back-Pressure (EBP) Sensor Line

1. LP turbocharger 2. EBP sensor line tube nut 3. EBP sensor line

22. Using EBP sensor line tube nut (2), install EBP sensor line (3) onto LP turbocharger (1). Torque EBP sensor

1. EBP sensor engine harness 4. EBP sensor line stud bolt 7. High-Pressure (HP)
connector 5. EBP sensor line turbocharger heat shield
2. Air inlet duct 6. EBP sensor line nut stud bolt
3. EBP sensor
23. Using EBP sensor line nut (6), secure EBP sensor line (5) to HP turbocharger heat shield stud bolt (7).
Torque EBP sensor line nut to 31 N·m (23 lb·ft).
24. Using EBP sensor line stud bolt (4), secure EBP sensor line (5) to air inlet duct (2). Torque EBP sensor line
stud bolt to 13 N·m (20 lb·ft).
25. Using new tie straps and tie-strap clips, install engine harness connector (1) into place on air inlet duct (2).
26. Connect EBP sensor engine harness connector (1) onto EBP sensor (3).

1. HP turbocharger wastegate 3. HP turbocharger 6. HP turbocharger wastegate
hose crimp clamp 4. HP turbocharger outlet duct actuator
2. HP Turbocharger wastegate 5. HP turbocharger outlet duct stud
hose bolts (2)
27. Install new O-ring seal on HP turbocharger outlet duct. Lubricate seal with P-80® lubricant.
28. Slide end of HP turbocharger outlet duct (4) into outlet of HP turbocharger (3).
29. Using 2 HP turbocharger outlet duct stud bolts (5), install HP turbocharger outlet duct (4) to engine. Torque
HP turbocharger outlet duct stud bolts to 62 N·m (45 lb·ft).
30. Position HP turbocharger wastegate hose (2) for installation.
31. Install new tie straps and tie-strap clips.
32. Using new HP turbocharger wastegate hose crimp clamp (1), install HP turbocharger wastegate hose (2)
onto HP turbocharger wastegate actuator (6).
High-Pressure (HP) Turbocharger

High-Pressure (HP) Turbocharger Removal
None

• Disposable Air and Fuel Caps ZTSE4891
Removal Procedure
Figure 251 High-Pressure (HP) Turbocharger Air Supply Duct Connections

1. Cab heater coolant return tube 4. LPCAC coolant supply tube 7. Water distribution housing
bolt bolts (2) 8. Hose clamp
2. Cab heater coolant return tube 5. High-Pressure (HP) 9. Coolant return hose
3. Low Pressure Charge Air Cooler turbocharger air supply duct
(LPCAC) coolant supply tube 6. Stud bolt
See High-Pressure (HP) Turbocharger Air Supply Duct Connections (Figure 746) to perform steps 1 through 3.
1. Remove cab heater return tube bolt (1) and stud bolt (6) securing cab heater return tube (2) to HP
turbocharger air supply duct (5).
2. Remove 2 LPCAC coolant supply tube bolts (4) securing LPCAC coolant supply tube (3) to HP turbocharger
air supply duct (5).
3. Remove hose clamp (8) securing coolant return hose to water distribution housing (7) and remove coolant
return hose (9) from water distribution housing. Discard O-ring.
Figure 252 LPCAC Coolant Supply Tube

1. Bolt 2. Water distribution housing 3. LPCAC coolant supply tube
See LPCAC Coolant Supply Tube (Figure 252) to perform step 4.

4. Remove bolt (1) securing LPCAC coolant supply tube (3) to water distribution housing (2), and remove
LPCAC coolant supply tube from engine. Discard O-ring.
Figure 253 Cab Heater Coolant Return Tube

1. Cab heater coolant return tube 4. Turbocharger 2 Compressor
2. Bolt Inlet Sensor (TC2CIS)
3. HP turbocharger air supply duct 5. Engine harness connector
See Cab Heater Coolant Return Tube (Figure 747) to perform steps 5 and 6.
5. Remove bolt (2) securing cab heater coolant return tube (1) to HP turbocharger air supply duct (3), and
remove cab heater coolant return tube from engine. Discard O-rings.
6. Disconnect engine harness connector (5) from TC2CIS (4).
Figure 254 HP Turbocharger Air Supply Duct

1. HP turbocharger 3. HP turbocharger air supply duct 5. Bolt
2. V-band clamp 4. Wiring harness clips (2) 6. Oil module assembly
See HP Turbocharger Air Supply Duct (Figure 748) to perform steps 7 through 9.
7. Remove wiring harness clips (4) from HP turbocharger air supply duct (3) and position wiring harness out
of way.
8. Remove and discard V-band (2) clamp securing HP turbocharger air supply duct (3) to HP turbocharger (1).
9. Remove bolt (5) securing HP turbocharger air supply duct (3) to oil module assembly (6), and remove HP
turbocharger air supply duct from engine. Discard HP turbocharger air supply duct O-ring seal.
Figure 255 HP Turbocharger Lower Mounting Nut

1. HP turbocharger 2. Exhaust manifold 3. Lower mounting nut
See HP Turbocharger Lower Mounting Nut (Figure 749) to perform step 10.
10. Remove and discard lower mounting nut (3) securing HP turbocharger (1) to exhaust manifold (2).
Figure 256 HP Turbocharger Upper Mounting Nuts

1. Exhaust manifold 2. Upper mounting nuts (2) 3. HP turbocharger
See HP Turbocharger Upper Mounting Nuts (Figure 750) to perform step 10.
12. Remove and discard 2 upper mounting nuts (2) securing HP turbocharger (3) to exhaust manifold (1) and
remove HP turbocharger from engine. Remove and discard HP turbocharger to exhaust manifold gasket.
High-Pressure (HP) Turbocharger Installation
Oil Filter installed (page 1126).

None
Torques
HP turbocharger air supply duct V-band clamp 6 N·m (4 lb·ft)

HP turbocharger mounting nuts 62 N·m (46 lb·ft)
HP turbocharger air supply duct bolt 62 N·m (46 lb·ft)
LPCAC coolant supply tube to water distribution housing bolt 13 N·m (10 lb·ft).
LPCAC coolant supply tube bolts 31 N·m (23 lb·ft)
Coolant return hose clamp 4 N·m (35 lb·in)
Cab heater coolant return tube bolt and stud bolt 13 N·m (10 lb·ft).
Cab heater coolant return tube bolt 31 N·m (23 lb·ft)

1. Exhaust manifold 2. HP turbocharger 3. HP turbocharger
upper-mounting nuts (2)
See HP Turbocharger Upper Mounting Nuts (Figure 940) to perform steps 1 and 2.
1. With help from assistant, move HP turbocharger (3) into place for installation.
2. Using 2 new HP turbocharger upper-mounting nuts (2) and new turbocharger to exhaust manifold gasket,
install HP turbocharger (3) onto exhaust manifold (1). Torque HP turbocharger upper-mounting nuts to finger
tight.

1. HP turbocharger 3. HP turbocharger lower-mounting
2. Exhaust manifold nut

3. Install new HP turbocharger lower-mounting nut (3) to secure HP turbocharger (1) to exhaust manifold (2).
Torque HP turbocharger lower-mounting nut to finger tight.

1. HP turbocharger 3. HP turbocharger air supply duct 5. HP turbocharger air supply duct
2. HP turbocharger air supply duct 4. Wiring harness clips (2) bolt
V-band clamp 6. Oil module assembly
4. Install new HP turbocharger air supply duct O-ring seal onto HP turbocharger (1). Apply P-80® lubricant to
HP turbocharger air supply duct O-ring seal.
5. With new HP turbocharger air supply duct V-band clamp (2) in place on HP turbocharger air supply duct (3),
slide HP turbocharger air supply duct over inlet of HP turbocharger (1).
6. To secure HP turbocharger air supply duct (3) to HP turbocharger (1), torque HP turbocharger air supply
duct V-band clamp to 6 N·m (4 lb·ft).
Figure 260 HP Turbocharger Upper Mounting Nuts Final Torque

See HP Turbocharger Upper Mounting Nuts Final Torque (Figure 943) to perform step 7.
7. To secure HP turbocharger (3) onto exhaust manifold (1), torque 2 HP turbocharger upper-mounting nuts
(2) to 62 N·m (46 lb·ft).
Figure 261 HP Turbocharger Lower Mounting Nut Final Torque

See HP Turbocharger Lower Mounting Nut Final Torque (Figure 944) to perform step 8.
8. To secure HP turbocharger (1) to exhaust manifold (2), torque HP turbocharger lower-mounting nut (3) to
62 N·m (46 lb·ft).
Figure 262 HP Turbocharger Air Supply Duct Final Torque

See HP Turbocharger Air Supply Duct Final Torque (Figure 945) to perform steps 9 and 10.
9. To secure HP turbocharger air supply duct (3) to oil module assembly (6), torque HP turbocharger air supply
duct bolt (5) to 62 N·m (46 lb·ft).
10. Install wiring harness and 2 wiring harness clips (4) onto HP turbocharger air supply duct (3).
Figure 263 Low-Pressure Charge Air Cooler (LPCAC) Coolant Supply Tube
1. LPCAC coolant supply tube to 2. Water distribution housing
water distribution housing bolt 3. LPCAC coolant supply tube
See LPCAC Coolant Supply Tube (Figure 946) to perform steps 11 and 12.
11. Install new O-ring onto LPCAC coolant supply tube (3) and lubricate O-ring with P-80® lubricant.
12. Using LPCAC coolant supply tube to water distribution housing bolt (1), install LPCAC coolant supply tube
(3) into water distribution housing (2). Torque LPCAC coolant supply tube to water distribution housing bolt
to 13 N·m (10 lb·ft).
Figure 264 HP Turbocharger Air Supply Duct Connections

bolt bolts (2) 8. Coolant return hose clamp
2. Cab heater coolant return tube 5. HP turbocharger air supply duct 9. Coolant return hose
3. LPCAC coolant supply tube 6. Cab heater coolant return tube
stud bolt
See High-Pressure (HP) Turbocharger Air Supply Duct Connections (Figure 947) to perform steps 13 through
16.
13. Using 2 LPCAC coolant supply tube bolts (4), install LPCAC coolant supply tube (3) onto HP turbocharger
air supply duct (5). Torque LPCAC coolant supply tube bolts to 31 N·m (23 lb·ft).
14. Using coolant return hose clamp (8), install coolant return hose (9) onto water distribution housing (7). Torque
coolant return hose clamp to 4 N·m (35 lb·in).
15. Install 2 new O-rings onto cab heater coolant return tube (2) and apply P-80® lubricant to O-rings.
16. Using cab heater return tube bolt (1) and cab heater coolant return tube stud bolt (6), install cab heater
return tube (2) into HP turbocharger air supply duct (5). Torque both the cab heater coolant return tube bolt
and stud bolt to 13 N·m (10 lb·ft).

1. Cab heater coolant return tube 3. HP turbocharger air supply duct 5. Engine harness connector
bolt Inlet Sensor (TC2CIS)
17. Connect engine harness connector (5) onto TC2CIS (4).
18. Using cab heater coolant return tube bolt (2), install cab heater coolant return tube (1) onto HP turbocharger
air supply duct (3). Torque cab heater coolant return tube bolt to 31 N·m (23 lb·ft).
Perform Low-Pressure (LP) Turbocharger Installation (page 1138) procedure.
High-Pressure (HP) Turbocharger Center Section

High-Pressure (HP) Turbocharger Center Section Removal
Overview
This section provides complete, self-contained instructions for the removal and replacement of the HP
turbocharger center section.

• Coolant Management Tool KL5007NAV
• Rubber Lubricant P-80® or equivalent
HP turbocharger air supply duct bolt 46 lb-ft (62 N·m)

HP turbocharger air supply duct V-band clamp 4 lb-ft (6 N·m)
HP turbocharger center section V-band clamp 110 lb-in (12.4 N·m)
Turbocharger oil drain tube bolts 23 lb·ft (31 N·m)
Turbocharger oil supply tube bolts 19 lb-ft (26 N·m)
Coolant return hose clamp 35 lb-in (4 N·m)
LPCAC coolant supply tube to water distribution housing bolt 10 lb-ft (13 N·m)
LPCAC coolant supply hose clamp 31 lb-in (3.5 N·m)
LPCAC coolant return hose clamp 31 lb-in (3.5 N·m)
LPCAC coolant supply tube bolt 23 lb-ft (31 N·m)
Cab heater coolant return tube bolt 10 lb-ft (13 N·m)
Cab heater coolant return tube stud bolt 10 lb-ft (13 N·m)
Upper air intake duct bolt 23 lb-ft (31 N·m)
Lower air intake duct bolt 46 lb-ft (62 N·m)
HP turbocharger outlet duct stud bolts 46 lb·ft (62 N·m)
HP turbocharger heat-shield bolt and stud bolt 23 lb·ft (31 N·m)
Equipment Condition
The following steps must be completed before actual exhaust manifold procedure can be performed:
1. Open Hood.
2. Obtain Service Information.
5. Using Coolant Management Tool KL5007NAV, drain coolant. Place suitable coolant drain pan under truck.
6. Remove left rear side panel.
9. Remove Fender, Inner Panel /Right Side.
Figure 266 High-Pressure (HP) and Low-Pressure (LP) Turbochargers and Connections
1. HP turbocharger 5. HP turbocharger air supply duct 8. HP turbocharger outlet duct
2. Air intake duct 6. High-Pressure Charge Air 9. Low-Pressure (LP) turbocharger
3. Air intake coupler Cooler (HPCAC)
4. Turbocharger 2 Compressor 7. High-Pressure Charge Air
Inlet Pressure (TC2CIP) sensor Cooler (HPCAC) pipe
See High-Pressure (HP) and Low-Pressure (LP) Turbochargers and Connections (Figure 266) to perform steps
10 through 12.
10. Loosen two clamps and remove air intake coupler (3).
11. Remove HPCAC pipe (7) connected to HPCAC (6) and HP turbocharger outlet duct (8).
12. Install cap from Disposable Air and Fuel Caps ZTSE4891 onto HPCAC (6).
Figure 267 Air Intake Duct and HP turbocharger Outlet Duct

1. HP turbocharger heat shield 6. Engine wiring harness 11. Exhaust Back Pressure (EBP)
2. HP turbocharger 7. HP turbocharger air supply duct sensor line
3. Exhaust Back Pressure (EBP) 8. Engine Oil Pressure (EOP)
sensor sensor
4. Air intake duct 9. HP turbocharger outlet duct
5. Turbocharger 2 Compressor 10. LP turbocharger
Inlet Pressure (TC2CIP) sensor
See Air Intake Duct and HP turbocharger Outlet Duct (Figure 267) to perform steps 13 through 19.
13. Disconnect engine harness connectors at Exhaust Back Pressure (EBP) sensor (3), TC2CIP sensor (5) and
EOP sensor (8).
14. Remove two hold down nuts securing engine wiring harness (6) to HP turbocharger air supply duct (7).
15. Move engine wiring harness (6) out of the way and secure.
16. Remove two stud bolts from HP turbocharger out duct (9) and remove HP turbocharger out duct from HP
turbocharger (2). Remove and discard HP turbocharger out duct O-ring seal.
17. Remove one bolt and one stud bolt securing HP turbocharger heat shield (1) to HP turbocharger (2) and
remove HP turbocharger heat shield.
18. Remove bolt securing EBP sensor (3) to air intake duct (4). Reposition and secure EBP sensor line (11)
and EBP sensor (3) together as a unit out of the way. See Low-Pressure (LP) Turbocharger Removal (page
862).
19. Remove two air intake duct bolts and air intake duct (4).Install cap from Disposable Air and Fuel Caps
ZTSE4891 on intake to LP turbocharger (10).
Figure 268 Cab Heater Coolant Return Tube, LPCAC Coolant Supply Tube, and Coolant Hose
1. HP turbocharger 4. Clip 8. LPCAC coolant supply hose
2. Cab heater coolant return tube 5. LPCAC coolant supply tube 9. LPCAC coolant return hose
3. Turbocharger oil supply tube 6. HP turbocharger air supply duct 10. Turbocharger oil return tube
assembly 7. Coolant supply hose 11. LP turbocharger
See Cab Heater Coolant Return Tube, LPCAC Coolant Supply Tube, and Coolant Hose (Figure 268) to perform
steps 20 through 23.
20. Remove clip (4) securing cab heater return tube (2) to turbocharger oil supply tube assembly (3)
21. Remove cab heater return tube (2). See High-Pressure (HP) Turbocharger Removal (page 855).
22. Remove LPCAC coolant supply tube (5). See High-Pressure (HP) Turbocharger Removal (page 855).
23. Remove coolant supply hose (7). See High-Pressure (HP) Turbocharger Removal (page 855).
24. Loosen LPCAC coolant return hose clamp and remove HP turbocharger air supply duct (6) from LPCAC
coolant return hose (9). Discard LPCAC coolant supply tube O-ring.
Figure 269 High-Pressure (HP) Turbocharger

1. HP turbocharger 3. Oil supply tee fitting
2. Turbocharger oil supply tube 4. Turbocharger oil return tube
assembly 5. LP turbocharger
See High-Pressure (HP) Turbocharger (Figure 269) to perform steps 24 and 25.
25. Remove turbocharger oil supply tube assembly (2). See Low-Pressure (LP) Turbocharger Removal (page
862).
26. Disconnect turbocharger oil return tube (4) from HP Turbocharger (1) only. See Low-Pressure (LP)
Turbocharger Removal (page 862).
Removal Procedure
Figure 270 HP Turbocharger Center Section

1. HP turbocharger turbine housing 4. HP turbocharger V-band clamp 8. DMR tube seal (extension tube)
2. HP turbocharger center section 5. O-ring seal 9. Low Pressure Charge Air Cooler
V-Band clamp 6. HP turbocharger air supply duct (LPCAC)
3. HP turbocharger center section 7. HP turbocharger air supply duct
(and compressor housing) bolt
See HP Turbocharger Center Section (Figure 270) to perform steps 1 through 7.

1. Remove mounting bolt (7) from HP turbocharger air supply duct (6), but do not remove HP turbocharger air
supply duct from HP turbocharger center section (3) at this time.
2. Loosen HP turbocharger center section V-band clamp (2) and position clamp over oil passages.
3. Loosen HP turbocharger V-band clamp (4).
4. Using a soft-blow mallet, gently tap HP turbocharger center section (3) until loose.
5. Remove HP turbocharger center section and compressor housing (3) together with HP turbocharger air
supply duct (6) assembly from engine as a unit.
6. Once free from HP turbocharger turbine housing (1) separate HP turbocharger center section (3) and HP
7. Discard O-ring seal (5) and DMR tube seal (8).
High-Pressure (HP) Turbocharger Center Section Installation
Figure 271 High-Pressure (HP) Turbocharger Center Section Lubrication

1. Turbocharger oil supply port 3. Turbocharger assembly shaft
2. Turbocharger oil drain port 4. Dowel (3)
See High-Pressure (HP) Turbocharger Center Section Lubrication (Figure 271) to perform step 1.
1. On work bench lubricate new HP turbocharger center section by rotating turbocharger assembly shaft (3)
and adding oil to turbocharger oil supply port (1) until oil comes out of turbocharger oil drain port (2).
Figure 272 HP Turbocharger Center Section

1. HP turbocharger turbine housing 4. HP turbocharger V-band clamp 8. DMR tube seal (extension tube)
2. HP turbocharger center section 5. O-ring seal 9. Low Pressure Charge Air Cooler
V-Band clamp 6. HP turbocharger air supply duct (LPCAC)
3. HP turbocharger center section 7. HP turbocharger air supply duct
(and compressor housing) bolt
See HP Turbocharger Center Section (Figure 272) to perform steps 2 through 10.
2. Clean flange on HP turbocharger turbine housing (1) with suitable solvent and clean emery cloth.
3. With new HP turbocharger center section V-band clamp (2) in place on HP turbocharger turbine housing
(1), install new HP turbocharger center section and compressor housing (3) into HP turbocharger turbine
housing (1) and let it rest freely.
4. Lubricate new O-ring seal (4) with P-80® rubber lubricant or equivalent and install on HP turbocharger air
supply duct (6) outlet.
5. Lubricate new DMR tube seal (extension tube) (8) with P-80® rubber lubricant or equivalent and install into
LPCAC (9) air outlet using Extension Tube Installer ZTSE6043.
6. Position bolt (7) in place and install HP turbocharger air supply duct (6) into LPCAC (9) air outlet containing
the new tube seal.
install HP turbocharger air supply duct with new O-ring seal to inlet of HP turbocharger center section (3),
then place HP turbocharger center section back into the HP turbocharger turbine housing (1).
8. Align three dowels on HP turbocharger center section (3) with alignment holes on the HP turbocharger
turbine housing (1) and fully seat center section to turbine housing. To locate dowels, see High-Pressure
(HP) Turbocharger Center Section Lubrication (Figure 271).
9. Tighten HP turbocharger air supply duct bolt (7). See Torque Specifications (page 377).
10. Tighten HP turbocharger center section V-band clamp (2) and HP turbocharger V-band clamp (4). See
Torque Specifications (page 377).
Figure 273 High-Pressure (HP) Turbocharger

1. HP turbocharger 3. Oil supply tee fitting
2. Turbocharger oil supply tube 4. Turbocharger oil return tube
assembly 5. LP turbocharger
See High-Pressure (HP) Turbocharger (Figure 273) to perform steps 1 through 4.

1. Install turbocharger oil return tube (4) to HP Turbocharger (1). See Low-Pressure (LP) Turbocharger
2. Tighten connection to turbocharger oil return tube assembly. See Torque Specifications (page 377).
3. Install new turbocharger oil supply tube assembly (2) to oil supply tee fitting (3), HP and LP turbochargers
(1 and 5). See Low-Pressure (LP) Turbocharger Installation (page 1138).
4. Tighten connections to turbocharger oil supply tube assembly. See Torque Specifications (page 377).
Figure 274 Cab Heater Coolant Return Tube, LPCAC Coolant Supply Tube, and Coolant Hose
1. HP turbocharger 4. Clip 8. LPCAC coolant supply hose
2. Cab heater coolant return tube 5. LPCAC coolant supply tube 9. LPCAC coolant return hose
3. Turbocharger oil supply tube 6. HP turbocharger air supply duct 10. Turbocharger oil return tube
assembly 7. Coolant return hose 11. LP turbocharger
See Cab Heater Coolant Return Tube, LPCAC Coolant Supply Tube, and Coolant Hose (Figure 274) to perform
steps 5 through 8.
5. Using LPCAC coolant return hose clamp, install LPCAC coolant return hose (9) onto HP turbocharger air
supply duct (6) with new O-ring. See High-Pressure (HP) Turbocharger Installation (page 1129). Tighten
LPCAC coolant return hose clamp. See Torque Specifications (page 377).
6. Install coolant return hose (7). See High-Pressure (HP) Turbocharger Installation (page 1129).
7. Install LPCAC coolant supply tube (5). See Low-Pressure (LP) Turbocharger Installation (page 1138).
8. Install cab heater coolant return tube (2). See High-Pressure (HP) Turbocharger Installation (page 1129).
Figure 275 Air Intake Duct and HP Turbocharger Outlet Duct

1. HP turbocharger heat shield 6. Engine wiring harness 11. Exhaust Back Pressure (EBP)
2. HP turbocharger 7. HP turbocharger air supply duct sensor line
3. Exhaust Back Pressure (EBP) 8. Engine Oil Pressure (EOP)
sensor sensor
4. Air intake duct 9. HP turbocharger outlet duct
5. Turbocharger 2 Compressor 10. LP turbocharger
Inlet Pressure (TC2CIP) sensor
See Air Intake Duct and HP Turbocharger Outlet Duct (Figure 275) to perform steps 9 through 14.
9. Remove cap on intake to LP turbocharger (10). Install air intake duct (4) with new O-ring seal onto LP
turbocharger (10) and secure with two air intake duct bolts. See Low-Pressure Charge Air Cooler (LPCAC)
Installation (page 1147). Tighten air intake duct bolts. See Torque Specifications (page 377).
10. Move EBP sensor line (11) and EBP sensor (3) into position and secure EBP sensor to air intake duct (4).
See Low-Pressure Charge Air Cooler (LPCAC) Installation (page 1147).
11. Using one HP turbocharger heat-shield stud bolt and one HP turbocharger heat-shield bolt, install HP
turbocharger heat shield (1). Tighten bolts. See Torque Specifications (page 377).
12. Install HP turbocharger outlet duct (9) with new O-ring seal and secure with two HP turbocharger outlet duct
stud bolts. See Low-Pressure Charge Air Cooler (LPCAC) Installation (page 1147). Tighten HP turbocharger
outlet duct stud bolts. See Torque Specifications (page 377).
13. Reposition engine wiring harness (6) and install two hold down nuts to secure engine wiring harness to HP
14. Connect engine harness connectors at EOP sensor (8), TC2CIP sensor (5), and Exhaust Back Pressure
(EBP) sensor (3).
Figure 276 High-Pressure (HP) and Low-Pressure (LP) Turbochargers and Connections
1. HP turbocharger 5. HP turbocharger air supply duct 8. HP turbocharger outlet duct
2. Air intake duct 6. High-Pressure Charge Air 9. Low-Pressure (LP) turbocharger
3. Air intake coupler Cooler (HPCAC)
4. Turbocharger 2 Compressor 7. High-Pressure Charge Air
Inlet Pressure (TC2CIP) sensor Cooler (HPCAC) pipe
See High-Pressure (HP) and Low-Pressure (LP) Turbochargers and Connections (Figure 276) to perform steps
15 through 17.
15. Remove disposable cap from HPCAC (6).
16. Install HPCAC pipe (7) to HPCAC (6) and HP turbocharger outlet duct (8).
17. Install air intake coupler (3).
18. Install Fender, Inner Panel /Right Side.
19. Connect battery-to-ground cable.

20. Install battery-box cover.
21. Install left rear side panel.
22. Using Coolant Management Tool KL5007NAV, fill coolant.
23. Close hood.
Special Torques
Special Tools
P-80® lubricant Obtain Locally
Extension Tube Installer ZTSE6043
Air Compressor and Power Steering System
components.
Power Steering Pressure Tubes
Power Steering Pressure Tubes Removal
Figure 277 Power steering pump and Pressure tubes

1. Power steering pump
2. High-pressure tube fitting nut
3. 1/2” 90 degree tube elbow
4. 1-1/6” 90 degree tube elbow
5. Low-pressure tube fitting nut
1. Place a drain pan under the power steering pump to catch any fluid.
2. Loosen high-pressure tube fitting nut and disconnect tube from 1/2” 90 degree tube elbow.
3. Loosen low-pressure tube fitting nut and disconnect tube from 1-1/16” 90 degree elbow.
Figure 278 Pressure tubes support bracket

1. Power steering (low-pressure) tube assembly
2. Extension clip
3. M6 nut
4. M6 x 20 stud
5. Rear support bracket
6. Power steering (high-pressure) tube assembly
4. Remove rear support bracket M6 nut from extension clip stud at the oil pan.
5. If equipped, remove front support bracket M6 nut from support bracket.
6. Remove high-pressure and low-pressure tubes as an assembly.
NOTE: If replacing high-pressure and low-pressure tubes, do steps 7 and 8.
7. Remove the rear support brackets and rubber isolator from the high-pressure and low-pressure tubes.
8. If equipped, remove front support brackets and rubber isolator from the high-pressure and low-pressure
tubes.
Power Steering Pressure Tubes Installation

NOTE: If high-pressure and low-pressure tubes were replaced, do steps 1 and 2.
1. If equipped and removed, install front support brackets and rubber isolator onto the high- and low-pressure
tubes.
2. If removed, install rear support brackets and rubber isolator onto the high- and low-pressure tubes.
Figure 279 Pressure tubes support bracket

1. High- and low-pressure tube assembly
2. Extension clip
3. M6 x 1.0 nut
4. M6 x 20 bolt
5. Rear support bracket
6. Power steering (high-pressure) tube assembly
3. Position high-pressure and low-pressure tube as an assembly. Install M6 x 1.0 nut onto extension clip stud
to secure rear support bracket at the oil pan. Tighten nut to standard torque (page 1201).
4. If equipped, install front support bracket to extension clip stud on front engine support and secure with M6
x 1.0 flange nut. Tighten nut to standard torque (page 1201).
Figure 280 Pressure tubes

2. High-pressure tube
4. 1-1/16” 90 degree elbow
5. Low-pressure tube
NOTE: Do the following steps if fittings were removed or if power steering pump was replaced.
5. Loosely install the high-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the
elbow, tighten 1/2" 90 degree tube elbow lock nut to special torque (page 1243).
6. Loosely install the low-pressure tube fitting nut to the elbow. Using an appropriate size wrench to hold the
elbow, tighten 1-1/16" 90 degree elbow lock nut to special torque (page 1243).
7. Tighten the high-pressure and low-pressure tube fitting nuts to special torque (page 1243).
Power Steering Elbows

Power Steering Elbows Removal
NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows
are leaking.
Figure 281 Power steering pump and 90 degree elbows

1. Loosen the lock nut and rotate the 1/2” 90 degree tube elbow counterclockwise to remove from power
steering pump.
2. Loosen the lock nut and rotate the 1-1/16” 90 degree elbow counterclockwise to remove from power steering
pump.
Power Steering Elbows Installation
Figure 282 Power steering elbows

NOTE: This procedure should be completed only if replacing power steering pump, or if one or both of the elbows
were removed.
1. Check seals on elbow for damage. Replace as necessary.
2. Install 1/2” 90 degree tube elbow to power steering pump. Lock nuts should not be tightened until power
steering lines are installed for proper orientation.
3. Install 1-1/16” 90 degree elbow to power steering pump. Lock nuts should not be tightened until power
steering lines are installed for proper orientation.
Power Steering Pump

Power Steering Pump Removal
Figure 283 Power steering pump

2. Air compressor
3. M10 x 40 bolt and lock washer (2)
1. Remove two M10 x 40 bolts, lock washers and power steering pump.
2. Check pump collar O-ring for damage and replace as necessary.
Figure 284 Power steering pump adapter

1. Power steering pump adapter
2. Air compressor
3. Remove power steering pump adapter from air compressor bore.

Power Steering Pump Installation
Figure 285 Power steering pump adapter

1. Power steering pump adapter
2. Air compressor
1. Install power steering pump adapter to air compressor bore.
Figure 286 Power steering pump (typical)

2. Air compressor
3. M10 x 40 bolt (2)
2. If pump collar O-ring was removed or damaged, install a new O-ring. Lubricate the new O-ring with P80®
rubber lubricant (page 1231) or equivalent.
3. Install power steering pump and two M10 x 40 bolts. Tighten bolts to special torque (page 1243).
Air Compressor Coolant Hoses

Air Compressor Coolant Hoses Removal
Figure 287 Air compressor coolant hoses

1. Coolant return hose
2. Coolant return tube (one cylinder air compressor) or Coolant supply hose (two cylinder air compressor)
3. Air compressor
1. Place suitable container under air compressor to collect any residual coolant.
Figure 288 Air compressor coolant hose removal

1. Coolant Line Release Tool
2. Coolant hose
2. Insert Coolant Line Release Tool (page 1231) into retaining clips of air compressor coolant hose and remove
from crankcase.
3. Using Coolant Line Release Tool, release and remove air compressor coolant tube from air compressor.
4. Recycle or dispose of any coolant according to applicable regulations.

Air Compressor Coolant Hoses Installation
Figure 289 Air compressor coolant hoses

1. Coolant return hose
2. Coolant return tube (one-cylinder air compressor) or Coolant supply hose (two-cylinder air compressor)
3. Air compressor
1. Depending on compressor model, straight and 45° coolant fittings are used. If loosened, tighten fittings as
follows:
One-cylinder compressors
• Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 1243).
• If equipped, tighten M16 45° fitting (at crankcase) to special torque (page 1243).
• If equipped, tighten M18 straight fittings (at air compressor) to special torque (page 1243).
Two-cylinder compressors
• Tighten M16 straight fittings (at crankcase or air compressor) to special torque (page 1243).
• If equipped, tighten M16 45° fitting (at crankcase or air compressor) to special torque (page 1243).
2. Check air compressor coolant supply and return hose O-rings before installation. Replace O-rings as
needed.
3. Place coolant supply hose in position between crankcase and air compressor coolant fittings.
4. Press down on quick-connect fittings until a click is heard to install hose. Lightly pull on hose to make sure
it is locked.
5. Repeat steps 3 and 4 to install air compressor coolant return hose.
Air Compressor
Air Compressor Removal
Figure 290 Air compressor (typical)

1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)
WARNING: To prevent personal injury or death, get assistance to remove and install the air
compressor and power steering pump assembly.
NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the air compressor
mounting hole next to the power steering pump.
1. For one-cylinder air compressor, remove two M8 x 40 bolts and four M8 x 110 bolts.
2. For two-cylinder air compressor, remove two M8 x 40 bolts, four M8 x 110 bolts and M10 x 110 bolt.
3. Remove air compressor from alignment dowels.
Air Compressor Installation
Figure 291 Air compressor (typical)

1. M8 x 40 bolt (2)
2. M8 x 110 bolt (4)
WARNING: To prevent personal injury or death, get assistance to remove and install the air
compressor and power steering pump assembly.
NOTE: For two-cylinder air compressor only, an additional M10 x 110 bolt is located in the mounting hole next
to the power steering pump.
1. Apply Loctite® 515 to crankcase and air compressor mating surface.
2. For one-cylinder air compressor, position air compressor and install two M8 x 40 bolts and four M8 x 110
bolts. Tighten bolts to special torque (page 1243).
3. For two-cylinder air compressor, position air compressor and install two M8 x 40 bolts, four M8 x 110 bolts
and M10 x 110 bolt. Tighten bolts to special torque (page 1243).
Air Compressor and Power Steering System Cleaning

All Components
1. Cover coolant, fluid and air openings to ensure dirt does not enter air compressor and power steering pump.
2. Clean foreign material from sealing surfaces of air compressor. Use a scraper to clean sealing material from
the sealing surfaces.
Special Torques
1-1/16" 90 degree elbow lock nut 55 N·m (40 lb·ft)
1/2" 90 degree tube elbow lock nut 45 N·m (33 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (one cylinder) 35 N·m (26 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (two cylinder) 31 N·m (23 lb·ft)
(Two cylinder) Air compressor M10 x 110 bolt 67 N·m (49 lb·ft)
High-pressure tube fitting nut 62 N·m (45 lb·ft)
M16 straight fitting 35 N·m (26 lb·ft)
M16 45° fitting 17.5 N·m (13 lb·ft)
M18 straight fitting 37.5 N·m (28 lb·ft)
Low-pressure tube fitting nut 164 N·m (120 lb·ft)
Power steering pump M10 x 40 bolt 67 N·m (49 lb·ft)
Special Tools
Coolant Line Release Tool ZTSE4778
Loctite® 515 Obtain locally
P80® rubber lubricant or equivalent Obtain locally
Fuel System
components.
WARNING: To prevent personal injury or death, remove ground cable from the negative terminal of
last.
WARNING: To prevent personal injury or death, do not turn ignition key to ON if fuel system parts
are removed or disconnected. Activation of the fuel pump could spill fuel and create a fire.
prior to this section.
• Inlet Air Heater
• Turbochargers
High-pressure Fuel Lines
HPFP to Rail Supply Tube Damper Assembly Removal
Overview
This section provides instructions for the removal of the HPFP to Rail Supply Tube Damper Assembly.
WARNING: To prevent personal injury or death, engine must be stationary for at least 5 minutes
before doing any work on high-pressure fuel system to allow for system depressurization.
WARNING: To prevent personal injury or death, whenever any fuel line (tubing) in the high-pressure
fuel system is removed, it must be replaced with new.
CAUTION: To prevent engine damage, plug component connections immediately after each fuel line is removed.

• Crowfoot wrench – Obtain locally
• Disposable Air and Fuel Caps – ZTSE4891
Equipment Condition
2. Remove Engine Control Module (ECM) and mounting bracket. See Engine Control Module (ECM) and
Mounting Bracket Removal (page 159).
Removal Procedure
Figure 292 High-Pressure fuel Pump (HPFP) to Rail Supply Tube Damper Assembly
1. HPFP to rail supply tube damper 3. Line fitting nut at fuel rail (2) 5. High Pressure Fuel Pump
assembly 4. Line fitting nut at HPFP (2) (HPFP)
2. Fuel rail
See High-Pressure fuel Pump (HPFP) to Rail Supply Tube Damper Assembly (Figure 292) to perform step 3.
3. Loosen line fitting nuts at HPFP (4) and fuel rail (3) and remove HPFP to rail supply tube damper assembly
(1). Cap open HPFP (5) and fuel rail (2) connections with clean Disposable Air and Fuel Caps (page 370).
None.
HPFP to Rail Supply Tube Damper Assembly Installation

Line fitting nut at HPFP 17 lb-ft (23 N·m) plus 60°
Line fitting nut at fuel rail 17 lb-ft (23 N·m) plus 60°
Figure 293 High-Pressure fuel Pump (HPFP) to Rail Supply Tube Damper Assembly
1. HPFP to rail supply tube damper 3. Line fitting nut at fuel rail (2) 5. High Pressure Fuel Pump
assembly 4. Line fitting nut at HPFP (2) (HPFP)
2. Fuel rail
CAUTION: To prevent engine damage, replace HPFP to rail supply tube damper assembly as an assembly.
See High-Pressure fuel Pump (HPFP) to Rail Supply Tube Damper Assembly (Figure 293) to perform steps 1
and 2.
1. Install new HPFP to rail supply tube damper assembly (1) between HPFP (5) and fuel rail (2).
2. Tighten line fitting nut at HPFP (4) and line fitting nut at fuel rail (3) to 17 lb-ft (23 N·m) plus an additional 60°.
None.
3. Install Engine Control Module (ECM) and mounting bracket. See Engine Control Module (ECM) and
Mounting Bracket Installation (page 661).
High-pressure Fuel Line Removal
Overview
This section provides instructions for the removal of high-pressure fuel lines.

Equipment Condition
1. When removing high-pressure connector bodies for cylinders 1, 2, and 3, remove Engine Control Module
(ECM) and mounting bracket. See Engine Control Module (ECM) and Mounting Bracket Removal (page
159).
2. When removing cylinder 3 high-pressure connector body, remove high-pressure fuel pump (HPFP) to rail
supply tube damper assembly. See HPFP to Rail Supply Tube Damper Assembly Removal (page 370).
Removal Procedure
Figure 294 Harness 21-way Connector Bracket

1. Harness 21-way connector
bracket
2. M8 x 16 bolt (3)
See Harness 21-way Connector Bracket (Figure 299) to perform step 3.

3. Disconnect air supply line from harness 21-way connector bracket.
Figure 295 Cylinder 1 High-pressure Rail to Injector Tube Assembly

1. Cylinder 1 high-pressure 3. High-pressure rail to injector 4. Cylinder 1 high-pressure rail to
connector body tube assembly fitting injector tube assembly
2. Fuel rail
See Cylinder 1 High-pressure Rail to Injector Tube Assembly (Figure 295) to perform step 4.
4. Using a crowfoot wrench, loosen high-pressure rail to injector tube assembly fitting (3) that secures cylinder
1 high-pressure rail to injector tube assembly (4) at cylinder 1 high-pressure connector body (1) and fuel rail
(2).
5. Remove high-pressure rail to injector tube assembly and dispose.
Figure 296 Cylinders 2-6 High-pressure Rail to Injector Tube Assemblies

1. Cylinder head 3. Cylinder 5 high-pressure rail to 5. Cylinder 3 high-pressure rail to
2. Cylinder 6 high-pressure rail to injector tube injector tube
injector tube 4. Cylinder 4 high-pressure rail to 6. Cylinder 2 high-pressure rail to
injector tube injector tube
See Cylinders 2-6 High-pressure Rail to Injector Tube Assemblies (Figure 296) to perform step 6.
6. Remove high-pressure rail to injector tube assemblies for cylinders 2 through 6 as required and dispose.
Cap open high-pressure connector body and fuel rail connections with clean Disposable Air and Fuel Caps
(page 374).
None.
High-pressure Fuel Line Installation
Overview
This section provides instructions for the installation of high-pressure fuel lines.

Equipment Condition
None.
High-pressure rail to injector tube assembly fitting 17 lb-ft (23 N·m)

Figure 297 Cylinder 1 High-pressure Rail to Injector Tube Assembly

1. Cylinder 1 high-pressure 3. High-pressure rail to injector 4. Cylinder 1 high-pressure rail to
connector body tube assembly fitting injector tube assembly
2. Fuel rail
See Cylinder 1 High-pressure Rail to Injector Tube Assembly (Figure 297) to perform steps 1 and 2.
1. Install new high-pressure rail to injector tube assembly (4) for cylinder 1 between fuel rail (2) and cylinder
head.
2. Hand tighten high-pressure rail to injector tube assembly fitting (3) at fuel rail (2) and cylinder 1 high-pressure
connector body (1).
Figure 298 Cylinders 2-6 High-pressure Rail to Injector Tube Assemblies

1. Cylinder head 3. Cylinder 5 high-pressure rail to 5. Cylinder 3 high-pressure rail to
2. Cylinder 6 high-pressure rail to injector tube injector tube
injector tube 4. Cylinder 4 high-pressure rail to 6. Cylinder 2 high-pressure rail to
injector tube injector tube
See Cylinders 2-6 High-pressure Rail to Injector Tube Assemblies (Figure 298) to perform step 3.
3. Repeat steps 1 and 2 to install new high-pressure rail to injector tube assemblies for cylinders 2 through 6.
Figure 299 Harness 21-way Connector Bracket

1. Harness 21-way connector
bracket
2. M8 x 16 bolt (3)
See Harness 21-way Connector Bracket (Figure 299) to perform step 4.

4. Connect air supply line to harness 21-way connector bracket.
None.
Injector and Fuel Drain (Return) Lines

Injector and Fuel Drain (Return) Lines Removal
NOTE: It is not necessary to disassemble the fuel drain lines unless individual components are leaking or
damaged.
Figure 300 Fuel drain (return) tube

1. Fuel rail
2. 14.7 x 22 seal ring (4)
3. M14 banjo bolt (2)
4. Fuel drain tube
5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee)
1. Remove M8 x 16 bolt and closed (P) clamp securing fuel drain tube to crankcase.
2. Loosen fuel drain line fitting nut at the fuel return hex manifold tee and disconnect tube from fuel return line.
3. Remove M14 banjo bolt and two 14.7 x 22 seal rings to disconnect fuel drain tube at fuel rail. Discard seal
rings.
4. Remove M14 banjo bolt and 14.7 x 22 seal rings connecting fuel drain tube at cylinder head. Remove fuel
drain tube and discard seal rings.
Injector and Fuel Drain (Return) Lines Installation
Figure 301 Fuel drain tube connections

1. Fuel rail
2. 14.7 x 22 seal ring (4)
3. M14 banjo bolt (2)
4. Fuel drain tube
5. M8 x 16 bolt and closed (P) clamp assembly
6. Line fitting nut
7. Fuel drain hose (hex manifold tee)
1. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to cylinder head. Do not
tighten at this time.
2. Install M14 banjo bolt with two new 14.7 x 22 seal rings to connect fuel drain tube to fuel rail. Do not tighten
at this time.
NOTE: Use a backup wrench when tightening fitting nut on hex manifold tee.
3. Connect fuel drain tube to fuel return hex manifold tee at fuel filter bracket. Tighten drain line fitting nut to
special torque (page 1244).
4. Tighten fuel drain tube M14 banjo bolts at fuel rail and cylinder head to special torque (page 1244).
5. Install closed (P) clamp and M8 x 16 bolt to secure drain tube to crankcase. Tighten bolt to standard torque
(page 1201).
Fuel Rail Assembly

Fuel Rail Assembly Removal
Figure 302 Fuel rail and pressure limiting valve

1. M8 x 40 bolt (3)
2. Fuel rail assembly
3. Pressure limiting valve
WARNING: To prevent personal injury or death, the engine must be stationary for at least 5 minutes
to allow for system depressurization, before doing work on the high-pressure fuel system.
NOTE: The pressure limiting valve should not be removed from the fuel rail assembly. Replace the entire fuel
rail assembly if the pressure limiting valve is defective. Use ServiceMaxx®to verify fuel pressure following the
procedure in the Engine Diagnostic Manual .
1. Support fuel rail to prevent it from falling during removal.
2. Remove three M8 x 40 bolts and remove fuel rail from cylinder head.
Fuel Rail Assembly Installation

NOTE: The pressure limiting valve should not be removed from the fuel rail assembly. Replace the entire fuel
rail assembly if the pressure limiting valve is defective. Use ServiceMaxx® to verify fuel pressure following the
procedure in the Engine Diagnostic Manual.
Figure 303 Fuel rail and pressure limiting valve

1. M8 x 40 bolt (3)
2. Fuel rail assembly
3. Pressure limiting valve
1. Support fuel rail assembly in position against underside of cylinder head. Install and hand tighten three M8
x 40 bolts.
2. Tighten bolts to special torque (page 1244).
Fuel Primer Pump Assembly

Fuel Primer Pump Assembly Removal
Figure 304 Fuel primer pump assembly

1. Fuel primer pump assembly
2. M8 x 25 bolt (2)
NOTE: The fuel primer pump assembly can be removed as an assembly along with the fuel filter housing. If the
fuel primer pump assembly is to be replaced, remove two M8 x 25 bolts and remove pump assembly from filter
housing.
1. Remove two M8 x 25 bolts.
2. Remove fuel primer pump assembly from fuel filter housing.
Fuel Primer Pump Assembly Installation
Figure 305 Fuel primer pump assembly

1. Check valve
2. Threaded union
3. 14.7 x 22 seal ring (3)
4. Fuel primer pump assembly
5. M8 x 25 bolt (2)
7. Banjo fitting
8. Fuel supply adapter
1. If removed from fuel filter housing, install fuel primer pump assembly and two M8 x 25 bolts. Tighten bolts
NOTE: If fuel primer pump assembly was replaced or fittings were previously removed, continue with step 2.
2. Install banjo fitting with two new 14.7 x 22 seal rings and fuel supply adapter in fuel primer pump assembly
inlet port. Tighten adapter to special torque (page 1244).
3. Install check valve on banjo fitting. Tighten check valve to special torque (page 1244) and install dust cap.
4. Install threaded union and 14.7 x 22 seal ring in fuel primer pump assembly outlet port. Tighten threaded
union to special torque (page 1244).
Fuel Supply and Drain (Return) Lines

Fuel Supply and Drain (Return) Lines Removal
Figure 306 Fuel Line Disconnect Tool ZTSE4773 11.8 mm (Typical)

1. Release button (2)
2. Fuel Line Disconnect Tool ZTSE4773 11.8 mm
3. Quick-connect 90° fitting
NOTE: Use Fuel Line Disconnect Tool 11.8 mm (page 1232) to disconnect all Low-Pressure (LP) fuel line
quick-connect fittings.
1. Slide Fuel Line Disconnect Tool (Figure 306) (Item 2) over release buttons (Figure 306) (Item 1) on quick
connect 90° fitting (Figure 306) (Item 3).
2. Pull quick-connect 90° fitting to disconnect.
Figure 307 After-Filter Fuel Supply Hose Connections

1. Quick‐connect 90° fitting (at 2. Quick‐connect 90° fitting (at 4. 14.7 x 22 mm seal rings (2)
high‐pressure fuel pump inlet) Aftertreatment (AFT) fuel doser 5. M14 banjo bolt
module) 6. C-clip (3)
3. After‐filter fuel supply hose
3. Disconnect after-filter fuel supply hose assembly quick-connect 90° fittings at high‐pressure fuel pump inlet
(Figure 307) (Item 1) and at AFT fuel doser module (Figure 307) (Item 2). .
4. Cap openings using clean Disposable Air and Fuel Caps ZTSE4891.
5. Remove c-clips (Figure 307) (Item 5) , M14 banjo bolt (Figure 307) (Item 5), 4.7 x 22 mm seal rings (Figure
307) (Item 4) and remove after-filter fuel supply hose assembly (Figure 307) (Item 3). Discard seal rings.
Figure 308 Pre-Pump Fuel Supply Hose Connections

1. Quick-connect 90° fitting (at HPFP)
2. Quick-connect 90° fitting (at primer pump)
3. C-clip (2)
4. Pre-pump fuel supply hose
6. Disconnect pre-pump fuel supply hose assembly quick-connect 90° fittings at HPFP (Figure 308) (Item 1)
and at fuel primer pump assembly (Figure 308) (Item 2). Remove c-clips (Figure 308) (Item 3) and hose
(Figure 308) (Item 4), and cap openings.
Figure 309 Pre-Filter Fuel Supply Hose Connections

2. Quick-connect 90° fitting (at fuel filter housing)
3. Pre-filter fuel supply hose
7. Disconnect pre-filter fuel supply hose assembly quick-connect 90° fittings at HPFP (Figure 309) (Item 1) and
at fuel filter housing (Figure 309) (Item 2). Remove hose (Figure 309) (Item 3) and cap openings.
Figure 310 Fuel Drain Hose Connections

1. Quick‐connect 90° fitting (at 4. AFT fuel doser module bracket 7. 8 x 13 single retainer (2)
high‐pressure fuel pump return) 5. Fuel filter housing bracket 8. Fuel drain hose
2. M6 x 16 bolt 6. Quick‐connect 90° fitting (at fuel
3. Closed (P) clamp filter housing)
8. Remove M6 x 16 bolt (Figure 310) (Item 2) and closed (P) clamp (Figure 310) (Item 3).
9. Disconnect fuel drain hose assembly quick-connect 90° fittings at high‐pressure fuel pump return (Figure
310) (Item 1) and at fuel filter housing (Figure 310) (Item 6).
10. Cap openings using clean Disposable Air and Fuel Caps ZTSE4891.
11. Disconnect 8 x 13 single retainers (Figure 310) (Item 7) and remove fuel drain hose (Figure 310) (Item 8)
from engine.
Fuel Supply and Drain (Return) Lines Installation

CAUTION: To avoid fuel system damage, verify all retainers and c-clips are installed in correct position as shown,
to prevent fuel line rubbing and leaks.
Figure 311 Fuel Drain Hose Retainers (Typical)

1. Quick‐connect 90° fitting (at 4. AFT fuel doser module bracket 7. 8 x 13 single retainer (2)
high‐pressure fuel pump return) 5. Fuel filter housing bracket 8. Fuel drain return hose
2. M6 x 16 bolt 6. Quick‐connect 90° fitting (at fuel
3. Closed (P) clamp filter housing)
1. Check that O-rings are in place in fuel drain quick-connect 90° fittings (Items 1 and 4) and not damaged.
2. Place fuel drain hose (Figure 311) (Item 8) in position at bottom of fuel filter housing bracket (Figure 311)
(Item 5) and attach to bracket with two 8 x 13 single retainers (Figure 311) (Item 7).
3. Connect fuel drain hose at high pressure fuel pump inlet by pushing on quick-connect 90° fitting (Figure 311)
(Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated.
4. Connect fuel drain hose to fuel filter housing by pushing on quick-connect 90° fitting (Figure 311) (Item 6)
until an audible click is heard. Pull quick-connect fitting to make sure it is seated.
5. Install closed (P) clamp (Figure 311) (Item 3) and M6 x 16 bolt (Figure 311) (Item 2) to attach end fitting of
fuel drain hose from hex manifold tee to AFT fuel doser module bracket (Figure 311) (Item 4). Tighten bolt
to 115 lb·in (13 N·m).
6. Cap unconnected end of hex manifold tee using Disposable Air and Fuel Caps ZTSE4891 to prevent dirt
from entering fuel system until final connection with injector and fuel rail drain tube is made.
Figure 312 Pre-Filter Fuel Supply Hose Assembly

2. Quick-connect 90° fitting (at fuel filter housing)
3. Pre-filter fuel supply hose
7. Check that O-rings are in place in pre-filter fuel supply quick-connect 90° fittings and not damaged. Replace
as necessary.
8. Install pre-filter fuel supply hose (Figure 312) (Item 3). Push on quick-connect 90° fitting at HPFP (Figure
312) (Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the
procedure for the quick-connect 90° fitting at fuel filter housing (Figure 312) (Item 2).
Figure 313 Pre-Pump Fuel Supply Hose Assembly

2. Quick-connect 90° fitting (at fuel primer pump)
3. C-clip (2)
4. Pre-pump fuel supply hose
9. Check that O-rings are in place in pre-pump fuel supply hose quick-connect 90° fittings and not damaged.
10. Install pre-pump fuel supply hose (Figure 313) (Item 4). Push on quick-connect 90° fitting at HPFP (Figure
313) (Item 1) until an audible click is heard. Pull quick-connect fitting to make sure it is seated. Repeat the
procedure for the quick-connect 90° fitting at fuel primer pump assembly (Figure 313) (Item 2).
CAUTION: Install c-clips in location shown (Figure 313) to prevent damage to fuel lines.
11. Install c-clips (Figure 313) (Item 3) between pre-pump fuel supply hose and pre-filter fuel supply hose.
Figure 314 After-Filter Fuel Supply Hose Connections

1. Quick‐connect 90° fitting (at 2. Quick‐connect 90° fitting (at 4. 14.7 x 22 mm seal rings (2)
high‐pressure fuel pump inlet) Aftertreatment (AFT) fuel doser 5. M14 banjo bolt
module) 6. C-clip (2)
3. After‐filter fuel supply hose
12. Check that O-rings are in place in after-filter fuel supply hose quick-connect 90° fittings and not damaged.
13. Install after-filter fuel supply hose (Figure 314) (Item 3). Position banjo fitting with two new 14.7 x 22 seal
rings (Figure 314) (Item 4) at filter housing and install M14 banjo bolt (Figure 314) (Item 5).
14. Tighten banjo bolt to 22 lb·ft (30 N·m).
15. Push on quick-connect 90° fitting at high-pressure fuel pump inlet (Figure 314) (Item 1) until an audible click
is heard. Pull quick-connect fitting to make sure it is seated.
CAUTION: Install c-clips in location shown to prevent damage to fuel lines.
16. Install C-clips (Figure 314) (Item 6) between after filter fuel supply hose and fuel drain hose.
17. Cap quick-connect 90° connector at AFT fuel doser module (Figure 314) (Item 2) to prevent dirt from entering
fuel system until final connection to metering valve can be made.
Fuel Filter Housing Assembly

Fuel Filter Housing Assembly Removal
Figure 315 AFT Fuel Doser Module bracket

1. M8 x 16 bolts (3)
2. AFT fuel doser module bracket
1. Remove four M8 x 20 bolts (Figure 315) (Item 1) and remove AFT fuel doser module bracket (Figure 315)
(Item 2).
Figure 316 Fuel filter housing assembly

1. Fuel filter housing assembly
2. M8 x 45 bolt (3)
2. Remove three M8 x 45 bolts and remove fuel filter housing assembly.
Figure 317 Fuel filter bracket assembly

1. 9 ID x 18 OD x 10.5 spacer (3)
2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer
3. Remove four M8 x 30 bolts and spacers; remove fuel filter bracket from crankcase.
Fuel Filter Housing Assembly Installation
Figure 318 Fuel filter bracket assembly

1. 9 ID x 18 OD x 10.5 spacer (3)
2. M8 x 30 bolt (4)
3. 9 ID x 17 OD x 6.5 spacer
1. If removed, position fuel filter bracket assembly with brace on crankcase and install four M8 x 30 bolts and
spacers. Tighten bolts to special torque (page 1244).
Figure 319 Fuel filter housing assembly

1. Fuel filter housing assembly
2. M8 x 45 bolts (3)
2. Install fuel filter housing assembly and three M8 x 45 bolts. Tighten bolts to special torque (page 1244).
Figure 320 AFT Fuel Doser Module bracket (typical)

1. M8 x 16 bolts (3)
2. AFT Fuel Doser Module bracket
3. Position AFT Fuel Doser Module bracket (Figure 320) (Item 2) on filter housing and install four M8 x 16 bolts
(Figure 320) (Item 1). Tighten bolts to 23 lb·ft (31 N·m).
Fuel Filter Stand Pipe Replacement

If diagnostic testing indicated replacement of the fuel filter stand pipe, remove the stand pipe and replace with
new following this procedure.
Figure 321 Fuel Filter Stand Pipe

1. Stand pipe O-ring
2. Stand pipe
4. Fuel filter cap
5. Fuel filter cap O-ring
6. Fuel filter element
1. Remove fuel filter cap and O-ring.

2. Using an appropriate wrench, loosen and remove stand pipe from housing.
3. Remove O-ring from center tube at bottom of stand pipe.
4. Apply P-80® rubber lubricant or equivalent (page 1232) to new O-ring and install O-ring on center tube in
bore at bottom of stand pipe.
5. Insert stand pipe into housing assembly and carefully thread pipe into bore in bottom of housing.
6. Tighten the stand pipe to special torque (page 1244).
7. Apply P-80® rubber lubricant or equivalent (page 1232) to filter cap O-ring and place in position in housing
O-ring groove.
8. Insert new filter element in filter housing.
9. Install filter cap and tighten to special torque (page 1244).
Radial Shaft Seal

Radial Shaft Seal Removal
NOTE: Do not remove HPFP pulley if removing HPFP.
Figure 322 HPFP Pulley

1. HPFP pulley
1. Remove M16 x 40 LH bolt (Figure 322) (Item 2). Clean any sealer off of bolt threads.
2. Remove HPFP pulley (Figure 322) (Item 1) from drive belt shaft assembly. Clean any sealer from shaft and
pulley.
Figure 323 HPFP Pulley Housing and Seal

1. HPFP pulley housing
2. M10 x 40 bolt (4)
3. 30.2 x 3 O-ring
4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft
3. With an awl and hammer, punch two holes 180° apart in radial shaft seal.
4. Thread a slide hammer (page 1232) with correct size screw into one of the two holes.
5. Slide hammer until one side of seal begins to pull out of housing. Move slide hammer to other hole and
repeat until radial shaft seal is removed.
Radial Shaft Seal Installation
Figure 324 HPFP Pulley Housing and Seal

2. M10 x 40 bolt (4)
3. 30.2 x 3 O-ring
4. 55 x 70 x 8 radial shaft seal
5. Drive belt shaft
NOTE: Apply Loctite® 515(page 1232) to joining surfaces of HPFP pulley housing (Figure 324) (Item 1) and
drive housing if removed.
1. If removed, install four M10 x 40 bolts (Figure 324) (Item 2) and tighten to 46 lb·ft (62 N·m).
2. Using Fan Hub/High Pressure Drive Seal Installer ZTSE6066 (page 1232), drive new 55 x 70 x 8 radial shaft
seal (Figure 324) (Item 4) into housing. Seal is fully installed when tool bottoms out on housing.
Figure 325 HPFP Pulley

3. Install HPFP pulley (Figure 325) (Item 1) onto drive belt shaft.
4. Install M16 x 40 LH bolt (Figure 325) (Item 2). Tighten bolt to 207 lb·ft (280 N·m).
Fuel Pressure Control Valve (FPCV)

Fuel Pressure Control Valve (FPCV) Removal
Figure 326 FPCV

1. Screw (2)
2. Fuel Pressure Control Valve (FPCV)
1. Remove two screws (Figure 326) (Item 1) securing FPCV (Figure 326) (Item 2) to High-Pressure Fuel Pump
(HPFP).
2. Remove FPCV from HPFP housing.
Fuel Pressure Control Valve (FPCV) Installation
Figure 327 FPCV

1. Screw (2)
2. Fuel Pressure Control Valve (FPCV)
1. Install FPCV (Figure 327) (Item 2) into High-Pressure Fuel Pump (HPFP) housing.
2. Tighten two screws (Figure 327) (Item 1) to 71 lb·in (8 N·m).
Piston Overflow Valve (KUEV)

Piston Overflow Valve (KUEV) Removal
Figure 328 KUEV

1. Piston Overflow Valve (KUEV)
1. Remove KUEV (Figure 328) (Item 1) from High-Pressure Fuel Pump (HPFP) housing.
Piston Overflow Valve (KUEV) Installation
Figure 329 KUEV

1. Piston Overflow Valve (KUEV)
1. Install KUEV into High-Pressure Fuel Pump (HPFP) housing. Tighten to 37 lb·ft (49 N·m).
High-pressure Fuel Pump (HPFP) and Drive Housing

High-pressure Fuel Pump (HPFP) and Drive Housing Removal
NOTE: The High-Pressure Fuel Pump (HPFP) and drive housing can be removed as an assembly without
removing the fuel filter assembly or HPFP pulley.
Figure 330 HPFP Support Bracket

1. HPFP
2. M12 x 30 bolt (2)
3. Support bracket
4. M14 x 30 bolt (2)
1. Remove two M12 x 30 (Figure 330) (Item 2) and two M14 x 30 (Figure 330) (Item 4) bolts and remove
support bracket (Figure 330) (Item 3) from below HPFP (Figure 330) (Item 1).
Figure 331 HPFP and Drive Housing

1. Drive housing
2. M12 x 90 bolt
3. M12 x 130 bolt (2)
4. M12 x 40 bolt
2. Remove M12 x 40 (Figure 331) (Item 4), M12 x 90 (Figure 331) (Item 2), and two M12 x 130 bolts (Figure
331) (Item 3) and remove HPFP and drive housing assembly (Figure 331) (Item 1) from crankcase.
Figure 332 Dowel Pin and Sleeve

1. Dowel pin
2. Sleeve
NOTE: A dowel pin (Figure 332) (Item 1) and sleeve (Figure 332) (Item 2) is used to ensure correct placement of
drive housing on the engine block. Holding Plate ZTSE6044 may be bolted to the drive housing with the dowel
pin and sleeve in place.
Figure 333 Drive Housing Secured to Holding Plate ZTSE6044

1. Drive housing
3. HPFP
4. Holding Plate ZTSE6044
5. M10 x 40 bolt (4)
3. Secure Holding Plate (Figure 333) (Item 4) in a vise.

4. Install drive housing (Figure 333) (Item 1) and HPFP (Figure 333) (Item 3) to Holding Plate with M12 x 40,
M12 x 90 and two M12 x 130 bolts. Tighten bolts to 77 lb·ft (105 N·m). Holding Plate will prevent the HPFP
gear from turning while loosening the M24 jam nut.
5. Remove four M10 x 40 bolts (Figure 333) (Item 5) and remove HPFP pulley housing (Figure 333) (Item 2)
from drive housing.
Figure 334 Drive Housing With HPFP Pulley Housing Removed

1. Holding Plate
2. M24 jam nut
3. 25 x 44 x 4 washer
4. Drive housing and HPFP
6. Remove the M24 jam nut (Figure 334) (Item 2) and 25 x 44 x 4 washer (Figure 334) (Item 3) securing HPFP
gear to pump shaft.
Figure 335 HPFP Guide Studs

1. M10 x 40 bolt (4)
2. Guide Stud 12–454–01–2 (2)
7. Remove four M10 x 40 bolts (Figure 335) (Item 2). Install two Guide Studs (Figure 335) (Item 2) on opposite
sides of the HPFP.
Figure 336 HPFP Removal Tool 12–454–01 On Drive Housing

1. M10 x 40 bolt (4)
2. Forcing Screw Adapter (flush with Forcing Screw Adapter Holding Plate) 12–454–01–4
3. Socket Head Bolt 12–454–01–3 (2)
4. Forcing Screw Adapter Holding Plate 12–454–01–1
8. Install Forcing Screw Adapter Holding Plate (Figure 336) (Item 4) on drive housing with four M10 x 40 bolts
(Figure 336) (Item 1). Tighten M10 x 40 bolts to 46 lb·ft (62 N·m).
9. Place two Socket Head Bolts (Figure 336) (Item 3) through Forcing Screw Adapter (Figure 336) (Item 2) and
thread them into holes in HPFP gear. Tighten bolts only until Forcing Screw Adapter is flush with Forcing
Screw Adapter Holding Plate.
Figure 337 HPFP Removal

1. Forcing Screw Adapter Holding Plate
2. Forcing Screw Adapter
3. M10 x 40 bolt (4)
4. Socket Head Bolt (2)
5. Forcing Screw 12–454–01–5
10. Install Forcing Screw (Figure 337) (Item 5) by hand into Forcing Screw Adapter until it contacts HPFP shaft.
11. Turn Forcing Screw clockwise until HPFP is removed from drive housing.
12. Remove Socket Head Bolts, Forcing Screw Adapter, and Forcing Screw Adapter Holding Plate from drive
housing.
Figure 338 Drive Housing Separated From HPFP

1. HPFP gear 4. HPFP 6. Quick-connect M16 x 1.5
2. Drive housing 5. Seal ring, 16.7 x 24 (4) connector (4)
3. 100 x 3.349 O-ring
13. Remove drive housing from Holding Plate and remove HPFP gear (Figure 338) (Item 1) from drive housing.
14. Remove and discard 100 x 3.349 O-ring (Figure 338) (Item 3) from HPFP.
15. If required, remove four M16 x 1.5 quick-connect connectors (Figure 338) (Item 6) and discard four 16.7 x
24 seal rings (Figure 338) (Item 5).
High-pressure Fuel Pump (HPFP) and Drive Housing Installation
Figure 339 High-Pressure Fuel Pump (HPFP) and Drive Housing Assembly
1. HPFP 4. 25 x 44 x 4 washer 7. HPFP gear
2. Dowel pin 5. M24 jam nut 8. 100 x 3.349 O-ring
3. Drive housing 6. Sleeve 9. M10 x 40 bolts (4)
1. Install a new 100 x 3.349 O-ring (Figure 339) (Item 8) on fuel pump mounting flange collar.
Figure 340 HPFP Guide Studs

1. M10 x 40 bolt (4)
2. Guide Stud 12–454–01–2 (2)
2. Install two Guide Studs (Figure 340) (Item 2) on opposite sides of HPFP.
3. Place HPFP gear (Figure 339) (Item 7) into drive housing and position drive housing on pump.
4. Remove two Guide Studs from HPFP.
5. Install four M10 x 40 bolts (Figure 340) (Item 1) hand-tight.
6. Install 25 x 44 x 4 washer (Figure 339) (Item 4) and M24 jam nut (Figure 339) (Item 5), hand-tight to secure
gear on HPFP shaft.
Figure 341 Drive Housing With HPFP Pulley Housing Removed

1. Holding Plate ZTSE6044
2. M24 jam nut
3. 25 x 44 x 4 washer
4. Drive housing and HPFP
7. Secure Holding Plate (Figure 341) (Item 1) in a vise.

8. Install drive housing and HPFP (Figure 341) (Item 4) to Holding Plate with M12 x 40, M12 x 90 and two M12
x 130 bolts. Tighten bolts to 77 lb·ft (105 N·m). Holding Plate will prevent the HPFP gear from turning while
tightening the M24 jam nut (Figure 341) (Item 2).
9. Tighten M24 jam nut to 210 lb·ft (285 N·m).
Figure 342 Drive Housing Secured to Holding Plate

1. Drive housing
3. HPFP
4. Holding Plate
5. M10 x 40 bolt (4)
10. Tighten four M10 x 40 bolts (Figure 342) (Item 5) to 46 lb·ft (62 N·m) to secure HPFP pulley housing (Figure
342) (Item 2) to drive housing (Figure 342) (Item 1).
11. Remove drive housing and HPFP from Holding Plate (Figure 342) (Item 4).
Figure 343 Dowel Pin and Sleeve Placement

1. Dowel pin
2. Sleeve
12. Check that dowel pin (Figure 343) (Item 1) and sleeve (Figure 343) (Item 2) are properly seated in drive
housing or crankcase.
Figure 344 HPFP and Drive Housing

1. Drive housing
2. M12 x 90 bolt
3. M12 x 130 bolt (2)
4. 16.7 x 24 seal ring (4)
5. HPFP
6. Quick-connect M16 x 1.5 connector (4)
7. M12 x 40 bolt
13. If required, install four M16 x 1.5 quick-connect connectors (Figure 344) (Item 6) with new 16.7 x 24 seal
rings (Figure 344) (Item 4). Tighten connectors to 22 lb·ft (30 N·m).
14. Apply Loctite® 515 to mating surfaces of drive housing and crankcase.
15. Position HPFP (Figure 344) (Item 5) and drive housing assembly (Figure 344) (Item 1) on crankcase using
care to align pump drive gear with idler gear. Install M12 x 40 (Figure 344) (Item 7), M12 x 90 (Figure 344)
(Item 2), and two M12 x 130 bolts (Figure 344) (Item 3) and tighten bolts to 77 lb·ft 105 (N·m).
Figure 345 HPFP and Support (Bracket)

1. HPFP
2. M12 x 30 bolt (2)
3. Support (bracket)
4. M14 x 30 bolt (2)
16. Place support bracket (Figure 345) (Item 3) in position below HPFP (Figure 345) (Item 1) and install two
M12 x 30 (Figure 345) (Item 2) and two M14 x 30 bolts (Figure 345) (Item 4).
17. Tighten two M12 x 30 bolts to 79 lb·ft (107 N·m).
18. Tighten two M14 x 30 bolts to 126 lb·ft (172 N·m).
CAUTION: To prevent damage to the High-Pressure Fuel Pump (HPFP), do not start the engine until the fuel
system is properly primed. The Fuel System Priming Tool should be used to prime the fuel system. If the Fuel
System Priming Tool is not available, prime the fuel system using the hand primer pump method. See Fuel
System Priming (page 440).
Fuel Injectors
Fuel Injectors Removal
Overview
This section provides instructions for the removal and replacement of any one, multiple, or all fuel injectors.

• Injector puller – ZTSE4770
• Fuel Injector Cups – ZTSE4892
• Fuel Injector Rack Holder – ZTSE4299B
Equipment Condition
The following steps must be completed before injector replacement procedure can be performed:
Step Required Procedure Injectors Injector 3 Injectors

1, 2 4, 5, 6
1 Disconnect batteries. x x x
2 Remove inner fender from driver’s side. x x x
3 Turn wheel to right. x x x
4 Remove air filter housing and air intake tube.
See Air Filter Housing and Air Intake Tube x x x
Removal (page 285).
5 Remove Engine Control Module (ECM) and
mounting bracket. See Engine Control Module
x x
(ECM) and Mounting Bracket Removal (page
159).
6 Remove upper valve cover. See Upper Valve
x x x
Cover Removal (page 660).
7 Remove engine brake housing assembly. See
Engine Brake Housing Assembly Removal x x x
(page 628).
8 Remove high-pressure fuel pump to rail supply
tube damper assembly. See HPFP to Rail
x
Supply Tube Damper Assembly Removal (page
370).
8 Remove high-pressure fuel lines. See
x x x
High-pressure Fuel Line Removal (page 374).
Figure 346 Fuel Injector Connections

1. Injector harness nuts (12) 2. Engine injector harness
See Fuel Injector Connections (Figure 346) to perform step 1.

1. Loosen two injector harness nuts (1) per injector harness (2) as required and position injector harness(es)
aside. Do not use power tools. Injector harness nuts are part of the injector harness and cannot be
separated.
Figure 347 Injector Hold-down Clamp

1. M8 x 50 bolt (6) and rounded 2. Injector hold-down clamp (6)
washer (6) 3. Thrust washer (6)
See Injector Hold-down Clamp (Figure 347) to perform step 2.

2. Remove M8 x 50 hold-down clamp bolt and rounded washer (1) as required. Make sure that washer comes
off with bolt.
Figure 348 Injector Puller

1. Clamping sleeve 4. Knurled nut 7. Plate column nuts (2)
2. Extractor plate 5. Extractor nut
3. Extractor 6. Plate column (2)
3. Use Injector Puller (Figure 348) ZTSE4770 to remove injectors.

Figure 349 Injector Extractor (typical)

1. Extractor (part of Injector Puller) 2. Injector
4. Install extractor (1) on injector (2).
Figure 350 Clamping Sleeve on Extractor (typical)

1. Extractor 2. Clamping sleeve
5. Slide clamping sleeve (2) over extractor (1).

Figure 351 Extractor Plate and Plate Columns (typical)

1. Extractor plate 2. Plate column (2)
See Extractor Plate and Plate Columns (Figure 351) to perform steps 6 and 7.
6. Position two plate columns (2) on two opposite cylinder head bolts, and slide extractor plate (1) over extractor
and plate columns. For injector 4, use plate column adapter (extension) with plate columns.
7. Install and finger-tighten plate column nuts on plate columns.
Figure 352 Extractor Nut (typical)

1. Knurled nut 2. Extractor nut
See Extractor Nut (Figure 352) to perform steps 8 through 10.

8. Install knurled nut (1) and extractor nut (2) with the extractor nut backed out.
9. Hold knurled nut and tighten extractor nut to remove injector, combustion washer and hold-down clamp.
NOTE: Make sure that no combustion washer remains in the injector bore after the injector is removed.
10. Cover cylinder head injector bore with appropriate size plugs from Disposable Air and Fuel Caps (page 424).
Figure 353 Injector Seals (typical)

1. Injector assembly 2. O-ring 3. Combustion washer
See Injector Seals (Figure 353) to perform steps 11 through 13.

11. Using a small non-metallic hand tool, carefully remove and discard combustion washer (3) and O-ring (2).
Wipe injector nozzle with a lint-free cloth.
CAUTION: To prevent engine damage, do not clean fuel injectors with parts solvent or other chemicals.
12. Clean injector tip with Fuel Injector Tip Cleaning Brush (page 1232).
13. Insert injector into Fuel Injector Cup , and place in Fuel Injector Rack Holder .
Fuel Injectors Installation

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.

• Injector Installer – ZTSE4777
Injector hold-down clamp bolt 18 lb-ft (25 N·m)
High-pressure connector retaining nut TBD
Injector harness nut 16 lb-in (1.8 N·m)
Figure 354 Thrust Washer

CAUTION: To prevent engine damage, verify all thrust washers are properly installed in cylinder head.
Figure 355 Injection Quantity Adjustment (IQA) code
NOTE: The Injection Quantity Adjustment (IQA) code is printed in capital letters and numbers near the top of
the fuel injector.
1. Record the IQA code of each new fuel injector and its corresponding cylinder number so the new code can
be programed into the ECM, after fuel injectors are installed.
Figure 356 Injector Seals (typical)

1. Injector assembly 2. O-ring 3. Combustion washer
CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing
injector.
2. Install a new combustion washer (3) onto injector tip.
3. Lubricate new O-ring (2) with clean engine oil and install in recess at mid-point of injector.
Figure 357 Injector and Injector Hold-down Clamp Orientation (typical)

1. Injector hold-down clamp 2. Injector fuel inlet opening
4. Slide injector into hold-down clamp (1) with injector fuel inlet opening (2) on opposite side of hold-down
clamp.
Figure 358 Injector and Injector Hold-down Clamp Installation (typical)

1. Injector hold-down clamp 2. Injector
CAUTION: To prevent engine damage, align injector and hold-down clamp correctly with cylinder head. Do not
twist injector when inserting injector into cylinder head.
NOTE: Make sure injector bore in cylinder head is clean and no old combustion washer remains inside the bore.
5. Install injector (2) by lowering injector and hold-down clamp (1) as one unit into injector bore.
6. Using Injector Installer (page 661) ZTSE4777, firmly press injector and hold-down clamp and make sure
injector is fully seated into cylinder head.
CAUTION: To prevent engine damage, six new high-pressure connector bodies must be installed (step 8) and
aligned before tightening M8 x 50 bolts for six fuel injectors.
Figure 359 Alignment of High-pressure Connector Body (typical)

1. Cylinder 1 high-pressure 3. Cylinder 3 high-pressure 5. Cylinder head
connector body retaining nut connector body assembly 6. Locating ball
2. Cylinder 1 high-pressure 4. Cylinder 2 high-pressure
connector body connector body assembly
7. Align locating ball (6) on each new high-pressure connector body (2) with notch in cylinder head (5) and
install new high-pressure connector bodies as required.
Figure 360 Injector Hold-down Clamp Bolt

8. Install M8 x 50 bolt and rounded washer (1) finger tight only.
Figure 361 High-pressure Connector Body (typical)

1. High-pressure connector 2. High-pressure connector body
retaining nut (6) (6)
9. Install high-pressure connector retaining nuts (1) onto high-pressure connector bodies (2) as required and
tighten nuts to 41 lb-ft (55 N·m).
10. Completely loosen high-pressure retaining nuts; then, retighten nuts to 7-1 lb·ft (10 N·m).
Figure 362 Injector Hold-down Clamp Bolt

1. Injector hold-down clamp bolt 2. Injector hold-down clamp (6)
(6) and rounded washer (6) 3. Thrust washer (6)
11. Tighten injector hold-down clamp bolts (1) to 18 lb-ft (25 N·m).
12. Tighten injector hold-down clamp bolts an additional 90°.
Figure 363 High-pressure Connector Body (typical)

1. High-pressure connector 2. High-pressure connector body
13. Tighten high-pressure connector retaining nuts to 15 lb-ft (20 N·m).

14. Tighten high-pressure connector retaining nuts an additional 32°.
Figure 364 Injector Connections

1. Injector harness nuts (12) 2. Injector harness
CAUTION: To prevent engine damage, hold injector harness terminals to prevent twisting or turning while
tightening the injector harness nuts. Kinked harness terminals can result in an oil leak path between the
protective cover and the wire.
CAUTION: To prevent engine damage, use a torque wrench to tighten injector harness nuts. Do not use power
tools.
15. Connect injector harness (2) to injectors. Make sure harness terminals are in straight alignment with harness.
Hold terminals stationary to avoid twisting and tighten injector harness nuts (1) to 16 lb-in (1.8 N·m). Do not
use power tools.
16. See N13 Engine Diagnostic Manual Performance Diagnostics section, for instructions on how to program
the Engine Control Module (ECM), using ServiceMaxx™, with Injection Quantity Adjustment (IQA) codes
for fuel injectors being replaced.
Step Required Procedure Injectors Injector 3 Injectors

1, 2 4, 5, 6
1 Install high-pressure fuel lines. See x x x
High-pressure Fuel Line Installation (page 377).
2 Install high-pressure fuel pump to rail supply x
tube damper assembly. See HPFP to Rail
Supply Tube Damper Assembly Installation
(page 372).
3 Install engine brake housing assembly. See x x x
Engine Brake Housing Assembly Installation
(page 631).
4 Install upper valve cover. See Upper Valve x x x
Cover Installation (page 661).
5 Install Engine Control Module (ECM) and x x
mounting bracket. See Engine Control Module
(ECM) and Mounting Bracket Installation (page
661).
6 Install air filter housing and air intake tube. x x x
See Air Filter Housing and Air Intake Tube
7 Install inner fender on driver’s side. x x x
8 Connect batteries. x x x
Filter and Fuel Strainer Element

Refer to Navistar N13 Engine Operation and Maintenance Manual for filter element and fuel strainer element
service procedures.
Fuel System Priming

Fuel System Priming Tool Method
CAUTION: To prevent damage to the high-pressure fuel pump, do not start the engine until the fuel system is
properly primed. The Fuel System Priming Tool should be used to prime the fuel system. If the Fuel System
Priming Tool is not available, prime the fuel system using the hand primer pump method.
1. Obtain Fuel System Priming Tool (page 1232).
NOTE: Fuel System Priming Tool ball valves should be in the closed position, unless suction and pressure hoses
are connected to the vehicle fuel system.
Figure 365 Fuel System Priming Tool

1. Pressure hose 3. Suction hose 5. Ball valve (2)
2. Pressure regulator selector lever 4. Sight glass 6. Filler cap (filter housing)
CAUTION: To prevent damage to fuel system components, make sure pressure regulator handle is in the 50
psi (345 kPa) position (as shown) when servicing N13 engines.
2. Fill Fuel System Priming Tool fuel filter housing with clean diesel fuel, the first time the tool is used and any
time there is no diesel fuel in the filter housing.
3. Put a fuel drain pan under the chassis mounted primary fuel filter / water separator.
4. If necessary, fill the chassis mounted fuel filter with clean diesel fuel. Fill the cartridge type filter from the top
or pump the hand primer button for the spin-on type filter.
NOTE: For different vehicles the chassis mounted primary fuel filter / water separator is mounted in different
locations than what is shown in (Figure 367) and (Figure 368).
NOTE: The Fuel System Priming Tool will work with either of the primary fuel filter / water separators shown in
(Figure 366) or (Figure 367).
Figure 366 Chassis mounted primary fuel filter / water separator (optional)
1. Fuel output to engine
2. Chassis mounted primary fuel filter / water separator
3. Fuel input from tank
Figure 367 Chassis mounted primary fuel filter / water separator (typical)
1. Chassis mounted primary fuel filter / water separator
2. Fuel input from tank
3. Fuel output to engine
5. Disconnect fuel supply line to engine (fuel output to engine) by pushing red release tab and pulling line off
the primary fuel filter housing (Figure 368).
Figure 368 Chassis mounted primary fuel filter / water separator (typical)
2. Red release tab
6. Connect Fuel System Priming Tool suction hose to the primary fuel filter output (Figure 369).
Figure 369 Fuel Priming Tool suction hose connected to primary fuel filter output
2. Fuel System Priming Tool suction hose
3. Ball valve (closed)
7. Connect Fuel System Priming Tool pressure hose to the fuel supply line to engine (Figure 370).
Figure 370 Connecting Fuel System Priming Tool pressure hose to the fuel supply line to engine
2. Fuel System Priming Tool pressure hose
Figure 371 Ball valves closed

1. Pressure hose ball valve closed
2. Suction hose ball valve closed
8. Open pressure and suction hose ball valves (Figure 372) .
Figure 372 Ball valves open

1. Pressure hose ball valve open
2. Suction hose ball valve open
Figure 373 Pressure regulator selector lever
9. Set Fuel System Priming Tool pressure regulator selector lever to 50 psi (345 kPa) (Figure 373).
Figure 374 Fuel System Priming Tool connected to vehicle and electrical power
10. Connect electrical power and press the Fuel System Priming Tool power button (Figure 374).
11. Run Fuel System Priming Tool for a minimum of 2 minutes after no bubbles are visible in the sight glass
(Figure 375).
Figure 375 Fuel System Priming Tool sight glass

1. Sight glass
12. Turn Fuel System Priming Tool off.

13. Close pressure and suction hose ball valves (Figure 371).
Figure 376 Ball valves closed

1. Pressure hose ball valve closed
2. Suction hose ball valve closed
14. Disconnect Fuel System Priming Tool pressure and suction hoses.
15. Connect fuel supply line to engine to the chassis mounted primary fuel filter / water separator (Figure 377).
Figure 377 Chassis mounted primary fuel filter / water separator

2. Red release tab

Hand Primer Pump Method

NOTE: Priming the fuel system by hand is not necessary if the Fuel System Priming Tool was used to prime the
fuel system.
Figure 378 Fuel primer pump

1. Fuel primer pump
2. Fuel filter cover
4. Water drain valve (closed)
1. Prime engine at hand primer pump:

A. Turn the fuel primer pump knob counterclockwise to unlock the pump stem.
B. Pump the fuel priming pump a minimum of 250 times (approximately 2 minutes). Continue pumping
even after higher pumping force is required. Make sure to raise and lower the knob completely on
each stroke.
C. After priming, depress the fuel primer pump knob fully and turn the fuel primer pump knob clockwise
until tight to secure the pump stem.
CAUTION: To prevent engine damage, if engine fails to start after 20 seconds of cranking, stop cranking engine
and wait two minutes to allow the starter motor to cool.
2. Start engine and check for fuel leaks. Let engine run for 2 minutes. If engine does not start after 20 seconds
of cranking, wait 2 minutes before trying to start the engine again. If the engine does not start, reprime the
low-pressure fuel system using the above procedure.
4. Flip up and secure front bumper (if equipped).
5. Close and secure hood.
6. Remove wheel chocks.
Fuel System Cleaning and Inspection

Low-pressure and High-pressure Fuel System Components
1. Inspect low-pressure fuel lines for kinks, obstructions or other damage. Replace if necessary.
2. Inspect low-pressure fuel line quick-connect fitting O-ring seals for damage. Replace low-pressure fuel lines
if necessary.
3. Inspect fuel filter housing assembly and fuel primer pump assembly for damage. Replace if necessary.
4. Inspect high-pressure pump input shaft and driving sleeve splines for wear or damage. Replace if necessary.
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.
Engine Mounted Fuel Filter Assembly Cleaning and Inspection
Figure 379 Engine Mounted Fuel Filter Assembly

A. Fuel filter module D. Fuel plug G. Fuel primer pump assembly
B. Fuel filter housing E. Fuel supply port H. Fuel primer pump housing
C. Fuel filter housing O-ring groove F. Fuel filter module fitting
See Engine Mounted Fuel Filter Assembly (Figure 379) to perform steps 1 through 7.
1. Remove fuel filter housing (B) from fuel filter module (A).
2. Using a suitable solvent, clean fuel filter module, fuel filter housing, and fuel primer pump housing (A, B,
and H) to remove dirt, grease, and deposits.
3. Clean fuel supply port and fuel filter module fitting (E and F) with steam and then dry with filtered compressed
air.
4. Inspect fuel filter module, fuel filter housing, fuel primer pump assembly, and fuel primer pump housing (A,
B, G, and H) for cracks, pitting and other notable damage. Repair or replace as necessary.
5. Inspect fuel filter housing O-ring groove (C) for cracks, uneven sealing surface, and other notable damage.
6. Inspect fuel plug and fuel filter module fitting (D and F) for signs of leaking. Repair or replace as necessary.
7. Inspect fuel supply port and fuel filter module fitting (D and F) for damage to threads. Repair or replace as
necessary.
Fuel Injector Bore

1. Use Injector Sleeve Brushes (page 1232) in injector bore to remove deposits.
2. Use filtered compressed air to clean out debris from injector bores.
Fuel Injector Harness

Inspect injector wiring harness for kinked wires or terminals. Replace harness if kinks are found. Kinked wires
can result in oil leaking in between the harness protective foam covering and the wires.
Specifications
Fuel strainer filtration 300 microns
Fuel filter element filtration 3-5 microns
Special Torques
Banjo bolt, M14 30 N·m (22 lb·ft)
Check valve 35 N·m (26 lb·ft)
Closed (P) clamp and M6 x 16 bolt 13 N·m (115 lb·in)
Forcing Screw Adapter Holding Plate M10 x 40 bolts 27 N·m (20 lb·ft)
Fuel drain line fitting nut 26 N·m (19 lb·ft)
Fuel filter bracket M8 x 30 bolt 35 N·m (26 lb·ft)
Fuel filter housing assembly M8 x 45 bolt 35 N·m (26 lb·ft)
Fuel filter cap 25 N·m (18 lb·ft)
Fuel filter stand pipe 12 N·m (106 lb·in)
Fuel Pressure Control Valve (FPCV) screws 8 N·m (71 lb·in)
Fuel primer pump assembly M8 x 25 bolt 30 N·m (22 lb·ft)
Fuel rail M8 x 40 bolt 35 N·m (26 lb·ft)
Fuel strainer cover 10 N·m (89 lb·in)
Fuel supply adapter 30 N·m (22 lb·ft)
High-pressure connector (body) retaining nut See tightening steps in procedure
Drive housing M12 x 40, M12 x 90, M12 x 130 bolt 105 N·m (77 lb·ft)
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lb·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lb·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lb·ft)
Holding plate M12 bolts 47 N·m (35 lb·ft)
Injector harness nut 1.8 N·m (16 lb·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Piston Overflow Valve (KUEV) 49 N·m (37 lb·ft)
Pressure limiting valve 110 N·m (81 lb·ft)
Quick-connect M16 x 1.5 connector 30 N·m (22 lb·ft)
Support bracket M12 x 30 bolts 107 N·m (79 lb·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lb·ft)
Special Tools
Crowfoot wrench Obtain locally
Fan Hub/High Pressure Drive Seal Installer ZTSE6066
Forcing Screw 12-454-01-05
Forcing Screw Adapter 12-454-01-04
Forcing Screw Adapter Holding Plate 12-454-01-01
Fuel Injector Cups ZTSE4892
Fuel Injector Rack Holder ZTSE4299B
Fuel System Priming Tool 15-922-01
Guide Stud 12-454-01-02
High-Pressure Pump Removal Tool 12-454-01
Holding Plate ZTSE6044
Injector Installer ZTSE4777
Injector Puller ZTSE4770
Injector Sleeve Brushes ZTSE4751
P80® Rubber Lubricant or equivalent Obtain locally
Socket Head Bolt 12-454-01-03
Slide hammer Obtain locally
Oil Cooler, Filter Housing, and Crankcase Ventilation System
WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the
parking brake, and block the wheels before doing diagnostic or service procedures.
components.
WARNING: To prevent personal injury or death, remove the ground cable from the negative
terminal of the main battery before disconnecting or connecting electrical components. Always
connect the ground cable last.
• Turbochargers
• Fuel System
Oil Filter Cover and Filter

Oil Filter Cover and Filter Removal
Figure 380 Oil filter cover

1. Filter cover
2. O-ring seal
3. Oil filter
1. Place absorbent material under the engine and oil module assembly.
2. Unscrew oil filter cover from oil module using a 36 mm wrench.
3. Rotate oil filter element slightly and remove oil filter from filter cover.
4. Remove and discard O-ring seal from exterior of oil filter cover.
5. Dispose of oil filter according to local regulations.
Oil Filter Cover and Filter Installation

1. Lubricate new O-ring with clean engine oil and install onto exterior of oil filter cover.
2. Install oil filter into oil filter cover.
Figure 381 Oil filter cover

1. Filter cover
2. O-ring seal
3. Oil filter
3. Install oil filter, O-ring seal and oil filter cover as an assembly into oil module. Tighten 36mm cover hex to
CAUTION: To prevent engine damage, do not start or allow engine to run until first changing engine oil.
4. Drain and replace engine oil with recommended type and amount. See Engine Operation and Maintenance
Manual for oil type, capacity and fill procedure.
5. Replace engine coolant with recommended type and amount. See Engine Operation and Maintenance
Manual for coolant type, capacity and fill procedure.
NOTE: Three additional bolts secure the oil module assembly. These bolts are installed along with the HP turbo
air supply duct (two M10 x 200 bolts) and the air inlet duct for the LP turbocharger (one M10 x 140 bolt). See
"TURBOCHARGERS" for procedures.
Crankcase Oil Separator (CCOS)

Crankcase Oil Separator (CCOS) Removal
Figure 382 Open breather tube assembly

1. Open breather tube assembly
2. Clamp (spring)
3. CCOS outlet
1. Remove spring clamp (2) that secures open breather tube assembly (1) to CCOS outlet (3).
2. Remove open breather tube assembly (1) from centrifuge outlet (3).
Figure 383 Crankcase Oil Separator (CCOS)

1. CCOS
2. CCOS bolts (4)
3. Remove 4 CCOS bolts (2) that secure CCOS (1) to oil module assembly.
4. Remove CCOS (1) from engine.
Crankcase Oil Separator (CCOS) Installation
Figure 384 Crankcase Oil Separator (CCOS)

1. CCOS
2. M6 socket head bolt (4)
1. Install centrifuge with base and new formed seal. Lubricate new formed seal with clean engine oil.
2. Install four M6 socket head bolts. Tighten bolts to standard torque (page 1201).
Figure 385 Open breather tube assembly

2. Clamp (spring)
3. CCOS outlet
3. Slide spring clamp over open breather tube assembly.

4. Connect open breather tube assembly to centrifuge outlet.
5. Install spring clamp and tighten.
Oil Module Assembly

Oil Module Assembly Removal
Figure 386 Open breather tube and heater return tube

2. M6 x 16 bolt (3)
3. Tube clamp (2)
4. Tube clamp (2) (for hydrocarbon injector (HCI) coolant return tube assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
7. Pipe single cushioned clamp
1. Remove two tube clamp M6 x 16 bolts securing open breather tube to low-pressure charge air cooler
(LPCAC).
2. If not previously done, unclip two tube clamps securing HCI coolant return tube assembly to open breather
tube assembly.
CAUTION: To prevent engine damage, when manipulating the open breather tube assembly, do not create a
severe bend to the elbow hose that connects the tube to the oil module centrifuge outlet. The hose can crack.
3. If not previously done, release hose clamp (spring type) securing HCI coolant return tube assembly and
disconnect tube from open breather tube.
4. Remove hose clamp (spring type) securing heater return tube to open breather tube assembly. Remove
open breather tube assembly.
5. Remove M6 x 16 bolt and pipe single cushioned clamp securing heater return tube to LPCAC.
6. Loosen tube nut securing heater return tube to straight fitting on water distribution housing. Remove heater
return tube.
CAUTION: To prevent engine damage, drain all coolant from the engine through the radiator when removing
the oil module assembly. Coolant can enter the oil sump and contaminate the engine oil. Engine oil must be
drained and replaced after oil module removal and installation, before the engine is started.
7. Drain coolant from engine through radiator.
Figure 387 Oil module assembly (non-servicable items)

1. Plug (with seal)
2. Bottom cover
CAUTION: To prevent engine damage, do not remove oil module assembly plugs, seals or bottom cover to drain
the coolant or oil. These parts are not serviceable.
Figure 388 Oil module flange

1. Extension tube (DMR20 x DN14)
4. M8 x 45 bolt (3)
5. Engine oil temperature sensor
8. If not previously done, disconnect engine oil temperature sensor connector. Remove engine oil temperature
sensor from oil module flange if needed. See "ENGINE ELECTRICAL" for procedure.
9. Remove three M8 x 45 bolts then remove oil module flange by pulling away from cylinder head to disengage
extension tubes. Discard the oil module flange seal (formed).
CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surfaces.
10. Remove DMR20 x DN14 and DMR37 x DN29 extension tubes. Inspect for damage. Replace as necessary.
Figure 389 Oil module assembly

1. M10 x 80 bolt (7)
2. M10 x 170 bolt
3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer
11. Remove seven M10 x 80 bolts, three M10 x 110 bolts, M10 x 170 bolt, M8 x 150 bolt (from water pump
into front side of oil module assembly) and 9 x 16 x 15 spacer (between oil module assembly and water
distribution housing).
12. Remove oil module assembly and gasket from engine. Discard oil module assembly gasket.
Oil Module Assembly Installation

1. Position new gasket onto oil module assembly.

1. M10 x 80 bolt (7)
2. M10 x 170 bolt
3. M10 x 110 bolt (3)
4. M8 x 150 bolt location (from water pump) includes 9 x 16 x 15 spacer
CAUTION: To prevent engine damage, do not use any silicone or other sealant when installing oil module
assembly.
2. Position oil module assembly and install seven M10 x 80 bolts, M10 x 170 bolt and three M10 x 110 bolts.
3. Tighten oil module bolts to special torque (page 1245).
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 1245).

4. M8 x 45 bolt (3)
6. Lubricate sealing surfaces of DMR20 x DN14 and DMR37 x DN29 extension tubes with P-80® rubber
lubricant or equivalent (page 1232) and insert into oil module flange.
7. Install extension tubes into oil module flange using Extension Tube Installer Large and Extension Tube
Installer Small (page 1232).
8. Position oil module with new formed seal onto oil module while gently pushing extension tubes into cylinder
head. Install three M8 x 45 bolts. Tighten bolts to special torque (page 1245).
9. If not previously done, install engine oil temperature sensor into oil module flange if needed. See "ENGINE
ELECTRICAL" for procedure. Connect temperature sensor electrical connector.
Figure 392 Open breather tube and heater return tube

2. M6 x 16 bolt (3)
3. Tube clamp (2)
4. Tube clamp (2) (for HCI coolant return tube assembly)
5. Hose clamp (spring type)
6. Heater return tube assembly
7. Pipe single cushioned clamp
10. Install two tube clamps onto open breather tube. Position open breather tube assembly to LPCAC and install
two M6 x 16 bolts. Tighten bolts to special torque (page 1245).
11. If not previously done, snap two tube clamps over open breather tube assembly and HCI coolant return tube
assembly.
12. If not previously done, install HCI coolant return tube onto open breather tube assembly and install hose
clamp (spring type). See HCI Coolant Return Tube (page 201).
13. Position heater return tube assembly to straight fitting on water distribution housing and loosely tighten tube
nut.
14. Install pipe single cushioned clamp onto heater return tube assembly and install M6 x 16 bolt into LPCAC
and tighten to special torque (page 1245).
15. Install heater return tube assembly hose onto open breather tube and install hose clamp (spring type).
16. Tighten heater return tube assembly tube nut to special torque (page 1245).
Oil Cooler
Oil Cooler Removal
Figure 393 Oil cooler bolts

1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2)
1. Remove two M8 x 45 and two M8 x 90 bolts.
Figure 394 Oil cooler
2. Remove oil cooler from oil module assembly.

Figure 395 Oil cooler gaskets
3. Remove two oil cooler gaskets from oil module assembly. Discard gaskets.
Oil Cooler Cleaning
CAUTION: To prevent engine damage, replace the oil cooler if an engine bearing fails. Bearing debris cannot
be removed from the oil cooler.
1. The oil cooler can be cleaned in solvent and dried with filtered compressed air.
• Clean oil cooler in suitable solvent.
• Flush and drain oil cooler to remove any residue. Dry components with filtered compressed air.
Oil Cooler Installation
Figure 396 Oil cooler bolts

1. M8 x 45 bolt (2)
2. M8 x 90 bolt (2)
1. Install two M8 x 45 and two M8 x 90 bolts through oil module assembly.
Figure 397 Oil cooler gaskets
2. Install new oil cooler gaskets over threads of installed bolts.

Figure 398 Oil cooler installation
3. Install oil cooler over gaskets and into oil module. Hand-tighten bolts.
NOTE: Ensure gaskets remain in place during cooler installation.
Tighten two M8 x 45 and two M8 x 90 bolts to special torque (page 1245).
Oil Pressure Relief Valve

Oil Pressure Relief Valve Removal
NOTE: Perform this procedure if replacing oil pressure relief valve for oil pressure-related issues.
Figure 399 Oil pressure relief valve
1. Remove oil pressure relief valve. Clean and inspect oil pressure relief valve. Replace if necessary.
Oil Pressure Relief Valve Assembly

NOTE: Perform this procedure if oil pressure relief valve is removed.
Figure 400 Oil pressure relief valve
1. Install oil pressure relief valve. Tighten valve to special torque (page 1245).
Oil Cooler, Filter Housing, and Crankcase Ventilation System Cleaning, Inspection, and Testing
Oil Filter and Oil Cooler
Figure 401 Oil Module Assembly

A. Oil module assembly D. Oil module assembly sealing F. Oil pressure relief valve port
B. Oil filter housing O-ring groove surface
C. Oil filter housing E. Oil cooler sealing surfaces (2)
See Oil Module Assembly (Figure 401) to perform steps 1 through 7.

1. Use a suitable solvent to clean oil module assembly and oil filter housing (A and C), and dry with filtered,
compressed air.
2. Using a scraper and / or wire brush, clean oil module assembly sealing surface and oil cooler sealing surfaces
(D and E).
3. After cleaning oil module assembly sealing surface and oil cooler sealing surfaces (D and E), use a
non-caustic brake cleaner to clean sealing surfaces for inspection.
4. Using filtered, compressed air, clean any dirt and / or deposits from oil pressure relief valve port (F).
5. Inspect oil module assembly and oil filter housing (A and C) for cracks, pitting, and other notable damage.
6. Inspect oil filter housing O-ring groove, oil module assembly sealing surface, and oil cooler sealing surfaces
(B, D, and E) for cracks, pitting, and other notable damage. Repair or replace as necessary.
7. Inspect oil pressure relief valve port (F) for plugging, deposits, and other notable damage. Repair or replace
as necessary.
Figure 402 Oil Cooler

A. Oil cooler C. Oil cooler mounting bolt holes
B. Oil cooler sealing surfaces (2) (4)
See Oil Cooler (Figure 402) to perform steps 8 through 13.

8. Using a suitable, non-caustic solvent, clean oil cooler (A) and dry with filtered, compressed air.
9. Using a scraper and / or wire brush, clean oil cooler sealing surfaces (B).
10. After cleaning oil cooler sealing surfaces (B), use a non-caustic brake cleaner to clean sealing surfaces for
inspection.
11. Clean oil cooler mounting bolt holes (C) with steam and dry with filtered, compressed air.
12. Inspect oil cooler and oil cooler sealing surfaces (A and B) for cracks, pitting, signs of leaks, plugging, and
other notable damage. Repair or replace as necessary.
13. Inspect oil cooler mounting bolt holes (C) for stripped or damaged threads and other notable damage. Repair
Oil Cooler Leak Test
Figure 403 Engine oil cooler pressure test

1. Air pressure regulator
2. Engine Oil Cooler Pressure Test Plate
1. Install Engine Oil Cooler Pressure Test Plate (2) on oil cooler.
2. Attach an air pressure regulator (1) to Engine Oil Cooler Pressure Test Plate (2). Connect to compressed
air supply and adjust air pressure to approximately 172 to 207 kPa (25 to 30 psi).
3. Immerse oil cooler in large container of clean water.
4. Inspect oil cooler and test plate for leaks. If test plate fittings leak, tighten fittings and continue looking for
leaks. Air bubbles at any location from oil cooler indicate leaks. Replace oil cooler if leaking.
5. Dry oil cooler using filtered, compressed air.
Extension Tubes
1. Wipe extension tubes clean and inspect for tears, cuts or other damage to sealing surfaces. Replace as
necessary.
Crankcase Oil Separator (CCOS) and Breather Tube

1. Clean breather tube assembly with hot water and dry with filtered, compressed air.
2. Clean CCOS using a non-caustic cleaner and dry with filtered, compressed air.
Figure 404 Breather Tube Assembly

A. Breather tube B. Breather elbow C. Breather tube coolant ports (2)
See Breather Tube Assembly (Figure 404) to perform steps 3 through 5.

3. Inspect breather tube (A) for cracks, bending, kinks, plugging, and other notable damage. Repair or replace
as necessary.
4. Inspect breather elbow (B) for cracks, kinks, rubber degradation, plugging, and other notable damage.
5. Inspect breather tube coolant ports (C) for kinks, pitting, cracks, plugging, and other notable damage. Repair
Figure 405 CCOS

A. CCOS housing C. O-ring sealing surface E. Separator wheel
B. Breather tube port D. Separator wheel vanes
See CCOS (Figure 405) to perform steps 6 through 9.

6. Inspect CCOS housing and breather tube port (A and B) for cracks, leaks, and other notable damage. Repair
7. Inspect O-ring sealing surface (C) for cracks, pitting, and other notable damage. Repair or replace as
necessary.
8. Inspect separator wheel vanes (D) for cracks, bent vanes, and other notable damage. Repair or replace as
necessary.
9. Spin separator wheel (E) by hand and check for any binding or sticking. Repair or replace as necessary.
Figure 406 Oil Module Assembly Oil Passageways

See Oil Module Assembly Oil Passageways (Figure 406) to perform step 10.
10. Inspect oil module assembly (1) oil passageway. Clean any obstructions or dirt as necessary.
Special Torques
Heater return tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Heater return tube assembly tube nut 11 N·m (97 lb·in)
Oil cooler bolts, M8 x 45 and M8 x 90 25 N·m (18 lb·ft)
Oil filter cover 40 N·m (30 lb·ft)
Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110 65 N·m (48 lb·ft)
Oil module flange bolts, M8 x 45 24 N·m (18 lb·ft)
Oil pressure relief valve 40 N·m (30 lb·ft)
Open breather tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Water pump bolt, M8 x 150 (front side of oil module) 35 N·m (26 lb·ft)
Special Tools
Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
Exhaust Gas Recirculation (EGR) System

Exhaust Gas Recirculation (EGR) Cooler
Exhaust Gas Recirculation (EGR) Cooler Removal
Figure 407 EGR Cooler Exhaust Outlet Hose

1. EGR cooler outlet 2. EGR cooler exhaust outlet hose 3. EGR cooler exhaust outlet hose
clamps (2) 4. EGR outlet manifold
See Outer EGR Heat Shield (Figure 432) to perform steps 1 and 2.
2. Loosen 2 EGR cooler exhaust outlet hose clamps (2) and remove EGR cooler exhaust outlet hose (3) from
EGR cooler exhaust outlet (1) and EGR outlet manifold (4).


heat shield (1).
Figure 409 EGR Valve Bellows Tube

1. EGR valve 2. EGR valve bellows tube V-band 3. EGR valve bellows tube
clamps (2) 4. EGR cooler
See EGR Valve Bellows Tube (Figure 430) to perform step 4.

4. Remove 2 EGR valve bellows tube V-band clamps (2) between EGR valve (1) and EGR cooler (4). Remove
EGR valve bellows tube (3). Discard V-band clamps.
5. Remove EGR valve jumper harness clips as necessary.
Figure 410 Supply Line Removal

1. EGR valve coolant supply line 3. EGR cooler 5. EBPV air supply line bolts (3)
2. EGR valve coolant supply line 4. Exhaust Back-Pressure Valve
stud bolts (2) (EBPV) air supply line
See Supply Line Removal (Figure 429) to perform steps 6 and 7.

6. Remove 2 EGR valve coolant supply line stud bolts (2) securing EGR valve coolant supply line (1) to EGR
cooler (3).
7. Remove 3 EBPV air supply line bolts (5) securing EBPV air supply line (4) to EGR cooler (3).
Figure 411 T-fitting Connections

1. EGR valve coolant supply line 2. EGR valve coolant supply line 3. T-fitting
spring clamp
See T-fitting Connections (Figure 428) to perform step 8.

8. Remove EGR valve coolant supply line spring clamp (2) and remove EGR valve coolant supply line (1) from
T-fitting (3).

tube nut
valve (1).
valve (1).
Figure 413 EGR Cooler Chassis Connections

1. EGR cooler 2. Bunk heater coolant supply line 3. Deaeration hose location
location 4. Heater hose location
See EGR Cooler Chassis Connections (Figure 426) to perform steps 11 through 13.
11. Disconnect heater hose (4) from EGR cooler (1).
12. Optional - If not already done, remove rear bunk heater coolant supply line (2) from EGR cooler (1) if
equipped
13. If not already done, remove deaeration hose (3) from EGR cooler (1).
Figure 414 Low-Temperature Radiator (LTR) Hose

1. Low-Temperature Radiator 2. Hose clamp
(LTR) hose 3. LTR thermostat housing
See Low-Temperature Radiator (LTR) Hose (Figure 425) to perform step 14.
14. Loosen hose clamp (2) and remove Low-Temperature Radiator (LTR) hose (1) from LTR thermostat housing
(3).
Figure 415 Upper EGR Cooler Mounting Points

1. Upper EGR cooler support 2. Cylinder head
bracket mounting bolts (2) 3. EGR cooler support bracket
See Upper EGR Cooler Mounting Points (Figure 421) to perform step 15.
15. Remove 2 upper EGR cooler support bracket mounting bolts (1) securing EGR cooler support bracket (3)
to cylinder head (2).
Figure 416 Lower EGR Cooler Mounting Points

1. Lower EGR cooler support 2. EGR cooler support bracket
bracket mounting bolts (5) 3. EGR cooler
See EGR Cooler Lower Support Bracket Mounting (Figure 420) to perform steps 16 and 17.
16. Remove 5 lower EGR cooler support bracket mounting bolts (1) from EGR cooler support bracket (2) and
remove EGR cooler (3) from engine.
17. Remove EGR cooler outlet seal and discard.
Figure 417 Coolant Manifold Pipe Support Bracket

1. Cylinder head 2. EGR coolant supply tube bracket 3. EGR coolant supply tube
bolts (4) 4. EGR coolant supply tube bracket
See Coolant Manifold Pipe Support Bracket to perform steps 18 through 20.
18. Remove 2 EGR coolant supply tube bracket bolts (2) that secure supply tube bracket (4) to cylinder head
(1).
19. Remove 2 EGR Coolant supply tube bracket bolts (2) that secure supply tube bracket (4) to EGR coolant
supply tube (3). Remove EGR coolant supply tube bracket.
20. Remove EGR coolant supply tube (3) from engine.

Test Procedure
components.

1. Exhaust gas outlet plug 9. Coolant inlet block-off 14. Bubble test hose assembly
12-892-07-01 12-892-07-06 12-892-07-04
2. EGR cooler exhaust outlet port 10. Exhaust gas inlet plug 15. Container of water (half full)
3. Block-off plugs 12-892-07-10 (3) 12-892-07-02 16. EGR cooler coolant return port
4. Sleeper cab heat block-off 11. EGR cooler exhaust gas inlet 17. Coolant outlet clamp
12-892-07-05 port 12-892-07-07
5. Bunk heater port 12. EGR valve supply port 18. Regulator assembly
6. Main cab heat plug 12-892-07-03 13. EGR valve supply adapter 12-892-07-08
7. EGR cooler main cab heat port 12-892-07-09
8. EGR cooler coolant inlet port
1. Install exhaust gas outlet plug 12-892-07-01 (1) into EGR cooler exhaust gas outlet port (2). Tighten knurled
ring to seal.
2. Install exhaust gas inlet plug 12-892-07-02 (10) into EGR cooler exhaust gas inlet port (11). Tighten knurled
ring to seal.
knob to seal.
4. Install EGR valve supply adapter 12-892-07-09 (13) into EGRV supply port (12) and tighten to seal.
6. Install main cab heat plug 12-892-07-03 (6) into EGR cooler main cab heat port (7). Tighten knurled knob
to seal.
7. Insert coolant inlet block-off 12-892-07-06 (9) into EGR cooler coolant inlet port (8). Tighten knurled knobs
to seal.
9. Install bubble test hose assembly 12-892-07-04 (14) onto EGR valve supply adapter 12-892-07-09 (13.
10. Install regulator assembly 12-892-07-08 (18) onto exhaust gas outlet plug 12-892-07-01 (1).
14. Insert bubble test hose assembly (14) into a container of clean water filled half full (15). Keeping end of
Expected Outcome
Exhaust Gas Recirculation (EGR) Cooler Installation

• Coolant Management Tool – KL5007NAV
Torques
Coolant manifold pipe to EGR cooler mounting bolts 31 N·m (23 lb·ft)
Coolant manifold pipe support bracket bolts 31 N·m (23 lb·ft)
Upper EGR cooler support bracket mounting bolts 8 N·m (6 lb·ft) then 31 N·m (23 lb·ft)
Lower EGR cooler support bracket mounting bolts 62 N·m (46 lb·ft)
Rear bunk heater coolant supply line bolt 13 N·m (10 lb·ft)
EGR valve coolant supply line tube nut 40 N·m (30 lb·ft)
EGR valve coolant return line tube nut 40 N·m (30 lb·ft)
EBPV air supply line bolts 13 N·m (10 lb·ft)
EGR valve coolant supply line stud bolts 31 N·m (23 lb·ft)
EGR valve bellows V-band clamps 14.5 N·m (11 lb·ft)
EGR valve heat shield bolts 18 N·m (13 lb·ft)
EGR cooler exhaust outlet hose clamps 4 N·m (2.95 lb·ft)

See Coolant Manifold Pipe Support Bracket (Figure 419) to perform steps 1 through 4.
1. Install new O-rings onto EGR coolant supply tube and lube O-rings with P-80® lubricant.
2. Apply P-80® lubricant in rear coolant manifold bore.
3. Install EGR coolant supply tube (3) into rear coolant manifold.
4. Using 4 EGR coolant supply tube bracket bolts (2), install EGR coolant supply tube bracket and (4) EGR
coolant supply tube (3) onto cylinder head (1). Torque bolts to finger tight.
Figure 420 Lower Exhaust Gas Recirculation (EGR) Cooler Mounting Points
See Lower Exhaust Gas Recirculation (EGR) Cooler Mounting Points (Figure 420) to perform steps 5 and 6.
5. Install new EGR cooler outlet seal onto EGR cooler (3).
NOTE: Insert coolant manifold pipe into EGR cooler during installation of EGR cooler.
6. Using 5 lower EGR cooler support bracket mounting bolts (1), install EGR cooler support bracket (2) with
EGR cooler (3) onto cylinder head. Torque bolts to finger tight.

7. Using 2 upper EGR cooler support bracket mounting bolts (1), secure EGR cooler support bracket (3) to
cylinder head (2). Torque bolts to 8 N·m (6 lb·ft).
Figure 422 Lower Exhaust Gas Recirculation (EGR) Cooler Mounting Bolt Torque Procedure
See Lower Exhaust Gas Recirculation (EGR) Cooler Mounting Bolt Torque Procedure (Figure 422) to perform
step 8.
8. Torque 5 lower EGR cooler support bracket mounting bolts (5) that secure EGR cooler (3) and EGR cooler
support bracket (2) to cylinder head to 62 N·m (46 lb·ft).
Figure 423 Upper EGR Cooler Mounting Bolt Torque Procedure

See Upper EGR Cooler Mounting Bolt Torque Procedure (Figure 423) to perform step 9.
9. Torque 2 upper EGR cooler support bracket mounting bolts (1) that secure EGR cooler support bracket (3)
to cylinder head to 31 N·m (23 lb·ft).
Figure 424 Coolant Manifold Pipe Support Bracket Torque Procedure

1. Coolant manifold pipe support 3. Coolant manifold pipe 6. Coolant manifold pipe support
bracket bolt 1 4. Coolant manifold pipe to EGR bracket bolt 3
2. Coolant manifold pipe support cooler mounting bolts (2) 7. Coolant manifold pipe support
bracket bolt 2 5. EGR cooler bracket bolt 4
See Coolant Manifold Pipe Support Bracket Torque Procedure (Figure 424) to perform steps 10 through 13.
10. Using 2 coolant manifold pipe to EGR cooler mounting bolts (4), secure coolant manifold pipe (3) to EGR
cooler (5). Torque bolts to 31 N·m (23 lb·ft).
11. Torque coolant manifold pipe support bracket bolts 1 and 2 (1 and 2) to 6.8 N·m (5 lb·ft).
12. Torque coolant manifold pipe support bracket bolts 3 and 4 (6 and 7) to 31 N·m (23 lb·ft).

1. Low-Temperature Radiator 2. Hose clamp
(LTR) hose 3. LTR thermostat housing
14. Using hose clamp (2), install Low-Temperature Radiator (LTR) hose (1) onto LTR thermostat housing (3).

15. Install deaeration hose (3) onto EGR cooler (1).
16. Install rear bunk heater coolant supply line (2) onto EGR cooler (1) if equipped. Torque bolt to 13 N·m (10
lb·ft).
17. Install heater hose (4) onto EGR cooler (1).

tube nut
18. Using new O-ring and EGR valve coolant supply line tube nut (2), install EGR valve coolant supply line (3)
onto EGR valve (1). Torque EGR valve coolant supply line tube nut to 40 N·m (30 lb·ft).
19. Using new O-ring and EGR valve coolant return line tube nut (5), install EGR valve coolant return line (4)

spring clamp

20. Using EGR valve coolant supply line spring clamp (2), install EGR valve coolant supply line (1) onto T-fitting
(3).
Figure 429 Supply Line Installation

stud bolts (2) (EBPV) air supply line
See Supply Line Installation (Figure 429) to perform steps 21 and 22.
21. Using 3 EBPV air supply line bolts (5), install EBPV air supply line (4) onto EGR cooler (3). Torque bolts to
13 N·m (10 lb·ft).
22. Using 2 EGR valve coolant supply line stud bolts (2), install EGR valve coolant supply line (1) to EGR cooler
(3). Torque bolts to 31 N·m (23 lb·ft).

NOTE: Ensure that V-band clamp orientation is 90° from horizontal (stud of V-band clamp should be pointing
vertically).
23. Using 2 new EGR valve bellows tube V-band clamps (2) and 2 new EGR valve bellows gaskets, install
EGR valve bellows tube (3) between EGR valve (1) and EGR cooler (4). Torque EGR valve bellows V-band
clamps 14.5 N·m (11 lb·ft).
24. Install EGR valve jumper harness clips as necessary.


25. Using 5 EGR valve heat shield bolts (3), install EGR valve heat shield (1) onto EGR valve (2) and EGR
cooler (4). Torque EGR valve heat shield bolts to 18 N·m (13 lb·ft).

See EGR Cooler Exhaust Outlet Hose (Figure 432) to perform steps 26 and 27.
26. Apply P-80® lubricant to both ends of EGR cooler exhaust outlet hose (3).
27. Using 2 hose clamps (2), install EGR cooler exhaust outlet hose (3) between EGR cooler exhaust outlet (1)
and EGR outlet manifold (4). Torque EGR cooler outlet hose clamps to 4 N·m (2.95 lb·ft).
EGR Valve
EGR Valve Removal


heat shield (1).

tube nut
valve (1).
valve (1).

5. Remove 2 EGR valve coolant return line stud bolts (3) that secure EGR valve coolant return line (2) to EGR
cooler (1).

6. Remove EGR valve jumper harness connector (2) from EGR valve (1). Cut tie straps as necessary.
7. Move both EGR valve coolant lines (3 and 4) out of way. Do not bend or kink EGR valve coolant lines.

See EGR Valve Bellows (Figure 437) to perform steps 8 through 11.
8. Remove 2 EGR valve bellows V-band clamps (2) from EGR valve to EGR cooler bellows tube (6). Discard
both EGR valve bellows V-band clamps.
9. Remove EGR valve to EGR cooler bellows tube (6) from EGR valve (5) and EGR cooler (7). Discard 2 EGR
valve bellows gaskets (3).
10. Remove 2 EGR valve bellows V-band clamps (2) from EGR valve to rear exhaust manifold bellows tube (4).
Discard EGR valve bellows V-band clamps.
11. Remove EGR valve to rear exhaust manifold bellows tube (4) from EGR valve (5) and rear exhaust manifold
(1). Discard 2 EGR valve bellows gaskets (3).
Figure 438 EGR Valve


12. Remove 4 EGR valve bolts (2) that secure EGR valve (1) to EGR valve mounting bracket (3). Remove EGR
valve.
EGR Valve Cleaning, Inspection, and Testing
Figure 439 EGR Valve Inspection Points

A. EGR valve bellow sealing C. Coolant ports F. EGR valve
surfaces (4) D. EGR valve bellows (2)
B. EGR valve connector E. EGR valve sealing surfaces (2)
See EGR Valve Inspection Points (Figure 439) to perform steps 1 through 7.
1. Clean all sealing surfaces (A and E) to ensure proper sealing of gaskets, hoses, and fittings.
2. Inspect all sealing surfaces (A and E) for cracking, pitting, or damage. Repair or replace as necessary.
3. Inspect EGR valve (F) for cracks, pitting, carbon build-up, or damage. Repair or replace as necessary.
4.
NOTE: Outside presence of carbon on the EGR valve does not indicate a defective part.
Inspect EGR valve (F) for carbon build up. If carbon build up is present clean from EGR valve using suitable
non-caustic solvent.
5. Inspect EGR valve connector (B) for corrosion or damage; loose, bent, or broken pins; missing or damaged
seals; or broken connector housing. Repair or replace as necessary.
6. Inspect coolant ports (C) for obstruction and deposits. Clean as necessary.
7. Inspect EGR valve bellows (D) for cracks, dents, or damage. Repair or replace as necessary.
EGR Valve Installation

Torques
EGR valve bolts 72 N·m (53 lb·ft)

EGR valve coolant return line stud bolts 31 N·m (23 lb·ft)


1. Using 4 EGR valve bolts (2), install EGR valve (1) onto EGR valve mounting bracket (3). Torque EGR valve
bolts to 72 N·m (53 lb·ft).

See EGR Valve Bellows (Figure 441) to perform steps 2 and 3.

2. Using 2 EGR valve bellows V-band clamps (2) and 2 new EGR valve bellows gaskets (3), install EGR valve
to rear exhaust manifold bellows tube (4) between EGR valve (5) and rear exhaust manifold (1). Torque
EGR valve bellows V-band clamps to 14.5 N·m (11 lb·ft).
3. Using 2 EGR valve bellows V-band clamps (2) and 2 new EGR valve bellows gaskets (3), install EGR valve
to EGR cooler bellows tube (6) between EGR valve (5) and EGR cooler (7). Torque EGR valve bellows
V-band clamps to 14.5 N·m (11 lb·ft).

4. Install EGR valve jumper harness connector (2) onto EGR valve (1). Install new tie straps as necessary.
5. Move both EGR valve coolant lines (3 and 4) in position for installation.

tube nut
onto EGR valve (1). Torque EGR valve coolant return line tube nut to 40 N·m (30 lb·ft).

8. Using 2 EGR valve coolant supply line stud bolts (3), install EGR valve coolant return line (2) to EGR cooler
(1). Torque EGR valve coolant return line stud bolts to 31 N·m (23 lb·ft).


Special Torques
Special Torques
EGR valve bolts 72 N·m (53 lb·ft).
Special Tools
Exhaust Gas Recirculation (EGR) Valve Replacement

Overview
This section provides instruction specifically for removal of the EGR Valve when not doing a complete engine
tear-down.
Equipment Condition
None

None
Procedure
Figure 446 EGR Valve Heat Shield

1. EGR valve heat shield 2. EGR valve heat shield bolt(5)
See EGR Valve Heat Shield (Figure 446) to perform step 1.

1. Remove five EGR valve heat shield bolts (2) and EGR valve heat shield (1).

1. Rear exhaust manifold 3. EGR valve bellows tube V-band 4. EGR valve
2. EGR valve bellows tube (2) clamps (2) 5. EGR Tube
See EGR Valve Bellows Tube V-band Clamp (Figure 447) to perform step 2.
2. Remove two EGR valve bellows tube V-band clamps (3), one from each side of EGR valve (4). Discard
V-band clamps.
Figure 448 EGR Valve Cable Harness and Coolant Lines

1. EGR valve 3. EGR valve coolant supply line 5. EGR valve coolant supply line
2. EGR valve cable harness tube nut 6. EGR valve coolant return line
assembly 4. EGR valve coolant return line
tube nut
See EGR Valve Cable Harness and Coolant Lines (Figure 448) to perform steps 3 through 5.
3. Disconnect EGR valve cable harness assembly (2).
valve (1).
valve (1).
Figure 449 EGR Valve Removal

1. EGR valve gasket (2) 3. EGR valve mounting bolt (4)
2. EGR valve 4. EGR valve support frame
See EGR Valve Removal to perform steps 6 and 7.

6. Remove four EGR valve mounting bolts (3) from EGR valve (2).
7. Remove EGR valve (2) with two EGR valve gaskets (1) from EGR valve support frame (5). Discard gaskets.
EGR Valve Disassembly, Cleaning, Inspection, and Reassembly

For EGR valve disassembly, see Exhaust Gas Recirculation (EGR) Valve Disassembly in Engine Disassembly
Procedures.
For EGR valve cleaning and inspection, see Exhaust Gas Recirculation (EGR) Valve Cleaning and Inspection
in Engine Disassembly Procedures.
For EGR valve reassembly, see Exhaust Gas Recirculation (EGR) Valve Reassembly (page 000) in Engine
Disassembly Procedures.

1. EGR valve gasket (2) 3. EGR valve mounting bolt (4)
2. EGR valve 4. EGR valve support frame
See EGR Valve Installation (Figure 450) to perform steps 1 through 4.

1. Place two new EGR valve gaskets (1) on EGR valve (2).
2. Position EGR valve (2) with new EGR valve gaskets (1) on EGR valve support frame (5).
3. Secure EGR valve (2) to EGR valve support frame (1) with four EGR valve mounting bolts (3).
4. Tighten four EGR valve mounting bolts (3) to standard torque.
Figure 451 EGR Valve Cable Harness and Coolant Lines

1. EGR valve 3. EGR valve coolant supply line 5. EGR valve coolant supply line
2. EGR valve cable harness tube nut 6. EGR valve coolant return line
assembly 4. EGR valve coolant return line
tube nut
See EGR Valve Cable Harness and Coolant Lines (Figure 451) to perform steps 5 through 7.
5. Connect EGR valve cable harness assembly (2) to EGR valve (1).
6. Attach EGR valve coolant supply line nut (3) to EGR valve (1) and tighten to special torque.
7. Attach EGR valve coolant return line nut (4) to EGR valve (1) and tighten to special torque.

1. Rear exhaust manifold 3. EGR valve bellows tube V-band 4. EGR valve
2. EGR valve bellows tube (2) clamps (2) 5. EGR Tube

8. Install two new EGR valve bellows tube V-band clamps (3), one on each side of EGR valve (4) securing
EGR valve (4) to two EGR valve bellows tubes (2).
Figure 453 EGR Valve Heat Shield

1. EGR valve heat shield 2. EGR valve heat shield bolt(5)
See EGR Valve Heat Shield (Figure 453) to perform step 9.

9. Install EGR valve heat shield (1) and secure with five EGR valve heat shield bolts (2). Tighten bolts to
standard torque.
None
Engine Throttle Valve (ETV), Air Intake Throttle Duct Assembly, and
Exhaust Manifold System
components.
• 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
Engine Throttle Valve (ETV)
Engine Throttle Valve (ETV) Removal
CAUTION: To prevent engine damage, make sure gasket debris and dirt do not enter cylinder head opening.

1. Intake Air Heater (IAH) igniter 5. Charge Air Cooler Outlet 8. ETV inlet O-ring
supply line Temperature (CACOT) sensor 9. Intake Air Heater (IAH) igniter
2. ETV 6. CACOT sensor engine harness 10. IAH igniter supply line tube nut
3. Bolts (3) connector

1. Disconnect engine harness connectors (6, and 7) from CACOT sensor (5) and ETV (2).
3. Loosen IAH igniter fuel supply line tube nut (10) and remove IAH igniter supply line (1) from IAH Igniter (9).
4. Remove and ETV inlet O-ring (8) from ETV (2) and discard.
5. Remove 3 bolts (3) securing ETV (2) to air intake throttle duct (4) and remove ETV from engine.

1. ETV 2. O-ring 3. CACOT sensor
See CACOT Sensor (Figure 455) to perform step 6.

6. Loosen and remove CACOT sensor (3) from ETV (1) and discard O-ring (2).
Engine Throttle Valve (ETV) Cleaning and Inspection
CAUTION: Be careful not to remove the orange coating on interior of Engine Throttle Valve (ETV) when cleaning
carbon build-up. Failure to comply could result in serious engine damage or failure.
Figure 456 ETV

A. ETV inlet O-ring sealing surface D. ETV butterfly F. Charge Air Cooler Outlet
B. ETV E. ETV electrical connector Temperature (CACOT) sensor
C. ETV to air intake throttle duct port
sealing surface
See ETV (Figure 456) to perform steps 1 through 6.

1. Cover ETV electrical connector (E) with plastic and duct tape prior to cleaning.
2. Using a suitable, non-caustic solvent, clean interior and exterior of ETV (B) and ETV butterfly (D). Ensure
no carbon build-up remains when finished.
3. Dry with filtered, compressed air.
4. Inspect ETV inlet O-ring sealing surface, ETV, ETV to air intake throttle duct sealing surface, and ETV
butterfly (A, B, C, and D) for cracking, pitting, and other notable damage. Repair or replace as necessary.
5. Inspect EGR valve electrical connector (E) for corroded terminals; loose, bent, or broken pins; or broken
housing. Repair or replace as necessary.
6. Inspect CACOT sensor port (F) for damaged or missing threads and other notable damage. Repair or
Engine Throttle Valve (ETV) Installation

None
Torques
Charge Air Cooler Outlet Temperature (CACOT) sensor 14 N·m (10 lb·ft)
Engine Throttle Valve (ETV) bolts 31 N·m (23 lb·ft)

1. ETV 2. O-ring 3. CACOT sensor
See CACOT Sensor (Figure 457) to perform step 1.

1. Install CACOT sensor (3) with new O-ring (2) into ETV (1). Torque sensor to 14 N·m (10 lb·ft).

1. IAH igniter supply line 5. CACOT sensor 8. ETV inlet O-ring
2. ETV 6. CACOT sensor engine harness 9. IAH igniter
3. Bolts (3) connector 10. IAH igniter supply line tube nut

2. Using 3 bolts (3) and new ETV to air intake throttle duct O-ring, install ETV (2) on air intake throttle duct (4).
Torque bolts to 31 N·m (23 lb·ft)
3. Install CACOT and ETV engine harness connectors (6 and 7) onto CACOT sensor (5) and ETV (2).
4. Install IAH igniter fuel supply line (1) onto IAH igniter (9) and torque IAH igniter fuel supply line tube nut (10)
until tight.
5. Install all necessary tie straps.
6. Install new ETV inlet O-ring (8) onto ETV (2).
Air Intake Throttle Duct

Air Intake Throttle Duct Removal
Figure 459 Air Intake Throttle Duct

1. Air intake throttle duct 4. Lower Exhaust Gas 6. EGR outlet manifold
2. Intake Manifold Pressure (IMP) Recirculation (EGR) outlet
sensor manifold mounting bolt
3. IMP sensor engine harness 5. Upper EGR outlet manifold
connector mounting bolts (2)
See Air Intake Throttle Duct (Figure 459) to perform steps 1 and 2.
1. Disconnect IMP sensor engine harness connector (3) from IMP sensor (2).
2. Remove 2 upper EGR outlet manifold mounting bolts (5) and 1 lower EGR outlet manifold mounting bolt (4)
securing air intake throttle duct (1) to EGR outlet manifold (6).
Figure 460 Lower Mounting Bolt

1. EGR outlet manifold 3. Lower EGR outlet manifold
2. Air intake throttle duct mounting bolt
See Lower Mounting Bolt (Figure 460) to perform step 3.

3. Remove lower EGR inlet manifold mounting bolt (3) that secures air intake throttle duct (2) to EGR inlet
manifold (1).
Figure 461 Upper Air Intake Throttle Duct Mounting Bolt

1. Cylinder head 2. Upper air intake throttle duct 3. Air intake throttle duct
mounting bolt
See Upper Air Intake Throttle Duct Mounting Bolt (Figure 461) to perform step 4.
4. Remove upper air intake throttle duct mounting bolt (2) that secure air intake throttle duct (3) to cylinder
head (1).
Figure 462 Lower Air Intake Throttle Duct Mounting Bolts

1. Cylinder head 2. Lower air intake throttle duct 3. Air intake throttle duct
mounting bolts (2)
See Lower Air Intake Throttle Duct Mounting Bolt (Figure 462) to perform step 5.
5. Remove 2 lower air intake throttle duct mounting bolts (2) that secure air intake throttle duct (3) to cylinder
head (1).
Figure 463 Air Intake Throttle Duct Components

1. O-ring gasket 4. IMP sensor O-ring 7. Air intake throttle duct gasket
2. Air intake throttle duct 5. IAH igniter
3. IMP sensor 6. EGR inlet manifold gaskets (2)
See Air Intake Throttle Duct Components (Figure 463) to perform steps 6 through 9.
6. Remove O-ring gasket (1) from air intake throttle duct (2) and discard.
7. Loosen and remove IMP sensor (3) from air intake throttle duct (2). Discard IMP sensor O-ring (4).
8. Loosen and remove IAH igniter (5) from air intake throttle duct (2).
9. Remove 2 EGR manifold gaskets (6) and air intake throttle duct gasket (7) from air intake throttle duct (2)
and discard.
Air Intake Throttle Duct Cleaning and Inspection
CAUTION: Be careful not to remove the orange coating on interior of air intake throttle duct when cleaning
carbon build-up. Failure to comply could result in serious engine damage or failure.

A. ETV to air intake throttle duct D. Intake Air Heater (IAH) igniter F. EGR inlet manifold mounting
sealing surface port bolt holes
B. Air intake throttle duct E. Exhaust Gas Recirculation G. Air intake manifold to cylinder
C. Intake Manifold Pressure (IMP) (EGR) inlet manifold to air intake head sealing surface.
sensor port throttle duct sealing surface
See Air Intake Throttle Duct (Figure 464) to perform steps 1 through 3.
1. Using a suitable, non-caustic solvent, clean air intake throttle duct (B). Ensure no carbon build-up remains
when finished.
2. Inspect ETV to air intake throttle duct sealing surface, air intake throttle duct, IAH igniter port, EGR inlet
manifold to air intake throttle duct sealing surface, and air intake manifold to cylinder head sealing surface
(A, B, D, E, and G) for cracks, pitting, and other notable damage. Repair or replace as necessary.
3. Inspect IMP sensor port and EGR inlet manifold mounting bolt holes (C and F) for damaged or missing
threads and other notable damage. Repair or replace as necessary.
Air Intake Throttle Duct Installation

None
Torques
IAH igniter 14 N·m (10 lb·ft)

IMP sensor 14 N·m (10 lb·ft)
Air intake throttle duct bolts 31 N·m (23 lb·ft)
EGR inlet manifold mounting bolts 31 N·m (23 lb·ft)
Figure 465 Air Intake Throttle Duct Components

1. O-ring gasket 4. IMP sensor O-ring 7. Air intake throttle duct gasket
2. Air intake throttle duct 5. Intake Air Heater (IAH) igniter
3. IMP sensor 6. EGR inlet manifold gaskets (2)
See Air Intake Throttle Duct Components (Figure 465) to perform steps 1 through 4.
1. Install 2 new EGR manifold gaskets (6) and air intake throttle duct gasket (7) for air intake throttle duct (2)
and discard.
2. Using loctite, install IAH igniter (5) into air intake throttle duct (2). Torque IAH igniter to 14 N·m (10 lb·ft).
3. Install IMP sensor (3) with new IMP sensor O-ring (4) into air intake throttle duct (2). Torque sensor to 14
N·m (10 lb·ft).
4. Install new O-ring gasket (1) onto air intake throttle duct (2).
Figure 466 Lower Air Intake Throttle Duct Mounting Bolts

1. Cylinder head 2. Lower air intake throttle duct 3. Air intake throttle duct
mounting bolts (2)
See Lower Air Intake Throttle Duct Mounting Bolt (Figure 466) to perform step 5.
5. Using 2 lower air intake throttle duct mounting bolts (2) and a new intake throttle duct gasket, install intake
throttle duct (3) onto cylinder head (1).
Figure 467 Upper Air Intake Throttle Duct Mounting Bolt

1. Cylinder head 2. Upper air intake throttle duct 3. Air intake throttle duct
mounting bolt
See Upper Air Intake Throttle Duct Mounting Bolt (Figure 467) to perform step 6.
6. Install upper air intake throttle duct mounting bolt (2) to secure air intake throttle duct (3) to cylinder head
(1). Torque all intake throttle duct mounting bolts to 31 N·m (23 lb·ft).
Figure 468 Lower Mounting Bolt

1. EGR inlet manifold 3. Lower EGR inlet manifold
2. Air intake throttle duct mounting bolt
See Lower Mounting Bolt (Figure 468) to perform step 7.

7. Using lower EGR inlet manifold mounting bolt (3) and new EGR inlet manifold to air intake throttle duct
gasket, install air intake throttle duct (2) onto EGR inlet manifold (1).

1. Air intake throttle duct 4. Lower EGR inlet manifold 6. EGR inlet manifold
2. IMP sensor mounting bolt
3. IMP sensor engine harness 5. Upper EGR inlet manifold
connector mounting bolts (2)
See Air Intake Throttle Duct (Figure 469) to perform steps 8 and 9.
8. Using 2 upper EGR inlet manifold mounting bolts (5), lower EGR inlet manifold mounting bolt (4), and new
EGR inlet manifold to air intake throttle duct gasket, secure air intake throttle duct (1) to EGR inlet manifold
(6). Torque both upper EGR inlet manifold mounting bolts and both lower EGR inlet manifold mounting bolts
to 31 N·m (23 lb·ft)
9. Connect IMP sensor engine harness connector (3) to IMP sensor (2).
Exhaust Gas Recirculation (EGR) Outlet Manifold

Exhaust Gas Recirculation (EGR) Outlet Manifold Removal
Figure 470 EGR Outlet Manifold

1. EGR cooler 4. EGR outlet manifold 6. EGRT sensor engine harness
2. Hose clamp 5. EGR Temperature (EGRT) connector
3. EGR outlet hose sensor
See EGR Outlet Manifold (Figure 470) to perform steps 1 and 2.

1. Remove EGRT sensor engine harness connector (6) from EGRT sensor (5).
2. Remove hose clamp (2) that secures EGR outlet hose (3) to EGR cooler (1) and remove EGR outlet manifold
(4) with EGR outlet hose (3) from engine.
Figure 471 Exhaust Gas Recirculation Temperature (EGRT) Sensor

1. EGR outlet hose 3. EGR outlet manifold
2. EGR outlet hose clamp 4. EGRT sensor
See EGRT Sensor (Figure 471) to perform steps 3 and 4.

3. Loosen and remove EGRT sensor (4) from EGR outlet manifold (3).
4. Loosen and remove EGR outlet hose clamp (2) and EGR outlet hose (1) from EGR outlet manifold (3).
Exhaust Gas Recirculation (EGR) Outlet Manifold Cleaning and Inspection
CAUTION: Be careful not to remove the orange coating on interior of air intake throttle duct when cleaning
carbon build up. Failure to comply could result in serious engine damage or failure.

A. EGR outlet hose D. Exhaust Gas Recirculation E. EGRT sensor
B. EGR outlet hose sealing surface Temperature (EGRT) sensor F. EGR outlet manifold sealing
C. EGR outlet manifold orifice surface
See EGR Outlet Manifold (Figure 472) to perform steps 1 through 5.

1. Using a suitable non-caustic solvent, clean interior and exterior of EGR outlet manifold (C). Ensure there is
no carbon build up remaining when finished.
2. Inspect EGR outlet hose (A) for cracks, softness, leaks, and other notable damage. Repair or replace as
necessary
3. Inspect EGR outlet hose sealing surface, EGR outlet manifold, and EGR outlet manifold sealing surface (B,
C, and F) for cracks, pitting, and other notable damage. Repair or replace as necessary.
4. Inspect EGRT sensor orifice (D) for damaged or missing threads and other notable damage. Repair or
5. Inspect EGRT sensor (E) for corroded terminals; loose, bent, or broken pins; or broken sensor housing.
Exhaust Gas Recirculation (EGR) Outlet Manifold Installation

None
Torques
EGR 14 N·m (10 lb·ft)
Figure 473 Exhaust Gas Recirculation Temperature (EGRT) Sensor

1. EGR outlet hose 3. EGR outlet manifold
2. EGR outlet hose clamp 4. EGRT sensor
See EGRT Sensor (Figure 473) to perform steps 1 and 2.

1. Install EGRT sensor (4) into EGR outlet manifold (3). Torque to 14 N·m (10 lb·ft).
2. Using EGR outlet hose clamp (2), install EGR outlet hose (1) onto EGR outlet manifold (3). Tighten hose
clamp.

1. EGR cooler 4. EGR outlet manifold 6. EGRT sensor engine harness
2. Hose clamp 5. EGRT sensor connector
3. EGR outlet hose
See EGR Outlet Manifold (Figure 474) to perform steps 3 and 4.

3. Using hose clamp (2), install EGR outlet manifold (4) with EGR outlet hose (3) onto EGR cooler (1). Tighten
hose clamp.
4. Install EGRT sensor engine harness connector (6) onto EGRT sensor (5).
Exhaust Manifold
Exhaust Manifold Removal

1. Exhaust manifold heat shield 2. Rear exhaust manifold heat 3. Rear exhaust manifold
bolts (4) shield
1. Remove 4 exhaust manifold heat shield bolts (1) that secure rear exhaust manifold heat shield (2) to rear
exhaust manifold (3).
Figure 476 Exhaust Manifold

1. Exhaust manifold bolts and 2. Exhaust manifold sections (3)
spacers (18) 3. Cylinder head
See Exhaust Manifold (Figure 476) to perform steps 2 and 3.

2. Remove 18 exhaust-manifold bolts and spacers (1) , that secure exhaust manifold sections (2) to cylinder
head (3). Remove exhaust manifold from engine as a complete assembly. When removing exhaust
manifold, do not twist individual sections as this may skew alignment with other sections.
NOTE: Upon removal, exhaust manifold must lay flat with cylinder head side down on a bench or comparable,
clean and flat surface.
3. After exhaust manifold has been removed from cylinder head, store exhaust manifold cylinder head side
down on a flat surface. This will help maintain proper orientation and alignment.
Exhaust Manifold Cleaning, Inspection, and Testing

A. Exhaust manifold sections
B. Mica ring and ring seal sealing surfaces
C. Turbocharger mounting surface
D. EGR valve sealing surface
E. Cylinder head sealing surfaces
See Exhaust Manifold (Figure 477) to perform steps 1 through 4.

1. Using a suitable non-caustic solvent, clean cylinder head sealing surfaces, turbocharger mounting surface,
and EGR valve sealing surface (C, D, and E).
2. Clean mica ring and ring seal sealing surfaces (B).
3. Using steam or another suitable non-caustic solvent, clean exhaust manifold sections (A).
4. Inspect exhaust manifold sections (A) for significant damage or pitting that could cause exhaust leak at the
manifold. Repair or replace as necessary.
Figure 478 Rear Exhaust Manifold Warp Test

1. Left 2. Right 3. Diagonally
See Rear Exhaust Manifold Warp Test (Figure 478) to perform steps 5 through 7.
5. Use a straightedge and feeler gauge to check sealing surface flatness on rear exhaust manifold.
6. Check flatness by placing straightedge on left, right, and diagonally (1, 2, and 3) across rear exhaust
manifold.
7. If rear exhaust manifold is warped more than 0.1 mm (0.004 in), replace rear exhaust manifold.
Figure 479 Center Exhaust Manifold Warp Test

See Center Exhaust Manifold Warp Test (Figure 479) to perform steps 8 through 10.
8. Use a straightedge and feeler gauge to check sealing surface flatness on center exhaust manifold.
9. Check flatness by placing straightedge on left, right, and diagonally (1, 2, and 3) across center exhaust
manifold.
10. If center exhaust manifold is warped more than 0.1 mm (0.004 in), replace center exhaust manifold.
Figure 480 Front Exhaust Manifold Warp Test

See Front Exhaust Manifold Warp Test (Figure 480) to perform steps 11 through 13.
11. Use a straightedge and feeler gauge to check sealing surface flatness on front exhaust manifold.
12. Check flatness by placing straightedge on left, right, and diagonally (1, 2, and 3) across front exhaust
manifold.
13. If front exhaust manifold is warped more than 0.1 mm (0.004 in), replace front exhaust manifold.
Exhaust Manifold Installation

None
Torques
Exhaust manifold cuff constant-torque clamp 8 N·m (70 lb·in)

Exhaust manifold bolts 20 N·m (15 lb·ft) + 90 degrees
Front exhaust manifold heat shield bolts 18 N·m (13 lb·ft)
Rear exhaust manifold heat shield bolts 18 N·m (13 lb·ft)
CAUTION: If engine is not equipped with exhaust manifold cuff assembly, install front and rear exhaust manifold
cuff assembly.
Figure 481 Mica Ring Installation (rear manifold side)

1. Rear exhaust manifold side of 2. Center exhaust manifold 3. Top of mica ring
center exhaust manifold shoulder 4. Bottom of mica ring
See Mica Ring Installation (rear manifold side) (Figure 481) to perform steps 1 through 3.
1. Angle mica ring to 45 degrees (as shown), and seat bottom of mica ring (4) against center exhaust manifold
shoulder (2) on rear manifold side of center exhaust manifold (1).
2. Using fingers or rubber pad and rod, carefully push top of mica ring (3) until flush with center exhaust manifold
shoulder (2).
3. Repeat steps 1 and 2 for mica ring installation on front exhaust manifold side of center exhaust manifold.
Figure 482 Exhaust Manifold Reassembly

1. Rear exhaust manifold 5. Front exhaust manifold 7. Front exhaust manifold heat
2. Exhaust manifold ring seals (2) 6. Front exhaust manifold heat shield bolts (3)
3. Center exhaust manifold shield
4. Mica ring (2)
See Exhaust Manifold Reassembly (Figure 482) to perform steps 4 through 8.

4. Using 3 front exhaust manifold heat shield bolts (7), install front exhaust manifold heat shield (6) on front
exhaust manifold (5). Torque front exhaust manifold heat shield bolts to 18 N·m (13 lb·ft).
5. Using P-80® rubber lubricant, lubricate and install new ring seals (2) on both the front and rear exhaust
manifolds (1 and 5).
6. Ensure seal is pushed all the way to the stop.
NOTE: For a proper, leak-free reassembly, reassemble exhaust manifolds while laying them flat with cylinder
head side down on a bench or comparable clean, flat surface.
7. Using care not to damage mica ring (4), install front exhaust manifold (5) in center exhaust manifold (3).
8. Using care not to damage mica ring (4), install rear exhaust manifold (1) in center exhaust manifold (3).
Figure 483 Exhaust Manifold Cuff

1. Rear exhaust manifold 3. Exhaust manifold cuff 4. Center exhaust manifold
2. Exhaust manifold cuff halves (4) constant-torque clamps (2) 5. Front exhaust manifold
See Exhaust Manifold Cuff (Figure 483) to perform steps 9 through 13.
9. Clean exhaust manifold cuff sealing surface.
10. Using a new exhaust manifold cuff assembly, install sticky tape that comes with new cuff around exhaust
manifold cuff sealing surface.
11. Install exhaust manifold cuff halves (2) on exhaust manifold (1, 4, and 5).
12. Using marks made for exhaust manifold orientation during disassembly, install exhaust manifold cuff
constant-torque clamp (3) on exhaust manifold cuff assembly. Torque exhaust manifold constant-torque
clamp to 8 N·m (70 lb·in).
13. If both cuffs need to be replaced, repeat steps 9-12.

spacers (18) 3. Cylinder head
See Exhaust Manifold (Figure 484) to perform step 14.

14. Using 18 exhaust-manifold bolts and spacers (1), carefully install exhaust manifold sections (2) on cylinder
head (3) as an assembly. Torque exhaust manifold bolts to finger tight.
Figure 485 Torque Sequence
See Torque Sequence (Figure 485) to perform steps 15 through 17.

15. Using the torque sequence above, torque all exhaust manifold bolts to 20 N·m (15 lb·ft).
16. Following the same torque sequence, verify all exhaust manifold bolts are torqued to 20 N·m (15 lb·ft).
17. Following the torque sequence used in steps 15 and 16, torque exhaust manifold bolts an additional 90
degrees.

bolts (4) shield
18. Using 4 exhaust manifold heat shield bolts (1), install rear exhaust manifold heat shield (2) on rear exhaust
manifold (3). Torque bolts to 18 N·m (13 lb·ft).
Exhaust Manifold Cuff

See Exhaust Manifold Cuff Replacement (Figure 487) to perform steps 1 and 2.
1. Mark orientation of exhaust manifold cuff constant-torque clamps (3) in relation to exhaust manifolds (1, 4,
and 5) for reassembly.
2. Remove exhaust manifold cuff constant-torque clamp (3) from exhaust manifolds (1, 4, and 5). Remove 2
exhaust manifold cuff halves (2) from exhaust manifolds. Discard exhaust manifold cuff halves.
3. If both cuffs need to be replaced, repeat steps 1 and 2.
Exhaust Manifold Disassembly
Figure 488 Exhaust Manifold Disassembly

1. Rear exhaust manifold 5. Front exhaust manifold 7. Front exhaust manifold heat
2. Exhaust manifold ring seals (2) 6. Front exhaust manifold heat shield bolts (3)
3. Center exhaust manifold shield
4. Mica ring (2)
See Exhaust Manifold Disassembly (Figure 488) to perform steps 1 through 5.

1. Remove rear exhaust manifold (1) from center exhaust manifold (3) by pulling rear exhaust manifold away
from center exhaust manifold.
2. Remove front exhaust manifold (5) from center exhaust manifold (3) by pulling front exhaust manifold away
from center exhaust manifold.
3. Using a pick tool or equivalent, remove and discard 2 mica rings (4) from inside of center exhaust manifold
(3).
4. Remove and discard 2 exhaust manifold ring seals (2) from front and rear exhaust manifolds (1 and 5).
5. Remove 3 exhaust manifold heat shield bolts (7) from front exhaust manifold heat shield (6) and remove
heat shield from front exhaust manifold (5).
Special Torques
Special Torques
Intake Manifold Pressure (IMP) sensor 14 N·m (10 lb·ft)
Exhaust Gas Recirculation (EGR) inlet manifold mounting bolts 31 N·m (23 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT) sensor 14 N·m (10 lb·ft)
Exhaust manifold bolts 20 N·m (15 lb·ft) + 90°
IAH igniter 14 N·m (10 lb·ft)
Front Cover, Fan Drive, Cooling System, and Related Components
components.
• Exhaust Gas Recirculation (EGR) System
Pulley (High Mount Fan)

Pulley (High Mount Fan) Removal
Figure 489 Pulley assembly

1. Shoulder bolt
2. Pulley assembly
1. Remove shoulder bolt and pulley assembly.

Pulley (High Mount Fan) Installation
Figure 490 Pulley assembly

1. Shoulder bolt
2. Pulley assembly
1. Install pulley assembly and shoulder bolt. Tighten shoulder bolt to special torque (page 622).
Tensioner Bracket (High Mount Fan)

Tensioner Bracket (High Mount Fan) Removal
Figure 491 Fan drive tensioner assembly (high mount)

1. Fan drive tensioner assembly
2. M10 x 70 countersunk screw
1. Remove M10 x 70 countersunk screw and fan drive tensioner.
Figure 492 Tensioner bracket

1. M8 x 30 bolt (3)
2. Tensioner bracket
2. Remove three M8 x 30 bolts and tensioner bracket.

Tensioner Bracket (High Mount Fan) Installation
Figure 493 Tensioner bracket

1. M8 x 30 bolt (3)
2. Tensioner bracket
1. Install tensioner bracket and three M8 x 30 bolts. Tighten bolts to standard torque (page 1201).
Figure 494 Fan drive tensioner assembly (high mount)

1. Fan drive tensioner assembly
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 622).
High Mount Fan Drive

High Mount Fan Drive Removal
Figure 495 Fan drive clutch assembly (typical)

1. Fan drive clutch assembly
2. M10 x 150 - 12.9 bolt (5)
3. M10 x 65 bolt
1. Disconnect air line from back of fan drive clutch assembly.

2. Remove five M10 x 150 - 12.9 bolts and M10 x 65 bolt. Remove fan drive clutch.
3. Discard six M10 bolts.
High Mount Fan Drive Installation
Figure 496 Fan drive clutch assembly (typical)

1. Fan drive clutch assembly
2. M10 x 150 - 12.9 bolt (5)
3. M10 x 65 bolt
CAUTION: To prevent engine damage, clean and blow dry crankcase bolt holes with filtered compressed air.
Debris or fluids in bolt holes may cause binding and incorrect bolt torque.
1. Using filtered compressed air, clean thread holes of fan drive clutch assembly.
2. Install fan drive clutch assembly and five new M10 x 150 - 12.9 and one new M10 x 65 bolt with engine oil
lightly applied to threads.
Figure 497 High mount fan drive bolt tightening sequence

3. Tighten M10 bolts using sequence indicated above as follows.

a. Tighten six M10 bolts to 37 N·m (27 lb·ft).
b. Re-tighten six bolts to 37 N·m (27 lb·ft).
c. Angle-tighten five M10 x 150 - 12.9 bolts an additional 90° in sequence.
d. Tighten M10 x 65 bolt to 62 N·m (46 lb·ft).
4. Connect air line to back of fan drive clutch assembly.
Coolant Outlet Manifold and Thermostat Assembly

Coolant Outlet Manifold and Thermostat Assembly Removal
Figure 498 Coolant outlet manifold (low mount fan)

1. M8 x 70 bolt
2. M8 x 130 bolt (2)
3. Fan coupling bracket
4. Coolant outlet manifold
5. Bushing (2)
Figure 499 Coolant outlet manifold (high mount fan)

1. M8 x 70 bolt (3)
1. Remove coolant outlet manifold bolts as follows.

a. If equipped with low mount fan, remove M8 x 70 bolt, two M8 x 130 bolts, bracket and two bushings.
b. If equipped with high mount fan, remove three M8 x 70 bolts.

2. Remove coolant outlet manifold.
Figure 500 Thermostat assembly

1. Thermostat housing
2. Seals (part of thermostat assembly) (2)
3. Thermostat assembly (2)
4. Ball valves (part of thermostat assembly)
3. Remove two thermostat assemblies from thermostat housing.

Coolant Outlet Manifold and Thermostat Assembly Installation
Figure 501 Thermostat assembly

2. Seals (part of thermostat assembly) (2)
3. Thermostat assembly (2)
4. Ball valves (part of thermostat assembly)
1. Install two thermostat assemblies into thermostat housing with ball valves at 12 o'clock position.
Figure 502 Coolant outlet manifold (low mount fan)

1. M8 x 70 bolt
2. M8 x 130 bolt (2)
3. Fan coupling bracket
5. Bushing (2)
Figure 503 Coolant outlet manifold (high mount fan)

1. M8 x 70 bolt (3)
2. Install coolant outlet manifold.

3. If equipped with low mount fan, install bracket and two bushings.
4. Install coolant outlet manifold bolts as follows.
a. If equipped with low mount fan, install one M8 x 70 bolt and two M8 x 130 bolts. Tighten bolts to special
torque (page 622).
b. If equipped with high mount fan, install three M8 x 70 bolts. Tighten bolts to special torque (page 622).
Low-Temperature (LT) Coolant Manifold and LT Thermostat

Low-Temperature (LT) Coolant Manifold and LT Thermostat Removal
Figure 504 Low-Temperature (LT) Radiator Hose

1. Hose clamp 3. LT thermostat cap assembly 5. LT coolant manifold
2. Low-Temperature (LT) radiator mounting bolts (3)
hose 4. LT thermostat cap assembly
See Low-Temperature (LT) Radiator Hose (Figure 504) to perform steps 2 and 3.
2. Remove hose clamp (1) that secures LT radiator hose (2) to LT thermostat cap assembly (4) and remove
LT radiator hose from LT thermostat cap assembly. Position radiator hose out of way.
3. Remove 3 LT thermostat cap assembly mounting bolts (3) that secure LT thermostat cap assembly (4) to
LT coolant manifold (5) and remove LT thermostat cap assembly from LT coolant manifold.
Figure 505 LT Thermostat

1. LT thermostat seal 2. LT thermostat 3. LT coolant manifold
See LT Thermostat (Figure 505) to perform step 4.

4. Remove LT thermostat (2) with LT thermostat seal (1) from LT coolant manifold (3) and discard.
Figure 506 Engine Wiring Harness

1. Engine Coolant Temperature 2 3. LT coolant manifold 6. LT coolant manifold stud bolt
(ECT2) sensor engine wiring 4. Engine wiring harness 7. Low-Pressure Charge Air Cooler
harness connector 5. Engine wiring harness mounting (LPCAC) coolant supply tube
2. ECT2 sensor nut 8. LPCAC coolant supply tube bolt
See Engine Wiring Harness (Figure 506) to perform steps 5 through 9.

5. Remove any tie straps or clips that secure engine wiring harness (4) to LT coolant manifold (3).
6. Disconnect ECT2 sensor engine wiring harness connector (1) from ECT2 sensor (2).
7. Remove engine wiring harness mounting nut (5) that secures engine wiring harness (4) to LT coolant
manifold stud bolt (6).
8. Remove LPCAC coolant supply tube bolt (8) that secures LPCAC coolant supply tube (7) to LT coolant
manifold (3).
9. Position LPCAC coolant supply tube (7) and engine wiring harness (4) out of way.
Figure 507 LT Coolant Manifold

1. ECT2 sensor 3. LT coolant manifold mounting 4. Water distribution housing
2. LT coolant manifold bolt (2) 5. LT coolant manifold stud bolt
10. Loosen and remove ECT2 sensor (1) from LT coolant manifold (2). Discard O-ring seal.
11. Remove 1 LT coolant manifold stud bolt (5) and 2 LT coolant manifold mounting bolts (3) that secure LT
coolant manifold (2) to water distribution housing (4).
12. Remove LT coolant manifold (2) from water distribution housing (4) and discard gasket.
Low-Temperature (LT) Coolant Manifold and LT Thermostat Installation

• P-80® Lubricant (obtain locally)
Torques
LT coolant manifold bolts 31 N·m (23 lb·ft)

LT coolant manifold stud bolt 31 N·m (23 lb·ft)
ECT2 sensor 18 N·m (13 lb·ft)
LPCAC coolant supply tube bolt 13 N·m (10 lb·ft)
Engine wiring harness mounting nut 31 N·m (23 lb·ft)
LT thermostat cap assembly mounting bolts 31 N·m (23 lb·ft)
LT radiator hose clamp 4 N·m (3 lb·ft)
Figure 508 LT Coolant Manifold

1. ECT2 sensor 3. LT coolant manifold mounting 4. Water distribution housing
2. LT coolant manifold bolt (2) 5. LT coolant manifold stud bolt

1. Install new O-ring gasket onto LT coolant manifold (2) and lubricate with P-80® lubricant.
2. Using 1 LT coolant manifold stud bolt (5) and 2 LT coolant manifold mounting bolts (3), install LT coolant
manifold (2) to water distribution housing (4). Torque LT coolant manifold bolts (3) and stud bolt (5) to 31
N·m (23 lb·ft).
3. Install ECT2 sensor (1) with new O-ring seal into LT coolant manifold (2). Torque ECT2 sensor to 18 N·m
(13 lb·ft).

1. Engine Coolant Temperature 2 3. LT coolant manifold 6. LT coolant manifold stud bolt
(ECT2) sensor engine wiring 4. Engine wiring harness 7. Low-Pressure Charge Air Cooler
harness connector 5. Engine wiring harness mounting (LPCAC) coolant supply tube
2. ECT2 sensor nut 8. LPCAC coolant supply tube bolt

4. Install new O-ring gasket onto LPCAC coolant supply tube (7) and lubricate with P-80® lubricant.
5. Using LPCAC coolant supply tube bolt (8), install LPCAC coolant supply tube (7) to LT coolant manifold (3).
Torque LPCAC coolant supply tube bolt to 13 N·m (10 lb·ft).
6. Using engine wiring harness mounting nut (5) install engine wiring harness (4) onto LT coolant manifold stud
bolt (6). torque engine wiring harness mounting nut to 31 N·m (23 lb·ft).
7. Connect ECT2 sensor engine wiring harness connector (1) to ECT2 sensor (2).
8. Install any tie straps and / or clips that secure engine wiring harness (4) to LT coolant manifold (3).
Figure 510 LT Thermostat

1. LT thermostat seal 2. LT thermostat 3. LT coolant manifold
See LT Thermostat (Figure 510) to perform step 9.

9. Install new LT thermostat (2) with new LT thermostat seal (1) into LT coolant manifold (3).
Figure 511 Low-Temperature (LT) Radiator Hose

1. Hose clamp 3. LT thermostat cap assembly 5. LT coolant manifold
2. Low-Temperature (LT) radiator mounting bolts (3)
hose 4. LT thermostat cap assembly
See Low-Temperature (LT) Radiator Hose (Figure 511) to perform steps 10 and 11.
10. Using 3 LT thermostat cap assembly mounting bolts (3), install LT thermostat cap assembly (4) onto LT
coolant manifold (5). torque LT thermostat cap assembly mounting bolts to 31 N·m (23 lb·ft).
11. Using hose clamp (1), secure LT radiator hose (2) to LT thermostat cap assembly (4). Torque hose clamp
to 4 N·m (3 lb·ft).
Automatic Belt Tensioner and Idler Pulleys

Automatic Belt Tensioner and Idler Pulleys Remvoal
Figure 512 Automatic belt tensioner and idler pulleys (typical)

1. Idler pulley (2)
2. M12 x 55 bolt (2)
4. Automatic belt tensioner
1. Remove two M12 x 55 bolts and idler pulleys.

CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur,
resulting in improper alignment of the belt tensioner.
2. Remove M10 x 70 countersunk screw and automatic belt tensioner.
Automatic Belt Tensioner and Idler Pulleys Installation
Figure 513 Automatic belt tensioner and idler pulley (typical)

1. Idler pulley (2)
2. M12 x 55 bolt (2)
4. Automatic belt tensioner
CAUTION: To prevent engine damage, do not twist the belt tensioner; damage to the locating pin may occur,
resulting in improper alignment of the belt tensioner.
1. Install automatic belt tensioner and M10 x 70 countersunk screw. Make sure locating pin is placed into
locating hole. Tighten countersunk screw to special torque (page 622).
2. Install two idler pulleys and two M12 x 55 bolts. Tighten bolts to special torque (page 622).
Water Pump Assembly and Pulley

Water Pump Assembly and Pulley Removal
Figure 514 Water pump assembly and pulley

1. Water pump assembly
2. Water pump pulley
3. M8 x 16 bolt (4)
4. M8 x 130 bolt
5. M8 x 150 bolt
6. M8 x 40 bolt (7)
1. Remove four M8 x 16 bolts and water pump pulley.

NOTE: If the oil module is removed, the M8 x 150 bolt is also removed.
2. Remove M8 x 130, M8 x 150 and seven M8 x 40 bolts.
CAUTION: To prevent engine damage, do not drop water pump impeller or hit impeller with hard objects.
3. Remove water pump assembly and discard water pump gasket.
Water Pump Assembly and Pulley Installation
Figure 515 Water pump assembly and pulley

1. Water pump assembly
2. Water pump pulley
3. M8 x 16 bolt (4)
4. M8 x 130 bolt
5. M8 x 150 bolt
6. M8 x 40 bolt (7)
NOTE: If the oil module is removed, the M8 x 150 bolt is installed along with oil module.
1. Lubricate a new water pump gasket with clean coolant and install onto water pump.
2. Install water pump and secure with one M8 x 130, one M8 x 150 and seven M8 x 40 bolts in location shown.
Tighten M8 bolts to special torque (page 622).
3. Install water pump pulley and four M8 x 16 bolts. Tighten bolts to special torque (page 622).
Vibration Damper
Vibration Damper Removal
Figure 516 Vibration damper (low mount fan with damper hub)
1. M16 x 85 socket-head cap screw (8)
2. Vibration damper
3. Damper hub
4. M10 x 35 bolt (9)
Figure 517 Vibration damper (high mount fan with fan drive pulley)
2. Vibration damper
3. Fan drive pulley
4. M10 x 35 bolt (9)
WARNING: To prevent personal injury or death, support the vibration damper when removing bolts.
The damper can easily slide off the crankshaft.
NOTE: If equipped with high mount fan, remove fan drive pulley and vibration damper together. If equipped with
low mount fan, remove damper hub and vibration damper together.
1. Remove eight M16 x 85 socket-head cap screws.
2. Remove vibration damper with damper hub or fan drive pulley as an assembly.
3. For vibration damper replacement only, remove damper hub or fan drive pulley by removing nine M10 x 35
bolts.
Vibration Damper Assembly Cleaning and Inspection
Figure 518 Disassembly (Backside of Vibration Damper Assembly)

A. Vibration damper B. Fan-drive pulley bolts (9) C. Fan-drive pulley
See Disassembly (Figure 518) to perform steps 1 and 2.

1. Remove 9 fan-drive pulley bolts (B) that secure fan-drive pulley (C) to vibration damper (A).
2. Remove fan-drive pulley (C) from vibration damper (A).
Figure 519 Fan-Drive Pulley

A. Fan-drive pulley C. Fan-drive pulley bolt holes
B. Belt surface D. Vibration damper bolt holes
See Fan-Drive Pulley (Figure 519) to perform steps 3 through 5.

3. Using a non-caustic brake cleaner, clean fan-drive pulley and belt surface (A and B), then dry with filtered,
compressed air.
4. Inspect fan-drive pulley and belt surface (A and B) for cracks, pitting, and other notable damage. Repair or
5. Inspect fan-drive pulley bolt holes and vibration damper bolt holes (C and D) for thread damage,
inconsistency in circumference change, and other notable damage. Repair or replace as necessary.
Figure 520 Vibration Damper

A. Vibration damper B. Vibration damper bolt holes C. Vibration damper center section
See Vibration Damper (Figure 520) to perform steps 3 through 5.

6. Using a non-caustic brake cleaner, clean vibration damper (A) and then dry with filtered, compressed air.
7. Inspect vibration damper and vibration damper center section (A and C) for cracks, pitting, and other notable
damage. Repair or replace as necessary.
8. Inspect vibration damper bolt holes (B) for inconsistency in circumference and other notable damage. Repair
Vibration Damper Installation
Figure 521 Vibration damper (low mount fan with damper hub)
2. Vibration damper
3. Damper hub
4. M10 x 35 bolt (9)
Figure 522 Vibration damper (high mount fan with fan drive pulley)
2. Vibration damper
3. Fan drive pulley
4. M10 x 35 bolt (9)
NOTE: Install damper hub or fan drive pulley and vibration damper together as an assembly.
1. If previously disassembled, assemble damper hub or fan drive pulley to vibration damper with nine M10 x
35 bolts. Tighten bolts to special torque (page 622).
2. Install vibration damper assembly.
3. Install eight M16 x 85 socket-head cap screws. Using a crisscross pattern, tighten screws as follows.
a. Tighten socket-head cap screws to 150 N·m (111 lb·ft).
b. Angle-tighten socket-head cap screws an additional 90°.
Thermostat Housing
Thermostat Housing Removal
Figure 523 EGR cooler return manifold

1. EGR cooler return manifold
2. M8 x 145 bolt (4)
3. M8 x 30 bolt
4. Extension tube (DMR62 / 51)
CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface.
1. Remove extension tube (DMR62 / 51) from manifold. Inspect extension tube for damage, replace as needed.
2. Remove four M8 x 145 bolts and one M8 x 30 bolt.
3. Remove EGR cooler return manifold and discard gasket.
Figure 524 Thermostat housing

2. M8 x 75 bolt
3. M8 x 60 bolt
4. Remove M8 x 75 bolt and M8 x 60 bolt.

5. Remove thermostat housing and discard gasket.

1. Extension tube (DMR40 / DN32F) (2)
CAUTION: To prevent engine damage, do not remove extension tubes by grabbing sealing surface with pliers
or other tools that can mar the surface.
6. Remove two extension tubes (DMR40 / DN32F) from thermostat housing using a wood-handled tool. Gently
pry the extension tubes out until removed. Inspect extension tubes for damage, replace as needed.
Thermostat Housing Installation

1. Extension tube (DMR40 / DN32F) (2)
1. Lubricate sealing surfaces of two extension tubes (DMR40 / DN32F) with P-80® rubber lubricant or
equivalent (page 1233) and install into thermostat housing using Extension Tube Installer Small (page
1233).

2. M8 x 75 bolt
3. M8 x 60 bolt
2. Install new gasket and thermostat housing.

3. Install M8 x 75 bolt and M8 x 60 bolt. Do not tighten bolts until EGR cooler return manifold is installed.
Figure 528 EGR cooler return manifold

1. EGR cooler return manifold
2. M8 x 145 bolt (4)
3. M8 x 30 bolt
4. Extension tube (DMR62 / 51)
4. Install new thermostat housing gasket and EGR cooler return manifold.
5. Install four M8 x 145 bolts and one M8 x 30 bolt. Tighten bolts to special torque (page 622).
6. Tighten M8 x 75 and M8 x 60 thermostat housing bolts to standard torque (page 1201).
7. Lubricate sealing surfaces of extension tube (DMR62 / 51) with P-80® rubber lubricant or equivalent (page
1233) and install into EGR cooler return manifold using Extension Tube Installer Large (page 1233).
Water Distribution Housing

Water Distribution Housing Removal
Figure 529 Water distribution housing

1. Water distribution housing
2. M10 x 110 bolt with low mount fan drive or M10 x 150 - 12.9 bolt with high mount fan drive (5)
3. M8 x 150 bolt (2)
4. Engine water inlet (94°)
5. Coolant heater
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan)
1. Remove two M8 x 150 bolts.

• If equipped with low mount fan drive, five M10 x 110 bolts.
• If equipped with high mount fan drive, five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These bolts
are removed with high mount fan drive clutch assembly removal.)
2. Remove water distribution housing and discard gasket.
3. Remove two M10 x 30 bolts and separate engine water inlet from water distribution housing. Remove and
discard gasket.
4. Remove coolant heater from engine water inlet as needed.
Water Distribution Housing Installation
Figure 530 Water distribution housing

1. Water distribution housing
2. M10 x 110 bolt with low mount fan drive or M10 x 150 bolt - 12.9 with high mount fan drive (5)
3. M8 x 150 bolt (2)
4. Engine water inlet (94°)
5. Coolant heater
6. M10 x 30 bolt (2)
7. M10 x 65 bolt (only with high mount fan)
1. Install coolant heater into engine water inlet as needed. Tighten to special torque (page 622).
2. Install new gasket and install engine water inlet and two M10 x 30 bolts to water distribution housing. Tighten
bolts to special torque (page 622).
3. Lubricate a new water distribution housing gasket with clean coolant and install into water distribution
housing.
4. Install water distribution housing and secure as follows:
• If equipped with low mount fan drive, use five M10 x 110 bolts.
• If equipped with high mount fan drive, use five M10 x 150 - 12.9 bolts and one M10 x 65 bolt. (These
bolts are installed with high mount fan drive clutch assembly installation.)
Tighten low mount fan drive bolts to special torque (page 622).
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal

Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal Removal
Figure 531 Radial shaft seal removal

1. Radial shaft seal
2. Slide hammer
WARNING: To prevent personal injury or death, wear safety glasses with side shields when doing
the following procedure.
1. With an awl and hammer, punch two holes 180° apart in front oil seal.
2. Thread a slide hammer (page 1233) with correct size screw in one of the two holes.
3. Slide hammer until one side of seal begins to pull out of cover. Move slide hammer to other hole and repeat
until front oil seal is removed.
Front Belt- or Gear-Driven Fan Cover Radial Shaft Seal Installation
Figure 532 Radial shaft seal installation (typical)

1. Front belt- or gear-driven fan cover
2. Front Crankshaft Seal Installer
CAUTION: To avoid damage to the radial shaft seal, do not touch inner seal lip, allow oil or grease on any part
of the seal during installation.
1. Using Front Crankshaft Seal Installer (page 1233), install a new radial shaft seal into the front cover.
a. Install inner hub of tool to crankshaft flange. Use two bolts provided to secure tool.
b. Install radial shaft seal to inner hub of tool.
c. Install pressing hub and nut and tighten to install radial shaft seal. When tool bottoms out, seal is fully
installed.
Front Belt- or Gear-Driven Fan Cover

Front Belt- or Gear-Driven Fan Cover Removal
Figure 533 Front belt- or gear-driven fan cover bolts (high mount cover shown)
1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3)
3. M8 x 40 bolt (2)
4. M12 x 30 bolt (2)
WARNING: To prevent personal injury or death, use a suitable lifting device and get help when
removing, lowering and installing the front cover.
1. Remove two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts.
2. Remove front belt- or gear-driven fan cover and front cover gasket from crankcase dowels. Discard front
cover gasket.
Front Belt- or Gear-Driven Fan Cover Installation
Figure 534 Front belt- or gear-driven fan cover bolts (typical)

1. M8 x 25 bolt (13)
2. M12 x 75 bolt (3)
3. M8 x 40 bolt (2)
4. M12 x 30 bolt (2)
WARNING: To prevent personal injury or death, use a suitable lifting device and get help when
removing, lowering and installing the front cover.
1. Position a new front cover gasket on crankcase dowels.
2. Install front cover on crankcase dowels.
3. Install two M8 x 40 bolts, two M12 x 30 bolts, three M12 x 75 bolts and 13 M8 x 25 bolts in locations shown.
Tighten M8 bolts to standard torque (page 1201). Tighten M12 bolts to special torque (page 622).
Radial Shaft Seal (Fan Low Mount Drive)

Radial Shaft Seal (Fan Low Mount Drive) Removal
1. With an awl and hammer, punch two holes 180° apart in radial shaft seal.
Figure 535 Radial shaft seal removal
2. Thread a slide hammer (page 1233) with correct size screw in one of the two holes.
3. Slide hammer until one side of seal begins to pull out of fan drive. Move slide hammer to other hole and
repeat until radial shaft seal is removed. Discard radial shaft seal.
Radial Shaft Seal (Fan Low Mount Drive) Installation

1. Lubricate radial shaft seal with clean engine oil.
Figure 536 Radial shaft seal installation

1. Fan Seal Installer
2. Fan low mount drive assembly
2. Using Fan Seal Installer (page 1233), install new radial shaft seal until fully seated.
Fan Low Mount Drive Assembly

Fan Low Mount Drive Assembly Removal
Figure 537 O-ring 108 x 3
1. Remove and discard O-ring 108 x 3.
Figure 538 Fan low mount drive assembly

1. M8 x 25 bolt (4)
3. M8 x 40 bolt
2. Remove four M8 x 25 bolts, one M8 x 40 bolt and fan low mount drive assembly.
Fan Low Mount Drive Assembly Installation
Figure 539 Fan low mount drive assembly

1. M8 x 25 bolt (4)
3. M8 x 40 bolt
1. Install fan low mount drive, M8 x 40 bolt and four M8 x 25 bolts. Tighten bolts to standard torque (page
1201).
Figure 540 O-ring 108 x 3
2. Lubricate new O-ring 108 x 3 with clean engine oil and install on fan low mount drive assembly.
Special Torques
Automatic belt tensioner countersunk screw,
47 N·m (35 lb·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lb·ft)
M8 x 60
Coolant heater 41 N·m (30 lb·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lb·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lb·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lb·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lb·ft)
Front belt- or gear-driven fan cover bolts,
• M12 x 75 115 N·m (85 lb·ft)
• M12 x 30 115 N·m (85 lb·ft)
High mount fan drive clutch assembly bolts,
See tightening steps in procedure
M10
High mount fan drive tensioner countersunk
47 N·m (35 lb·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lb·ft)
Idler pulley bolt, M12 x 55 60 N·m (44 lb·ft)
Low mount fan drive bolt, M10 x 110 37 N·m (27 lb·ft)
LT coolant manifold bolts 31 N·m (23 lb·ft)
LT coolant manifold stud bolt 31 N·m (23 lb·ft)
ECT2 sensor 18 N·m (13 lb·ft)
LPCAC coolant supply tube bolt 13 N·m (10 lb·ft)
Engine wiring harness mounting nut 31 N·m (23 lb·ft)
LT thermostat cap assembly mounting bolts 31 N·m (23 lb·ft)
LT radiator hose clamp 4 N·m (3 lb·ft)
Vibration damper socket-head cap screws,
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lb·ft)
Water pump assembly bolts, M8 35 N·m (26 lb·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lb·ft)
Special Tools
Extension Tube Installer Large ZTSE6046
Extension Tube Installer Small ZTSE6047
Fan Seal Installer ZTSE6066
Front Crankshaft Seal Installer ZTSE4873
Front Cover, Fan Drive, Cooling System, and Related Components Cleaning, Inspection, and Testing
All Components
1. Clean water distribution housing, water pump, coolant outlet manifold, thermostat housing and front belt- or
gear-driven fan cover with a suitable non-caustic solvent.
2. Blow parts dry using filtered compressed air.
3. Clean coolant and oil seal mating surfaces on the crankcase, cylinder head, water distribution housing,
water pump assembly, coolant outlet manifold, thermostat housing and front belt- or gear-driven fan cover.
4. Inspect water distribution housing, coolant outlet manifold, vibration damper and front belt- or gear-driven
fan cover for damage, contamination or excessive wear. Replace parts if required.
5. Inspect belt automatic tensioners and pulleys to make sure tensioner arms and pulleys are properly in line
with the fan drive belt and accessory drive belt and not coming apart. Make sure tensioner arms are not
binding and pulley bearings are not loose. Replace belt tensioners if required.
6. Inspect idler pulleys to make sure pulleys are properly in line with the fan drive belt and accessory drive belt
and not coming apart. Replace idler pulleys if required.
7. Inspect thermostat assemblies. If thermostat assembly elements are stuck open, damaged, cracked or not
opening properly, replace thermostat assemblies.
8. Inspect water pump assembly. Wiggle water pump assembly hub and shaft. If water pump assembly
bearing has excess play, replace water pump assembly. Inspect water distribution housing and water pump
assembly for coolant leaks. Replace if leaking.
N13 Engine Brake by Jacobs

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.
Engine Brake Housing Assembly
Engine Brake Housing Assembly Removal
Overview
This section provides instructions for the removal of the engine brake housing assembly.

None
Equipment Condition
The following steps must be completed before engine brake housing assembly can be removed:
2. Remove air filter housing and air intake tube. See Air Filter Housing and Air Intake Tube Removal (page
285).
3. Remove upper valve cover. See Upper Valve Cover Removal (page 660).
Removal Procedure
Figure 541 Engine Brake Wiring Harness Assembly

1. Front engine brake assembly 3. Brake wiring harness 5. Solenoid
2. Solenoid connector nut (2 per 4. Wire tie snap (2 on front, 1 on
brake assembly) rear brake assembly)
See Front Engine Brake Wiring Harness Assembly (Figure 541) to perform steps 4 and 5.
4. Disconnect front engine brake assembly (1) brake wiring harness (3) connector leads from solenoid (5) by
disengaging two solenoid connector nuts (2) on front engine brake assembly. Do not use power tools. The
connector nuts are retained by the harness connectors.
5. Cut wire ties securing brake wiring harness (3) to wire tie snaps (4) on front engine brake assembly (1).
Position leads out of the way.
6. Repeat steps 4 and 5 to disconnect brake wiring harness connector leads from solenoid on rear engine
brake assembly.
Figure 542 Engine Brake Assembly

1. Front engine brake assembly 3. Brake housing socket-head bolt 4. Cylinder head
2. Brake housing bolt (3) (3) 5. Rear engine brake assembly
See Engine Brake Assembly (Figure 542) to perform steps 6 and 7.

7. Mark brake housings to indicate front and rear to insure they are reinstalled later in the correct locations.
8. Remove three brake housing socket-head bolts (3) and three brake housing bolts (2) and remove front
engine brake assembly (1) from cylinder head (4).
9. Repeat step 8 to remove rear engine brake assembly (5) from cylinder head (4).
None.
Engine Brake Housing Assembly Installation
Overview
This section provides instructions for the installation of the engine brake housing assembly.

None.
Brake housing M10 x 90 bolt 55 lb-ft (75 N·m)
Brake housing M12 x 100 (socket-head) screw 77 lb-ft (105 N·m)
Solenoid connector nut 31 lb-in (3.5 N·m)

1. Front engine brake assembly 3. Brake housing socket-head bolt 4. Cylinder head
2. Brake housing bolt (3) (3) 5. Rear engine brake assembly
See Engine Brake Assembly (Figure 543) to perform steps 1 through 5.
1. Carefully place previously marked front engine brake assembly in front position over camshaft and valve
train.
2. Install three brake housing socket-head bolts (3) and three brake housing bolts (2).
3. Torque three brake housing socket-head bolts (3) to 77 lb-ft (105 N·m).
4. Torque three brake housing bolts (2) to 55 lb-ft (75 N·m).
5. Repeat steps 2 through 4 to install rear engine brake housing assembly (5) in rear position over camshaft
and valve train.
Figure 544 Engine Brake Wiring Harness Assembly

1. Front engine brake assembly 3. Brake wiring harness 5. Solenoid
2. Solenoid connector nut (2 per 4. Wire tie snap (2 on front, 1 on
brake assembly) rear brake assembly)
See Engine Brake Wiring Harness Assembly (Figure 544) to perform steps 6 through 9.
CAUTION: To prevent engine damage, do not over torque nuts on wiring harness connector leads. Do not use
power tools. Too much torque will damage solenoid terminals.
6. Connect brake wiring harness (3) connector leads to solenoid (4) on front engine brake assembly (1). Make
sure harness terminal connectors are in straight alignment with harness.
7. Hold terminal connectors stationary to avoid twisting. Tighten solenoid connector nuts (2) to 31 lb-in (3.5
N·m).
8. Repeat steps 6 and 7 to connect brake wiring harness connector leads to solenoid on rear engine brake
assembly.
9. Install new wire ties to brake wiring harness (3) and secure to wire tie straps (4) as follows:
• Front engine brake assembly – two wire ties and two wire tie snaps
• Rear engine brake assembly – one wire tie and one wire tie snap
10. Install upper valve cover. See Upper Valve Cover Installation (page 661).
11. Install Engine Control Module (ECM) and mounting bracket. See Engine Control Module (ECM) and
Mounting Bracket Installation (page 661).
12. Install air filter housing and air intake tube. See Air Filter Housing and Air Intake Tube Installation (page
286).
Engine Brake Lash Adjustment

Engine Brake Lash Adjustment Installation
Figure 545 Engine brake lash adjustment

2. M10 (jam) nut
4. Slave piston
See Valve Lash Adjustment (page 657) for procedure covering both valve lash and engine brake lash
adjustments on engines so equipped.
Solenoid
Solenoid Disassembly
Figure 546 Solenoid

1. Solenoid assembly
2. M6 x 10 socket-head cap screw
3. Solenoid cover
4. Solenoid screen
1. If not already done, loosen connector nuts and disconnect harness connector leads from solenoid.
2. Remove M6 x 10 socket-head cap screw.
NOTE: Cover slides over solenoid and locks onto terminal ends. Cover is removed with solenoid as an assembly.
3. Remove solenoid and cover from brake housing.
4. Remove upper and lower seal rings from solenoid stem. Discard seal rings.
5. Remove and discard solenoid screen.
Solenoid Assembly Check
1. Clean brake housings, control valve assemblies, master piston rollers, slave pistons and springs with a
suitable non-caustic solvent.
2. Blow parts dry using filtered compressed air.
3. Inspect brake housings for cracks. Replace as required.
4. Check for missing or loose pipe plugs at sides and ends of brake housings. If pipe plugs are missing or
loose, replace brake housing assembly.
5. Inspect master piston rollers and associated camshaft lobes for excessive wear, spalling and galling.
Replace complete brake housing assembly if any master piston roller is determined unacceptable to reuse.
If camshaft lobes for engine brake have excessive wear, spalling or galling, replace camshaft.
6. Inspect slave pistons, springs and control valve assembly for worn or damaged parts. Replace parts that
are broken or deformed.
7. Inspect slave piston bores in brake housing. Insert slave pistons in respective bores and check for free
movement without binding. If there is binding, replace brake housing assembly.
8. Inspect control valve assembly bores in brake housing. Insert control valve assemblies in respective bores
and check for free movement without binding. If there is binding, replace brake housing assembly.
Figure 547 Solenoid assembly check

1. Solenoid screen (removed for check)
2. Pin
3. Button of armature
9. Hold solenoid assembly upside down in hand so you can look into the end where the solenoid screen was
removed. Move button of armature with finger while looking into the open end to verify pin moves freely
within the solenoid assembly. If pin does not move freely, replace solenoid.
10. Using an ohmmeter, check solenoid assembly resistance per the following steps:
• Check resistance across the two terminals. If resistance is out of specification (page 651), replace
solenoid assembly.
• Check resistance from each terminal to the solenoid can. This should be an “open circuit.” If a resistance
is measured, replace solenoid assembly.
Solenoid Assembly
Figure 548 Solenoid seal rings

1. Upper seal ring
2. Lower seal ring
3. Solenoid screen
1. Install new upper and lower seal rings in ring grooves on solenoid stem. Lubricate seal rings with clean
engine oil.
2. Clip solenoid screen on bottom of solenoid stem.
Figure 549 Solenoid

1. Solenoid assembly
3. Solenoid cover
4. Solenoid screen
3. Place solenoid in position on brake housing. Using hand pressure, press solenoid into bore until it snaps
into place.
4. If removed, install solenoid cover on solenoid.
5. Install M6 x 10 socket-head cap screw. Tighten screw to special torque (page 651).
Control Valve
Control Valve Disassembly
Figure 550 Control valve

1. Control valve retaining ring
2. Control valve cover
3. Outer spring
4. Inner spring
5. Control valve assembly
NOTE: Use same procedure to remove all control valves from engine.
1. Push down on control valve cover and hold to remove spring pressure from control valve retaining ring.
Using suitable snap-ring pliers, remove control valve retaining ring from housing control valve bore. Slowly
release control valve cover to relieve spring pressure.
2. Remove control valve cover from valve bore.
3. Using a pick, carefully remove inner and outer springs from bore.
4. Using a magnet or needle-nose pliers, remove control valve from housing bore.
Control Valve Assembly
Figure 551 Control valve

1. Control valve retaining ring
2. Control valve cover
3. Outer spring
4. Inner spring
5. Control valve assembly
1. Check that housing control valve bore is clean, free of any residue and debris.
2. Lubricate control valve assembly and springs with clean engine oil.
3. With hex stud end up, insert control valve assembly into housing bore. Ensure control valve assembly
moves smoothly and freely down bore.
4. Insert inner and outer springs into bore. Make sure that springs are properly seated with inner spring on
control valve and outer spring on step of control valve bore.
5. Install control valve cover over springs.
6. Using snap-ring pliers, install control valve retaining ring in housing bore to contain control valve assembly.
Ensure retaining ring is installed with sharp side up (away from control valve cover). Rotate retaining ring
to insure that it is properly seated in groove.
Master Piston
Master Piston Disassembly
Figure 552 Master piston

1. Master piston spring guide
2. Master piston roller spring
3. Master piston roller assembly
4. M6 x 30 master piston guide bolt
5. Master piston guide sleeve
The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning
master piston, replace brake housing assembly.
Master Piston Assembly
Figure 553 Master piston

1. Master piston spring guide
2. Master piston roller spring
3. Master piston roller assembly
4. M6 x 30 master piston guide bolt
5. Master piston guide sleeve
The master piston group currently is not a serviceable part. If a fault condition is traced to a malfunctioning
master piston, replace brake housing assembly.
Slave Piston
Slave Piston Disassembly
Figure 554 Slave piston

1. M10 (jam) nut
3. Slave piston
4. Slave piston spring
5. Slave piston washer
6. Slave piston retaining ring
WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove
or install slave piston. Slave piston springs are under heavy compression.
1. Remove M10 jam nut and back out slave piston adjusting screw until slave piston is fully retracted.
Use same procedure to remove all slave pistons from the engine.
Figure 555 Slave Piston Removal Tool

1. Clamp screw collar
2. Slave Piston Removal Tool
2. Place Jacobs® Slave Piston Removal Tool in position with hole in tool clamp bracket over slave piston
adjusting screw and clamp screw collar over slave piston stem.
3. Slowly tighten clamp screw until collar contacts slave piston washer. Continue tightening clamp screw to
compress slave piston spring and relieve spring pressure against slave piston retaining ring.
Figure 556 Slave piston retaining ring

4. Using snap-ring pliers, remove slave piston retaining ring from piston bore.
5. Slowly loosen tool clamp screw to release slave piston spring pressure and remove tool.
6. Grasp piston stem and remove slave piston, spring and washer.
7. Remove slave piston adjusting screw.
Slave Piston Assembly
Figure 557 Slave piston

1. M10 (jam) nut
3. Slave piston
4. Slave piston spring
5. Slave piston washer
1. Check that housing slave piston bore is clean, free of any residue and debris.
2. Lubricate slave piston, spring and washer with clean engine oil.
3. Assemble slave piston spring, washer and retaining ring on slave piston stem.
4. Insert slave piston, spring and washer assembly into housing bore.
NOTE: Retaining ring with proper orientation must be placed on stem before using Jacobs® Slave Piston
Removal Tool to compress spring in housing bore.
WARNING: To prevent personal injury or death, use Jacobs® Slave Piston Removal Tool to remove
or install slave piston. Slave piston springs are under heavy compression.

1. Clamp screw collar
5. Place slave piston retaining ring, oriented with sharp side up (away from washer), in position over slave
piston stem. Install Jacobs® Slave Piston Removal Tool with clamp screw collar on slave piston stem.
6. Slowly tighten clamp screw until screw collar contacts slave piston washer. Continue tightening clamp screw
to compress piston spring until washer is approximately 1/32 inch below retaining ring groove.

7. Using snap-ring pliers, install slave piston retaining ring in bore ring groove. Ensure retaining ring is oriented
with sharp side up (away from washer). Rotate retaining ring to ensure that it is properly seated in groove.
8. Slowly loosen tool clamp screw to release piston spring pressure and remove tool.
9. Install slave piston adjusting screw and jam nut. Do not tighten jam nut.
Specifications, Special Torques, and Special Tools
Specifications
Temperature Solenoid resistance
Cold — 25 ° C (77 ° F) 8.7–10 ohms
Hot — 121 ° C (250 ° F) 12–15.5 ohms
Special Torques
Brake housing M10 x 90 bolt 75 N·m (55 lb·ft)
Brake housing M12 x 100 (socket-head) screw 105 N·m (77 lb-ft)
Brake housing solenoid harness connector nut 3.5 N·m (31 lb·in)
Slave piston adjusting screw M10 (jam) nut 25 N·m (18 lb·ft)
Solenoid M6 x 10 socket-head cap screw 12.5 N·m (110 lb·in)
Special Tools
Jacobs® Slave Piston Removal Tool ZTSE6068

Cylinder Head, Camshaft and Valve Train
WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set
parking brake, and block wheels before doing diagnostic or service procedures.
components.
Cylinder Head, Camshaft and Valve Train Periodic Service
Crankshaft Rotation Procedure
Figure 560 High-pressure pump pulley

NOTE: The crankshaft can be rotated using the M16 x 40 LH bolt (left-hand thread) on the high-pressure pump
pulley. Care must be used to ensure the bolt is not loosened while the crankshaft is rotated.
1. Adjust a torque wrench to 162 N·m (120 lb-ft).

2. Place a 19 mm socket on the torque wrench.
3. Slowly rotate the M16 x 40 LH bolt (left-hand thread) bolt clockwise. Stop pulling if the torque wrench clicks.
Torque in excess of 162 N·m (120 lb-ft) may cause the bolt to loosen. Continue rotating to desired position
when compression leaks down and less force is needed to rotate the crankshaft.
Cylinder No. 1 TDC Procedure

1. Remove the upper valve cover and base. See Upper Valve Cover and Base (page 663).
Figure 561 Camshaft gear timing mark

1. Valve cover surface
2. Camshaft gear
3. Timing mark
2. Rotate crankshaft in direction of engine rotation until the camshaft timing gear mark aligns with the valve
cover surface on the intake side of the engine. See Crankshaft Rotation Procedure (page 653).
Figure 562 Flywheel housing timing index (typical)

3. Remove timing hole cover from lower side of flywheel housing.

4. Rotate crankshaft in direction needed to align the flywheel timing mark with flywheel housing timing index.
5. Recheck that the timing mark on camshaft gear is aligned with the valve cover gasket surface (on intake side
of cylinder head). If flywheel and camshaft gear marks are in agreement, the engine is at TDC for cylinder
1. Skip step 6 and proceed to Valve Overlap Procedure below.
CAUTION: To prevent engine damage, a new large idler gear must be installed, if the large idler gear has slipped.
6. If flywheel and camshaft gear marks are not in agreement, the large idler gear has slipped. See Rear Timing
Gears (page 770) for procedure to install a new large idler gear.
Valve Overlap Procedure

NOTE: Valve lash adjustments are done in firing order sequence (1, 5, 3, 6, 2, 4), using the valve overlap
method. Valve overlap happens on the companion cylinder near the end of the exhaust stroke and the beginning
of the intake stroke, when both valves are open for a short period of time.
1. Starting with cylinder 1 at TDC compression, set valve lash for cylinder 1, according to Valve Lash Adjustment
Procedure below.
2. After valves for cylinder 1 have been adjusted, rotate crankshaft slowly and watch valves for cylinder 2;
watch the exhaust valve as it closes, and watch for intake valve to start opening. When cylinder 2 intake
and exhaust valves are open equally, adjust valves on cylinder 5 according to the Valve Lash Adjustment
Procedure below.
3. Repeat Valve Overlap Procedure, in order for remaining cylinders 3, 6, 2, and 4. See Table 29 (page 659).
Valve Lash Adjustment Procedure

Figure 563 Valve Lash Adjustment (Typical)

1. Exhaust rocker arm
2. Intake rocker arm
3. Adjusting screw
4. Valve lash adjustment M10 nut
5. Valve bridge (intake/exhaust)
NOTE: Adjust engine valve lash and engine brake lash at 120,000 miles (190,000 km), 300,000 miles (480,000
km), then every 300,000 miles (480,000 km) thereafter.
1. Do Valve Overlap Procedure (page 656).
2. Loosen valve lash adjustment M10 nut (Figure 563) (Item 4) on intake rocker arm (Figure 563) (item 2).
3. Insert Lash Gauge ZTSE6076–5A 0.5 mm (0.020 in) between intake valve bridge (Figure 563) (Item 5) and
adjusting screw (Figure 563) (Item 3), and tighten adjusting screw until a slight drag on Lash Gauge 0.5 mm
(0.020 in) is felt.
4. Hold adjusting screw in position and tighten valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
NOTE: If equipped with N13 engine brake, go to step 6 to adjust exhaust valve lash and engine brake lash. If
no engine brake, continue to step 5.
5. For engines without brake, adjust exhaust valve lash as follows:
a. Loosen valve lash adjustment M10 nut on exhaust rocker arm (Figure 563) (item 1).
b. Insert Lash Gauge ZTSE6076–7A 0.8 mm (0.031 in) between exhaust valve bridge and adjusting screw
and tighten adjusting screw until a slight drag on Lash Gauge 0.8 mm (0.031 in) is felt.
c. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
d. Go to step 6.
Figure 564 Brake Lash Adjustment (Equipped with N13 Engine Brake)
2. Brake lash adjustment M10 (jam) nut
3. Engine brake housing assembly
5. Slave piston
6. For engines with N13 engine brake, adjust exhaust valve lash and engine brake lash as follows:
a. Loosen brake lash adjustment M10 (jam) nut (Figure 564) (Item 2) on engine brake housing assembly
(Figure 564) (Item 3), and back out slave piston adjusting screw (Figure 564) (Item 1) so slave piston
no longer contacts valve bridge.
b. Loosen valve lash adjustment M10 nut on exhaust rocker arm (Figure 563) (item 1).
c. Insert Lash Gauge 0.8 mm (0.031 in) on exhaust rocker arm between exhaust valve bridge (Figure 563)
(Item 5) and adjusting screw, and tighten adjusting screw (Figure 563) (Item 4) until a slight drag on
Lash Gauge 0.8 mm (0.031 in) is felt.
d. Hold adjusting screw in position and tighten exhaust valve lash adjustment M10 nut to 33 lb·ft (45 N·m).
e. Insert Lash Gauge 0.8 mm (0.031 in) on engine brake housing assembly between slave piston (Figure
564) (Item 5) and bridge actuator pin (Figure 564) (Item 4).
f. Turn adjusting screw in until slave piston contacts Lash Gauge 0.8 mm (0.031 in) and a slight drag on
Lash Gauge 0.8 mm (0.031 in) is felt.
g. Using a 5 mm Allen wrench, hold slave piston adjusting screw to prevent from turning and tighten jam
nut to 33 lb·ft (45 N·m).
Table 1
Cylinder at TDC compression Companion cylinder in valve overlap
1 6
5 2
3 4
6 1
2 5
4 3
7. Turn crankshaft in direction of engine rotation to position next cylinder in firing order at TDC compression
(one at a time) and adjust lash for the respective cylinder. See . For each cylinder positioned at TDC
compression, the companion cylinder will be in valve overlap as shown in following table.
Upper Valve Cover and Base

Upper Valve Cover Removal
Overview
This section provides instructions for the removal of the upper valve cover.

None.
Equipment Condition
The following steps must be completed before removing upper valve cover:
2. Remove air filter housing and air intake tube. See Air Filter Housing and Air Intake Tube Removal (page
285).
Removal Procedure
Figure 565 Upper Valve Cover

1. Upper valve cover bolt (18) 3. Rear engine brake housing 5. Front engine brake housing
2. Upper valve cover assembly assembly
4. Lower valve cover
3. Remove 18 upper valve cover bolts (1) securing upper valve cover (2) to lower valve cover (4) and remove
upper valve cover. Do not use power tools for four back bolts. Use hand ratchet.
Upper Valve Cover Installation
Overview
This section provides instructions for the installation of the upper valve cover.

None.
Upper valve cover bolts 23 lb-ft (31 N·m)

1. Upper valve cover bolt (18) 3. Rear engine brake housing 5. Front engine brake housing
2. Upper valve cover assembly assembly
4. Lower valve cover
1. Install upper valve cover (2) to lower valve cover (4) and secure with 18 upper valve cover bolts (1). Torque
bolts to 23 lb-ft (31 N·m).
2. Install air filter housing and air intake tube. See Air Filter Housing and Air Intake Tube Installation (page
286).
Upper Valve Cover and Base Removal
Figure 567 Upper Valve Cover and Base

1. Screw with damper (18)
2. M8 x 30 bolt (17)
3. Upper valve cover
4. Valve cover base
CAUTION: To prevent engine damage, do not use power tools to remove or install valve cover bolts. Threads
will be damaged if a bolt or nut is rotated too quickly.
NOTE: The upper valve cover can be removed separately or as an assembly with the valve cover base
depending on work being performed. If it is being removed as an assembly, start with step 2.
1. Remove 17 M8 x 30 bolts (Figure 567) (Item 2) and remove upper valve cover (Figure 567) (Item 3) from
base (Figure 567) (Item 4).
NOTE: The valve cover base screws can only be removed from valve cover as assemblies with the dampers.
Screws and dampers should only be removed from cover if replacing the valve cover gasket.
2. Release 18 screws with dampers (Figure 567) (Item 1) from cylinder head. Do not completely remove
screws from valve cover at this time.
3. Remove valve cover base (or assembly) from cylinder head.
NOTE: Valve cover gaskets can be reused and do not require removal from valve cover base unless damaged.
Figure 568 Valve Cover Gaskets

1. Valve cover base
3. Upper valve cover gasket
4. (Lower) valve cover gasket
4. Inspect upper (Figure 568) (Item 3) and lower (Figure 568) (Item 4) valve cover gaskets for damage. If
damaged, replace as follows:
a. Upper gasket — remove from groove in upper surface of valve cover base (Figure 568) (Item 1) and
discard gasket.
b. Lower gasket — completely remove 18 screws with dampers (Figure 568) (Item 2) to release gasket
from bottom of valve cover base. Discard gasket.
Upper Valve Cover and Base Installation
Figure 569 Valve Cover Gaskets

1. Valve cover base
3. Upper valve cover gasket
4. (Lower) valve cover gasket
1. Apply Loctite® 5127 sealant (page 1233) at sharp corners and curved surfaces to joining surfaces of cylinder
head and lower valve cover gasket (Figure 569) (Item 4).
2. If necessary, install a new lower and/or upper valve cover gasket (Figure 569) (Item 3).
3. If previously removed, install 18 screws with dampers (Figure 569) (Item 2) in valve cover base (Figure 569)
(Item 1) and through lower valve cover gasket.
Figure 570 Upper Valve Cover and Base

2. M8 x 30 bolt (17)
3. Upper valve cover
4. Valve cover base
4. Install valve cover base (Figure 570) (Item 4) on cylinder head and finger tighten 18 screws with dampers
(Figure 570).
Figure 571 Valve Cover Base Tightening Sequence

5. Tighten 18 screws with dampers (Figure 570) (Item 1) in sequence shown above (Figure 571). Tighten to
97 lb·in (11 N·m).
6. If removed, install upper valve cover (Figure 570) (Item 3) on valve cover base.
7. Install 17 M8 x 30 bolts (Figure 570) (Item 2) and tighten to 80 lb·in (9 N·m).
Rocker Arm Assembly (Non-Brake Engine)

Rocker Arm Assembly (Non-Brake Engine) Removal
CAUTION: To prevent engine damage, use permanent marker to identify internal engine components and their
orientation. Do not use paint or temporary markers.
Figure 572 Rocker Arm Assembly (Typical)

1. M12 x 60 (socket-head) screw (12)
2. Rocker arm assembly (6)
1. Mark rocker arm assemblies (Figure 572) (Item 2) 1 through 6 so each assembly can be installed in its
original cylinder location.
2. Remove 12 M12 x 60 socket-head screws (Figure 572) (Item 1).
3. Remove six rocker arm assemblies.
Figure 573 Rocker Bearing Block and Valve Bridges

1. Rocker bearing block (6)
2. Valve bridge (12)
4. Mark rocker bearing blocks (Figure 573) (Item 1) 1 through 6 so each block can be installed in its original
cylinder location.
5. Remove six rocker bearing blocks.
6. Mark valve bridges (Figure 573) (Item 2) so each bridge can be installed in its original location and orientation.
7. Remove 12 valve bridges.
Rocker Arm Assembly (Non-Brake Engine) Installation

1. Rocker bearing block (6)
2. Valve bridge (12)
NOTE: If original valve bridges are installed, make sure each is placed as previously marked in its original
location.
Figure 575 Valve Bridge Orientation (Typical)

1. Camshaft side
2. Exhaust manifold side
1. Place 12 new or previously marked valve bridges on intake and exhaust valves with milled end oriented
toward camshaft.
NOTE: If original rocker bearing blocks are installed, make sure each is placed as previously marked in its
original location.
2. Install six new, or previously marked rocker bearing blocks.
Figure 576 Rocker Arm Assembly (Typical)

1. M12 x 60 (socket-head) screw (12)
2. Rocker arm assembly (6)
NOTE: If original rocker arm assemblies are installed, make sure each is placed as previously marked in its
original location.
3. Install six new or previously marked rocker arm assemblies (Figure 576) (Item 2).
4. Install 12 M12 x 60 socket-head screws (Figure 576) (Item 1). Tighten screws to 77 lb·ft (105 N·m).
5. Adjust valve lash. See Cylinder No. 1 TDC Procedure .
Camshaft
Camshaft Removal
Figure 577 Camshaft end play check (typical)
1. Check camshaft end play as follows:

a. Mount dial indicator with magnetic base (page 1233) 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 698).
d. If end play exceeds specified limits, install a new camshaft.
Figure 578 Camshaft timing mark (typical)

1. Camshaft gear
2. Timing mark
2. Turn engine crankshaft in direction of engine rotation until timing mark on camshaft gear is aligned with
cylinder head surface.

3. Remove timing hole cover from lower side of flywheel housing and verify timing mark on flywheel is aligned
with flywheel housing timing index.
• If timing mark on flywheel is out of alignment, then the timing has slipped due to large idler gear slippage.
Install a new large idler gear. See Rear Timing Gears (page 770) section of this manual for procedures
to replace large idler gear.
• If timing mark on flywheel is aligned with flywheel housing timing index, continue to next step.
Figure 580 Camshaft bearing caps

1. Camshaft bearing cap (7)
2. M8 x 35 bolt (14)
4. Remove 14 M8 x 35 bolts.
5. Remove seven camshaft bearing caps from the cylinder head. Mark each bearing cap with location number
and orientation.
Figure 581 Camshaft bearing cap and bearing shell (typical)

1. Camshaft bearing cap
2. 4H x 8 x 10 dowel pin (2)
3. Bearing shell
6. Remove seven bearing shells from camshaft bearing caps. Mark each bearing shell with camshaft bearing
cap number and orientation.
7. If damaged, remove 14 - 4H x 8 x 10 dowel pins from seven camshaft bearing caps.
8. Remove camshaft.
9. Remove seven lower bearing shells from cylinder head. Mark each bearing shell with camshaft bearing cap
number and orientation.
Figure 582 Camshaft gear and camshaft timing disc (pulse wheel)
1. Timing (M6 x 20 dowel) pin
2. Camshaft gear
3. Camshaft timing disc (pulse wheel)
4. M8 x 30 bolt (3)
10. Remove three M8 x 30 bolts.

11. Remove camshaft timing disc and camshaft gear.
12. If damaged, remove timing pin from camshaft.
Camshaft Installation
Figure 583 Camshaft gear and camshaft timing disc (pulse wheel)
1. Timing (M6 x 20 dowel) pin
2. Camshaft gear
3. Camshaft timing disc (pulse wheel)
4. M8 x 30 bolt (3)
1. If previously removed, install timing (M6 x 20 dowel) pin into camshaft.

2. Align camshaft gear with timing pin and install on camshaft.
3. Align camshaft timing disc with timing pin and install on camshaft.
4. Install and finger-tighten three M8 x 30 bolts.
Figure 584 Camshaft lower bearing shell oil hole alignment (typical)
NOTE: If original camshaft bearings are installed, make sure to place them as previously marked in their original
location and orientation.
5. Install seven new or previously marked camshaft lower bearings on cylinder head. Make sure oil holes in
bearings are aligned with oil holes in cylinder head bearing support.
6. Rotate crankshaft so cylinder number 1 is positioned at TDC. See Crankshaft Rotation Procedure (page
653).

7. Verify timing mark on flywheel is aligned with flywheel housing timing index at bottom of flywheel housing.
Figure 586 Camshaft timing mark (typical)

1. Camshaft gear
2. Timing mark
8. Lower camshaft on cylinder head and make sure timing mark on camshaft gear is aligned with cylinder head
surface.
Figure 587 Camshaft bearing cap and bearing shell

1. Camshaft bearing cap
2. 4H x 8 x 10 dowel pin (2)
3. Bearing shell
NOTE: Make sure that each bearing cap has the two dowel pins installed.
9. If previously removed, install 14 - 4H x 8 x 10 dowel pins into seven camshaft bearing caps.
NOTE: If original bearings are installed, make sure each is placed as previously marked in its original location
and orientation.
10. Install seven new or previously marked bearing shells on camshaft bearing caps.
Figure 588 Camshaft bearing caps

1. Camshaft bearing cap (7)
2. M8 x 35 bolt (14)
11. Install seven previously marked camshaft bearing caps with each placed in its original location and
orientation.
12. Install 14 M8 x 35 bolts. Tighten bolts to special torque (page 698).
Figure 589 Camshaft gear bolts tightening

1. Camshaft gear
2. M8 x 30 bolt (3)
13. Tighten three M8 x 30 bolts to 15 N·m (133 lb·in).

14. Tighten three M8 x 30 bolts an additional 90° (1/4 turn).
Cylinder Head
Cylinder Head Removal
CAUTION: To prevent engine damage, remove fuel injectors before removing cylinder head.
1. Remove six fuel injectors. See Fuel Injectors .
Figure 590 Cylinder Head Lifting Bracket

1. Cylinder Head Lifting Bracket
2. M8 x 20 class 10.9 bolt (4)
2. Position Cylinder Head Lifting Bracket (page 1233) on rear end of cylinder head.
3. Install four M8 x 20 class 10.9 bolts (page 1233). Tighten bolts to standard torque (page 1201).
Figure 591 Cylinder head bolts

4. Use Head Bolt Torx® Socket (page 1233) and working in a circular pattern, loosen, remove, and discard 26
M18 x 246 Torx® bolts. Begin with the outer bolts and move inward.
Figure 592 Cylinder head removal
5. Lift cylinder head using a suitable lifting device.
WARNING: To prevent personal injury or death, use a hoist rated for the weight of the cylinder
head and follow the manufacturer's operative and safety instructions. Attach safety lifting hooks to the
cylinder head lifting bracket and lifting eye.
CAUTION: To prevent engine damage, do not scratch gasket surface of cylinder head.
CAUTION: To prevent engine damage, carefully set cylinder head on wooden blocks to protect the cylinder head
idler gear.
6. Place cylinder head on a clean, non-metallic surface.
7. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 1233).
8. Remove and discard cylinder head gasket.
Figure 593 8 mm dowel pin (2)
9. If damaged, remove two 8 mm dowel pins.

Cylinder Head Installation
Figure 594 8 mm dowel pin (2)
1. If previously removed, install two 8 mm dowel pins in crankcase.
CAUTION: Do not use chlorinated solvents on cylinder head bolts. If parts are not cleaned thoroughly, parts will
corrode over time. Be sure parts are clean, dry and free of chemicals other than engine oil.
CAUTION: To prevent engine damage, clean and blow dry threads in the crankcase bolt holes with filtered
compressed air. Dirt or oil in holes may cause binding or an incorrect torque reading.
CAUTION: To prevent engine damage, remove debris and contaminants from cylinder head gasket mating
surfaces. If debris is not removed, a faulty seal between the cylinder head, gasket and crankcase will cause oil,
coolant and compression leaks. Do not apply sealant to head gasket surfaces.
CAUTION: To prevent engine damage, install a new cylinder head gasket with part number facing up.
CAUTION: To prevent engine damage, check piston protrusion before installing cylinder head.
2. Check piston protrusion. See Preliminary Checks (page 775).
Figure 595 Cylinder head gasket

1. N13 cylinder head gasket 2. MaxxForce® 11 cylinder head 3. Right rear corner
gasket 4. Notch at right rear corner
CAUTION: To prevent engine damage, install correct cylinder head gasket for application.
3. Verify correct cylinder head gasket is used for application. N13 cylinder head gaskets (Figure 595) (Item 1)
have a notch at the right rear corner (Figure 595) (Item 4).
4. Install a new cylinder head gasket on crankcase, over dowel pins.

1. Cylinder Head Lifting Bracket
2. M8 x 20 class 10.9 bolt (4)
5. Position Cylinder Head Lifting Bracket (page 1233) on rear end of cylinder head.
6. Install four M8 x 20 class 10.9 bolts (page 1233). Tighten bolts to standard torque (page 1201).
Figure 597 Cylinder head installation
WARNING: To prevent personal injuries or death, use a hoist rated for the weight of the cylinder
head and follow the manufacturer's operation and safety instructions. Attach safety lifting hooks to the
CAUTION: To prevent engine damage, do not drop or slide cylinder head on cylinder head gasket. This can
damage the cylinder head gasket, dowel pins and the cylinder head idler gear.
7. Attach an appropriate hoist and lifting hooks to cylinder head lifting bracket and lifting eye.
8. Lower cylinder head onto crankcase and align cylinder head alignment dowels in the crankcase with dowel
holes in the cylinder head.
Figure 598 Cylinder head bolts
CAUTION: To prevent engine damage, install new cylinder head bolts when installing cylinder head. Apply a
light coat of clean engine oil to new bolt threads and under bolt head. Too much oil will cause hydrostatic lock
and give incorrect torque reading. Do not use anti-seize compound, grease, or any other lubricant on cylinder
head bolt threads.
9. Install 26 new lightly lubricated M18 x 246 Torx® bolts. Do not tighten bolts at this time.
10. Remove four M8 x 20 class 10.9 bolts and Cylinder Head Lifting Bracket (page 1233).
Figure 599 Cylinder head bolt tightening sequence
CAUTION: To prevent engine damage, use only permanent ink markers to identify bolt torque orientation.
CAUTION: To prevent engine damage, use a torque wrench to tighten cylinder head bolts; do not use an impact
wrench.
NOTE: For proper cylinder head surface seating and sealing, follow the correct tightening sequence.
11. Use Head Bolt Torx® Socket (page 1233) to tighten the M18 x 246 Torx® bolts in sequence indicated above
as follows:
1. Hand-tighten Torx® bolts.
2. Tighten Torx® bolts numbered 1 through 26 to 10 N·m (89 lb·in) in numerical sequence as shown.
3. Tighten Torx® bolts numbered 1 through 26 to 150 N·m (111 lb·ft) in numerical sequence.
4. Tighten Torx® bolts numbered 1 through 26 to 300 N·m (221 lb·ft) in numerical sequence.
5. Rotate Torx® bolts numbered 1 through 26 an additional 90° (1/4 turn) clockwise in numerical
sequence.
sequence for second time.
sequence for third time.
Cylinder Head Idler Gear

Cylinder Head Idler Gear Removal
Figure 600 DMR 63.10 cup plug removal
1. Use a punch to knock in bottom of DMR 63.10 cup plug. Remove and discard cup plug.
Figure 601 Cylinder head idler gear

1. Small gear shaft
2. Cylinder head idler gear
2. Remove three M8 x 30 socket-head cap screws, small gear shaft and cylinder head idler gear.
Cylinder Head Idler Gear Installation
Figure 602 Cylinder head idler gear

1. Small gear shaft
2. Cylinder head idler gear
1. Install small gear shaft and cylinder head idler gear.

2. Install three M8 x 30 socket-head cap screws. Tighten screws to special torque (page 698).
3. Clean cylinder head mating surfaces for cylinder head idler gear DMR 63.10 cup plug.
4. Apply Loctite® 262™ Threadlocker (page 1233) to the outside edge of new cylinder head idler gear cup plug.
Figure 603 DMR 63.10 cup plug installation
5. Drive new cup plug into the hole using a Bearing Installer (page 1233) approximately 6 mm (0.25 in) smaller
in diameter than the cup plug.
6. Recess cup plug 2.3 mm (0.9 in) below the machined surface.
Cylinder Head, Camshaft and Valve Train Cleaning, Inspection, and Testing
Cylinder Head and Crankcase Components
1. Use a scraper and wire brush to remove deposits and gasket material from valve heads and gasket surface.
2. Use a suitable solvent to remove dirt, grease and deposits from removed parts.
3. Clean all bolt holes. Make sure gasket surfaces are clean. Clean all surfaces and ports with steam, and
then dry with filtered compressed air.
installed.
CAUTION: To prevent engine damage, clean and dry threads in crankcase bolt holes with filtered compressed
air. Dirt or oil in holes may cause binding and incorrect torque readings.
Figure 604 Head bolt bottoming tap (typical)
5. Clean cylinder head bolt holes in crankcase with Head Bolt Bottoming Tap (page 1233).
6. Clean out debris with filtered compressed air.
Composite Valve Cover Assembly Cleaning and Inspection
Figure 605 Composite Valve Cover

A. Composite valve cover B. Composite valve cover sealing C. Composite valve cover bolt
surface holes
See Composite Valve Cover (Figure 605) to perform steps 1 through 3.

1. Use a scraper or wire brush to clean composite valve cover sealing surface (B).
2. Use a commercially available, non-caustic brake cleaner to clean composite valve cover (A).
3. Inspect composite valve cover, composite valve cover sealing surface, and composite valve cover bolt holes
(A, B, and C) for cracks, pitting, and other notable damage. Repair or replace as necessary.
Camshaft Bearings
1. With camshaft removed, install previously marked bearings and camshaft bearing caps. Tighten M8 x 35
bolts to special torque (page 698).
Figure 606 Camshaft bearing check (typical)
2. Use a telescoping gauge set (page 1233) and a 1 - 2 inch micrometer (page 1233) to measure camshaft
bearing inside diameter. If inside diameter does not meet specification (page 698), install new camshaft
bearings.
Fuel Injector Bore

1. Use Injector Sleeve Brushes (page 1233) in injector bore to remove deposits.
2. Use filtered compressed air to clean out debris from injector bores.
Valves Leak Test

NOTE: Position wooden blocks so the view of all the intake and exhaust valve heads and valve seat areas is
not restricted.
1. Position cylinder head on wooden blocks with cylinder head gasket surface facing down.
Figure 607 Air intake throttle duct (typical)

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
2. Apply Loctite® 5900 sealant or equivalent (page 1233) to joining surfaces of air intake throttle duct and
cylinder head.
3. Install air intake throttle duct.
4. Install M8 x 50 bolt and two M8 x 100 bolts. Tighten bolts to standard torque (page 1201).
5. Spray mineral spirits into exhaust ports.
6. Pour mineral spirits into air intake throttle duct until intake manifold inside cylinder head is filled.
Figure 608 Leak inspection

1. Inspection mirror
2. Reflection of valve
3. Flashlight
NOTE: Valve seats must not leak. If valve seats leak, install a new cylinder head. Cylinder head replacement
is not required if the cylinder head passes the valves leak test using mineral spirits.
7. Wait five minutes. Use an inspection mirror to inspect valve seat area for leakage of mineral spirits. If there
is no leakage of mineral spirits through the intake or exhaust valves, the cylinder head is acceptable for
reinstallation.
Figure 609 Air intake throttle duct

1. M8 x 50 bolt
2. M8 x 100 bolt (2)
8. Position a suitable container under air intake throttle duct to catch mineral spirits. M8 x 50 bolt and two M8
x 100 bolts.
9. Remove air intake throttle duct.
10. Lift rear end of cylinder head to drain all remaining mineral spirits out of the intake manifold.
Specifications
Camshaft
Camshaft bearing inside diameter 39.925 – 39.950 mm (1.57185 – 1.57283 in)
Camshaft end play 0.25 – 0.85 mm (0.0098 – 0.0334 in)
Exhaust valve clearance 0.8 mm (0.0315 in)
Intake valve clearance 0.5 mm (0.0197 in)
Cylinder Head Idler Gear Cup Plug
Cup plug, DMR 63.10 Recess 2.3 mm (0.9 in)
Special Torques
Camshaft gear M8 x 30 bolt See tightening steps in procedure
(Camshaft) bearing cap M8 x 35 bolt 25 N·m (18 lb·ft)
Cylinder head idler gear M8 x 30 socket-head cap screw 30 N·m (22 lb·ft)
Cylinder head M18 x 246 Torx® bolt See tightening steps in procedure
Rocker arm assembly M12 x 60 (socket-head) screw 105 N·m (77 lb·ft)
Upper valve cover M8 x 30 bolt 9 N·m (80 lb·in)
Valve cover base screw with damper 11 N·m (97 lb·in)
Valve lash adjustment M10 nut 45 N·m (33 lb·ft)
Special Tools
1 - 2 inch micrometer Obtain locally
Bearing installer Obtain locally
Connecting Rod Bolt Torx® Socket ZTSE4835
Cylinder Head Lifting Bracket ZTSE4869
Dial indicator with magnetic base Obtain locally
Feeler gauge (Jacobs® 96-020949) Obtain from Jacobs
Head Bolt Bottoming Tap ZTSE4855
Head Bolt Torx® Socket ZTSE4787
Lash Gauge 0.5 mm (0.020 in) ZTSE6076-5A
Loctite® 262™ Threadlocker Obtain locally
Loctite® 5127 sealant Obtain locally
Loctite® 5900 sealant or equivalent Obtain locally
M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally
Flywheel and Flywheel Housing
components.
NOTE: Refer to the following service section for information on removal of components prior to this section:
Pilot Bearing
Pilot Bearing Removal
Figure 610 Pilot bearing removal (typical)

1. Slide hammer and blind hole puller
2. Pilot bearing
1. Using a slide hammer (page 1234), install blind hole puller (page 1234), into pilot bearing.
2. Tap slide hammer and remove pilot bearing.

Pilot Bearing Installation
Figure 611 Pilot Bearing Installation Tool
1. Place pilot bearing in flywheel bore.

2. Using Pilot Bearing Installation Tool (page 1234), tap pilot bearing into flywheel. When tool bottoms out,
pilot bearing is fully installed.
Flywheel (Manual Transmission)

Flywheel (Manual Transmission) Removal
Figure 612 Flywheel removal

1. 12PT flange bolt (10)
2. Flywheel assembly
1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service
publications.)
2. Remove and discard two 12PT flange bolts at approximately 3 o'clock and 9 o'clock position.
3. Install two guide pins (make locally) into crankshaft flange.
4. Remove and discard remaining eight 12PT flange bolts.
5. Slide wear plate (reinforcement ring) and four flexplates off guide pins.
6. Slide flywheel assembly off guide pins and out of flywheel housing.
7. Remove guide pins from crankshaft flange.
Flywheel (Manual Transmission) Preliminary Checks and Measurements

1. Inspect flywheel for cracks around webbing and bolt holes.
2. Inspect flywheel for heat cracks and extensive scoring.
3. Inspect all ring gear teeth for starter pinion damage.
4. Replace flywheel if necessary.
Flywheel Surface Runout

CAUTION: To prevent engine damage, check runout of flywheel surface for correct alignment of engine
to transmission. Failure to ensure correct bore concentricity and face runout may reduce life of clutch or
transmission.
Figure 613 Flywheel surface runout

1. Dial indicator with magnetic base
2. Flywheel
1. Attach dial indicator with magnetic base (page 1234) to surface of lifting eye. Place indicator tip against
flywheel.
NOTE: Keep crankshaft end play at zero and rotate in same direction for all measurements.
2. Push the flywheel inward to eliminate crankshaft end play, zero dial indicator.
3. While pushing inward on the flywheel to eliminate crankshaft end play, slowly rotate crankshaft one complete
revolution. See Crankshaft Rotation Procedure (page 653). Compare total dial indicator variation (highest
- lowest reading) to specification (page 1234).
Flywheel and Flywheel Housing Reconditioning

NOTE: Flywheels used with manual transmissions may be resurfaced to correct minor wear and scoring. If
flywheel meets the following requirements it can be resurfaced.
WARNING: To prevent personal injury or death, do not machine flywheel beyond minimum
thickness specified for flywheel resurfacing.
Figure 614 Flywheel surface dimension (typical)

1. Flywheel thickness (dimension “A”)
2. Clutch disc mounting face
3. Crankshaft timing gear face
NOTE: Flywheel resurfacing information is provided for guidance only. Navistar, Inc. assumes no responsibility
either for the results of any work performed in accordance with this information or for the ability of service
personnel to detect cracks.
WARNING: To prevent personal injury or death, carefully examine flywheel for any cracks or heat
checks before and after resurfacing. Cracks in the flywheel can cause it to separate. If there are any
questions, do not reuse the flywheel.
1. Check flywheel for cracks and damage. Replace flywheel if required.
2. Using 1-2 inch micrometer (page 1234), measure flywheel thickness and compare to minimum required
thickness specification (dimension “A”) (page 1234). Discard flywheel if below minimum thickness
specification or if flywheel will be below minimum thickness after resurfacing.
3. Resurface flywheel. See Flywheel Resurfacing Machine operators manual for instructions on flywheel
resurfacing procedure.
4. Check flywheel for cracks and damage after resurfacing. Replace flywheel if required.
5. Measure flywheel thickness after resurfacing and compare to minimum required thickness specification.
Discard flywheel if below minimum thickness specification.
Flywheel (Manual Transmission) Installation

1. Install two guide pins (made locally) into crankshaft flange at approximately 3 o'clock and 9 o'clock position.
Figure 615 Flywheel assembly and bolts

2. Flywheel assembly
3. 8 x 60-ST pin
2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft timing gear pin and slide flywheel
onto guide pins.
CAUTION: To prevent engine damage, always install new flywheel mounting bolts.
CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate
mounting bolts.
3. Loosely install eight new 12PT flange bolts to secure flywheel assembly to crankshaft.
4. Remove both guide pins and loosely install two remaining new 12PT flange bolts.
Figure 616 Flywheel bolt tightening sequence
NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from
turning.
5. Tighten 12PT flange bolts using sequence indicated above as follows:
a. Tighten bolts to 110 N·m (81 lb·ft).
b. Angle tighten bolts 90°.
c. Angle tighten bolts an additional 90°.
Flywheel and Flexplate Assembly (Automatic Transmission)

Flywheel and Flexplate Assembly (Automatic Transmission) Removal
Figure 617 Flywheel and flexplate assembly

1. Flexplate and flywheel assembly
3. Guide pin (2)
4. Wear plate (reinforcement ring)
1. Remove transmission and torque converter assembly. (See transmission manufacturer’s service
publications.)
2. Remove and discard two 12PT flange bolts, 180 degrees from each other (approximately 3 o’clock and 9
o’clock positions).
3. Install two guide pins (made locally) in place of two removed 12PT flange bolts.
4. Remove and discard the remaining eight 12PT flange bolts.
NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an
assembly.
5. Slide wear plate (reinforcement ring) and four flexplates off guide pins.
6. Slide flywheel assembly off guide pins and out of flywheel housing.
7. Remove guide pins from crankshaft flange.
Flywheel and Flexplate Assemblies Cleaning and Inspection

1. Inspect flywheel for cracks around webbing and bolt holes.
2. Inspect flywheel for extensive heat cracks and scoring.
3. If equipped, inspect flexplate for cracks, damage or warpage. Replace if required.
4. Inspect all ring gear teeth for starter pinion damage.
5. Replace flywheel if necessary.
Flywheel and Flexplate Assembly (Automatic Transmission) Installation
Figure 618 Flywheel and flexplate assembly

1. Flexplate and flywheel assembly
3. Guide pin (2)
4. Wear plate (reinforcement ring)
1. Install two guide pins (made locally) into crankshaft flange 180° apart (approximately 3 o’clock and 9 o’clock
positions).
2. Align crankshaft timing gear pin hole in flywheel assembly with crankshaft gear pin and slide flywheel onto
guide pins.
CAUTION: To prevent engine damage, always install new flywheel mounting bolts.
CAUTION: To prevent engine damage, do not use anti-seize compounds or grease on new flywheel or flexplate
mounting bolts.
NOTE: The individual components of the flexplate assembly are non-servicable. Replace the flexplate as an
assembly.
3. Slide flexplate assembly over guide pins.
4. Slide wear plate (reinforcement plate) over guide pins with logo and part number visible towards rear and
install eight new 12PT flange bolts hand tight.
5. Remove guide pins and install remaining two 12PT flange bolts.
Figure 619 Flywheel and flexplate assembly bolt tightening sequence (typical)
NOTE: For proper flywheel installation, follow the correct tightening sequence while keeping the crankshaft from
turning.
6. Tighten 12PT flange bolts using sequence above as follows:
a. Tighten bolts to 110 N•m (81 lb·ft).
b. Angle tighten bolts 90°
c. Angle tighten bolts an additional 90°.
Radial Shaft Ring Seal

Radial Shaft Ring Seal Removal
Figure 620 Radial shaft ring seal removal

1. Slide hammer
2. Radial shaft ring seal
1. With an awl and hammer, punch two holes 180° apart in radial shaft ring seal.
2. Thread a slide hammer (page 1234) with correct size screw into one of the two holes.
3. Slide hammer until one side of seal begins to pull out of flywheel housing. Move slide hammer to other hole
and repeat until seal is completely removed.
Radial Shaft Ring Seal Installation
Figure 621 Radial shaft ring seal installation (typical)

1. Rear Oil Seal Installer
2. Radial shaft ring seal
CAUTION: To avoid damage to the radial shaft ring seal, do not touch inner seal lip or allow oil or grease on any
part of the seal during installation.
1. Using Rear Oil Seal Installer (page 1234), install ring radial shaft seal into flywheel housing.
a. Install inner hub of tool to crankshaft flange. Use two bolts provided with tool.
b. Install radial shaft seal to inner hub of tool.
c. Install pressing hub and nut and tighten to install seal. When tool bottoms out, seal is fully installed.
Lifting Eyes
Lifting Eyes Removal
Figure 622 Lifting eye

1. M16 x 150 bolt (4)
2. Lifting eye (2)
1. Remove four M16 x 150 bolts.

2. Remove two lifting eyes.
Lifting Eyes Installation
Figure 623 Lifting eyes

1. M16 x 150 bolt (4)
2. Lifting eye (2)
1. Install two lifting eyes.

2. Install four M16 x 150 lifting eye bolts. Tighten bolts to special torque (page 726).
Flywheel Housing
Flywheel Housing Removal
WARNING: To prevent personal injury or death, support the flywheel housing before removing
bolts and breaking sealant bond between flywheel housing and crankcase.
WARNING: To prevent personal injury or death, get help when removing or installing the flywheel
housing.
Figure 624 Right offset engine mounting support assembly

1. Right offset engine mounting support
2. PDO base bracket
3. Flywheel housing
4. 3/4" x 2” bolt with 3/4” washer (6)
1. Remove six 3/4" x 2” bolts with washers, PDO base bracket and engine mounting support from right side of
flywheel housing.
2. Remove 3/4" x 2” bolts with washers, extension bracket and engine mounting support from the left side of
flywheel housing.
Figure 625 Flywheel housing (typical)

1. M10 x 30 bolt (12)
2. M10 x 40 bolt (3)
3. Flywheel housing
WARNING: To prevent personal injury or death, support the flywheel housing before removing
bolts and breaking sealant bond between housing and crankcase.
3. Remove 12 M10 x 30 and three M10 x 40 bolts from flywheel housing.
4. Use a thin gasket scraper to separate sealant between flywheel housing and crankcase.
housing.
5. Remove flywheel housing with aid of an assistant.
Flywheel Housing Cleaning and Inspection
NOTE: Gasket surfaces must be oil-free for good adhesion of liquid gasket during assembly.
Figure 626 Flywheel Housing

A. Flywheel housing
B. Flywheel housing sealing
surface
See Flywheel Housing (Figure 626) to perform steps 1 through 3.

1. Use a scraper or wire brush to remove sealant from flywheel housing sealing surface (B).
2. Use a commercially available, non-caustic brake cleaner to clean flywheel housing sealing surface (B).
3. Inspect flywheel housing and flywheel housing sealing surface (A and B) for cracks, pitting, and other notable
damage. Repair or replace as necessary.
Figure 627 Crankcase

A. Crankcase B. Crankcase sealing surface C. Crankshaft timing gear
See Crankcase (Figure 627) to perform steps 4 through 8.

4. Clean foreign material from crankcase sealing surface (B). Use a scraper or wire brush to remove sealant
from gasket surfaces.
5. Use a commercially available, non-caustic brake cleaner to clean crankcase sealing surface (B).
6. Clean crankshaft timing gear (C) with a stiff brush and suitable solvent. Dry with filtered, compressed air.
7. Inspect crankcase and crankcase sealing surface (A and B) for cracking, pitting, and other notable damage.
8. Inspect crankshaft timing gear (C) for cracks, abnormal wear, and other notable damage. Repair or replace
as necessary.
Flywheel Housing Installation

CAUTION: To prevent engine damage, apply Liquid Gasket and component within 5 minutes of application to
inhibit the formation of a skin and ensure a leak proof joint.
Figure 628 Flywheel housing to crankcase alignment dowel pins

1. Flywheel housing to crankcase mating surface
2. Flywheel housing to crankcase dowel pin (2)
1. Verify flywheel housing alignment dowels are installed into the crankcase and are not damaged. Replace
as necessary.
Figure 629 Flywheel housing sealant application

1. Apply sealant on mating surface
2. Front of flywheel housing
2. Apply Loctite 5900 or Wacker® A–442 RTV sealant (page 1234) to mating surfaces of flywheel housing and
crankcase.
housing.
3. Install flywheel housing to crankcase with the aid of an assistant.
Figure 630 Flywheel housing (typical)

1. M10 x 30 bolt (12)
2. M10 x 40 bolt (3)
3. Flywheel housing
4. Install 12 M10 x 30 and three M10 x 40 flywheel housing bolts. Tighten bolts to special torque (page 726).
Figure 631 Right offset engine mounting support assembly

1. Right offset engine mounting support
2. PDO base bracket
3. Flywheel housing
4. 3/4" x 2” bolt with 3/4” washer (6)
5. Install 3/4" x 2” bolts, washer, extension bracket and rear engine mount on left side of flywheel housing.
Tighten to standard torque (page 1201).
6. Install 3/4" x 2” bolts, washer, PDO base bracket and engine mounting support on right side of flywheel
housing. Tighten to standard torque (page 1201).
Flywheel and Flywheel Housing Cleaning and Inspection

All Components
1. Clean foreign material from gasket surfaces of crankcase and flywheel housing. Use a scraper or wire brush
to remove sealant from gasket surfaces.
2. Gasket surfaces must be oil-free for good adhesion of liquid gasket during assembly. Use a commercially
available, non-caustic brake cleaner to clean gasket surfaces of crankcase and flywheel housing.
3. Wash flywheel, flexplate (if equipped) and flywheel housing. Dry all with filtered compressed air.
4. Wash crankshaft timing gear with a stiff brush and suitable solvent. Dry all with filtered compressed air.
Specifications
Flywheel minimum thickness (dimension “A”) 46 mm (1.811 in)
Flywheel maximum surface runout 0.20 mm (0.0079 in)
Special Torques
12PT flange bolts See tightening steps in procedure.
Flywheel housing bolts, M10 x 30 and M10 x 40 65 N·m (48 lb·ft)
Lifting eye bolts, M16 x 150 280 N·m (207 lb·ft)
Timing hole cover screws 2 N·m (18 lb·in)
Special Tools
1-2 inch micrometer Obtain locally
Blind hole puller Obtain locally
Brake cleaner (non-caustic) Obtain locally
Loctite 5900® Obtain locally
Wacker® A–442 RTV sealant Obtain locally
Pilot Bearing Installation Tool ZTSE4898
Rear Oil Seal Installer ZTSE4875
Oil Pan and Oil Pickup Tube
WARNING: To prevent personal injury or death, shift the transmission to park or neutral, set the
parking brake, and block the wheels before doing diagnostic or service procedures.
components.
NOTE: Refer to the following service section for information on removal of components prior to this section.
• Engine Electrical — required for preheater removal.
Oil Pan
Oil Pan Removal
1. Remove oil drain plug and O-ring and drain oil into a suitable container.
2. If equipped, remove oil pan heater element and discard O-ring.
3. Recycle or dispose of oil according to applicable regulations.
Figure 632 Cooling tube brackets and extension bracket support (typical)
1. M8 x 40 bolt (3)
2. Cooling tube bracket (right angle) (2)
3. Extension bracket support (T-bracket)
4. Remove three M8 x 40 bolts, two cooling tube brackets, and one extension bracket support.
Figure 633 Oil pan clamps (typical)

1. M8 x 40 bolt (19)
2. Oil pan clamp – front left 599 mm (23.5 in)
3. Oil pan clamp – rear left 461 mm (18 in)
4. Oil pan clamp – rear right 461 mm (18 in)
5. Oil pan clamp – front right 599 mm (23.5 in)
5. Remove 19 M8 x 40 bolts.
6. Remove four oil pan clamps.
7. Remove oil pan and oil pan gasket as an assembly.
8. Clean and inspect the oil pan gasket. Discard gasket if damaged.
Oil Pan Cleaning and Inspection

1. Inspect bottom of oil pan for metallic debris or other evidence of engine damage. Investigate any
abnormalities as required.
2. Clean oil pan with a suitable solvent.
3. Dry with filtered compressed air.
4. Inspect oil pan for warping, dents and cracks. Replace the oil pan if necessary.
Oil Pan Installation

1. Clean oil pickup tube and supports with a suitable solvent.
3. Inspect oil pickup tube and supports for cracks, damage or pickup screen blockage. Replace if necessary.
Oil Pickup Tube — Front Sump

Oil Pickup Tube — Front Sump Removal
Figure 634 Oil pickup tube (front sump, typical)

1. M8 x 25 bolt (2)
2. Oil pickup tube
3. M8 x 16 bolt (2)
1. Remove two M8 x 16 bolts and pickup tube with supports as an assembly.

2. Only if required, remove the two M8 x 25 bolts, prevailing torque nuts, D9/19/4 washers and oil pickup tube
supports.
Figure 635 Oil pickup tube O-ring
3. Remove and discard oil pickup tube O-ring.

Oil Pickup Tube — Front Sump Cleaning and Inspection

Oil Pickup Tube — Front Sump Installation
1. Install a new oil pickup tube O-ring. Lubricate O-ring with clean engine oil.
Figure 637 Oil pickup tube (front sump, typical)

1. M8 x 25 bolt (2)
2. Oil pickup tube
3. M8 x 16 bolt (2)
2. If required, position two oil pickup tube supports and loosely install two M8 x 25 bolts, prevailing torque nuts
and D9/19/4 washers.
3. Install oil pickup tube and two M8 x 16 bolts.
4. Tighten two M8 x 16 bolts to standard torque (page 1201).
5. Tighten two prevailing torque nuts (M8) and M8 x 25 bolts to standard torque (page 1201).
Oil Recovery
Oil Recovery Removal
Figure 638 High-pressure pump support and plug

1. Plug
2. M14 x 30 bolt (2)
3. High-pressure pump support
1. Remove and save two M14 x 30 bolts that secure the high-pressure pump support.
2. Remove and save two M12 x 30 bolts that secure the high-pressure pump support. to the bottom of
high-pressure pump.
3. Remove and save the high-pressure support.
4. Remove plug from crankcase. Discard plug and seal ring.
Figure 639 Oil pickup tube

1. M8 x 16 bolt
2. Oil pickup tube support
3. M8 x 25 bolt and M8 nut
5. Remove M8 x 25 bolt and M8 nut that secure the oil pickup tube support to the clamp on the oil pickup tube.
Discard M8 x 25 bolt; save M8 nut.
6. Remove and discard M8 x 16 bolt that secures other end of oil pickup tube support .
7. Remove and save oil pickup tube support.
Oil Recovery Installation
Figure 640 Straight fitting assembly and seal ring

1. Straight fitting assembly
2. Seal ring
1. Lubricate new seal ring with clean engine oil and put ring onto new straight fitting assembly.
Figure 641 Straight fitting assembly
2. Thread straight fitting assembly into the crankcase (where plug was removed in Figure 1) and tighten fitting
to 55 N·m (40 lb·ft).
Figure 642 Oil recovery support assembly and oil pickup tube
1. Oil recovery support assembly (includes M6 x 20 stud)
2. M8 x 30 bolt and M8 nut
3. Oil pickup tube support
5. Spacer (30 mm)
3. Position new oil recovery support assembly onto saved oil pickup tube support. Secure by installing a new
M8 x 30 bolt and saved M8 nut. Tighten nut to 13 N·m (115 lb·in).
4. Position new 30 mm spacer onto other end of oil pickup tube support and install new M8 x 50 stud bolt.
Tighten bolt to 31 N·m (23 lb·ft).
Figure 643 P-clamps on oil recovery tube

1. P-clamp (3)
2. Brazed end
5. Position three new P-clamps onto mew oil recovery tube as shown.
Figure 644 Oil recovery tube (brazed end)
6. Coat brazed end of oil recovery tube with P80® rubber lubricant or equivalent.
7. Insert brazed end of oil recovery tube into straight fitting assembly in crankcase; position P-clamp onto M6
x 20 stud in oil recovery support and P-clamp onto M8 x 50 stud bolt.
Figure 645 P-clamps

1. M6 nut
2. M8 nut
3. M8 x 60 bolt
4. Spacer (43 mm)
8. Install new M6 nut onto M6 x 20 stud on oil recovery support.

9. Install new M8 nut onto M8 x 50 stud bolt.
10. Position new 43 mm spacer under P-clamp and install new M8 x 60 bolt.
11. Tighten M8 nut and M8 x 60 bolt to 31 N·m (23 lb·ft).
12. Tighten M6 nut to 13 N·m (115 lb·in).
Figure 646 High-pressure pump support and straight fitting assembly

1. Straight fitting assembly
2. M14 x 30 bolt (2)
3. High-pressure pump support
13. Install high-pressure pump support.

14. Secure the high-pressure pump support to the bottom of the high-pressure pump using the previously saved
M12 x 30 bolts. Hand tighten bolts.
15. Secure the high-pressure pump support to the crankcase using the previously saved M14 x 30 bolts. Hand
tighten bolts.
16. Tighten M12 x 30 bolts to 105 N·m (77 lb·ft).
17. Tighten M14 x 30 bolts to 172 N·m (126 lb·ft).
Oil Pickup Tube — Rear Sump

Oil Pickup Tube — Rear Sump Removal
Figure 647 Oil pickup tube (rear sump)

1. M8 x 16 bolt (4)
2. M8 x 25 bolt (3)
3. Oil pickup tube
4. Tube support
1. Remove four M8 x 16 bolts holding oil pickup tube supports to crankcase.

2. Remove oil pickup tube and supports as an assembly.
3. Only if required, remove M8 x 25 bolts, prevailing torque nuts and D9/19/4 washers and supports.

Oil Pickup Tube — Rear Sump Cleaning and Inspection

Oil Pickup Tube — Rear Sump Installation

1. Lubricate a new oil pickup tube O-ring with clean engine oil and install onto tube.
Figure 649 Rear sump oil tube assembly

1. O-ring, 32 x 5
2. Prevailing torque nut (4)
3. D9/19/4 washers (4)
4. Supports (short) (3)
5. M8 x 25 bolt (4)
6. Support (long)
7. Oil pickup tube
2. If oil pickup tube supports were removed, loosely install with four M8 x 25 bolts, D9/19/4 washers and
prevailing torque nuts.
3. Install oil pickup tube and supports as an assembly.
Figure 650 Oil pickup tube

1. M8 x 16 bolts (4)
2. M8 x 25 bolts (3)
3. Oil pickup tube
4. Tube support
4. Install four M8 x 16 bolts through oil pickup tube supports.

5. Tighten four M8 x 16 bolts to standard torque (page 1201).
6. Tighten three M8 x 25 bolts and prevailing torque nuts to standard torque (page 1201).
Special Torques
Special Torques
Drain plug, M27 x 2 75 N·m (55 lb·ft)
Oil pan bolts, M8 x 40 See tightening steps in procedure.
Oil pan heater element or replacement drain plug 75 N·m (55 lb·ft)
Oil Fill Tube Assembly

Oil Fill Tube Assembly Removal
Overview
This section provides instruction for removal of the oil fill tube assembly when not doing a complete engine
tear-down.
Equipment Condition
None

None
Oil fill tube adapter 26 lb-ft (35 N·m)

Oil fill tube hose clamp 46 lb-in (5.1 N·m)
Procedure
Figure 651 Oil Fill Tube Assembly

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing
See Oil Fill Tube Assembly (Figure 651) to perform steps 1 and 2.
1. Remove oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support
bracket (3).
2. Loosen two oil fill tube hose clamps (5) securing oil fill tube hose (6) to oil fill tube (1) and oil fill tube adapter
Figure 652 Oil Fill Tube Assembly Removal

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump
See Oil Fill Tube Assembly Removal (Figure 652) to perform steps 3 through 5.
3. Remove oil fill tube (4) from oil fill tube hose (5) and oil fill tube hose (5) from oil fill tube adapter (2).
4. Discard two oil fill tube hose clamps (3).
5. If replacement is determined necessary per Oil Fill Tube Assembly Leak Inspection (page 753), remove oil
fill tube adapter (2) from accessory drive housing (1). Discard oil fill tube adapter.
Oil Fill Tube Adapter Mount Cleaning and Inspection
Figure 653 Oil Fill Tube Adapter Thread Mount

1. Accessory drive housing
2. Oil fill tube adapter threaded
mount
See Oil Fill Tube Adapter Thread Mount to perform step 1.

1. Clean oil fill tube adapter threaded mount (2) in accessory drive housing (1) with a soft cloth.
Oil Fill Tube Assembly Installation

Procedure
Figure 654 Oil Fill Tube Assembly Installation

1. Accessory drive housing 3. Oil fill tube hose clamp (2) 5. Oil fill tube hose
2. Oil fill tube adapter 4. Oil fill tube 6. High Pressure (HP) fuel pump
See Oil Fill Tube Assembly Installation (Figure 654) to perform steps 1 through 9.
If not replacing oil fill tube adapter (2), go directly to step 4.
1. Apply Loctite 545 full 360° on first three threads of oil fill tube adapter (2).
2. Install oil fill tube adapter (2) to accessory drive housing (1).
3. Tighten oil fill tube adapter. See Torque Specifications (page 747).
4. Install oil fill tube hose (5) to oil fill tube adapter (2).
5. Secure oil fill hose tube (5) to oil fill tube adapter (2) with oil fill tube hose clamp (3), observing proper
orientation of clamp.
6. Tighten oil fill tube hose clamp. See Torque Specifications (page 747).
7. Place second oil fill tube hose clamp over oil fill hose tube (5), observing proper orientation of clamp, then
install oil fill tube (2) to oil fill hose tube (5).
8. Position oil fill tube hose clamp (3) to secure oil fill tube (4) to oil fill hose tube (5).
9. Tighten oil fill tube hose clamp. See Torque Specifications (page 747).

1. Oil fill tube 3. Oil fill tube assembly support 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting bracket 6. Oil fill tube hose
bolt 4. High Pressure (HP) fuel pump 7. Accessory drive housing
See Oil Fill Tube Assembly (Figure 655) to perform steps 10 and 11.
10. Install oil fill tube assembly mounting bolt (2) securing oil fill tube (1) to oil fill tube assembly support bracket
(3).
11. Tighten oil fill tube assembly mounting bolt (2) to standard torque.
Oil Fill Tube Assembly Leak Inspection
Overview
Inspect Oil Fill Tube Assembly for leaks and / or cracks or damage.
Tools Required
None
Equipment Condition
Steam clean and insert dye into engine oil. Road test vehicle, bringing up to operating temperature.

1. Oil fill tube 3. High Pressure (HP) fuel pump 5. Oil fill tube hose clamp (2)
2. Oil fill tube assembly mounting 4. Oil fill tube assembly support 6. Oil fill tube hose
bolt bracket 7. Accessory drive housing
See Oil Fill Tube Assembly (Figure 656) to locate oil fill tube assembly components.
Figure 657 Oil Fill Tube Assembly Tube and Hose Inspection
A. Oil fill tube hose sealing surface B. Oil fill tube
(2) C. Oil fill hose
See Oil Fill Tube Assembly Tube and Hose Inspection (Figure 657) to perform steps 1 through 4.
1. Inspect for oil leaks, cracked or damaged components at following locations:
• Oil fill tube (B)
• Oil fill hose (C)
2. If no indications of oil leaks are present and oil fill hose (C) and oil fill tube (B) show no signs of cracks of
damage, inspection is complete.
3. If oil fill hose (C) and / or oil fill tube (B) show indications of oil leaks or signs of cracks of damage, remove
oil fill hose and oil fill tube. See Oil Fill Tube Assembly Removal (page 747). Discard and proceed to Step 5.
4. If indications of oil leaks are present but oil fill hose (C) and oil fill tube (B) show no signs of cracks of damage,
remove oil fill hose and oil fill tube. See Oil Fill Tube Assembly Removal (page 747). Then proceed to Step
5.
Figure 658 Oil Fill Tube Adapter Inspection

A. Oil fill tube adapter to accessory
drive housing sealing surface
B. Oil fill tube adapter
See Oil Fill Tube Adapter Inspection (Figure 658) to perform steps 5 through 7.
5. Inspect for oil leaks at oil fill tube adapter to accessory drive housing sealing surface (A).
6. Inspect for cracked or damaged oil fill tube adapter (B).
7. If oil leak is present at oil fill tube adapter to accessory drive housing sealing surface (A) and / or if oil fill
tube adapter (B) is cracked or damaged, replace oil fill tube adapter. See Oil Fill Tube Assembly Removal
(page 747).
Expected Outcome
Oil Fill Tube Assembly should be free of oil leaks and / or cracks or damaged components.
Oil Pump and Timing Gears
components.
• Front Cover, Fan Drive, Cooling System and Related Components
• Cylinder Head, Camshaft and Valve Train
• Flywheel and Flywheel Housing
Preliminary Checks
Figure 659 (Front) idler gear backlash measurement (typical)

1. Rotate engine and look for any damaged gear teeth. See Crankshaft Rotation Procedure(page 653).
Replace damaged gears as necessary.
2. Place dial indicator with magnetic base on front of crankcase with indicator tip on front idler gear. Position
dial indicator tangent (90°) relative to plane of gear tooth.
3. Turn front idler gear clockwise and zero dial indicator.
4. Turn front idler gear back and forth while reading dial indicator. Compare dial indicator reading with
specifications (page 773).
5. If front idler gear backlash exceeds specification, replace gear.
Figure 660 (Rear) large idler gear backlash measurement (typical)
6. Place dial indicator with magnetic base on rear of crankcase with indicator tip on large idler gear tooth.
Position dial indicator tangent (90°) relative to plane of gear tooth.
7. Turn large idler gear clockwise and zero dial indicator.
8. Turn large idler gear back and forth while reading dial indicator. Compare dial indicator reading with
9. If backlash exceeds specification, replace large idler gear.
Figure 661 Crankcase idler gear backlash measurement (typical)
10. Place dial indicator with magnetic base (page 773) on top rear of crankcase with indicator tip on crankcase
idler gear. Position dial indicator tangent (90°) relative to plane of gear tooth.
11. Turn crankcase idler gear clockwise and zero dial indicator.
12. Turn crankcase idler gear back and forth while reading dial indicator. Compare dial indicator reading with
13. If crankcase idler gear backlash exceeds specification, replace crankcase idler gear.
Oil Pump
Oil Pump Removal
Figure 662 Oil pump cover (typical)

1. M6 x 25 bolt (8)
2. Oil pump cover
1. Remove eight M6 x 20 bolts or M6 x 25 bolts.

2. Remove oil pump cover.
3. Remove and discard O-ring.
Figure 663 Oil pump pinion (gear) and ring gear

1. (Oil pump) ring gear
2. Oil pump pinion (gear)
3. Marks for reassembly (towards front)
4. Use a permanent marker to mark the front of oil pump pinion (gear) and ring gear for correct assembly
orientation.
5. Remove oil pump pinion gear and ring gear.
Figure 664 (Oil pump) pinion axle

2. (Oil pump) pinion axle
3. O-ring 22 x 2
6. Remove M10 x 35 socket-head cap screw and oil pump pinion axle.
7. Remove and discard O-ring 22 x 2.
Oil Pump Cleaning and Inspection

1. Wash all parts thoroughly in a suitable solvent.
3. Inspect pinion (gear) for oil pump, oil pump ring gear and oil pump cover for nicks, burrs or scoring.
4. Replace any damaged components.
5. Temporarily install oil pump components in crankcase without O-ring and tighten M6 x 25 bolts to standard
torque (page 1201). See Oil Pump (page 762).
Figure 665 Pinion (gear) for oil pump and ring gear end play measurement (typical)
6. Using a feeler gauge , measure end play between oil pump cover and oil pump gears.
NOTE: There are two oil pump assemblies. When replacing oil pump parts, be sure you are ordering the correct
set.
7. If end play exceeds specification (page 773), replace oil pump cover, pinion (gear) for oil pump and ring
gear as a set.
8. Remove oil pump components for final assembly.
Oil Pump Installation

1. Lubricate new O-ring 22 x 2 with clean engine oil and install oil pump pinion axle.
Figure 666 Pinion axle (oil pump)

2. Pinion axle (oil pump)
3. O-ring 22 x 2
2. Install oil pump pinion axle and M10 x 35 cap screw. Tighten screw to special torque .
Figure 667 Pinion (gear) for oil pump and ring gear
1. (Oil pump) ring gear
2. Pinion (gear) for oil pump
3. Marks for reassembly (toward front)
3. Lubricate pinion (gear) for oil pump and ring gear with clean engine oil.
4. Install pinion gear and ring gear with previously made index marks facing towards front.
5. Lubricate new oil pump cover O-ring with clean engine oil and install on cover.
Figure 668 Oil pump cover (typical)

1. M6 x 25 bolt (8)
2. Oil pump cover
6. Install oil pump cover.

7. Install eight M6 x 20 or M6 x 25 bolts. Tighten bolts to standard torque (page 1201).
Front Crank Gears

Front Crank Gears Removal
Figure 669 Front crank gear (typical)
1. Using a gear puller , remove front crank gear.
Figure 670 (Front) idler gear (typical)

2. Gear stud (front idler)
3. Idler gear
2. Remove three M12 x 50 cap screws, gear stud and idler gear.
Front Crank Gears Cleaning and Inspection
1. Wash timing gears and gear pins with a stiff brush and suitable solvent. Dry all with filtered compressed air.
2. Inspect timing gears for irregular wear pattern and worn or damaged teeth. Replace as necessary.
3. Inspect timing gear shafts for worn or damaged bearing surfaces. Replace as necessary.
Front Crank Gears Installation
Figure 671 (Front) idler gear (typical)

2. Gear stud (not flywheel side)
3. Idler gear
1. Install idler gear and gear stud.

2. Install three front idler gear M12 x 50 cap screws. Tighten screws to special torque .
Figure 672 Front crank gear (typical)
3. Install two suitable alignment bolts 180° apart through front crank gear into front of crankshaft.
4. Using a hammer and brass drift, carefully install front crank gear.
5. Remove two alignment bolts.
Rear Timing Gears

Rear Timing Gears Removal
Figure 673 Idler gear assembly and timing marks

1. M14 x 80 bolt (4)
2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear)
5. Timing mark (rear crank gear)
1. Remove four M14 x 80 bolts, big gear stud and idler gear assembly.
Figure 674 Crankcase idler gear (typical)

2. Small gear stud
3. Crankcase idler gear
2. Remove three M8 x 30 cap screws, small gear stud and crankcase idler gear.
Figure 675 Rear crank gear assembly (typical)

1. Rear crank gear
2. Pin 8 x 60-ST
3. Using a gear puller , remove rear crank gear assembly.
Figure 676 Air compressor coupled idler gear assembly (typical)

1. M12 x 55 bolt (3)
2. Air compressor gear stud
3. Air compressor idler gear assembly
4. Remove three M12 x 55 bolts and air compressor gear stud, air compressor idler gear assembly and thrust
washer for air compressor gear stud (not shown, behind gear assembly).
Rear Timing Gears Cleaning and Inspection
1. Wash timing gears and gear pins with a stiff brush and suitable solvent. Dry all with filtered compressed air.
2. Inspect timing gears for irregular wear pattern and worn or damaged teeth. Replace as necessary.
3. Inspect timing gear shafts for worn or damaged bearing surfaces. Replace as necessary.
Rear Timing Gears Installation
Figure 677 Air compressor coupled idler gear assembly (typical)

1. M12 x 55 bolt (3)
2. Air compressor gear stud
3. Air compressor idler gear assembly
CAUTION: To prevent engine damage, install thrust washer for air compressor gear stud with larger chamfer
side facing crankcase.
1. Install air compressor thrust washer (with larger chamfer side facing crankcase), air compressor gear stud
and air compressor coupled idler gear assembly.
2. Install three M12 x 55 bolts. Tighten bolts to special torque .
Figure 678 Crankshaft alignment pin hole (typical)
3. Rotate crankshaft so that alignment pin hole is at 6 o'clock position. See Crankshaft Rotation Procedure
(page 653). This positions cylinder No. 1 at Top Dead Center (TDC).
Figure 679 Rear crank gear assembly (typical)

1. Rear crank gear
2. Pin 8 x 60-ST
4. Using a hammer and brass drift, install rear crank gear so pin in gear engages crankshaft alignment pin
hole.
Figure 680 Crankcase idler gear (typical)

2. Small gear stud
3. Crankcase idler gear
CAUTION: To prevent engine damage, insert the crankcase idler gear into the crankcase with the flatter contact
surface facing outwards.
5. Install crankcase idler gear and small gear stud.
6. Install three crankcase idler gear M8 x 30 socket-head cap screws. Tighten cap screws to special torque .
Figure 681 Large Idler gear assembly and timing marks

1. M14 x 80 bolt (4)
2. Big gear stud
3. Large idler gear
4. Timing mark (large idler gear)
5. Timing mark (rear crank gear)
NOTE: Large idler gear has two timing marks 180° apart; either may be used.
7. Install big gear stud and large idler gear, aligning timing mark with timing mark on rear crank gear (flywheel
side).
8. Install four M14 x 80 bolts. Tighten bolts to special torque .
Specifications
Front Timing Gears
(Front) idler gear backlash 0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump
Oil pump pinion (gear) and ring gear end play 0.030 - 0.120 mm (0.0012 - 0.0047 in)
Rear Timing Gears
Idler larger gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Large idler gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Special Torques
Air compressor coupled idler gear, M12 x 55 bolts 107 N·m (79 lb·ft)
Crankcase idler gear, M8 x 30 socket-head cap screws 30 N·m (22 lb·ft)
(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lb·ft)
Larger idler gear, M14 x 80 bolts 175 N·m (129 lb·ft)
Oil pump pinion axle, M10 x 35 socket-head cap screw 65 N·m (48 lb·ft)
Special Tools
Feeler gauge Obtain locally
Gear puller Obtain locally
Power Cylinders
components.
• N13 Engine Brake by Jacobs
• Turbochargers
• Fuel System
• Oil Cooler, Filter Housing, and Crankcase Ventilation
• Air Intake Throttle Duct and Exhaust Manifold
• Cylinder Head, Camshaft, and Valve Train
• Flywheel and Flywheel Housing (as needed)
• Oil Pan and Oil Suction Tube
Preliminary Checks
NOTE: Evaluate piston protrusion before removing any piston and connecting rod assemblies. This helps identify
bent or twisted connecting rods.
Figure 682 Piston protrusion check
NOTE: Piston protrusion readings are done in line with piston pin, eliminating rocking movement of piston at
any other position of measurement.
1. Check piston protrusion as follows:
a. Make sure crankcase deck surface is clean.
b. Zero dial indicator with magnetic base (page 1234) on crankcase deck surface.
c. Position dial indicator tip over piston head at 3 o'clock position.
d. Rotate crankshaft in direction of normal rotation to raise piston to its maximum outward protrusion at
cylinder Top Dead Center (TDC). Push down on piston crown before taking reading. Read this maximum
protrusion on dial indicator.
e. Reposition dial indicator tip on piston head at 9 o'clock position.
f. Rotate crankshaft to raise piston to its maximum protrusion. Push down on piston crown before taking
reading. Read maximum protrusion on dial indicator.
g. Average the two readings. Replace piston and connecting rod if protrusion is not within specification
(page 798).
Piston and Connecting Rod

Piston and Connecting Rod Removal
CAUTION: To prevent engine damage, check for a carbon ridge on top of cylinder sleeves. If found, remove
carbon ridge with a suitable tool before removing rod and piston assemblies.
1. Scrape carbon ridge from top of cylinder bore, if necessary. Use care not to damage sleeve bore surface.
CAUTION: To prevent engine damage, mark with permanent marker or tag each connecting rod and cap with the
correct cylinder number. This engine has “cracked” (fractured) type connecting rods. Do not alter or damage
fractured mating surfaces of the rod and cap. A cap from one connecting rod is NOT interchangeable with
another connecting rod. The matching connecting rod and cap numbers or symbols indicate a matched set.
CAUTION: To prevent engine damage, install connecting rod cap and connecting rod with matching serial
numbers on the same side. If the rod cap is reversed or not installed on its matching connecting rod, the
fractured mating surfaces will be damaged. A new connecting rod assembly must be installed. Do NOT attempt
to reuse a rod that has been misassembled to its cap, assembled with the wrong cap or has been cross-threaded
while attempting assembly. Serious engine damage can result.
2. Rotate crankshaft to position journals for removal of connecting rod assemblies. Mark connecting rod
locations.
Figure 683 Connecting rod cap

1. Connecting rod bolt M12 x 64 (2)
2. Connecting rod cap
CAUTION: To prevent engine damage, assemble connecting rod cap and connecting rod with their fractured
mating surfaces in the original orientation. Matching numbers must be next to each other.
NOTE: When removed, make sure matching connecting rod and connecting rod cap numbers stay together as
a set. A cap from one connecting rod is not interchangeable with any other connecting rod.
3. Using Exhaust Manifold Bolt Torx® Socket (page 1234), remove two connecting rod bolts and connecting
rod cap. Save bolts for reuse during connecting rod bore check procedure.
CAUTION: To prevent engine damage, do not push on fractured surface of connecting rod.
CAUTION: To prevent engine damage, do not damage piston cooling jet when removing connecting rod and
piston assembly. If jet is bent during piston assembly or removal, replace jet.
4. Remove piston and connecting rod assemblies from cylinder sleeves as follows:
a. Rotate engine to a vertical position.
b. Use a wooden or plastic handle and push piston and connecting rod assembly from cylinder sleeve.
c. Once piston rings are free of cylinder bore, remove piston and connecting rod assembly from cylinder
sleeve.
d. Mark each piston and rod assembly with cylinder number from which each was removed, using a
permanent marker.
Figure 684 Correct connecting rod and cap joint fit
CAUTION: To prevent engine damage, use permanent markers to identify internal engine components and their
NOTE: Upper connecting rod bearings have an oil hole and lower connecting rod bearings do not.
5. Remove connecting rod upper and lower bearings by pushing out. Mark connecting rod bearings for position
and orientation and set aside for inspection.
Connecting Rod Inspection

CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or
connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other
surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure.
CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface
of connecting rods.
1. Inspect connecting rod bolt threads for nicks or damage. Replace as required.
2. Inspect connecting rod and cap mating surfaces and bearing bore for any indication of damage. Bore must
be smooth and free of scoring or nicks. Replace connecting rod if necessary.
Figure 685 Inside diameter of piston pin bore
3. Inspect connecting rod piston pin bore for wear as follows:

a. Using a telescoping gauge (page 1234) and a 2 - 3 inch micrometer (page 1234), measure piston pin
bore at two locations 90° apart.
b. If inside diameter of piston pin bore exceeds specification (page 798), replace connecting rod.
Connecting Rod Bore Check

CAUTION: To prevent engine damage, do not use power tools to remove or install connecting rod cap bolts.
1. Lightly lubricate USED connecting rod bolts with clean engine oil. Assemble cap to connecting rod without
bearings. Tighten bolts to an initial torque of 100 N·m (74 lb·ft).
2. Rotate each rod bolt 90° clockwise (1/4 turn).
Figure 686 Connecting rod bore measurement
3. Using a telescoping gauge (page 1234) and a 3 - 4 inch micrometer (page 1234), measure connecting rod
bearing bore diameter in three locations. If connecting rod bore diameter does not meet specification (page
798), replace connecting rod.
4. After all connecting rod bores are inspected, disassemble connecting rods and discard used connecting rod
bolts.
5. With connecting rod cap removed, inspect surface finish of connecting rod bearing bore. Bore must be
smooth and free of scoring, nicks, or burrs. Replace connecting rod assembly as necessary.
Piston and Connecting Rod Installation

1. Verify proper connecting rod orientation. Assemble connecting rod cap to connecting rod with matching
identification code on same crankshaft journal from which it was removed. Be certain that longer leg of
connecting rod is positioned towards left side of crankcase.
Figure 687 Connecting rod chamfer pointing to front of engine

2. Chamfer
3. Connecting rod bolt (2)
4. Arrow pointing to front of engine
2. Secure connecting rod cap (Figure 687) (Item 1) with two connecting rod bolts (Figure 687) (Item 3).
Finger-tighten only.
3. Verify chamfer (Figure 687) (Item 2) on connecting rod cap is pointing in same direction as arrow mark
stamped on top of piston (Figure 688). If chamfer is not pointing in same direction as arrow mark on piston,
reinstall piston on connecting rod (page 795).
4. Remove connecting rod cap from connecting rod.
5. Turn crankshaft so crank pin (connecting rod journal) on the cylinder to receive piston installation is at the
bottom of its stroke.
6. Lightly coat piston and piston rings with clean engine oil.
7. Coat cylinder sleeve walls, crankshaft journals and Piston Ring Compressor (obtain locally) with clean engine
oil.
8. Place piston in Piston Ring Compressor.
NOTE: Upper connecting rod bearings have an oil hole and lower connecting rod bearings do not.
9. Install connecting rod bearings in connecting rod and cap. Bearings with oil hole go in the upper position.
Coat bearings with clean engine oil.
Be sure that all bearing locator tabs and oil holes are in alignment with connecting rod and cap and that
bearings are flush to fractured mating faces of rod and cap.
Figure 688 Arrow mark on piston (typical)
CAUTION: To prevent engine damage, the arrow stamped on top of piston must face front of engine.
CAUTION: To prevent engine damage, do not damage piston cooling jet when installing connecting rod and
piston assembly. If jet is bent during piston assembly installation, replace jet.
NOTE: Before installing piston and connecting rod assembly, make sure all piston cooling jets are installed.
10. Carefully put piston and piston ring compressor combination and connecting rod assembly in cylinder sleeve
with arrow mark facing towards front of engine.
Figure 689 Piston and connecting rod assembly installation (typical)
11. Once piston and connecting rod assembly has been inserted in cylinder sleeve, use a handle (wood or
plastic) of a hammer to tap piston into cylinder sleeve. Guide connecting rod in place on crankshaft. Do not
let edges of connecting rod or fractured mating face of rod touch the crankshaft journal. Before installing
cap with bearing and starting bolts, be sure that bearings are still flush with connecting rod and cap fractured
mating faces and have NOT rotated.
CAUTION: To prevent engine damage, lightly lubricate bolt threads and mating surfaces of bolt flanges with
clean engine oil. Too much oil causes hydrostatic lock and gives incorrect torque reading.
12. Lightly apply clean engine oil to new bolt threads for connecting rod and upper and lower bearings in cap
before installing bolts.
Figure 690 Correct connecting rod and cap joint fit
CAUTION: To prevent engine damage, clean fractured mating surfaces of the connecting rod and rod cap with
filtered compressed air.
13. Use filtered compressed air to clean debris from fractured mating surfaces of the connecting rod and rod
cap.
CAUTION: To prevent engine damage, install connecting rods with correct caps in the correct direction. If a rod
cap is reversed, an offset will be seen at the mating surfaces. If a reverse assembly is installed on the crankshaft,
the connecting rod must be replaced. Also, check crank pin (connecting rod journal) fillets for damage that would
require replacement of the crankshaft.
14. Assemble cap to connecting rod with matching identification code on same crankshaft journal from which it
was removed. Be certain that longer leg of connecting rod is positioned towards left side of crankcase.
Figure 691 Connecting rod cap (typical)

CAUTION: To prevent engine damage, install new connecting rod bolts.

CAUTION: To prevent engine damage, do not use powered tools to install connecting rod bolts; rotating bolts
too quickly can damage threads.
CAUTION: To prevent engine damage, do not rotate crankshaft until connecting rod bolts are fully tightened, as
this may cause bearings to rotate in place.
15. Install two New connecting rod bolts (Figure 691) (Item 1).
16. Using Exhaust Manifold Bolt Torx® Socket ZTSE4843, tighten connecting rod bolts evenly to an initial torque
of 100 N·m (74 lb·ft).
17. Rotate (tighten) connecting rod bolts an additional 90 degrees (1/4 turn).
18. Repeat installation procedure for remaining piston and connecting rod assemblies.
Cylinder Sleeves
Cylinder Sleeves Removal
Figure 692 Cylinder sleeve removal
NOTE: Care must be taken not to damage piston cooling jets during cylinder sleeve removal.
1. Remove six cylinder sleeves from crankcase as follows:
a. Insert Cylinder Sleeve Puller (page 1234) into cylinder sleeve.
b. Engage removal tool hooks under bottom edge of cylinder sleeve.
c. Position removal tool feet diagonally on crankcase deck surface.
d. Turn threaded shaft clockwise to extract cylinder sleeve.
e. Mark cylinder sleeves for position and set aside for inspection.
2. Remove and discard two cylinder sleeve O-rings from each crankcase cylinder sleeve.
Cylinder Sleeves Inspection

1. Install six cylinder sleeves (without cylinder sleeve O-rings) into crankcase.
Figure 693 Cylinder sleeve bore measurement
2. Using a dial bore gauge (page 1234), measure the cylinder sleeve inside diameter at 120° intervals, at four
different depths of cylinder sleeve. If cylinder sleeve inside diameter is not within specification (page 798),
replace cylinder sleeve.
Figure 694 Cylinder sleeve protrusion measurement

1. Dial indicator with magnetic base
2. Sleeve Protrusion Hold Down Clamp
3. Check cylinder sleeve protrusion above crankcase deck as follows:

a. Install Sleeve Protrusion Hold Down Clamps (page 1234) using four included bolts. Torque bolts to
b. Place dial indicator with magnetic base (page 1234) 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 on cylinder sleeve flange. Record reading.
e. Measure cylinder sleeve protrusion at three locations evenly spaced around the cylinder sleeve.
f. If any of the three readings of cylinder sleeve protrusion are not within specification (page 798), 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.
Cylinder Sleeves Installation

1. Lubricate two new cylinder sleeve O-rings with clean engine oil and install in crankcase cylinder sleeve bore.
2. Using a soft-faced hammer, install cylinder sleeve by striking evenly until seated.
Piston
Piston Disassembly
Figure 695 Piston pin retainer (typical)
1. Using a pair of pliers, remove two piston pin retainers.

CAUTION: To prevent engine damage, do not mark piston pin for cylinder and location on outer diameter; place
mark only on flat end or tapered inside surface.
2. Remove piston pin from its bore by hand and separate connecting rod from piston.
Figure 696 Piston ring removal (typical)
NOTE: Only expand piston rings enough to fit over top of piston.
NOTE: Keep piston rings organized for each cylinder.
3. Using piston ring expansion pliers (page 1234), remove top compression ring, taper face compression ring,
and bevelled oil ring.
Piston Inspection
1. Inspect pistons for scuffed or scored skirts, cracked or worn ring lands and cracked or scuffed pin bores.
Replace damaged pistons.
Figure 697 Second and third ring groove clearance check (typical)
NOTE: It is not possible to measure side clearance of top compression ring groove.
2. Check side clearance of taper face compression ring groove as follows:
a. Place edge of a new taper face compression ring in its respective ring groove. Roll taper face
compression ring all around ring groove to ensure ring is free in its groove.
b. With edge of taper face compression ring in taper face compression ring groove, use a feeler gauge
(page 1234) to measure side clearance between ring and groove.
c. Compare taper face compression ring side clearance to specification (page 798). Excessive side
clearance indicates ring groove wear and requires piston replacement.
3. Check side clearance of bevelled oil ring groove as follows:
a. Place edge of a new bevelled oil ring in its respective ring groove. Roll bevelled oil ring all around ring
groove to ensure ring is free in its groove.
b. With edge of bevelled oil ring in the bevelled oil ring groove, use a feeler gauge (page 1234) to measure
side clearance between ring and groove.
c. Compare bevelled oil ring side clearance to specification (page 798). Excessive side clearance indicates
ring groove wear and requires piston replacement.
Figure 698 Piston skirt diameter measurement
4. Using a 4 - 5 inch micrometer (page 1234), measure diameter of piston at intervals given in specifications
(page 798). If measurements do not meet specification, replace piston.
Piston Ring Inspection

CAUTION: To prevent engine damage, install new piston rings if a piston is removed. Faulty piston rings cannot
always be detected visually.
1. Inspect new piston rings for cleanliness.
Figure 699 Piston ring end gap clearance in cylinder bore
2. Before installing new piston rings, check ring gap for each ring as follows:
a. Push piston ring down into cylinder bore. Make sure the piston ring is square with cylinder wall. An
inverted piston head can be used to push piston ring to desired location of measurement (usually at top
of piston stroke).
b. Use a feeler gauge (page 1234) to measure ring gap between ends of each piston ring.
c. If gap ring does not meet specification (page 798), select another ring or recheck cylinder sleeve wear.
Piston Ring Cleaning

CAUTION: To prevent engine damage, do not use caustic solvents, wire brushes or bead blasting media to
clean aluminum pistons.
CAUTION: To prevent engine damage, do not use solvents or a wire brush to clean the fractured mating surface
of connecting rods.
1. Use a soap and water solution to clean pistons. Soak piston first and then clean with a non-metallic brush.
2. Clean piston ring grooves thoroughly.
3. The following disassembled components may be cleaned using a suitable solvent:
• Piston pins
• Piston pin retainers
4. Thoroughly clean connecting rod bolt holes and threads.
Piston Assembly
Figure 700 Piston ring installation (typical)
CAUTION: To prevent engine damage, install piston rings correctly. Both top compression and taper face
compression rings have the same identification markings. The marking must face up for the ring to be installed
correctly. The taper face compression ring has a rectangular cross section and goes in the middle groove. The
top compression ring has a keystone cross section and goes in the top groove.
NOTE: Only expand piston rings enough to fit over top of piston.
1. Using piston ring expansion pliers (obtain locally) , install piston rings. Be careful not to “wind” ring into
groove.
a. Install expansion spring component of bevelled oil ring into bottom piston groove.
b. Install oil scraper component of bevelled oil ring over expansion spring with the gap 180° from the spring
wire latch.
c. Install taper face compression ring into middle piston groove. Make sure ring is installed with
identification mark facing up.
d. Install top compression ring into top piston groove. Make sure ring is installed with identification mark
facing up.
2. Space ring gaps approximately 120° apart after ring installation.
3. Connect piston to connecting rod as follows:
a. Lubricate connecting rod piston pin bore, piston pin bore and piston pin with clean engine oil.
b. Set piston crown down so arrow mark stamped on piston crown is at 6 o'clock position.
c. Using pliers, install one piston pin retainer into groove. Be sure that retainer is fully seated in groove
and that tang ends point up.
d. Hold connecting rod so open end faces 3 o'clock position of piston when installed.
e. Place connecting rod into piston.
Figure 701 Piston pin retainer
f. Slide piston pin through piston holes, stopping at installed piston pin retainer.
g. Using pliers, install second piston pin retainer.
Engine Run-in Procedure
Use the following engine run-in procedure after installing new pistons, piston rings, piston pins, or cylinder
sleeves:
1. Start engine and run at low idle with no load. If engine does not exceed 138 kPa (20 psi) oil pressure within
20 to 30 seconds, shutdown engine and correct the problem.
2. Run engine at low idle with no load for 5 minutes and check for any of the following problems:
• Unusual noise
• Coolant leaks
• Oil leaks
• Fuel leaks
• Air leaks
• Excessive exhaust smoke
• Excessive vibration
• Loose turbocharger mounting
3. Turn engine off and correct any of these problems to prevent engine or turbocharger damage.
4. Wait 15 minutes for oil level to stabilize, then check engine oil level. Add oil if needed. See appropriate
Engine Operation and Maintenance Manual for correct grade and viscosity of engine oil.
5. Start engine and drive vehicle (unloaded) for 30 minutes in city mode, then drive vehicle (unloaded) for an
additional 60 minutes in highway mode. Verify no loss in power.
6. Return to idle and check for leaks.
7. Turn off engine and repair any leaks.
Specifications
Connecting Rods
Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)
Connecting rod bearing bore diameter
95.000 to 95.022 mm (3.7402 to 3.7402 in)
(crankshaft end)
Pistons — N13
Skirt diameter measured 26.9 mm from piston
bottom edge, 90° to piston pin axis in “window” 125.950 ± 0.013 mm (4.9587 ± 0.0005 in)
on skirt graphite layer, where applicable
Piston protrusion measured from crankcase
0.3 ± 0.22 mm (0.0118 ± 0.009 in)
deck to piston
Piston pin bore inside diameter, measured
52.04 - 52.05 mm (2.0490 - 2.0492 in)
horizontally 26 mm from piston center
Piston pin running clearance 0.040 - 0.058 mm (0.0016 - 0.0023 in)
Piston Pins
Outside diameter 51.992 - 52.000 mm (2.0469 - 2.0472 in)
Piston Rings — N13
Top compression ring
Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Taper face compression ring
Ring gap 1.00 - 1.20 mm (0.0394 - 0.0472 in)
Side clearance 0.09 - 0.13 mm (0.0035 - 0.0051 in)
Bevelled oil ring
Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)
Cylinder sleeve dimensions — N13
Sleeve protrusion 0.050 - 0.085 mm (0.0019 - 0.0033 in)
Sleeve inside diameter (bore) 126 ± 0.01 mm (4.9606 ± 0.0004 in)
Special Torques
Connecting rod bolts See tightening steps in procedure
Sleeve Protrusion Hold Down Clamp bolts 80 N·m (59 lb·ft)
Special Tools
Cylinder Sleeve Puller ZTSE2536
Dial bore gauge Obtain locally
Exhaust Manifold Bolt Torx® Socket ZTSE4843
Piston ring compressor Obtain locally
Piston ring expansion pliers Obtain locally
Sleeve Protrusion Hold Down Clamps ZTSE4825
Telescoping gauge Obtain locally
Crankcase and Crankshaft
components.
• Mounting Engine on Stand
• Exhaust Back Pressure Control
• Turbochargers
• Air Compressor and Power Steering
• Fuel System
• Oil Cooler, Filter Housing and Crankcase Ventilation
• Air Intake Throttle Duct and Exhaust Manifold
• Front Cover, Fan Drive, Cooling System and Related Components
• N13 Engine Brake by Jacobs (if equipped)
• Cylinder Head, Camshaft and Valve Train
• Flywheel and Flywheel Housing
• Oil Pan and Oil Pickup Tube
• Oil Pump and Timing Gears
• Power Cylinders
Preliminary Checks
Figure 702 Crankshaft end play
1. Check crankshaft end play as follows:

a. Mount dial indicator with magnetic base (page 1235) on crankcase with indicator tip on end of crankshaft
as shown.
b. Move crankshaft forward with pry bar and zero the dial indicator.
c. Move crankshaft back and forth while reading dial indicator. Compare dial indicator reading with
specification (page 818).
d. If end play exceeds specified limits, replace main bearing thrust washers.
Crankshaft
Crankshaft Removal
1. Position engine so that bottom of main bearing caps are facing upwards.
CAUTION: To prevent engine damage, use permanent markers to identify internal components or their
2. Mark main bearing caps for location and orientation.
Figure 703 Main bearing caps

1. M18 x 160.5 collar bolt (14)
2. Main bearing cap (7)
CAUTION: To prevent engine damage, do not drop main bearing caps. Damage to the fractured mating surface
of a main bearing cap will require replacement of the crankcase and mated main bearing caps.
3. Remove 14 M18 x 160.5 collar bolts and seven main bearing caps. Save bolts for Main Bearings
Measurement procedure (page 807).
4. Remove seven lower main bearings and two lower thrust washers from main bearing caps by pushing out.
5. Number removed lower main bearings and lower thrust washers on back side (not running surface) and set
aside for inspection.
Figure 704 Crankshaft removal
WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a
safety latch on hook.
CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft.
NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables.
6. Attach lifting sling (page 1235) to crankshaft. Lift crankshaft up and out of crankcase and set aside for
inspection.
7. Remove upper main bearings and upper thrust washers from crankcase by pushing out.
8. Number removed upper main bearings and upper thrust washers on back side (not running surface) to match
the previously removed lower main bearings and lower thrust washers and set aside for inspection.
Crankshaft Cleaning and Inspection
1. Clean crankshaft with a suitable, non-caustic solvent.
Figure 705 Crankshaft

A. Crankshaft C. Connecting rod journal (6)
B. Oil passage (13) D. Main bearing journal (7)
See Crankshaft (Figure 705) to perform steps 2 through 5.

2. Using a stiff nylon brush, clean oil passages (B) in crankshaft (A). Loosen accumulated dirt, sludge, and
deposits.
3. Flush oil passages (B) with a suitable non-caustic solvent.
4. Dry crankshaft (A) and oil passages (B) with dry compressed air.
5. Inspect connecting rod journals and main bearing journals (C and D) for scratches, grooves, and scoring.
Crankshaft Measurement
1. Inspect crankshaft journals (main and connecting rod) for scratches, grooves and scoring.
Figure 706 Crankshaft main bearing journal measurement
Figure 707 Crankshaft connecting rod bearing journal measurement
CAUTION: To prevent engine damage, do not rework bearings or bearing caps to reduce journal-to-bearing
running clearances. Grind or install new crankshaft.
2. Use a 3 - 4 inch micrometer (page 1235) to measure diameter of each connecting rod journal, and a 4 - 5
inch micrometer (page 1235) to measure diameter of each main journal. Measure each journal at both sides
next to fillet radius at two directions 90° apart. Move micrometer over entire width of journal. If journal wear
exceeds specification (page 818), have crankshaft machined, or replace crankshaft.
Main Bearings Measurement
Figure 708 Main bearing uninstalled outside diameter (free spread) measurement
1. Inspect each main bearing for scratches, grooves, scoring, pitting and wear. Replace bearings as required.
2. Using a flat surface, place an individual bearing half on the surface as shown.
3. Using a 4 - 5 inch micrometer (page 1235), measure across the ends of the bearing half as shown.
4. If the measurement falls outside of the uninstalled bearing outside diameter (free spread) specification (page
818), replace upper and lower bearing halves as a set. Measure all upper and lower bearing halves and
replace bearings as required.
5. Install upper main bearings into crankcase and lower main bearings into main bearing caps in their original
positions and orientation.
CAUTION: To prevent engine damage, install main bearing caps with their fractured mating surfaces in the
original orientation.
6. Lightly coat used collar bolt threads and under bolt heads with clean engine oil. Do not use new bolts for
this inspection procedure.
7. With crankshaft still removed, install seven main bearing caps and 14 previously removed M18 x 160.5 collar
bolts.
8. Tighten M18 x 160.5 collar bolts in main bearings caps as follows:
a. Tighten collar bolts at No. 6 main bearing cap to 10 N·m (88 lb·in).
b. Tighten remaining collar bolts to 10 N·m (88 lb·in).
c. Tighten collar bolts at No. 6 main bearing cap to 100 N·m (74 lb·ft).
d. Tighten remaining collar bolts to 100 N·m (74 lb·ft).
e. Tighten collar bolts at No. 6 main bearing cap to 300 N·m (221 lb·ft).
f. Tighten remaining collar bolts to 300 N·m (221 lb·ft).
g. Turn collar No. 6 main bearing cap an additional 90° clockwise.
h. Turn remaining collar bolts an additional 90° clockwise.
Figure 709 Main bearing installed diameter measurement
9. Using a dial bore gauge (page 1235), measure main bearing installed inside diameter. If measurement does
not meet specification (page 818), replace main bearings.
10. Remove 14 M18 x 160.5 collar bolts, seven main bearing caps, upper main bearings and lower main
bearings. Discard used collar bolts.
Crankcase Cleaning
CAUTION: To prevent engine damage, do not use chlorinated solvents on bolts or crankcase tapped holes.
Parts should be clean, dry and free of any chemicals other than engine oil.
NOTE: Thoroughly clean and inspect crankcase before and after reconditioning.
1. Clean crankcase in a chemical bath or hot tank. This removes all carbonized material and mineral deposits
in coolant passages.
CAUTION: To prevent engine damage, do not use a wire brush to clean the fractured mating surface of crankcase
and main bearing caps.
2. If a hot tank is not available, do the following steps:
a. Use non-metallic stiff bristle brushes and scrapers to clean gasket material from machined surfaces of
crankcase.
b. Clean crankcase in solvent.
c. Dry with filtered compressed air.
Figure 710 Cylinder head bolt holes
CAUTION: To prevent engine damage, clean and dry threads in the crankcase bolt holes with filtered
compressed air. Dirt or oil in holes may cause binding and incorrect torque readings.
3. Clean cylinder head bolt holes with Head Bolt Bottoming Tap (page 1235).
4. Clean collar bolt holes with Main Bolt Bottoming Tap (page 1235).
5. Clean out debris with filtered compressed air.
Crankshaft Installation
NOTE: Make sure crankshaft and bearings have been inspected per instructions in this section before
proceeding.
1. Use a lint-free cloth to wipe crankcase bearing saddles free of oil.
Figure 711 Main bearing
NOTE: When inserting main bearings, make sure oil is not between back side of bearing and crankcase bearing
saddles.
2. Place upper main bearings in crankcase. Make sure locking tabs on bearings are snapped into saddle and
oil holes in bearings line up with oil holes in crankcase.
3. Lubricate running surface of bearings with clean engine oil.
Figure 712 Crankshaft installation
WARNING: To prevent personal injury or death, use a correct size lifting sling and hoist with a
safety latch on hook.
CAUTION: To prevent engine damage, do not bend, drop or damage crankshaft.
NOTE: Use only a soft-sided lifting sling. Do not use chains or steel cables.
4. Attach lifting sling (page 1235) to crankshaft. Orient crankshaft with front flange (8 bolt holes) and rear flange
(10 bolt holes) at crankcase front and rear, respectively. Carefully lower crankshaft down into crankcase.
Figure 713 Thrust washer installation
NOTE: Make sure oil grooves on thrust washers face outward towards crankshaft thrust surface.
5. Install two upper thrust washers into crankcase at No. 6 main location as follows:
a. Set upper thrust washer on top of crankshaft at No. 6 main journal with grooves towards crankshaft
thrust surface.
b. Pivot upper thrust washer around crankshaft and down into position.
6. Install two lower thrust washers onto No. 6 main bearing cap. Make sure lower thrust washer locking tabs
align with notches in main bearing cap.
7. Place lower main bearings in main bearing caps. Make sure locking tabs on bearings are snapped into main
bearing caps.
8. Lubricate bearings with clean engine oil.
Figure 714 Main bearing caps

1. Collar M18 x 160.5 bolt (14)
9. Install seven main bearing caps and 14 new M18 x 160.5 collar bolts.
10. Tighten collar bolts as follows:

a. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 10 N·m (88 lb·in).
b. Tighten remaining collar bolts to 10 N·m (88 lb·in).
c. Rotate crankshaft to verify that crankshaft does not bind. Correct as required.
d. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 100 N·m (74 lb·ft).
e. Tighten remaining collar bolts to 100 N·m (74 lb·ft).
f. Tighten two collar bolts at No. 6 (thrust washer location) main bearing cap to 300 N·m (221 lb·ft).
g. Tighten remaining collar bolts to 300 N·m (221 lb·ft).
h. Turn two collar bolts at No. 6 (thrust washer location) main bearing cap bolts an additional 90°.
i. Turn remaining collar bolts an additional 90°.
Piston Cooling Jets

Piston Cooling Jets Removal
Figure 715 Piston cooling jet

1. M6 x 12 bolt (6)
2. Piston cooling jet (6)
1. Remove six M6 x 12 bolts and six piston cooling jets.

Piston Cooling Jets Cleaning and Inspection

1. Hold each piston cooling jet under running water. Water should stream from jet end.
2. Clear blocked piston cooling jets using filtered compressed air. Replace piston cooling jet if blockage cannot
be cleared.
3. Replace any cracked or bent jets.
Piston Cooling Jets Installation
Figure 716 Piston cooling jet

1. M6 x 12 bolt (6)
2. Piston cooling jet (6)
1. Install six piston cooling jets and six M6 x 12 bolts.

2. Tighten bolts to special torque (page 818).
Specifications
Crankshaft
Main Bearing:
Journal diameter 103.98 - 104.00 mm (4.0937 - 4.0945 in)
Installed bearing inside diameter 104.044 - 104.09 mm (4.0962 - 4.0980 in)
Uninstalled bearing outside diameter (free
111.20 - 112.40 mm (4.3779 - 4.4252 in)
spread)
Connecting Rod Bearing:
Crankshaft end play:
Maximum service 0.200 - 0.401 mm (0.0079 - 0.0158 in)
Special Torques
Collar bolts (main bearing cap), M18 x 160.5 See tightening procedure and sequence
(page 813)
Piston cooling jet bolts, M6 x 12 13 N·m (115 lb·in)
Special Tools
Lifting sling Obtain locally
Main Bolt Bottoming Tap ZTSE4854
ENGINE DISASSEMBLY PROCEDURES 819
Table of Contents
Overview. . . ................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .821
Engine Disassembly Removal Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .821

Exhaust Gas Recirculation (EGR) Cooler Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .821
Exhaust Gas Recirculation (EGR) Valve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .832
Aftertreatment Fuel Injector (AFTFI) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .837
Exhaust Back-Pressure Valve (EBPV) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .840
Low-Pressure Charge Air Cooler (LPCAC) Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .848
High-Pressure (HP) Turbocharger Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .855
Low-Pressure (LP) Turbocharger Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .862
Oil Filter Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .874
Exhaust Manifold Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .876
Rear Coolant Manifold Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .879
Engine Control Module (ECM) and ECM Mounting Bracket Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .881
High-Pressure (HP) Fuel Line Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .885
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Removal. . . . . . . . . . . . . . . . . . . .890
Coolant Outlet Manifold and Thermostat Housing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .894
Upper Valve Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .898
Engine Brake Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .900
Lower Valve and 16-pin E2 Engine Harness Cover Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .905
Rocker Arm Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .908
Injector Removal.................. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .912
96-pin E1 Engine Harness Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .921
Fuel Rail Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .932
Cylinder Head Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .934
Oil Pan Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .938
Oil Sump Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .940
Piston Cooling Jet Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .942
Pistons and Connecting Rod Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .944
Cylinder Liner Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .948
Crankshaft Main Bearing Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .951
Engine Disassembly, Cleaning, Inspection, Testing, and Assembly Procedures. . . . . . . . . . . . . . . . . . . . . . . . . .953

General Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .953
General Inspection Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .955
Exhaust Gas Recirculation (EGR) Cooler Bench Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .956
Exhaust Gas Recirculation (EGR) Cooler Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .960
Exhaust Gas Recirculation (EGR) Valve Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .963
Exhaust Gas Recirculation (EGR) Valve Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .965
Exhaust Gas Recirculation (EGR) Valve Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .968
Aftertreatment Fuel Injector (AFTFI) Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .970
Exhaust Back-Pressure Valve (EBPV) Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .972
Low-Pressure (LP) Turbocharger Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .975
High-Pressure (HP) Turbocharger Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. . . . . . . .981
Exhaust Manifold Cuff Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .987
Rear Coolant Manifold Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .989
820 ENGINE DISASSEMBLY PROCEDURES
Engine Control Module (ECM) and ECM Mounting Bracket Cleaning and Inspection. . . . . . . . . . .992
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Inspection. . . . . . . . . . . . . . . . . .994
Coolant Outlet Manifold and Thermostat Housing Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . .997
Coolant Outlet Manifold and Thermostat Housing Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1000
Coolant Outlet Manifold and Thermostat Housing Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1003
Upper Valve Cover Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1006
Engine Brake Assemblies Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1008
Engine Brake Assembly Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1010
Lower Valve Cover and 16-pin E2 Engine Harness Cleaning and Inspection. . . . . . . . . . . . . . . . . . . .1012
Rocker Arm Assembly Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1014
96-pin E1 Engine Harness Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1016
Fuel Rail Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1020
Cylinder Head and Crankcase Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1022
Oil Pan Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1026
Oil Sump Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1028
Piston Cooling Jet Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1030
Piston and Connecting Rod Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1032
Piston and Connecting Rod Reassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1034
Cylinder Liner Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1037
Engine In-Frame Disassembly Installation Procedures and Special Torque Specifications. . . . . . . . . . . .1041
Crankshaft Main Bearing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1041
Cylinder Liner Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1043
Piston Cooling Jet Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1045
Piston and Connecting Rod Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1047
Oil Sump Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1055
Oil Pan Installation..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1057
Cylinder Head Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1061
Fuel Rail Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1066
96-pin E1 Engine Harness Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1068
Injector Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1078
Lower Valve Cover and 16-pin E2 Engine Harness Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1086
Rocker Arm Assembly and Engine Brake Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1091
Upper Valve Cover Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1095
Coolant Outlet Manifold and Thermostat Housing Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1097
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Installation. . . . . . . . . . . . . . . .1102
High-Pressure (HP) Fuel Line Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1105
Engine Control Module (ECM) and ECM Mounting Bracket Installation. . . . . . . . . . . . . . . . . . . . . . . . . . .1112
Exhaust Manifold Assembly Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1117
Rear Coolant Manifold Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1122
Oil Module Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1126
High-Pressure (HP) Turbocharger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1129
Low-Pressure (LP) Turbocharger Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1138
Low-Pressure Charge Air Cooler (LPCAC) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1147
Exhaust Back-Pressure Valve (EBPV) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1158
Aftertreatment Fuel Injector (AFTFI) Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1167
Exhaust Gas Recirculation (EGR) Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1170
Exhaust Gas Recirculation (EGR) Cooler Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1175
Overview
The engine disassembly procedures section is used to guide a technician through an in-frame engine
disassembly. These procedures are authored and sequenced to minimize repair time by enabling the technician
to disassemble and reassemble the engine by removing and reinstalling components as large assemblies.
Disassembling and reassembling engine components as large assemblies enables quick access to vital engine
components in need of repair.
Engine Disassembly Removal Procedures

Exhaust Gas Recirculation (EGR) Cooler Removal
Overview
The following disassembly removal procedure is designed to enable removal of the Exhaust Gas Recirculation
(EGR) cooler assembly, while allowing for proper testing or replacement procedures to be performed without
further disassembly or reassembly.
components.


replaced.
Removal Procedure

1. EGR cooler outlet 3. EGR cooler exhaust outlet hose
2. Hose clamps (2) 4. EGR outlet manifold
See Outer EGR Heat Shield (Figure 718) to perform step 1.

1. Loosen 2 hose clamps (2) and remove EGR cooler exhaust outlet hose (3) from EGR cooler exhaust outlet
(1) and EGR outlet manifold (4).


heat shield (1).


3. Remove 2 EGR valve bellows tube V-band clamps (2) between EGR valve (1) and EGR cooler (4). Remove
EGR valve bellows tube (3). Discard V-band clamps.
4. Remove EGR valve harness clips as necessary.
Figure 721 Supply Line Removal

bolts (2) (EBPV) air supply line
See Supply Line Removal (Figure 721) to perform steps 5 and 6.

5. Remove 2 EGR valve coolant supply line bolts (2) securing EGR valve coolant supply line (1) to EGR cooler
(3).
6. Remove 3 EBPV air supply line bolts (5) securing EBPV air supply line (4) to EGR cooler (3).

spring clamp

7. Remove EGR valve coolant supply line spring clamp (2) and remove EGR valve coolant supply line (1) from
T-fitting (3).

tube nut
valve (1).
valve (1).

10. Remove 2 EGR coolant supply tube bracket bolts (2) securing supply tube bracket (4) to cylinder head (1).
11. Remove 2 EGR Coolant supply tube bracket bolts (2) securing supply tube bracket (4) to EGR coolant
supply tube (3). Remove EGR coolant supply tube bracket.
12. Remove EGR coolant supply tube (3) from engine.

13. Remove 2 upper EGR cooler support bracket mounting bolts (1) securing EGR cooler support bracket (3)
to cylinder head (2).

See Lower EGR Cooler Mounting Points (Figure 726) to perform steps 14 and 15.
14. Remove 5 lower EGR cooler support bracket mounting bolts (1) from EGR cooler support bracket (2) and
remove EGR cooler (3) from engine.
15. Remove EGR cooler outlet seal and discard.
Perform Exhaust Gas Recirculation (EGR) Valve Removal (page 832) procedure.
EGR cooler removed (page 821).

None
Removal Procedure

1. V-band clamp 3. EGR valve
2. Bolts (4) 4. Exhaust manifold
See EGR Valve Removal (Figure 727) to perform steps 1 and 2.

1. Remove V-band clamp securing EGR valve to exhaust manifold. Discard V-band clamp.
2. Remove 4 bolts securing EGR valve to EGR valve mounting bracket and remove EGR valve from engine.
Figure 728 Inner EGR Valve Heat Shield Bolt Removal

1. Bolt 2. Inner EGR valve heat shield
See Inner EGR Valve Heat Shield Bolt Removal (Figure 728) to perform step 3.
3. Remove bolt from inner EGR valve heat shield.
Figure 729 Inner EGR Heat Shield

1. Inner EGR heat shield 2. Bolts (5)
See Inner EGR Heat Shield (Figure 729) to perform step 4.

4. Remove 5 bolts securing inner EGR heat shield to engine and remove inner EGR heat shield.
Figure 730 EGR Valve Mounting Bracket

1. Bolts (5) 2. EGR valve mounting bracket
See EGR Valve Mounting Bracket (Figure 730) to perform step 5.

5. Remove 5 bolts from EGR valve mounting bracket and remove EGR valve mounting bracket from engine.
Perform Aftertreatment Fuel Injector (AFTFI) Removal (page 837) procedure.
Aftertreatment Fuel Injector (AFTFI) Removal
Exhaust Gas Recirculation (EGR) valve removed (page 832).

Removal Procedure
Figure 731 AFTFI Connections

1. AFTFI electrical connector 4. AFTFI mounting bolts (2) 7. AFTFI
2. AFTFI connector mounting 5. Coolant supply line 8. Coolant return line.
bracket 6. Exhaust Back-Pressure Valve
3. AFTFI fuel supply tube (EBPV) assembly
See AFTFI Connections (Figure 731) to perform steps 1 through 9.

1. Disconnect AFTFI electrical connector from AFTFI.
3. Disconnect AFTFI electrical connector from AFTFI connector mounting bracket.
4. Remove zip ties and fasteners that secure AFTFI harness as necessary.
5. Disconnect AFTFI fuel supply tube and use Air and Fuel Cap and Plug Kit ZTSE4891 to cap fuel line.
6. Disconnect coolant supply line from AFTFI and discard O-ring.
7. Disconnect coolant return line from AFTFI, discard O-ring, and remove return line from engine.
passage. If protection caps are used, they should be new or ultrasonically cleaned before using.
8. Remove 2 AFTFI mounting bolts from AFTFI.
9. Remove AFTFI assembly from EBPV assembly. Discard metal gasket and fibrous insulator.
Perform Exhaust Back-Pressure Valve (EBPV) Removal (page 840) procedure.
Exhaust Back-Pressure Valve (EBPV) Removal
Aftertreatment Fuel Injector (AFTFI) removed (page 837).

None
Removal Procedure

1. Bolt 3. Nut
See EBPV Heat Shield (Figure 732) to perform steps 1 and 2.

1. Remove nut and bolt that secure heat shield to the EBPV assembly.
2. Remove heat shield with spacer from engine.

1. O2 sensor harness connector 4. Bolt 6. NOxin sensor module

3. Remove necessary tie straps securing Nitrogen Oxides In (NOxin) sensor module wiring and Oxygen (O2)
sensor wiring to rear coolant manifold.
4. Disconnect O2 sensor harness connector.
5. Remove O2 sensor harness connector from rear coolant manifold.
6. Disconnect engine harness connector from NOx in sensor module.
7. Remove 2 bolts securing NOx in module to rear coolant manifold
8. Remove bolt securing O2 sensor harness to rear coolant manifold.

1. EBPV actuator 2. EBPV air supply line
See Air Supply Line (Figure 734) to perform steps 9 and 10.
9. Remove EBPV air supply line from EBPV actuator.
10. Position supply line out of way.

1. EBPV assembly support bracket 2. Bolts (2) 3. EBPV assembly
11. Remove 2 bolts securing EBPV assembly support bracket to EBPV assembly

12. Remove 2 stud bolts securing down-pipe support bracket to engine bell housing and remove down-pipe
support bracket from engine.

13. Remove 3 lower bolts with spacers securing EBPV assembly to LP turbocharger.


14. Remove 3 upper bolts with spacers securing EBPV assembly to LP turbocharger and remove EBPV
assembly and gasket. Discard gasket.
Perform Turbocharger Assembly Removal procedure.
Low-Pressure Charge Air Cooler (LPCAC) Removal
Exhaust Back-Pressure Valve (EBPV) Assembly removed (page 840).

None
Removal Procedure

1. Bolt
2. Aftertreatment Fuel Injector (AFTFI) coolant return tube
3. Crankcase
See AFTFI Coolant Return Tube (Figure 739) to perform step 1.

1. Remove bolt securing AFTFI coolant return tube to crankcase.

See AFTFI Coolant Return Tube Hold-Down Clips (Figure 740) to perform steps 2 through 4.
2. Remove AFTFI coolant return tube from hold-down clips.
3. Remove spring clamp securing AFTFI coolant return tube to open breather tube assembly.
4. Remove AFTFI coolant return tube from open breather tube assembly.
Figure 741 Heater Return Tube

1. LPCAC 3. Heater return tube 5. Open breather tube assembly
2. Bolt 4. Spring clamp
See Heater Hose Tube (Figure 741) to perform steps 5 and 6.

5. Remove spring clamp securing heater hose return tube to open breather tube assembly.
6. Remove bolt securing heater hose return tube to LPCAC.

1. Stud bolts (2) 2. Open breather tube assembly 3. LPCAC

7. Remove two stud bolts securing open breather tube assembly to LPCAC.

1. Open breather tube assembly 2. Spring clamp 3. CCOS assembly
8. Remove spring clamp that secures open breather tube assembly to the CCOS assembly and remove open
breather tube from engine.
Figure 744 LPCAC

1. LPCAC 4. Coolant supply hose 7. Stud bolts (2)
2. Spring clamp 5. Spring clamp
3. Coolant return hose 6. Bolt

9. Remove spring clamp securing coolant supply hose to LPCAC and remove supply hose from LPCAC.
10. Remove spring clamp securing coolant return hose to LPCAC and remove return hose from LPCAC.
11. Remove 1 bolt and 2 stud bolts securing LPCAC to engine block and remove LPCAC from engine.
Perform Low-Pressure Turbocharger Removal (page 862) procedure.
High-Pressure (HP) Turbocharger Removal
None

Removal Procedure



2. Bolt Inlet Sensor (TC2CIS)
3. HP turbocharger air supply duct 5. Engine harness connector
7. Remove bolt (2) securing cab heater coolant return tube (1) to HP turbocharger air supply duct (3), and
remove cab heater coolant return tube from engine. Discard O-rings.
8. Disconnect engine harness connector (5) from TC2CIS (4).

1. HP turbocharger 3. HP turbocharger air supply duct 5. Bolt
2. V-band clamp 4. Wiring harness clips (2) 6. Oil module assembly
9. Remove wiring harness clips (4) from HP turbocharger air supply duct (3) and position wiring harness out
of way.
10. Remove and discard V-band (2) clamp securing HP turbocharger air supply duct (3) to HP turbocharger (1).
11. Remove bolt (5) securing HP turbocharger air supply duct (3) to oil module assembly (6), and remove HP
turbocharger air supply duct from engine. Discard HP turbocharger air supply duct O-ring seal.

1. HP turbocharger 2. Exhaust manifold 3. Lower mounting nut
12. Remove and discard lower mounting nut (3) securing HP turbocharger (1) to exhaust manifold (2).

1. Exhaust manifold 2. Upper mounting nuts (2) 3. HP turbocharger
See HP Turbocharger Upper Mounting Nuts (Figure 750) to perform step 10.
14. Remove and discard 2 upper mounting nuts (2) securing HP turbocharger (3) to exhaust manifold (1) and
remove HP turbocharger from engine. Remove and discard HP turbocharger to exhaust manifold gasket.
Low-Pressure (LP) Turbocharger Removal
Exhaust Back-Pressure Valve (EBPV) Assembly removed (page 840).

Removal Procedure

1. Crimp clamp 3. HP turbocharger
2. HP Turbocharger wastegate 4. HP turbocharger outlet duct
hose 5. Stud bolts (2)
1. Cut and remove crimp clamp (1) on HP turbocharger wastegate hose (2) and discard crimp clamp.
3. Note routing of HP turbocharger wastegate hose (2) and re-position for disassembly.
4. Remove 2 stud bolts (5) from HP turbocharger outlet duct (4) and remove HP turbocharger outlet duct from
HP turbocharger (3). Remove and discard HP turbocharger outlet duct O-ring seal.

1. Engine harness connector 4. Stud bolt 7. High-Pressure (HP)
2. Air inlet duct 5. EBP sensor line turbocharger heat shield
3. EBP sensor 6. Nut stud bolt
5. Disconnect engine harness connector (1) from EBP sensor (3).
7. Remove engine harness connector (1) from air inlet duct (2) and re-position for disassembly.
8. Remove stud bolt (4) securing EBP sensor line to air inlet duct (2).
9. Remove nut (6) securing EBP sensor line (5) to HP turbocharger heat shield stud bolt (7).
Figure 753 EBP Sensor Line

1. LP turbocharger 2. Tube nut 3. EBP sensor line

10. Loosen tube nut (2) securing EBP sensor line (3) to LP turbocharger (1) and Remove EBP sensor line from
engine.

1. HP turbocharger heat shield 3. Stud bolt
2. Bolt 4. HP turbocharger

11. Remove one bolt (2) and one stud bolt (3) securing HP turbocharger heat shield (1) to HP turbocharger (4)
and remove HP turbocharger heat shield.

1. Air inlet duct 2. Air inlet duct bolts (2) 3. LP turbocharger
See Air Inlet Duct (Figure 755) to perform step 12.

12. Remove 2 air inlet duct bolts (2) securing air inlet duct (1) to engine and remove air inlet duct from LP
turbocharger (3). Remove and discard air inlet duct O-ring seal.

1. Oil supply line 3. Engine Oil Pressure (EOP) 5. Oil supply t-fitting
2. Tube nut sensor 6. Nut
4. Engine harness connector 7. Stud bolt
13. Loosen tube nut (2) securing oil supply line to oil supply t-fitting (5).
14. Remove oil supply line (1) from oil supply t-fitting (5).
15. Disconnect engine harness connector (4) from EOP sensor (3).
16. Remove nut (6) securing oil supply T-fitting (5) to stud bolt (7).
housing.
17. Firmly grasp oil supply T-fitting (5) and pull oil supply T-fitting away from the engine until it slides past both
O-ring seals. Remove oil supply T-fitting from engine and discard O-rings.
1. LPCAC coolant supply line 3. High-Pressure (HP)
2. Bolts (2) turbocharger air supply duct
18. Remove 2 bolts (2) securing LPCAC coolant supply line (1) to HP turbocharger air supply duct (3).

1. Turbocharger oil supply line 3. HP turbocharger
2. Bolts (2) 4. LP turbocharger
19. Remove 2 bolts (2) securing turbocharger oil supply line (1) to HP and LP turbochargers (3 and 4).
20. Remove turbocharger oil supply line (1) from HP and LP turbochargers (3 and 4) and discard.

1. Bolts (4) 3. Turbocharger oil drain tube
2. HP turbocharger 4. LP turbocharger
See Turbocharger Oil Drain Tube (Figure 759) to perform steps 21 and 22.
21. Remove 4 bolts (1) securing turbocharger oil drain tube (3) to HP and LP turbochargers (2 and 4) and
remove turbocharger oil drain tube from turbochargers.
22. Pull turbocharger oil drain tube (3) up and out of crankcase. Discard turbocharger oil drain tube and O-rings.

1. Bolt 3. Stud bolts with spacers (2) 5. Crankcase
2. LP turbocharger 4. Turbocharger mounting bracket
See Turbocharger Mounting Bracket (Figure 760) to perform steps 23 and 24.
23. Remove bolt (1) securing turbocharger mounting bracket (4) to LP turbocharger (2).
24. Remove 2 stud bolts with spacers (3) securing turbocharger mounting bracket (4) to crankcase (5), and
remove turbocharger mounting bracket from engine.

1. LP turbocharger 2. Bolts (5) 3. HP turbocharger
See LP Turbocharger (Figure 760) to perform steps 25 and 26.

26. Remove and discard 5 bolts (2) securing LP turbocharger (1) to HP turbocharger (3) and remove LP
turbocharger from engine.
27. Using Disposable Air and Fuel Caps ZTSE4891, plug all LP turbocharger inlet and outlet ports after removal.
Perform High-Pressure (HP) Turbocharger Removal procedure .
Oil Filter Removal
Turbocharger Assembly removed .

None
Removal Procedure
Figure 762 Oil filter

1. Oil filter cover 2. Oil module assembly 3. O-ring
See Oil filter (Figure 762) to perform steps 1 and 2.

1. Place absorbent material under the engine and oil module assembly (2).
2. Unscrew and remove oil filter cover (1) from oil module assembly (2). Discard O-ring and oil filter.
Perform Exhaust Manifold Removal procedure.
Exhaust Manifold Assembly Removal
Oil filter removed (page 874).

None
Removal Procedure

bolts (4) shield
1. Remove 4 exhaust manifold heat shield bolts (1) that secure rear exhaust manifold heat shield (2) to rear
exhaust manifold (3).

spacers(18) 3. Cylinder head
See Exhaust Manifold (Figure 764) to perform steps 3 and 4Engine Control Module (ECM) and ECM Mounting
Bracket Removal.
2. Remove 18 exhaust-manifold bolts and spacers (1) securing exhaust manifold sections (2) to cylinder head
(3) . Remove exhaust manifold from engine as a complete assembly. When removing exhaust manifold, do
not twist individual sections as this may skew alignment with other sections.
NOTE: Upon removal, exhaust manifold must lay flat with cylinder head side down on a bench or comparable,
clean and flat surface.
3. After exhaust manifold has been removed from cylinder head, store exhaust manifold cylinder head side
down on a flat surface. This will help maintain proper orientation and alignment.
Perform Rear Coolant Manifold Removal (page 879) procedure.
Rear Coolant Manifold Removal
Exhaust manifold removed (page 890).

None
Removal Procedure

1. Bolts (3)
2. Aftertreatment Fuel Injector (AFTFI) fuel supply line
3. AFTFI fuel supply tube
5. Cylinder head
See Rear Coolant Manifold (Figure 765) to perform steps 1 through 3.

1. Remove tie straps as needed.
2. Disconnect AFTFI fuel supply line (2) from AFTFI fuel supply tube (3).
3. Remove 3 bolts (1) securing rear coolant manifold (4) to cylinder head (5) and remove coolant manifold.
Discard coolant manifold seals.
Perform Engine Control Module (ECM) and ECM Mounting Bracket Removal (page 881) procedure.
Engine Control Module (ECM) and ECM Mounting Bracket Removal
Rear coolant manifold removed (page 879).

None
Removal Procedure

1. Intake Air Heater (IAH) solenoid 6. Air Control Valve (ACV) supply 9. 96-pin E1 engine harness
2. IAH solenoid bolts (2) line connector
3. ECM mounting bolts (8) 7. Engine wiring harness 10. 16-pin E2 engine harness
4. ECM mounting bracket 8. Chassis connector sockets connector
5. ECM
1. If not already done, disconnect chassis harness connectors and IAH relay connector.
2. Disconnect 16-pin E2 engine harness connector (10) from ECM (5).
3. Disconnect 96-pin E1 engine harness connector (9) from ECM.
4. Remove 2 IAH solenoid bolts (2) securing IAH solenoid (1) to ECM mounting bracket (4).
5. Remove 8 ECM mounting bolts (8) securing ECM (5) to ECM mounting bracket (4) and remove ECM.
6. Remove any clips or tie straps securing engine wiring harness (7) to ECM mounting bracket (4).
7. Remove any tie straps securing ACV supply line (6) to ECM mounting bracket (4).
Figure 767 96-pin E1 Engine Harness

1. Bolt 2. ECM mounting bracket
See 96-pin E1 Engine Harness (Figure 767) to perform step 8.

8. Remove bolt (1) securing 96-pin E1 engine harness to ECM mounting bracket (2).

1. Bolts with rubber insulators (3) 2. ECM mounting bracket 3. Cylinder head

9. Remove 3 bolts with rubber insulators (1) securing ECM mounting bracket (2) to cylinder head (3) and
remove ECM mounting bracket.
Perform High-Pressure (HP) Fuel Line Removal (page 885) procedure.
High-Pressure (HP) Fuel Line Removal
Engine Control Module (ECM) and ECM mounting bracket removed (page 881).

Removal Procedure
Figure 769 21-Way Connector and Connector Bracket

1. Air supply line 3. 21-way connector bracket bolts 5. 21-way connector bolts (4)
2. 21-way connector bracket (2) 6. 21-way connector
4. Cylinder head
See 21-Way Connector and Connector Bracket (Figure 769) to perform steps 1 through 4.
1. If not already done, disconnect air supply line (1) from 21-way connector bracket (2).
2. Disconnect 21-way connector (6).
3. Remove four 21-way connector bolts (5) securing 21-way connector (6) to 21-way connector bracket (2)
and remove 21-way connector from connector bracket.
4. Remove two 21-way connector bracket bolts (2) securing 21-way connector bracket (2) to cylinder head (4)
and remove connector bracket from engine.
Figure 770 Fuel Rail Supply Lines

1. Fuel rail supply lines 3. Fuel rail 4. High-Pressure Fuel Pump
2. Tube nuts (4) (HPFP)
See Fuel Rail Supply Lines (Figure 770) to perform step 5.

5. Loosen four tube nuts (4) securing fuel rail supply lines (1) at HPFP (4) and fuel rail (3). Remove fuel rail
supply lines from HPFP and fuel rail.
Figure 771 High-Pressure Lines

1. Injector 1 high-pressure line 4. Injector 3 high-pressure line 8. Cylinder head
tube nuts (2) 5. Injector 4 high-pressure line 9. Fuel rail
2. Injector 1 high-pressure line 6. Injector 5 high-pressure line
3. Injector 2 high-pressure line 7. Injector 6 high-pressure line
See High-Pressure Lines (Figure 771) to perform steps 6 through 8.

6. Loosen two injector 1 high-pressure line tube nuts (1) at cylinder head (8) and fuel rail (9).
7. Remove and discard injector 1 high-pressure line (2). Cap open high-pressure connector body and fuel rail
connections with clean Disposable Air and Fuel Caps (page 885).
8. Following steps 6 and 7, remove and discard high-pressure lines for injectors 2 through 6. Cap open
high-pressure connector body and fuel rail connections.
Figure 772 Fuel Drain Tube

1. Fuel rail 3. Banjo bolt (2) 5. Cylinder head
2. Fuel drain tube 4. Seal ring (4)
See Fuel Drain Tube (Figure 772) to perform steps 9 and 10.
9. Remove banjo bolt (3) and two seal rings (4) securing fuel drain tube (2) to fuel rail (1).
10. Remove banjo bolt (3) and 2 seal rings (4) securing fuel drain tube (2) to cylinder head (5).
Follow-On Maintenance
Perform Engine Throttle Valve (ETV) Removal (page 890) procedure.
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Removal
High-Pressure (HP) Fuel Lines Removed (page 885).

None
Removal Procedure
Figure 773 ETV Assembly Engine Harness

1. Intake Air Heater (IAH) Igniter 5. EGRGT sensor 10. IAH Igniter
fuel supply line nut 6. Engine Throttle Valve (ETV)
2. Intake Manifold Pressure (IMP) engine harness connector
sensor 7. ETV
3. IMP engine harness connector 8. Charge Air Cooler Outlet
4. Exhaust Gas Recirculation Gas Temperature (CACOT) sensor
Temperature (EGRGT) sensor engine harness connector
engine harness connector 9. CACOT sensor

1. Disconnect engine harness connectors from CACOT sensor (9), IMP sensor (2), ETV (7), and EGRGT
sensor (4).
3. Loosen IAH Igniter fuel supply line nut (1) and remove fuel supply line from IAH Igniter (10).
Figure 774 Air Intake Throttle Duct Lower Bolts

1. Lower bolts (2) 2. Cylinder head 3. Air intake throttle duct
See Air Intake Throttle Duct Lower Bolts (Figure 774) to perform step 4.
4. Remove two lower bolts (1) securing air intake throttle duct (3) to cylinder head (2).
Figure 775 Air Intake Throttle Duct Upper Bolt

1. Cylinder head 2. Upper bolt 3. Air intake throttle duct
See Air Intake Throttle Duct Upper Bolt (Figure 775) to perform steps 5 and 6.
5. Remove upper bolt (2) securing air intake throttle duct (3) to cylinder head (1) and remove air intake throttle
duct.
6. Remove and discard gasket.
Perform Thermostat Housing Removal (page 894) procedure.
Coolant Outlet Manifold and Thermostat Housing Removal
Engine Throttle Valve (ETV) removed (page 890).

None
Removal Procedure
Figure 776 Wiring Harness

1. Bolt (2) 2. Engine wiring harness 3. Thermostat housing assembly
See Wiring Harness (Figure 776) to perform steps 1 through 3.

1. Remove two bolts (1) securing engine wiring harness (2) to thermostat housing assembly (3).
2. Cut tie straps as necessary.
3. Position engine wiring harness (2) away from thermostat housing assembly (3).
Figure 777 Upper Thermostat Housing Assembly Bolts

1. Upper bolt (4) 2. Thermostat housing assembly 3. Front cover
See Upper Thermostat Housing Assembly Bolts (Figure 777) to perform step 4.
4. Remove four upper bolts (1) securing thermostat housing assembly(2) to front cover (3).
Figure 778 Lower Thermostat Housing Assembly Bolts

1. Lower bolt (2) 2. Thermostat housing assembly 3. Front cover
See Lower Thermostat Housing Assembly Bolts (Figure 778) to perform step 5.
5. Remove two lower bolts (1) securing thermostat housing assembly (2) to front cover (3) and remove
thermostat housing assembly.
Perform Upper Valve Cover Removal (page 898) procedure.
Upper Valve Cover Removal
Thermostat Housing Assembly removed (page 894).

None
Removal Procedure

1. Bolts (18) 2. Upper valve cover 3. Lower valve cover
See Upper Valve Cover (Figure 779) to perform step 1.

1. Remove 18 bolts (1) securing upper valve cover (2) to lower valve cover (3) and remove upper valve cover.
Perform Engine Brake Assembly Removal (page 900) procedure.
Engine Brake Assembly Removal
Upper valve cover removed (page 898).

None
Removal Procedure
Figure 780 Engine Brake Solenoid Electrical Connections

1. Nut (4) 3. Rear engine brake solenoid 4. Engine brake solenoid electrical
2. Front engine brake solenoid connection (4)
See Engine Brake Solenoid Electrical Connections (Figure 780) to perform steps 1 through 4.
1. Mark front engine brake solenoid (2) and rear engine brake solenoid (3) to note location for installation.
2. Remove 2 nuts (1) securing engine brake solenoid electrical connections (4) to front engine brake solenoid
(2) and remove electrical connections from solenoid.
3. Remove 2 nuts (1) securing engine brake solenoid electrical connections (4) to rear engine brake solenoid
(3) and remove electrical connections from solenoid.
4. Cut and remove tie straps as necessary.
Figure 781 Engine Brake Adjusting Screws

1. Engine brake adjusting screw
jam nut (6)
2. Engine brake adjusting screw (6)
See Engine Brake Adjusting Screws (Figure 781) to perform steps 5 and 6.
5. Loosen six engine brake adjusting screw jam nuts (1) on engine brake.
6. Loosen six engine brake adjusting screws (2).
Figure 782 Intake and Exhaust Valve Lash Adjusters

1. Intake valve lash adjuster jam 3. Exhaust valve lash adjuster 4. Exhaust valve lash adjuster jam
nut (6) screw (6) nut (6)
2. Intake valve lash adjuster screw
See Intake and Exhaust Valve Lash Adjusters (Figure 782) to perform steps 7 through 10.
7. Loosen six intake valve lash adjuster jam nuts (1).
8. Loosen six intake valve lash adjuster screws (2).
9. Loosen six exhaust valve lash adjuster jam nuts (4).
10. Loosen six exhaust valve lash adjuster screws (3).
Figure 783 Front and Rear Engine Brake

1. Front engine brake housing bolt 3. Cylinder head 5. Rear engine brake housing
(6) 4. Rear engine brake housing bolt
2. Front engine brake housing (6)
See Front and Rear Engine Brake (Figure 783) to perform steps 11 through 14.
11. Remove six bolts (1) securing front engine brake housing (2) to cylinder head (3).
12. Remove front engine brake housing (2).
13. Remove six bolts (4) securing rear engine brake housing (5) to cylinder head (3).
14. Remove rear engine brake housing.
Perform Lower Valve Cover Removal (page 905) procedure.
Lower Valve and 16-pin E2 Engine Harness Cover Removal
Engine brake assembly removed (page 900).

None
Removal Procedure
Figure 784 Fuel Injector Electrical Connections (Front of Cylinder Head)

1. Fuel injector (6) 3. Injector wiring
2. Injector electrical connection nut 4. Lower valve cover
(12) 5. Fuel injector (6)
See Fuel Injector Electrical Connections (Front of Cylinder Head) (Figure 784) to perform steps 1 and 2.
1. Remove 12 injector electrical connection nuts (2) securing fuel injector electrical connections to six fuel
injectors (5).
2. Remove tie straps connecting injector wiring to lower valve cover (4) .
Figure 785 Lower Valve Cover

1. Screws with dampers (18) 2. Lower valve cover 3. Cylinder head
See Lower Valve Cover (Figure 785) to perform step 3.

3. Loosen 18 screws with dampers (1) securing lower valve cover (2) to cylinder head (3) and remove lower
valve cover.
Perform Rocker Arm Assembly Removal (page 908) procedure.
Rocker Arm Assembly Removal
Lower valve cover removed (page 905).

None
Removal Procedure
Figure 786 Intake and Exhaust Valve Lash Adjusters

1. Intake valve last adjuster jam 3. Exhaust valve lash adjuster
nut (6) screw (6)
2. Intake valve last adjuster screw 4. Exhaust valve lash adjuster jam
(6) nut (6)
See Intake and Exhaust Valve Lash Adjusters (Figure 786) to perform steps 1 and 2.
1. If not already done, loosen six intake valve lash adjuster jam nuts (1) and six exhaust valve lash adjuster
jam nuts (4).
2. If not already done, loosen 6 intake valve last adjuster screws (2) and 6 exhaust valve last adjuster screws
(3).
Figure 787 Rocker Arm Assemblies

1. Rocker arm assembly (6) 2. Cylinder head 3. Rocker arm assembly bolt (12)
See Rocker Arm Assemblies (Figure 787) to perform steps 3 and 4.

3. Remove 12 rocker arm assembly bolts (3) securing six rocker arm assemblies (1) to cylinder head (2). If
engine brake was previously removed there will only be six rocker arm assembly bolts to remove.
4. Remove six rocker arm assemblies (1) from engine.

1. Rocker bearing block (6) 2. Valve bridge (12)
See Rocker Bearing Block and Valve Bridges (Figure 788) to perform steps 5 through 8.
5. Mark rocker bearing blocks (1) 1 through 6 to ensure each block can be installed in original location.
6. Remove six rocker bearing blocks (1).
7. Mark valve bridges (2) so each bridge can be installed in its original location and orientation.
8. Remove 12 valve bridges.
Perform Injector Removal (page 912) procedure.
Injector Removal
Rocker arm assemblies removed (page 908).

• Injector Puller ZTSE4770
Removal Procedure
Figure 789 High-Pressure Connector Bodies

1. High-pressure connector body 2. Cylinder head 3. High-pressure connector body
See High-Pressure Connector Bodies (Figure 789) to perform steps 1 through 3.

1. Remove six high-pressure connector body retaining nuts (1).
2. Remove and discard six high-pressure connector bodies (3) and O-rings from cylinder head (2).
3. Cover cylinder head high-pressure connector body bores with appropriate size plugs from Disposable Air
and Fuel Caps (page 912).
Figure 790 Injectors and Hold-Down Clamps

1. Hold-down clamp bolt (6) 2. Cylinder head 3. Fuel injector (6)
See Injectors and Hold-Down Clamps (Figure 790) to perform step 4.

4. Remove six hold-down clamp bolts (1) securing fuel injectors (3) to cylinder head (2).
Figure 791 Thrust Washers

1. Thrust washers (6) 2. Cylinder head
See Thrust Washers (Figure 791) to perform step 5.

5. Remove six thrust washers (1) from cylinder head (2).
Figure 792 Injector Puller ZTSE4770

1. Clamping sleeve 4. Knurled nut 7. Plate column nut (2)
2. Extractor plate 5. Extractor nut
3. Extractor 6. Plate column (2)
See Injector Puller ZTSE4770 (Figure 792) to perform steps 6 through 9.

Figure 793 Injector Extractor (typical)

1. Extractor 2. Injector
See Injector Extractor (typical) (Figure 793) to perform step 6.

6. Install extractor (1) on injector (2).
Figure 794 Clamping Sleeve on Extractor (typical)

1. Extractor 2. Clamping sleeve
See Clamping Sleeve on Extractor (typical) (Figure 794) to perform step 7.

7. Slide clamping sleeve (2) over extractor (1).
Figure 795 Extractor Plate and Plate Columns (typical)

1. Extractor plate 2. Plate column (2)
See Extractor Plate and Plate Columns (typical) (Figure 795) to perform step 8.
8. Position two plate columns (2) on two opposite cylinder head bolts and slide extractor plate (1) over extractor
and plate columns.
Figure 796 Extractor Nut (typical)

1. Knurled nut 2. Extractor nut
See Extractor Nut (typical) (Figure 796) to perform steps 9 through 11.
9. Install knurled nut (1) and extractor nut (2) with the extractor nut backed out.
10. Hold knurled nut (1) and tighten extractor nut (2) to remove injector, combustion washer, and hold-down
clamp.
11. Remove six injectors and O-rings from cylinder head. Discard O-rings.
Perform Engine Wiring Harness Removal (page 921) procedure.
96-pin E1 Engine Harness Removal
Injectors Removed (page 912).

None
Removal Procedure
Figure 797 Crankshaft Position (CKP) and Camshaft Position (CMP) Sensors
1. CMP sensor engine harness 3. CKP sensor engine harness
connector connector
2. CMP sensor 4. CKP sensor
See CKP and CMP Sensors (Figure 797) to perform steps 1 and 2.
1. Disconnect CKP engine harness connector (3) from CKP sensor (4).
2. Disconnect CMP engine harness connector (1) from CMP sensor (2).
Figure 798 Crankcase Oil Separator Speed (CCOSS) and Engine Oil Temperature (EOT) Sensors
1. CCOSS sensor 3. EOT sensor
2. CCOSS sensor engine harness 4. EOT sensor engine harness
connector connector
See CCOSS and EOT Sensors (Figure 798) to perform steps 3 and 4.
3. Disconnect CCOSS sensor engine harness connector (2) from CCOSS sensor (1).
4. Disconnect EOT sensor engine harness connector (4) from EOT sensor (3).
Figure 799 Engine Coolant Temperature 1 (ECT1) Sensor

1. ECT1 sensor engine harness
connector
2. ECT1 sensor
See Engine Coolant Temperature 1 (ECT1) Sensor (Figure 799) to perform step 5.
5. Disconnect ECT1 sensor engine harness connector (1) from ECT1 sensor (2).
Figure 800 Intake Air Heater (IAH) Fuel Solenoid

1. IAH fuel solenoid engine harness
connector
2. IAH fuel solenoid
See IAH Fuel Solenoid (Figure 800) to perform step 6.

6. Disconnect IAH fuel solenoid engine harness connector (1) from IAH fuel solenoid (2).
Figure 801 Fuel Delivery Pressure (FDP) Sensor and High-Pressure Fuel Pump (HPFP)
1. HPFP 3. FDP sensor 4. FDP sensor engine harness
2. HPFP engine harness connector connector
See FDP Sensor and HPFP (Figure 801) to perform steps 7 and 8.
7. Disconnect FDP sensor engine harness connector (4) from FDP sensor (3).
8. Disconnect HPFP engine harness connector (2) from HPFP (1).
Figure 802 Intake Manifold Temperature (IMT) Sensor

1. IMT sensor engine harness
connector
2. IMT sensor
See IMT Sensor (Figure 802) to perform step 9.

9. Disconnect IMT sensor engine harness connector (1) from IMT sensor (2).
Figure 803 Fuel Rail Pressure (FRP) Sensor

1. FRP sensor engine harness
connector
2. FRP sensor
See FRP Sensor (Figure 803) to perform step 10.

10. Disconnect FRP sensor engine harness connector (1) from FRP sensor (2).
Figure 804 Engine Wiring Harness (Front of Cylinder Head)

1. Bolt 2. Engine wiring harness 3. Cylinder head
See Wiring Harness (Front of Cylinder Head) (Figure 804) to perform step 11.
11. Remove bolt (1) securing engine wiring harness 2) to left front of cylinder head (3).
Figure 805 Engine Wiring Harness (Rear of Cylinder Head)

1. Bolt 2. Cylinder head 3. Engine wiring harness
See Engine Wiring Harness (Rear of Cylinder Head) (Figure 805) to perform step 12.
12. Remove bolt (1) securing engine wiring harness (3) to rear of cylinder head (2).
Figure 806 Engine Wiring Harness (Engine Block)

1. Bolt (2) 2. Engine wiring harness 3. Crankcase
See Engine Wiring Harness (Engine Block) (Figure 806) to perform steps 13 and 14.
13. Remove two bolts (1) securing engine wiring harness (2) to crankcase (3).
14. Remove tie straps as necessary and completely remove engine wiring harness from engine.
Perform Fuel Rail Removal (page 932) procedure.
Fuel Rail Removal
Engine wiring harness removed (page 921).

None
Removal Procedure
Figure 807 Fuel Rail

1. Fuel rail 2. Cylinder head 3. Bolt (3)
See Fuel Rail (Figure 807) to perform steps 1 and 2.

1. Remove three bolts (3) securing fuel rail (1) to cylinder head (2).
2. Remove fuel rail (1) from cylinder head (2).
Perform Cylinder Head Removal (page 934) procedure.
Cylinder Head Removal
Fuel rail removed (page 932).

• Head Bolt Torx® Socket ZTSE4787
• Cylinder Head Lifting Bracket ZTSE4869
Removal Procedure
1. If not previously done, remove six fuel injectors. See Fuel Injector Removal (page 912) procedure.

1. Cylinder head lifting bracket 2. Bolts (4)
See Cylinder Head Lifting Bracket (Figure 808) to perform steps 2 and 3.
2. Position cylinder head lifting bracket (1) on rear of cylinder head.
3. Install 4 bolts (2) to secure lifting bracket to cylinder head. Tighten to standard torque.
Figure 809 Order of Cylinder Head Bolt Removal
See Order of Cylinder Head Bolt Removal (Figure 809) to perform step 4.
4. Beginning with outer bolts and moving inward in a circular pattern, use Head Bolt Torx® Socket to loosen,
remove, and discard 26 head bolts.
CAUTION: To prevent engine damage, carefully set cylinder head on wooden blocks to protect the cylinder head
idler gear.
Figure 810 Lifting Cylinder Head
See Lifting Cylinder Head (Figure 810) to perform step 5.

5. Lift cylinder head from engine using special tool Cylinder Head Lifting Bracket ZTSE4869.
6. Place cylinder head on clean, non-metallic surface.
7. Remove 4 bolts and Cylinder Head Lifting Bracket.
8. Remove and discard cylinder head gasket.
9. If damaged, remove two dowel pins.
Perform Oil Pan Removal (page 938) procedure.
Oil Pan Removal
Cylinder head removed (page 934).

None
Removal Procedure
Figure 811 Oil Pan

1. Oil pan bolts with hold-down 2. Tube bracket (6) 4. Oil pan
clamp (22) 3. Oil drain plug with O-ring
See Oil Pan (Figure 811) to perform step 1 through 5.

1. Remove oil drain plug with O-ring (3) and drain oil into suitable container.
2. If equipped, remove oil pan heater element and discard O-ring.
3. Recycle or dispose of oil according to applicable regulations.
4. Remove 22 oil pan bolts with hold-down clamps (1) and six tube brackets (2) from oil pan (4).
5. Remove oil pan and gasket as an assembly.
Perform Oil Sump Removal (page 940) procedure.
Oil Sump Removal
Oil pan removed (page 938).

None
Removal Procedure
Figure 812 Oil Sump

1. Bolt (4) 3. Crankcase
2. Oil sump supports (4) 4. Pickup tube
See Oil Sump (Figure 812) to perform steps 1 through 3.

1. Remove 4 bolts (1) securing oil pickup tube supports to crankcase.
2. Remove oil pickup tube and oil sump supports as an assembly.
Perform Piston Cooling Jet Removal (page 942) procedure.
Piston Cooling Jet Removal
Oil sump removed (page 940).

None
Removal Procedure
Figure 813 Piston Cooling Jets

1. Crankcase 2. Piston cooling jet (6) 3. Bolt (6)
NOTE: Rotating assembly removed from Piston Cooling Jets (Figure 813) for clarity.
See Piston Cooling Jets (Figure 813) to perform steps 1 and 2.
1. Remove six bolts (3) securing piston cooling jets (2) to crankcase.
2. Remove six piston cooling jets from crankcase (1). Discard piston cooling jet O-rings.
Perform Pistons and Connecting Rod Removal (page 944) procedure.
Pistons and Connecting Rod Removal
Piston cooling jets removed (page 942).

• Exhaust Manifold Bolt Torx® Socket ZTSE4843
Removal Procedure
1. Perform steps 2 through 5 until all 6 piston and connecting rod assemblies have been removed.
2. Scrape carbon ridge from top of cylinder bore if necessary. Use care not to damage sleeve bore surface.
CAUTION: To prevent engine damage, prior to removing rod bearing caps, mark all connecting rods and
connecting rod caps to ensure correct orientation and location of each connecting rod cap. Note the matching
serial numbers on the same side of the connecting rod and connecting rod cap. If the rod cap is reversed or
not installed on its matching connecting rod, the fractured mating surfaces will be damaged. A new connecting
rod assembly must be installed. Do NOT attempt to reuse a rod that has been incorrectly assembled to its
cap, assembled with the wrong cap, or cross-threaded while attempting assembly. Serious engine damage
can result.
3. Rotate crankshaft to position connecting rod journals for easy removal of connecting rod assemblies.
Figure 814 Piston and Connecting Rod Assembly

1. Connecting rod bolt (12) 2. Connecting rod cap (6) 3. Crankshaft
See Piston and Connecting Rod Assembly (Figure 814) to perform step 4.
4. Using Exhaust Manifold Bolt Torx® Socket ZTSE4843, remove two connecting rod bolts (1) and connecting
rod cap (2). Save bolts for reuse during connecting rod bore check procedure.
Figure 815 Anti-polish Ring (APR) Removal

1. Piston 2. Anti-Polish Ring (APR) 3. Cylinder sleeve
See Anti-polish Ring (APR) Removal (Figure 815) to perform step 5.

5. Remove Anti-polish ring (2).
Figure 816 Piston and Connecting Rod Assembly

1. Piston 3. Connecting rod assembly
2. Piston ring (3) 4. Cylinder sleeve
See Piston and Connecting Rod Assembly (Figure 816) to perform steps 6 through 9.
6. Use a wooden or plastic handle to push piston (1) and connecting rod assembly (2) from underneath
crankcase up through cylinder sleeve (4).
7. Once piston rings (2) are free of cylinder sleeve, remove piston and connecting rod assembly from cylinder
sleeve.
8. Using a permanent marker, mark each piston and rod assembly with cylinder number from which each was
removed.
9. Remove connecting rod upper and lower bearings by pushing out. Mark connecting rod bearings for position
and orientation and set aside for inspection.
Perform Cylinder Liner Removal (page 948) procedure.
Cylinder Liner Removal
Piston and connecting rod assemblies removed (page 944).

• Cylinder Sleeve Puller ZTSE2536
Removal Procedure
Figure 817 Cylinder Sleeve Puller
See Cylinder Sleeve Puller (Figure 817) to perform step 1.

1. Remove 6 cylinder sleeves from crankcase as follows:
a. Insert Cylinder Sleeve Puller ZTSE2536 into cylinder sleeve.
b. Engage removal tool hook under bottom edge of cylinder sleeve.
c. Position removal tool hooks under bottom edge of cylinder sleeve.
d. Turn threaded shaft clockwise to extract cylinder sleeve.
e. Mark cylinder sleeves for position and set aside for inspection.
Figure 818 Cylinder Sleeve O-rings

1. Cylinder sleeve (6) 2. O-rings (12)
See Cylinder Sleeve O-rings (Figure 818) to perform step 2.

2. Remove and discard two cylinder sleeve O-rings (2) from each crankcase cylinder sleeve (1).
3. Repeat steps 1 and 2 until all six cylinder sleeves have been removed.
Perform Crankshaft Main Bearing Removal (page 951) procedure.
Crankshaft Main Bearing Removal
Cylinder Liners Removed .

None
Removal Procedure
1. Perform main bearing removal and main bearing installation one at a time.
Figure 819 Main Bearing Removal

1. Collar bolt (14)
See Main Bearing Removal (Figure 819) to perform steps 2 through 5.
2. Remove two main collar bolts (1) from main bearing cap (2).
3. Remove main bearing cap.
4. Remove main bearings from crankshaft by rotating crankshaft counter-clockwise while applying pressure to
main bearing with suitable tool.
5. Discard used main bearings.
Figure 820 Crankshaft Main Bearing Journals

1. Main bearing journals
See Crankshaft Main Bearing Journals (Figure 820) to perform step 5.

6. Inspect crankshaft main bearing journals (1) for pitting, scoring, and gouges. Replace as necessary.
7. Perform Crankshaft Main Bearing Reassembly procedure.
Engine Disassembly, Cleaning, Inspection, Testing, and Assembly

Procedures
General Cleaning Procedure
NOTE: Do not use a caustic solution on turbochargers and related components.
1. Cover coolant, fluid, and air openings to ensure dirt does not enter air compressor and power steering pump.
installed.
6. Clean all bolt holes with steam and then dry with filtered compressed air.
7. Using a scraper and / or wire brush, clean coolant and oil seal mating surfaces on the crankcase, cylinder
head, water distribution housing, water pump assembly, coolant outlet manifold, thermostat housing, and
front belt- or gear-driven fan cover.
8. After removing foreign material from sealing surfaces, use a commercially available, non-caustic brake
cleaner to clean gasket surfaces of crankcase and flywheel housing.
General Inspection Procedure
Engine Wiring and Sensor Inspections

1. Inspect wiring harness(es) for worn conduit, frayed insulation, and / or heat damage to wires. Repair or
2. Inspect sensors for corroded terminals; loose, bent, or broken pins; or broken sensor housing. Repair or
3. Inspect connector terminals for corrosion or damage; loose, bent, or broken pins; missing or damaged seals;
or broken connector housing. Repair or replace as necessary.
Engine Component Inspections

4. Inspect engine components for fluid leaks. Repair or replace as necessary.
5. Inspect engine components for cracks, pitting, and other notable damage. Repair or replace as necessary.
6. Inspect engine components for carbon build-up, plugging, and other notable damage. Repair or replace as
necessary.
7. Inspect engine components for signs of excessive heat, warping, kinking, and other notable damage. Repair
8. Inspect internal engine components for spalling, galling, excessive wear, and other notable damage. Repair
Overview
The EGR cooler pressure test procedure was developed to determine if the EGR cooler is leaking coolant.
components.
EGR cooler disassembled (page 956).


2. EGR cooler strap (4) 4. ERG cooler bracket
replaced.
Test Procedure

1. Exhaust gas outlet plug 9. Coolant inlet block-off 14. Bubble test hose assembly
12-892-07-01 12-892-07-06 12-892-07-04
2. EGR cooler exhaust outlet port 10. Exhaust gas inlet plug 15. Container of water (half full)
3. Block-off plugs 12-892-07-10 (3) 12-892-07-02 16. EGR cooler coolant return port
4. Sleeper cab heat block-off 11. EGR cooler exhaust gas inlet 17. Coolant outlet clamp
12-892-07-05 port 12-892-07-07
5. Bunk heater port 12. EGR valve supply port 18. Regulator assembly
6. Main cab heat plug 12-892-07-03 13. EGR valve supply adapter 12-892-07-08
7. EGR cooler main cab heat port 12-892-07-09
8. EGR cooler coolant inlet port
1. Install exhaust gas outlet plug 12-892-07-01 (1) on EGR cooler exhaust gas outlet port (2). Tighten knurled
ring to seal.
2. Install exhaust gas inlet plug 12-892-07-02 (10) on EGR cooler exhaust gas inlet port (11). Tighten knurled
ring to seal.
knob to seal.
4. Install EGR valve supply adapter 12-892-07-09 (13) on EGR valve supply port (12) and tighten to seal.
6. Install main cab heat plug 12-892-07-03 (6) on EGR cooler main cab heat port (7). Tighten knurled knob to
seal.
7. Insert coolant inlet block-off 12-892-07-06 (9) on EGR cooler coolant inlet port (8). Tighten knurled knobs
to seal.
9. Install bubble test hose assembly 12-892-07-04 (14) on EGR valve supply adapter 12-892-07-09 (13).
10. Install regulator assembly 12-892-07-08 (18) on exhaust gas outlet plug 12-892-07-01 (1).
14. Insert bubble test hose assembly (14) into a container of clean water filled (half full) (15). Keeping end of
Expected Outcome
Perform Exhaust Gas Recirculation (EGR) Cooler Cleaning and Inspection (page 960) procedure.
Exhaust Gas Recirculation (EGR) Cooler Cleaning and Inspection
Overview
The following procedure is used to inspect the EGR cooler. EGR cooler should be free of cracks, pitting, leaking,
or other notable damage.
components.
EGR cooler removed (page 821).

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replaced.
Cleaning and Inspection Procedure
Figure 824 EGR Cooler Inspection Points

A. EGR cooler exhaust gas outlet D. EGR cooler cab coolant G. EGR cooler coolant inlet
sealing surface connection
B. EGR cooler E. Coolant pipe flange sealing
C. EGR cooler cab coolant surface
connection F. EGR cooler exhaust gas inlet
Some items shown as removed for clarity.

See EGR Cooler Inspection Points (Figure 824) to perform steps 1 and 2.
1. Clean all sealing surfaces (A, E) and connection points (C, D, F, G) to ensure proper sealing of gaskets,
hoses, and fittings.
2. Inspect all sealing surfaces (A, E) and connection points (C, D, F, G) for cracking, pitting, or notable damage.
Expected Outcome
EGR cooler should be free of cracks, pitting, carbon build-up, or other notable damage.
Perform Exhaust Gas Recirculation (EGR) Cooler Reassembly .
Exhaust Gas Recirculation (EGR) Valve Disassembly
EGR valve removed (page 832).

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Disassembly Procedure
components.
Figure 825 EGR Valve Disassembly

1. EGR valve bellow (2) 3. EGR valve 5. O-ring (2)
2. V-band clamp (2) 4. Coolant fitting (2)
See EGR Valve Disassembly (Figure 825) to perform steps 1 through 4.

1. Remove V-band clamps (2) that secure EGR valve bellows (1) to EGR valve (3). Discard V-band clamps.
2. Remove EGR valve bellows (1) from EGR valve (3).
3. Remove EGR valve bellow gaskets from EGR valve bellows. Discard gaskets.
4. Remove two coolant fittings (4) from EGR valve and discard O-rings.
Perform EGR Valve Cleaning and Inspection (page 965) procedure.
Exhaust Gas Recirculation (EGR) Valve Cleaning and Inspection
Overview
The following procedure is used to inspect EGR Valve. EGR valve must be inspected to ensure proper operation
of EGR system. EGR valve and EGR valve bellows should be free of cracks, pitting, leaking, or other notable
damage.
EGR valve disassembled (page 963).

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components.
Figure 826 EGR Valve Inspection Points

A. EGR valve bellow sealing C. Coolant port (2) F. EGR valve
surface (4) D. EGR valve bellow (2)
B. EGR valve connector E. EGR valve sealing surface (2)
See EGR Valve Inspection Points (Figure 826) to perform steps 1 through 7.
1. Clean all sealing surfaces (A, E) to ensure proper sealing of gaskets, hoses, and fittings.
2. Inspect all sealing surfaces (A, E) for cracking, pitting, or damage. Replace as necessary.
3. Inspect EGR valve (F) for cracks, pitting, carbon build-up, or damage. Replace as necessary.
NOTE: Outside presence of carbon on the EGR valve does not indicate a defective part.
4. Inspect EGR valve (F) for carbon build up. If carbon build up is present clean from EGR valve using suitable
non-caustic solvent.
5. Inspect EGR valve connector (B) for corrosion or damage; loose, bent, or broken pins; missing or damaged
seals; or broken connector housing. Replace as necessary.
6. Inspect coolant ports (C) for obstruction and deposits. Clean as necessary.
7. Inspect EGR valve bellows (D) for cracks, dents, or damage. Replace as necessary.
Expected Outcome
EGR valve and EGR valve bellows should be free of cracks, pitting, carbon build up, and other notable damage.
Perform Exhaust Gas Recirculation (EGR) Valve Reassembly (page 968) procedure.
Exhaust Gas Recirculation (EGR) Valve Reassembly
EGR valve cleaned and inspected (page 965).

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Torques
Coolant fittings 43 lb-ft (58 N·m)

V-band clamps 11 lb-ft (15 N·m)
Reassembly Procedure
components.
Figure 827 EGR Valve Reassembly

1. EGR valve bellow (2) 3. EGR valve 5. O-ring (2)
2. V-band clamp (2) 4. Coolant fitting (2)
See EGR Valve Reassembly (Figure 827) to perform steps 1 through 3.

1. Install two new O-rings on coolant fittings and install coolant fittings in EGR valve. Tighten coolant fittings.
See torque values (page 968).
2. Install two new gaskets on EGR valve side of EGR valve bellows.
3. Using two new V-band clamps, install EGR valve bellows on EGR valve. Tighten V-band clamps. See torque
values (page 968).
Perform Aftertreatment Fuel Injector (AFTFI) Inspection (page 970) procedure.
Aftertreatment Fuel Injector (AFTFI) Cleaning and Inspection
Overview
The following procedure is used to clean and inspect AFTFI. AFTFI must be inspected to ensure proper operation
of aftertreatment system. AFTFI should be free of cracks or other notable damage.
AFTFI removed (page 968).

• Fuel Injector Tip Cleaning Brush ZTSE4301
CAUTION: To prevent component damage, cleaning of the AFTFI using cleaner or solvents is NOT
recommended. Do not blast the injector with compressed air. Do not pull or otherwise manipulate the injector
nozzle tip.
Figure 828 Aftertreatment Fuel Injector (AFTFI)

A. AFTFI connector C. AFTFI E. Injector nozzle tip
B. AFTFI harness D. Coolant fittings (2)
See Aftertreatment Fuel Injector (AFTFI) (Figure 828) to perform steps 1 through 5.
1. Inspect AFTFI (C) and injector nozzle tip (E) for cracks or other damage. Replace as necessary.
2. Inspect injector nozzle tip (E) for any carbon buildup that may be present. Use Fuel Injector Tip Cleaning
Brush ZTSE4301 to clean carbon buildup from injector nozzle tip.
3. Inspect AFTFI harness (B) for worn conduit, frayed insulation, and heat damage to wires. Repair or replace
as necessary.
4. Inspect AFTFI connector (A) for corrosion or damage; loose, bent, or broken pins; missing or damaged
seals; or broken connector housing. Repair or replace as necessary.
5. Inspect AFTFI coolant fittings (D) for signs of leaking or damage. Replace as necessary.
Expected Outcome
AFTFI should be free of cracks, carbon build up, or other notable damage.
Perform Exhaust Back-Pressure Valve (EBPV) Cleaning and Inspection (page 972) procedure.
Exhaust Back-Pressure Valve (EBPV) Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the EBPV and down-pipe. EBPV and down-pipe must be
inspected to ensure proper operation of EBPV and Aftertreatment (AFT) system. EBPV and down-pipe should
be free of cracks, pitting, or other notable damage.
EBPV removed (page 840).

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CAUTION: To prevent damage to the AFT system or plugging of the Pre-Diesel Oxidation Catalyst (PDOC) /
Diesel Oxidation Catalyst (DOC) / Diesel Particulate Filter (DPF), ensure no carbon debris remains in EBPV
housing.
Figure 829 EBPV Inspection

A. Air supply line fitting C. AFTFI sealing surface E. EBPV actuator valve
B. EBPV housing assembly D. EBPV sealing surface
See EBPV Inspection(Figure 829) to perform steps 1 through 7.

1. Carefully remove carbon build-up from AFTFI sealing surface (C) with a chisel or other appropriate tool.
2. Inspect EBPV flap (E) for carbon build-up. Use steam to clean EBPV flap.
3. Inspect EBPV housing assembly (B) for remaining carbon build-up. Use steam to clean EBPV housing
assembly.
4. Inspect EBPV housing assembly (B) for cracks and other notable damage. Replace as necessary.
5. Use steam to clean AFTFI sealing surface (C) and EBPV sealing surface (D).
6. Inspect AFTFI sealing surface (C) and EBPV sealing surface (D) for pitting and other notable damage.
7. Inspect air supply line fitting (A) for damaged threads and other notable damage. Repair or replace as
necessary.
Figure 830 NOx Sensor and O2Sensor

A. NOx sensor module C. NOx sensor E. Down-pipe outlet
B. O2 sensor connector D. O2 sensor
See NOx Sensor and O2Sensor(Figure 830) to complete steps 8 through 10.
8. Inspect NOx sensor module (A) and O2 sensor connector (B) for corrosion or damage; loose, bent, or broken
pins; missing or damaged seals; or broken connector housings. Repair or replace as necessary.
9. Inspect NOx sensor (C) and O2 sensor (D) for worn conduit, frayed insulation, and heat damage to wires.
10. Inspect down-pipe outlet (E) for pitting and other notable damage. Replace as necessary.
Expected Outcome
EBPV and down-pipe should be free of cracks, pitting, or other notable damage.
Perform Turbocharger Assembly Disassembly procedure.
Low-Pressure (LP) Turbocharger Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the Low-Pressure (LP) turbocharger, impeller, turbine
wheel, and housing. LP turbocharger, impeller, turbine wheel, and housing must be inspected to ensure proper
operation and performance of the engine. Turbocharger housing should be free of cracks, pitting, and other
notable damage. Turbocharger impeller, and turbine wheel should be free of bends, nicks, and other notable
damage.
High-Pressure Turbocharger removed .

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WARNING: To prevent personal injury or death, discard turbocharger if compressor blades are
damaged.
CAUTION: To prevent turbocharger and / or engine damage, do not attempt to straighten bent impeller or turbine
wheel blades. Replace turbocharger (s) if blades are bent.
CAUTION: To prevent engine damage, do not allow cleaning solvent to contact bearings behind compressor
wheel.
Figure 831 Low-Pressure (LP) Turbocharger Compressor Outlet

A. LP turbocharger compressor B. LP turbocharger compressor
housing outlet interior housing outlet sealing surface
See Low-Pressure (LP) Turbocharger Compressor Outlet(Figure 831) to perform steps 1 through 3.
1. Clean LP turbocharger compressor housing outlet sealing surface (B) using non-abrasive and non-caustic
cleaning materials.
2. Inspect LP turbocharger compressor housing outlet interior (A) for coking.
3. Inspect LP turbocharger compressor housing outlet sealing surface (B) for pitting, cracks, and other notable
damage.
Figure 832 LP Turbocharger Compressor

A. Compressor housing C. Sealing surface
B. Impeller D. Shaft
See LP Turbocharger Compressor(Figure 832) to perform steps 4–7.

4. Clean sealing surface (C) using non-abrasive and non-caustic cleaning materials.
5. Inspect compressor housing (A) and sealing surface (C) for pitting, cracks, and other notable damage.
6. Inspect impeller (B) for blade erosion, bends, breakage, or deposits. Replace as necessary.
7. Turn shaft (D) by hand to determine if impeller (B) is contacting or rubbing housing. Shaft and impeller must
rotate freely. If contact or rubbing is detected, replace as necessary.
Figure 833 Low-Pressure (LP) Turbocharger Turbine Wheel

A. Turbine housing sealing surface C. Turbine wheel
B. Turbine housing D. Shaft
See Low-Pressure (LP) Turbocharger Turbine Wheel(Figure 833) to perform steps 8 through 11.
8. Clean turbine housing sealing surface (A) using non-abrasive and non-caustic cleaning materials.
9. Inspect turbine housing sealing surface (A) and turbine housing (B) for cracks, pitting, and other notable
damage. Replace as necessary.
10. Inspect turbine wheel (C) for blade erosion, bends, breakage, or deposits. Replace as necessary.
11. Turn shaft (D) by hand to determine if turbine wheel (C) is contacting or rubbing housing. Shaft and turbine
wheel must rotate freely. If contact or rubbing is detected, replace as necessary.
Figure 834 Turbocharger Center Section Coking (Oil Supply)

A. LP turbocharger center section B. Oil supply line orifice
See Turbocharger Center Section Coking (Oil Supply)(Figure 834) to perform step 12.
12. Inspect for coking inside LP turbocharger center section (A) by looking through oil supply line orifice (B).
Figure 835 Turbocharger Center Section Coking (Oil Drain)

A. LP turbocharger center section B. Oil drain tube orifice
See Turbocharger Center Section Coking (Oil Drain)(Figure 835) to perform step 13.
13. Inspect for coking inside LP turbocharger center section (A) by looking through oil drain tube orifice (B).
Expected Outcome
LP turbocharger should be free of cracks, pitting, and other notable damage. Turbocharger impeller, turbine
wheel, and housing should be free of bends, nicks, and other notable damage.
Perform High-Pressure (HP) Turbocharger Cleaning and Inspection (page 981) procedure.
High-Pressure (HP) Turbocharger Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the High-Pressure (HP) turbocharger, impeller, turbine
wheel, and housing. HP turbocharger, impeller, turbine wheel, and housing must be inspected to ensure proper
operation and performance of the engine. Turbocharger housing should be free of cracks, pitting, and other
notable damage. Turbocharger impeller, and turbine wheel should be free of bends, nicks, and other notable
damage.
Low-Pressure (LP) Turbocharger cleaned and inspected (page 975).

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WARNING: To prevent personal injury or death, discard turbocharger if compressor blades are
damaged.
CAUTION: To prevent turbocharger and / or engine damage, do not attempt to straighten bent impeller or turbine
wheel blades. Replace turbocharger (s) if blades are bent.
CAUTION: To prevent engine damage, do not allow cleaning solvent to contact bearings behind compressor
wheel.
Figure 836 High-Pressure (HP) Turbocharger Compressor Outlet

A. HP turbocharger compressor B. HP turbocharger compressor
housing outlet interior housing outlet sealing surface
See High-Pressure (HP) Turbocharger Compressor Outlet(Figure 836) to perform steps 1 through 3.
1. Clean HP turbocharger compressor housing outlet sealing surface (B) using non-abrasive and non-caustic
cleaning materials.
2. Inspect HP turbocharger compressor housing outlet interior (A) for coking.
3. Inspect HP turbocharger compressor housing outlet sealing surface (B) for pitting, cracks, and other notable
damage.
Figure 837 High-Pressure (HP) Turbocharger Compressor

A. Compressor housing C. O-ring sealing surface
B. Impeller D. Shaft
See High-Pressure (HP) Turbocharger Compressor(Figure 837) to perform steps 4 through 7.

4. Clean O-ring sealing surface (C) using non-abrasive and non-caustic cleaning materials.
5. Inspect compressor housing (A) and O-ring sealing surface (C) for cracks, pitting, and other notable damage.
6. Inspect impeller (B) for blade erosion, bends, breakage, or deposits. Replace as necessary.
7. Turn shaft (D) by hand to determine if impeller (B) is contacting or rubbing housing. Shaft and impeller must
rotate freely. If contact or rubbing is detected, replace as necessary.
Figure 838 HP Turbocharger Turbine Wheel

A. Turbine housing sealing surface C. Turbine wheel E. Alignment dowels (2)
B. Turbine housing D. Shaft F. Wastegate actuator mechanism
See HP Turbocharger Turbine Wheel(Figure 838) to perform steps 8 through 13.

8. Clean turbine housing sealing surface (A) using non-abrasive and non-caustic cleaning materials.
9. Inspect turbine housing sealing surface (A) and turbine housing (B) for pitting, cracks, and other notable
damage. Replace as necessary.
10. Inspect 2 alignment dowels (E) for corrosion and damage. Replace as necessary.
11. Inspect turbine wheel (C) for blade erosion, bends, breakage, or deposits. Replace as necessary.
12. Inspect wastegate actuator mechanism (F) for sticking, binding, and other notable damage or issues.
13. Turn shaft (D) by hand to determine if turbine wheel (C) is contacting or rubbing housing. Shaft and turbine
wheel must rotate freely. If contact or rubbing is detected, replace as necessary.
Figure 839 Turbocharger Center Section Coking (Oil Supply)

A. HP turbocharger center section B. Oil supply line orifice
See Turbocharger Center Section Coking (Oil Supply)(Figure 839) to perform step 14.
14. Inspect for coking inside HP turbocharger center section (A) by looking through oil supply line orifice (B).
Figure 840 Turbocharger Center Section Coking (Oil Drain)

A. HP turbocharger center section B. Oil drain tube orifice
See Turbocharger Center Section Coking (Oil Drain)(Figure 840) to perform step 15.
15. Inspect for coking inside HP turbocharger center section (A) by looking through oil drain tube orifice (B).
Expected Outcome
HP turbocharger should be free of cracks, pitting, and other notable damage. Turbocharger impeller, turbine
wheel, and housing should be free of bends, nicks, and other notable damage.
Perform Exhaust Manifold Disassembly procedure.
Exhaust Manifold Cuff Replacement
Exhaust manifold removed .

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Torques
CAUTION: If engine is not equipped with exhaust manifold cuff assembly, install front and rear exhaust manifold
cuff assembly.

See Exhaust Manifold Cuff (Figure 841) to perform steps 1 through 8.

1. Mark orientation of exhaust manifold cuff constant-torque clamp (3) in relation to exhaust manifolds (1, 4,
and 5) for reassembly.
2. Remove exhaust manifold cuff constant-torque clamp (3) from exhaust manifolds (1,4, and 5). Remove
exhaust manifold cuff halves (4) from exhaust manifolds. Discard cuff halves.
3. If both cuffs need to be replaced, repeat steps 1 and 2.
4. Clean exhaust manifold cuff sealing surface.
5. Using a new exhaust manifold cuff assembly, install sticky tape that comes with new cuff around exhaust
manifold cuff sealing surface.
6. Install exhaust manifold cuff halves (2) halves onto exhaust manifolds (1, 4, and 5).
7. Using marks made for exhaust manifold orientation during disassembly, install exhaust manifold cuff
constant-torque clamp (3) onto exhaust manifold cuff assembly. Torque clamp to 8 N·m (70 lb·in).
8. If both cuffs need to be replaced, repeat steps 1 through 7.
Rear Coolant Manifold Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the rear coolant manifold, Aftertreatment Fuel Injector
(AFTFI) coolant supply line, AFTFI fuel supply tube, and wiring harness mounting brackets. The rear coolant
manifold must be inspected to ensure proper function of cooling system. AFTFI fuel supply tube and AFTFI
coolant supply line must be inspected to ensure proper function of the AFTFI. Wiring harness mounting brackets
must be inspected to ensure they will function properly in securing the engine harness. Some vibration wear is
expected in the rear coolant manifold outlet bore, otherwise, all components should be free of cracks, pitting,
and other notable damage.
Rear coolant manifold removed (page 879).

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Figure 842 Sealing Surfaces and Connection Points

A. Coolant manifold pipe sealing B. Rear coolant manifold inlet C. Rear coolant manifold inlet
surface (cylinder head) connection point (crankcase) connection point
D. Harness clips
See Sealing Surfaces and Connection Points(Figure 842) to perform steps 1 through 6.
1. Clean coolant manifold pipe sealing surface (A) and connection points (B and C).
2. Inspect connection points (B and C) for cracking, pitting, or damage. Replace as necessary.
3. Inspect coolant manifold pipe sealing surface (A). Some vibration wear is expected in the rear coolant
manifold outlet bore, otherwise, it should be free of cracks, pitting, and other notable damage.
4. Using appropriate tool (3M Pad #7448 or #7447 is recommended) remove any nicks, burrs, and raised or
sharp edges from sealing surfaces (A, B, and C).
5. Clean all sealing surfaces (A, B, and C) using suitable non-caustic solvent.
6. Ensure harness clips (D) are not bent or damaged.
Figure 843 Coolant Plugs, Coolant Supply Line, and Fuel Supply Tube
A. Rear coolant manifold housing C. Aftertreatment Fuel Injector D. Wiring harness mounting
B. Coolant plugs (AFTFI) coolant supply line brackets
E. AFTFI fuel supply tube
See Coolant Plugs, Coolant Supply Line, and Fuel Supply Tube(Figure 843) to perform steps 7 through 10.
7. Inspect coolant plugs (B) and AFTFI coolant supply line (C) for signs of leaking. Replace plugs and O-rings
as necessary.
8. Inspect AFTFI fuel supply tube (E) for signs of leaking, kinks, or other damage. Replace AFTFI fuel supply
tube as necessary.
9. Inspect wiring harness mounting brackets (D) for cracking or damage. Replace as necessary.
10. Inspect rear coolant manifold housing (A) for cracks, leaks, or any other damage. Replace as necessary.
Expected Outcome
Some vibration wear is expected in the rear coolant manifold outlet bore, otherwise, all components should be
free of cracks, pitting, and other notable damage.
Perform Engine Control Module (ECM) and ECM Mounting Bracket Cleaning and Inspection (page 992)
procedure.
Engine Control Module (ECM) and ECM Mounting Bracket Cleaning and Inspection
Overview
The following procedure is used to inspect the ECM and ECM mounting bracket. ECM must be inspected to
ensure proper operation of engine electronic control system. ECM should be free of damaged seals, bent or
damaged pins, or other notable damage.
ECM and ECM mounting bracket removed (page 881).

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WARNING: To prevent personal injury or death, disconnect the main battery negative terminal
before disconnecting or connecting electrical components.
components.
Figure 844 ECM Connection Points

A. 16-pin injector E2 harness D. 58-pin chassis C2 harness G. 58-pin chassis C1 harness
terminal terminal pin recess terminal
B. 16-pin injector E2 harness E. 58-pin chassis C2 harness H. 96-pin engine E1 harness
terminal pin recess terminal terminal
C. Engine Control Module (ECM) F. 58-pin chassis C1 harness I. 96-pin engine E1 harness
terminal pin recess terminal pin recess
See ECM Connection Points(Figure 844) to perform steps 1 through 4.

1. Inspect exterior of ECM (C) for cracks and other notable damage. Replace as necessary.
2. Inspect rubber seal on harness connector and in ECM pin recesses (Figure 844) (Items B, D, F, and I).
3. Check for bent pins in ECM terminals (A, E, G, and H). Replace as necessary.
4. Inspect ECM mounting bracket (not shown) for cracks or other notable damage. Replace as necessary.
Expected Outcome
ECM should be free of damaged seals, bent or damaged pins, and other notable damage. ECM mounting
bracket should be free of cracks or other notable damage.
Perform Engine Throttle Valve (ETV) and Mixer Duct Assembly Cleaning and Inspection (page 1016) procedure.
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Inspection
Overview
The following procedure is used to inspect ETV and air intake throttle duct. ETV and air intake throttle duct
should be free of cracks, pitting, carbon build-up, corrosion, sensor and component electrical connector damage,
Engine Throttle Valve (ETV) Assembly removed (page 890).

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CAUTION: Be careful not to remove the orange coating on interior of Engine Throttle Valve (ETV) and air intake
throttle duct when cleaning carbon build-up. Failure to comply could result in serious engine damage or failure.
Figure 845 ETV and Air Intake Throttle Duct

A. ETV sealing surface F. Exhaust Gas Recirculation Gas J. Air intake throttle duct sealing
B. ETV Temperature (EGRGT) sensor surface
C. Intake Manifold Pressure (IMP) G. EGR gas outlet manifold K. ETV electrical connection
sensor H. Exhaust Gas Recirculation L. Charge Air Cooler Outlet
D. Intake Air Heater Igniter (IAH (EGR) cooler outlet hose Temperature (CACOT) sensor
Igniter) fuel line port threads I. EGR cooler outlet hose sealing
E. Air intake throttle duct surface
See ETV and Air Intake Throttle Duct (Figure 845) to perform steps 1 through 5.
1. When cleaning and inspecting ETV and air intake duct assembly, be careful not to damage or break sensor
housings while handling assembly.
2. Inspect sealing surfaces (A, I, and J) for cracking, pitting, and other notable damage. Replace as necessary.
3. Inspect EGR cooler outlet hose (H) for cracks, dry-rot, and other notable damage. Replace as necessary.
4. Inspect ETV (B) for cracks, pitting, and other notable damage. Replace as necessary.
5. Inspect air intake throttle duct and EGR gas outlet manifold (E and G) for cracks, pitting, carbon build-up,
and other notable damage. Clean carbon build-up if present. Otherwise, repair or replace as necessary.
6. Inspect sensors and electrical connections (C, F, K, and L) for corroded terminals; loose, bent, or broken
pins; or broken sensor housings. Repair or replace as necessary.
7. Inspect IAH Igniter (D) for damage. Repair or replace as necessary.
Expected Outcome
ETV and air intake throttle duct components should be free of cracks, pitting, carbon build-up, corrosion,
connector damage, and other notable damage.
Perform Coolant Outlet Manifold and Thermostat Housing Cleaning and Inspection (page 1026) procedure.
Coolant Outlet Manifold and Thermostat Housing Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the thermostats, coolant outlet manifold, and thermostat
housing assembly. The thermostats, coolant outlet manifold, and thermostat housing assembly must be
inspected to ensure proper operation and cooling of the engine, engine components, and proper heating of the
cab interior. The coolant outlet manifold and thermostat housing assembly should be free of cracks, warping,
or other notable damage.
Coolant outlet manifold and thermostat housing removed (page 894).

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Figure 846 Coolant Outlet Manifold and Thermostat Housing Assembly

A. Exhaust Gas Recirculation B. Thermostat housing D. Coolant outlet manifold sealing
(EGR) cooler return manifold C. Coolant outlet manifold surface
See Coolant Outlet Manifold and Thermostat Housing Assembly(Figure 846) to perform steps 1 through 4.
1. Clean thermostat housing (B), coolant outlet manifold (C), and coolant outlet manifold sealing surface (D)
with a suitable, non-caustic solvent.
2. Blow parts dry using filtered-compressed air.
3. Inspect EGR cooler return manifold (A), thermostat housing (B), and coolant outlet manifold (C) for cracks,
leaks, and other notable damage. Replace as necessary.
4. Inspect coolant outlet manifold sealing surface (D) for cracks, pitting, and other notable damage.
Figure 847 Thermostat Housing to Front Cover Sealing Surface

A. Thermostat housing to front
cover sealing surface
See Thermostat Housing to Front Cover Sealing Surface(Figure 847) to perform step 5.
5. Inspect thermostat housing to front cover sealing surface (A) for cracks, pitting, and other notable damage.
Preventative Maintenance Option: Thermostat Replacement

The adjustment, maintenance, and parts and labor associated with normal wear and tear (consumables) and
vehicle maintenance are the responsibility of the vehicle owner and are not covered under warranty.
For thermostat replacement, perform Thermostat Housing Disassembly (page 1000) procedure.
Expected Outcome
Coolant outlet manifold and thermostat housing assembly and all sealing surfaces should be free of cracks,
warping, pitting, leaks, and other notable damage. Thermostats should be free of sticking, cracking, damage,
and improper spring travel.
Perform Upper Valve Cover Inspection (page 1006) procedure.
Coolant Outlet Manifold and Thermostat Housing Disassembly
Coolant outlet manifold and thermostat housing cleaned and inspected (page 1026).

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components.
Figure 848 Coolant Outlet Manifold

1. Thermostat housing 3. Coolant outlet manifold bolts 4. Wiring support bracket
2. Coolant outlet manifold with spacers (2) 5. Coolant outlet manifold bolt
See Coolant Outlet Manifold (Figure 848) to perform steps 1 and 2.

1. Remove 2 coolant outlet manifold bolts with spacers securing wiring support bracket and coolant outlet
manifold to thermostat housing.
2. Remove coolant outlet manifold bolt securing coolant outlet manifold to thermostat housing and remove
coolant outlet manifold from thermostat housing.
Figure 849 Thermostat Assemblies

1. Thermostat housing 2. Thermostat assemblies (2)
See Thermostat Assemblies (Figure 849) to perform step 3.

3. Remove 2 thermostat assemblies (2) from thermostat housing.
Perform Coolant Outlet Manifold and Thermostat Housing Reassembly (page 1003) procedure.
Coolant Outlet Manifold and Thermostat Housing Reassembly
Equipment Condition
Coolant outlet manifold and thermostat housing disassembled (page 1000).
Torques
Coolant outlet manifold bolt 35 N·m (26 lb·ft)

Coolant outlet manifold bolts with spacers 31 N·m (23 lb·ft)
components.
Figure 850 Thermostat Assemblies

1. Thermostat housing 2. Thermostat assemblies (2)
See Thermostat Assemblies (Figure 850) to perform step 1.

1. Install 2 new thermostat assemblies (2) with new gaskets into thermostat housing.
Figure 851 Coolant Outlet Manifold

1. Thermostat housing 3. Coolant outlet manifold bolts 4. Wiring support bracket
2. Coolant outlet manifold with spacers (2) 5. Coolant outlet manifold bolt
See Coolant Outlet Manifold (Figure 851) to perform steps 2 and 3.

2. Using 2 coolant outlet manifold bolts with spacers (3), install wiring support bracket (4) and coolant outlet
manifold (2) on thermostat housing (1). Torque to 31 N·m (23 lb·ft).
3. Install coolant outlet manifold bolt (5) in coolant outlet manifold (2). Torque to 35 N·m (25 lb·ft).
Perform Upper Valve Cover and Injector Wiring Harness Cleaning and Inspection (page 1006) procedure.
Upper Valve Cover Inspection
Overview
The following procedure is used to clean and inspect the upper valve cover. Upper valve cover must be inspected
to prevent contamination, loss of engine oil, and damage to internal engine components. Upper valve cover
should be free of cracks, pitting, leaking, and other notable damage.
Upper valve cover removed (page 898).

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components.

A. Composite valve cover B. Composite valve cover sealing C. Composite valve cover bolt
surface holes
See Composite Valve Cover (Figure 852) to perform steps 1 through 3.

1. Use a scraper or wire brush to clean composite valve cover sealing surface (B).
2. Use a commercially available, non-caustic brake cleaner to clean composite valve cover (A).
3. Inspect composite valve cover, composite valve cover sealing surface, and composite valve cover bolt holes
(A, B, and C) for cracks, pitting, and other notable damage. Repair or replace as necessary.
Expected Outcome
Upper valve cover should be free of cracks, pitting, and other notable damage.
Perform Engine Brake Assembly Cleaning and Inspection (page 1008) procedure.
Engine Brake Assemblies Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the engine brake assemblies. Engine brake assemblies
must be inspected to ensure proper operation of the engine brake. Engine brake assemblies should be free of
cracks, spalling, galling, or other notable damage.
Engine brake assemblies removed (page 900).

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components.

A. Control valves C. Engine brake housing E. Solenoid assembly terminals
B. Solenoid assembly D. Master piston rollers
See Engine Brake Assembly(Figure 853) to performs steps 1 through 6.

1. Clean control valve, engine brake housing, and master piston rollers ( A, C, and D) with a suitable non-caustic
solvent.
2. Blow parts dry using filtered, compressed air.
3. Inspect engine brake housing (C) for cracks. Replace as necessary.
4. Inspect master piston rollers (D) for excessive wear, spalling, and galling. Replace complete engine brake
assembly if any master piston roller is determined to be unacceptable to reuse.
5. Check solenoid assembly and solenoid assembly terminals (B and E) for damage or corrosion. Replace as
necessary.
6. Repeat steps 1 through 5 for each engine brake assembly.
Expected Outcome
Engine brake assemblies should be free of cracks, spalling, galling, or other notable damage.
Perform Engine Brake Assembly Testing (page 1010) procedure.
Engine Brake Assembly Testing
Overview
This test procedure was developed to ensure the engine brake solenoid electrical components function properly.
Engine brake assembly cleaned and inspected (page 1008).

• Digital Multimeter (DMM)
Testing Procedure
components.
CAUTION: Disconnect ground cable (–) from the negative terminal of the battery.
Figure 854 Engine Brake Solenoid

1. Engine brake housing 2. Engine brake solenoid terminals 3. Engine brake solenoid can (2)
(4)
See Engine Brake Solenoid (Figure 853) to perform steps 1 and 2.

1. Using a DMM, measure resistance between terminals (2) on each solenoid. Resistance should measure
between 8.7 and 10 Ω. Replace solenoid assembly if out of specification.
2. Using a DMM, measure resistance between each engine brake solenoid terminals (2) and engine brake
solenoid can (3). If any continuity is present, replace solenoid assembly.
Perform Lower Valve Cover Cleaning and Inspection (page 1012) procedure.
Lower Valve Cover and 16-pin E2 Engine Harness Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the lower valve cover and 16-pin E2 engine harness. Lower
valve cover and 16-pin E2 engine harness must be inspected to prevent contamination or loss of engine oil,
damage to internal engine components, and ensure proper operation of injectors and engine brake. Lower valve
cover and 16-pin E2 engine harness should be free of cracks, pitting, leaking or damaged gaskets, corrosion,
damaged connectors, damaged wires, and other notable damage.
Lower valve cover removed (page 905).

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components.

A. Injector terminal ends D. Engine brake solenoid terminal G. 16-pin E2 engine harness
B. Upper valve cover sealing ends connector
surface E. Lower valve cover gasket
C. Lower valve cover F. 16-pin E2 engine harness
See Lower Valve Cover(Figure 855) to perform steps 1 through 6.

1. Clean upper valve cover sealing surface (B).
2. Inspect lower valve cover and lower valve cover gasket (C and E) for cracks or other notable damage.
3. Inspect upper valve cover sealing surface (B) for cracking, pitting, or damage. Replace as necessary.
4. Carefully inspect 16-pin E2 engine harness (F) for worn conduit, frayed insulation, or heat damage to wires.
5. Inspect injector and engine brake solenoid terminal ends (A and D) for damaged or missing terminal nuts
and other notable damage. Repair or replace as necessary.
6. Inspect 16-pin E2 engine harness connector (G) for corrosion or damage; loose, bent, or broken pins; a
missing or damaged seal; or broken connector housing. Repair or replace as necessary.
Expected Outcome
Lower valve cover and 16-pin E2 engine harness should be free of cracks, pitting, leaking, damaged gaskets,
corrosion, damaged connectors, damaged wires, and other notable damage.
Perform Rocker Arm Assembly Cleaning and Inspection Procedure (page 1014).
Rocker Arm Assembly Cleaning and Inspection
Overview
The following procedure is used to clean and inspect the rocker arm assemblies and valve bridges. Rocker arm
assemblies and valve bridges must be inspected to prevent damage and insure proper operation of the intake
and exhaust valves. Rocker arm assemblies and valve bridges should be free of cracks, excessive wear, and
other notable damage.
Rocker arm assemblies removed (page 908).

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components.
Figure 856 Rocker Arm Assembly

A. Rollers C. Rocker shaft E. Rocker arm pivot feet
B. Rocker arm D. Valve bridges
See Rocker Arm Assembly(Figure 856) for steps 1 through 6.

1. Clean rocker arm assemblies with a suitable, non-caustic solvent.
2. Inspect rollers (A) for pitting, abnormal wear, and sticking. Replace as necessary.
3. Inspect rocker arms (B) for excessive wear or damage. Replace as necessary.
4. Inspect valve bridges (D) for excessive or abnormal wear. Replace as necessary.
5. Ensure rocker arm pivot feet (E) swivel freely. Replace as necessary.
6. Ensure rocker arms (B) move freely on rocker shaft (C). Replace as necessary.
Expected Outcome
Rocker arm assemblies and valve guides should be free of cracks, excessive wear, or other notable damage.
Perform Engine Wiring Harness Cleaning and Inspection (page 1016) procedure.
96-pin E1 Engine Harness Cleaning and Inspection
Overview
The following procedure is used to inspect 96-pin E1 engine harness. The 96-pin E1 engine harness must be
inspected to ensure proper operation of the engine and engine components. The 96-pin E1 engine harness
should be free of cracks, corrosion, connector damage, and other notable damage.
Engine wiring harness removed (page 921).

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Figure 857 96-pin E1 engine Harness

A. Insulation C. Conduit D. Wiring harness connector
B. 96-pin E1 engine harness (example)
See 96–pin E1 Engine Harness(Figure 857) to perform step 1.

1. Carefully inspect 96-pin E1 engine harness (B) for worn conduit (C), frayed insulation (A), damaged wiring
harness connectors (D), and heat damage to wires. Repair or replace as necessary.
Figure 858 Exhaust Gas Recirculation (EGR) Valve Jumper Harness

A. EGR valve jumper harness EGR B. EGR valve jumper harness C. EGR valve jumper harness
valve connector engine harness connector
See Exhaust Gas Recirculation (EGR) Valve Jumper Harness(Figure 858) to perform steps 2 and 3.
2. Carefully inspect EGR valve jumper harness (B) for worn conduit, frayed insulation, and or heat damage or
burnt wiring. Repair or replace as necessary.
3. Inspect EGR valve jumper harness EGR valve connector and EGR valve jumper harness engine harness
connector (A and C) terminals for corrosion or damage; loose, bent, or broken pins; missing or damaged
seals; or broken connector housings. Repair or replace as necessary.
Figure 859 Wiring Harness Connector (example)

A. Connector body C. Connector seal
B. Retaining tab D. Metal terminals
See Wiring Harness Connector (example)(Figure 859) to perform step 4.

4. Inspect each connector body (A) for the following conditions and repair or replace as necessary.
• Broken retaining tabs (B).
• Corroded connectors and metal terminals (D).
• Metal terminals (D) incorrectly latched in connector body (A) or pushed back relative to other terminals
in same connector.
• Ensure each connector has its seals (C) in place. During disassembly, a seal may pull off of its connector
and remain in the mating socket of a sensor or actuator. A connector assembled without the correct seals
can be contaminated with moisture and have corroded terminals, causing a poor electrical connection.
Expected Outcome
The engine wiring harness should be free of cracks, corrosion, connector damage, and other notable damage.
Perform Fuel Rail Cleaning and Inspection (page 1020) procedure.
Fuel Rail Cleaning and Inspection
Overview
The following procedure is used to inspect the fuel rail, fuel rail fittings, and other fuel rail components. The fuel
rail, fuel rail fittings, and other fuel rail components must be inspected to ensure proper operation of the engine
and engine components. The fuel rail, fuel rail fittings, and other fuel rail components should be free of cracks,
corrosion, connector damage, and other notable damage.
Fuel rail removed (page 932).

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A. Fuel Rail Pressure (FRP) sensor C. Pressure limiting valve E. Fuel line fittings (8)
B. Fuel rail D. Fuel drain tube port
See Fuel Rail(Figure 860) to perform steps 1 through 6.

1. Clean fuel rail (B) with a suitable, non-caustic solvent.
2. Inspect fuel rail (B) for cracks, leaks, and other notable damage. Replace as necessary.
3. Inspect fuel line fittings (E) for damage to threads and other notable damage. Replace as necessary.
4. Inspect fuel drain tube port (D) for damage to threads and other notable damage. Replace as necessary.
5. Inspect pressure limiting valve (C) for signs of leaking and other notable damage. Pressure limiting valve
should not be removed from fuel rail. Replace fuel rail if pressure limiting valve is damaged.
6. Inspect FRP sensor (A) for corroded terminals; loose, bent, or broken pins; or broken sensor housing. Repair
Expected Outcome
Fuel rail, fuel rail fittings, and other fuel rail components should be free of cracks, corrosion, connector damage,
Perform Cylinder Head and Crankcase Cleaning and Inspection (page 1022) procedure.
Cylinder Head and Crankcase Cleaning and Inspection
Overview
The following procedure is used to clean the cylinder head and crankcase. The cylinder head and crankcase
must be cleaned to ensure accurate testing and proper installation of the cylinder head. Cylinder head and
crankcase should be clean prior to testing.
Cylinder head removed (page 934).

• Injector Sleeve Brushes ZTSE4751
• Head Bolt Bottoming Tap ZTSE4855
Cleaning Procedure
CAUTION: Do not use chlorinated solvents on cylinder head related bolts. If parts are not cleaned thoroughly,
parts will corrode over time. Ensure parts are clean, dry, and free of chemicals other than engine oil.
CAUTION: To prevent engine damage, do not scratch gasket-side surface of cylinder head
Figure 861 Cylinder Head Surface

A. Gasket surface B. Valve heads (24)
See Cylinder Head Surface(Figure 861) to perform steps 1 through 4.

1. Use a scraper and wire brush to remove deposits and gasket material from valve heads (B) and gasket
surface (A).
3. Clean all bolt holes. Ensure gasket surface (A) is clean. Clean all surfaces and ports with steam, and then
dry with filtered-compressed air.
installed.
CAUTION: To prevent engine damage, clean and dry threads in crankcase bolt holes with filtered compressed
air. Dirt or oil in holes may cause binding and incorrect torque readings.
5. Clean out debris with filtered-compressed air.
Figure 862 Injector Bores

A. Cylinder head B. Injector bores (6)
See Injector Bores(Figure 862) to perform steps 6 through 8.

6. Use Injector Sleeve Brushes in injector bores (B) to remove deposits.
7. Use filtered-compressed air to clean debris from injector bores (B).
8. Inspect camshaft lobes for excessive wear, spalling, and galling. Replace as necessary.
Crankcase Cleaning and Inspection
Figure 863 Crankcase

A. Cylinder head bolt holes (26) B. Machined crankcase surface C. Crankcase
See Crankcase(Figure 863) to perform steps 9 through 12.

9. Clean cylinder head bolt holes (A) with Head Bolt Bottoming Tap ZTSE4855.
10. Use non-metallic stiff bristle brushes and scrapers to clean gasket material from machined crankcase surface
(B).
11. Clean machined crankcase surface (B) with solvent.
12. Dry with filtered-compressed air.
Expected Outcome
Cylinder head and crankcase should be clean.
Perform Cylinder Head Testing procedure.
Oil Pan Cleaning and Inspection
Overview
The following procedure is used to clean and inspect oil pan and oil pan gasket. Oil pan and oil pan gasket must
be inspected to ensure proper operation and lubrication of engine and many other engine components. Oil pan
and oil pan gasket should be free of cracks, warping, dents, or other notable damage.
Oil pan removed (page 938).

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Figure 864 Oil Pan

A. Oil pan gasket B. Oil pan C. Oil drain plug
See Oil pan(Figure 864) to perform steps 1 through 8.

1. Remove oil pan gasket (A) from oil pan (B).
2. Clean oil pan gasket and oil pan (A and B) with a suitable solvent.
4. Inspect oil pan gasket (A) for cracks or other notable damage. Replace as necessary.
5. Inspect bottom of oil pan (B) for metallic debris or other evidence of engine damage. Investigate any
abnormalities as required.
6. Inspect oil pan (B) for warping, dents, and cracks. Replace as necessary.
7. Inspect oil drain plug (C) for damage to threads. Replace as necessary.
8. Install clean oil pan gasket (A) on clean oil pan (B).
Expected Outcome
Oil pan and oil pan gasket should be free of cracks, warping, dents, or other notable damage.
Perform Oil Sump Cleaning and Inspection (page 1028) procedure.
Oil Sump Cleaning and Inspection
Overview
The following procedure is used to clean and inspect oil sump. Oil sump must be inspected to ensure proper
operation and lubrication of the engine and many other engine components. Oil sump should be free of cracks,
plugging, and other notable damage.
Oil sump removed (page 940).

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Figure 865 Oil Sump Inspection (typical)

A. Oil pickup tube B. Oil pickup tube supports C. Oil pickup tube screen
See Oil Sump Inspection (typical)(Figure 865) to perform steps 1 through 4.

1. Clean oil pickup tube and oil pickup tube supports (A and B) with a suitable, non-caustic solvent.
2. Dry with filtered, compressed air.
3. Inspect oil pickup tube and oil pickup tube supports (A and B) for cracks and damage. Replace as necessary.
4. Inspect oil pickup tube and oil pickup tube screen (A and C) for plugging and blockages. Replace as
necessary.
Expected Outcome
The oil sump should be free of cracks, plugging, and other notable damage.
Perform Piston Cooling Jet Cleaning and Inspection (page 1030) procedure.
Piston Cooling Jet Cleaning and Inspection
Inspection Overview
The following procedure is used to clean and inspect piston cooling jets. Piston cooling jets must be inspected
to ensure proper cooling of pistons and cylinder walls. Piston cooling jets should be free of cracks, plugging,
Piston cooling jets removed (page 942).

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Figure 866 Piston Cooling Jet

A. Piston cooling jet
See Piston Cooling Jet(Figure 866) to perform steps 1 through 3.

1. Hold each piston cooling jet (A) under running water. Water should stream from jet end.
2. Clear blocked cooling jets (A) using filtered, compressed air. Replace piston cooling jet if blockage cannot
be cleared.
3. Inspect cooling jets (A) for cracks, plugging, or other notable damage. Replace as necessary.
Expected Outcome
Piston cooling jets should be free of cracks, plugging, and other notable damage.
Perform Piston and Connecting Rod Disassembly (page 1032) procedure.
Piston and Connecting Rod Disassembly
Piston cooling jets cleaned and inspected (page 1030).
Figure 867 Piston Pin Retainer (typical)

1. Piston pin retainer (2)
See Piston Pin Retainer (typical) (Figure 867) to perform steps 1 and 2.
1. Using a pair of pliers, remove 2 piston pin retainers (1).
2. Remove piston pin from its bore by hand and separate connecting rod from piston.
Perform Piston and Connecting Rod Reassembly (page 1034) procedure.
Piston and Connecting Rod Reassembly
Pistons and connecting rods disassembled (page 1032).

• Piston ring expansion pliers (obtain locally).
CAUTION: To prevent engine damage, install piston rings correctly. Both top compression and taper face
compression rings have the same identification markings. The marking must face up for the ring to be installed
correctly. The taper face compression ring has a rectangular cross section and goes in the middle groove. The
top compression ring has a keystone cross section and goes in the top groove.
CAUTION: To prevent damage, only expand piston rings enough to fit over top of piston.
Figure 868 Piston Ring Installation (typical)
See Piston Ring Installation (typical) (Figure 868) to perform steps 1 through 6.
1. Install expansion spring component of bevelled oil ring into bottom piston groove.
2. Using piston ring expansion pliers, install oil scraper component of bevelled oil ring over expansion spring
with the gap 180 degrees from spring wire latch.
3. Using piston ring expansion pliers, install taper face compression ring into middle piston groove. Make sure
ring is installed with identification mark facing up.
4. Using piston ring expansion pliers, install top compression ring into top piston groove. Make sure ring is
installed with identification mark facing up.
5. Lubricate connecting rod piston pin bore, piston pin bore, and piston pin with clean engine oil.
6. Set piston crown down so arrow mark stamped on piston crown is at 6-o'clock position.
Figure 869 Piston Pin Retainer

1. Piston pin retainer
See Piston Pin Retainer (Figure 869) to perform steps 7 through 11.
7. Using pliers, install one piston pin retainer (1) into groove. Ensure retainer is fully seated in groove and tang
ends point up.
8. Hold connecting rod so open end faces 3-o’clock position of piston when installed.
9. Place connecting rod into piston.
10. Slide piston pin through piston holes, stopping at installed piston pin retainer.
11. Using pliers, install second piston pin retainer (1).
Perform Cylinder Liner Inspection (page 1037)procedure.
Cylinder Liner Cleaning and Inspection
Piston and connecting rods reassembled (page 1034).
Inspection Overview
The following procedure is used to clean and inspect cylinder sleeves for proper fit into engine. Cylinder
sleeves must be inspected to ensure proper seal of the head gasket. Cylinder sleeves should measure within
specifications.
components.
Figure 870 Cylinder Sleeve Interior Diameter

A. Dial bore gauge B. Cylinder sleeve interior
See Cylinder Sleeve Interior Diameter(Figure 870) to perform steps 1 and 2.

1. Install six cylinder sleeves (without cylinder sleeve O-rings) into crankcase.
2. Using a dial bore gauge (A), measure the cylinder sleeve interior (B) diameter at 120 degree intervals at
four different depths of cylinder sleeve. If cylinder sleeve inside diameter is not within specification, replace
cylinder sleeve.
Figure 871 Cylinder Sleeve Protrusion

A. Cylinder sleeve flange B. Dial indicator with magnetic C. Crankcase deck surface
base
See Cylinder Sleeve Protrusion(Figure 871) to perform step 3.

3. Check cylinder sleeve protrusion above crankcase deck as follows:
A. Install Sleeve Protrusion Hold Down Clamps using four included bolts. Torque bolts to special
torque.
B. Place dial indicator with magnetic base (B) on crankcase deck surface (C).
C. Position dial indicator with magnetic base (B) tip on crankcase deck surface (C) adjacent to cylinder
sleeve flange (A). Zero dial indicator.
D. Carefully pivot dial indicator with magnetic base (B) until tip is resting on cylinder sleeve flange (A).
Record reading.
E. Measure cylinder sleeve protrusion at three locations evenly spaced around the cylinder sleeve.
F. If any of the three readings of cylinder sleeve protrusion are not within specification, 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.
Expected Outcome
Cylinder sleeves should fit properly in engine block.
Perform Crankshaft and Main Bearing Reassembly Procedure .
Engine In-Frame Disassembly Installation Procedures and Special Torque

Specifications
Crankshaft Main Bearing Installation
Crankshaft main bearing removed (page 951).

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Torques
Main Bearing Cap Collar Bolts Special torque sequence. Steps 8 - 13 of
Installation Procedure (page 1042)
CAUTION: To prevent damage to engine perform the following procedure one crankshaft journal at a time.
1. Lubricate running surface of bearings with clean engine oil.
2. Install main bearings to crankshaft by rotating crankshaft counter-clockwise while applying pressure to new
main bearing with suitable tool allowing main bearing to roll into place. Ensure locking tabs on bearings are
snapped into saddle and oil holes in bearings line up with oil holes in crankcase.
NOTE: Step 4 and Step 5 are for number 6 main location only.
3. Install two upper thrust washers into crankcase at number 6 main location as follows:
a. Set upper thrust washer on top of crankshaft at number 6 main journal with grooves towards
crankshaft thrust surface.
b. Pivot upper thrust washer around crankshaft and down into position.
4. Install 2 lower thrust washers onto No. 6 main bearing cap. Make sure lower thrust washer locking tabs
align with notches in main bearing cap.
5. Place lower main bearing in main bearing cap. Make sure locking tab on bearing is snapped into main
bearing cap.
6. Lubricate bearings with clean engine oil.
Figure 872 Main Bearing Installation

2. Collar bolts (14)
See Main Bearing Installation (Figure 872) to perform steps 7 through 12.
7. Install main bearing cap (1) and secure with 2 new main collar bolts (2).
8. Tighten 2 collar bolts (2) to 10 N·m (88 lb·in).
9. Rotate crankshaft to verify that crankshaft does not bind. Correct as required.
10. Tighten 2 collar bolts (2) to 100 N·m (74 lb·ft).
11. Tighten 2 collar bolts (2) to 300 N·m (221 lb·ft).
12. Tighten 2 collar bolts (2) an additional 90 degrees.
13. Repeat steps 8 through 13 until all main bearing caps are installed.
Perform Cylinder Liner Installation (page 1043) procedure.
Cylinder Liner Installation
Crankshaft main bearings installed (page 1041).

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Torques
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Figure 873 Cylinder Sleeve O-rings

1. Cylinder sleeve (6) 2. O-rings (12)
See Cylinder Sleeve O-rings (Figure 873) to perform steps 1 and 2.

1. Lubricate two new cylinder sleeve O-rings (2) with clean engine oil and install in crankcase cylinder sleeve
bore.
2. Using a soft-faced hammer, install cylinder sleeve (1) by striking cylinder sleeve evenly until seated.
Perform Piston Cooling Jet Installation (page 1045) procedure.
Piston Cooling Jet Installation
Cylinder Liner Installed (page 1043).

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Torques
Piston Cooling Jet Bolts 13 N·m (115 lb·in)
Figure 874 Piston Cooling Jets

1. Crankcase 2. Piston cooling jets (6) 3. Piston cooling jet bolts (6)
NOTE: Rotating assembly removed from Piston Cooling Jets (Figure 874) for clarity.
See Piston Cooling Jets (Figure 874) to perform steps 1 and 2.
1. Install 6 piston cooling jets (2) in crankcase (1) with new piston cooling jet O-rings.
2. Secure piston cooling jets (2) to crankcase with 6 piston cooling jet bolts (3). Torque piston cooling jet bolts
to 13 N·m (115 lb·in).
Perform Piston and Connecting Rod Installation (page 1047) procedure.
Piston and Connecting Rod Installation
Piston cooling jets installed (page 1043).

• Piston Coping Tool – 12-146-01
• Exhaust Manifold Bolt Torx® Socket – ZTSE4843
Torques
Connecting rod cap bolts 74 lb·ft (100 N·m) + 90 degrees
CAUTION: To prevent engine damage, do not allow fractured mating surfaces of the connecting rod or
connecting rod cap to contact any surface other than its matched fractured surface. Contacting any other
surface could cause misalignment of the mating surface, resulting in connecting rod bearing and engine failure.
1. Verify proper connecting rod orientation. Assemble connecting rod cap to connecting rod with matching
identification code on same crankshaft journal from which it was removed. Be certain that longer leg of
connecting rod is positioned toward left side of crankcase.
Figure 875 Connecting Rod Chamfer

2. Chamfer
4. Arrow pointing to front of engine
See Connecting Rod Chamfer (Figure 875) to perform step 2.

2. Secure connecting rod cap (1) with two connecting rod bolts (3). Finger-tighten only.
3. Verify chamfer (2) on connecting rod cap (1) is pointing in same direction as arrow mark stamped on top of
piston. If chamfer is not pointing in same direction as arrow mark on piston, reinstall piston on connecting
rod.
4. Remove connecting rod cap from connecting rod.
5. Turn crankshaft so connecting rod journal (on the cylinder to receive piston installation) is at the bottom of
its stroke.
Figure 876 Arrow Mark on Piston (Typical)
See Arrow Mark on Piston (typical) (Figure 876) to perform steps 3 through 8.
6. Lightly coat piston and piston rings with clean engine oil.
7. Coat cylinder sleeve walls, crankshaft journals, and Piston Coping Tool with clean engine oil.
CAUTION: To prevent engine damage make sure connecting rod bearings are installed properly. Upper
connecting rod bearings have an oil hole and lower connecting rod bearings do not.
8. Install connecting rod bearings in connecting rod and cap. Bearings with oil hole go on connecting rod side.
Coat bearings with clean engine oil. Ensure all bearing locator tabs and oil holes are in alignment with
connecting rod and cap and bearings are flush with fractured mating faces of rod and cap.
CAUTION: To prevent engine damage, the arrow stamped on top of piston must face front of engine.
CAUTION: To prevent engine damage, do not damage piston cooling jet when installing connecting rod and
piston assembly. If jet is bent during piston assembly installation, replace jet.
Figure 877 Coping Tool

1. Cylinder sleeve 3. Coping tool
2. Cylinder sleeve ridge 4. Coping tool lip
See Coping Tool (Figure 877) to perform step 9.

9. Install coping tool (3) onto cylinder sleeve (1), seating coping tool lip (4) in cylinder sleeve ridge (2).
Figure 878 Piston Installation

1. Piston 3. Connecting rod assembly
2. Piston ring (3) 4. Coping tool
See Piston Installation (Figure 878) to perform steps 10 through 13.

10. Position piston rings (2) so ring openings are staggered 120⁰ from adjacent rings for proper orientation.
11. Press back of piston rings into piston ring grooves so ring openings are extended out from piston (1).
12. Carefully insert piston (1) and connecting rod assembly (3) into tapered opening of piston coping tool (4)
with arrow mark facing towards front of engine.
13. Use a rubber mallet to tap piston (1) through piston coping tool (4) and into cylinder sleeve. Guide connecting
rod in place on crankshaft. Do not let edges of connecting rod or fractured mating face of rod touch the
crankshaft journal. Before installing cap with bearing and starting bolts, be sure that bearings are still flush
with connecting rod and cap fractured mating faces and have NOT rotated.
Figure 879 Anti-polish Ring (APR) Installation

1. Piston 2. Anti-Polish Ring (APR) 3. Cylinder sleeve
See Anti-polish Ring (APR) Installation (Figure 879) to perform steps 14 and 15.
14. Install Anti-polish ring (2).
CAUTION: To prevent engine damage, lightly lubricate bolt threads and mating surfaces of bolt flanges with
clean engine oil. Too much oil causes hydrostatic lock and gives incorrect torque reading.
15. Lightly apply clean engine oil to new bolt threads for connecting rod and upper and lower bearings in cap
before installing bolts.
Figure 880 Correct Connecting Rod and Cap Joint Fit
See Correct Connecting Rod and Cap Joint Fit (Figure 880) to perform steps 16 and 17.
CAUTION: To prevent engine damage, clean fractured mating surfaces of the connecting rod and rod cap with
filtered compressed air.
16. Use filtered compressed air to clean debris from fractured mating surfaces of the connecting rod and rod
cap.
CAUTION: To prevent engine damage, install connecting rods with correct caps in the correct direction. If a rod
cap is reversed, an offset will be seen at the mating surfaces. If a reverse assembly is installed on the crankshaft,
the connecting rod must be replaced. Also, check crank pin (connecting rod journal) fillets for damage that would
require replacement of the crankshaft.
17. Assemble cap to connecting rod with matching identification code on same crankshaft journal from which it
was removed. Be certain that longer leg of connecting rod is positioned towards left side of crankcase.
Figure 881 Connecting Rod Cap (typical)

1. Connecting rod cap bolt (2)
See Connecting Rod Cap (typical) (Figure 881) to perform steps 18 through 21.
CAUTION: To prevent engine damage, install new connecting rod bolts
CAUTION: To prevent engine damage, do not use powered tools to install connecting rod bolts. Rotating bolts
too quickly can damage threads.
CAUTION: To prevent engine damage, do not rotate crankshaft until connecting rod bolts are fully tightened, as
this may cause bearings to rotate in place.
18. Using 2 new connecting rod cap bolts (1), install connecting rod cap (2). Tighten connecting rod cap bolts
finger-tight.
19. Using Exhaust Manifold Bolt Torx® Socket ZTSE4843, tighten connecting rod cap bolts (1) evenly to an
initial torque of 74 lb·ft (100 N·m).
20. Rotate (tighten) connecting rod bolts an additional 90 degrees (1/4 turn).
21. Repeat installation procedure for remaining piston and connecting rod assemblies.
Perform Oil Sump Installation (page 1055) procedure.
Oil Sump Installation
Pistons and connecting rods installed (page 1047).

None
Torques
Oil Sump Bolts 31 N·m (23 lb·ft)
Figure 882 Oil Sump

1. Bolts (4) 3. Crankcase
2. Oil sump supports (4) 4. Oil pickup tube
See Oil Sump (Figure 882) to perform steps 1 and 2.

1. Install oil pickup tube (4) and oil sump supports (2) as an assembly to the crankcase (3) with a new O-ring.
2. Secure pickup tube (4) and oil sump supports (2) with 4 bolts (1). Torque bolts to 31 N·m (23 lb·ft).
Perform Oil Pan Installation (page 1057) procedure.
Oil Pan Installation
Oil sump installed (page 1055).

None
Torques
Oil pan drain plug 75 N·m (55 lb·ft)
Oil pan bolts with hold-down clamps 35 N·m (26 lb·ft). Steps 6 - 8 of Installation
Procedure (page 1060)
1. Lubricate oil pan gasket with clean engine oil and install oil pan gasket onto oil pan.
Figure 883 Oil Pan Installation

1. Oil pan bolts with hold-down clamp (4)
2. Oil pan
3. Crankcase
See Oil Pan Installation (Figure 883) to perform step 2.

2. Secure oil pan (2) to crankcase (3) with 4 oil pan bolts with hold-down clamps (1). Torque oil pan bolts with
hold-down clamps finger-tight.
Figure 884 Oil Pan Bolts with Hold-down Clamps

1. Oil pan bolts with hold-down 2. Tube brackets (6) 4. Oil pan
clamp (22) 3. Drain plug
See Oil Pan Bolts with Hold-down Clamps (Figure 884) to perform steps 3 through 5.
3. Position 6 tube brackets (2) in place on oil (4) pan and secure with 6 oil pan bolts with hold-down clamps
(1). Torque oil pan bolts with hold-down clamps finger-tight.
4. Install 12 remaining oil pan bolts with hold-down clamps (1). Torque oil pan bolts with hold-down clamps to
finger tight.
5. Lubricate new O-ring with clean engine oil and install on drain plug. Torque drain plug to 75 N·m (55 lb·ft).
Figure 885 Oil Pan Torque Sequence
See Oil Pan Torque Sequence (Figure 885) to perform steps 6 through 8.
6. Torque 22 oil pan bolts with hold-down clamps in sequence to 10 N·m (89 lb·in).
7. Torque 22 oil pan bolts with hold-down clamps in sequence to 35 N·m (26 lb·ft).
8. Re-torque 22 oil pan bolts with hold-down clamps in sequence to 35 N·m (26 lb·ft).
Perform Cylinder Head Installation (page 1061) procedure.
Cylinder Head Installation
Oil pan installed (page 1057).

• Cylinder head lifting bracket
• Torque wrench
• Head bolts torx® socket ZTSE4787
Torques
Cylinder Head Lifting Bracket Bolts 31 N·m (23 lb·ft)
Cylinder Head Bolts Special torque sequence. Steps 7 - 15 of
Installation Procedure (page 1064).
1. If previously removed, install 2 dowel pins in crankcase.
CAUTION: To prevent engine damage, clean and blow dry threads in the crankcase bolt holes with filtered
compressed air. Dirt or oil in holes may cause binding or an incorrect torque reading.
CAUTION: To prevent engine damage, remove debris and contaminants from cylinder head gasket mating
surfaces. If debris is not removed, a faulty seal between the cylinder head, gasket and crankcase will cause oil,
coolant and compression leaks. Do not apply sealant to head gasket surfaces.
CAUTION: To prevent engine damage, install a new cylinder head gasket with part number facing up.
2. Install a new cylinder head gasket on crankcase.

1. Cylinder head lifting bracket 2. Bolts (4)
See Cylinder Head Lifting Bracket (Figure 886) to perform steps 3 and 4.
3. Position cylinder head lifting bracket (1) on rear of cylinder head.
4. Using 4 bolts (2), secure lifting bracket to cylinder head. Torque bolts to 31 N·m (23 lb·ft).
Figure 887 Lifting Cylinder Head
See Lifting Cylinder Head (Figure 887) to perform step 5 and 6.
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.
Figure 888 Cylinder Head Bolt Torque Sequence
CAUTION: To prevent engine damage, install new cylinder head bolts when installing cylinder head. Apply a
light coat of clean engine oil to new bolt threads and under bolt head. Too much oil will cause hydrostatic lock
and give incorrect torque reading. Do not use anti-seize compound, grease, or any other lubricant on cylinder
head bolt threads.
CAUTION: To prevent engine damage, use only permanent ink markers to identify bolt torque orientation.
CAUTION: To prevent engine damage, use a torque wrench to tighten cylinder head bolts. Do not use an impact
wrench.
CAUTION: To prevent engine damage follow the correct tightening sequence.
See Cylinder Head Bolt Torque Sequence (Figure 888) to perform steps 7 through 15.
7. Install 26 new lightly lubricated cylinder head bolts (1 through 26). Do not tighten at this time.
8. Remove 4 bolts that secure cylinder head lifting bracket to cylinder head.
9. Hand tighten cylinder head bolts.
10. Use Head Bolt Torx® Socket ZTSE4787 tighten cylinder head bolts (1-26) in numerical order to 10 N·m (89
lb·in).
11. Use Head Bolt Torx® Socket ZTSE4787 tighten cylinder head bolts (1-26) in numerical order to 150 N·m
(111 lb·ft).
12. Use Head Bolt Torx® Socket ZTSE4787 tighten cylinder head bolts (1-26) in numerical order to 300 N·m
(221 lb·ft).
13. Use Head Bolt Torx® Socket ZTSE4787 rotate cylinder head bolts (1-26) in numerical order 90 degrees (1/4
turn) clockwise.
turn) clockwise.
turn) clockwise.
Perform Fuel Rail Installation (page 1066) procedure.
Fuel Rail Installation
Cylinder head installed (page 1061).

None
Torques
Fuel Rail Mounting Bolts Torqued in High-Pressure (HP) Fuel Line
Installation procedure (page 1105)

1. Fuel rail 2. Cylinder head 3. Fuel rail bolts (3)
See Fuel Rail (Figure 889) to perform step 1.

1. Secure fuel rail (1) to cylinder head (2) with 3 fuel rail bolts (3). Tighten bolts finger-tight. Bolts will be torqued
in High-Pressure (HP) Fuel Line Installation procedure (page 1105).
Perform 96-pin E1 Engine Harness Installation (page 1068) procedure.
96-pin E1 Engine Harness Installation
Fuel rail installed (page 1066).

None
Torques
96-pin E1 Engine Wiring Harness to Engine Block Bolt 35 N·m (26 lb·ft)
96-pin E1 Engine Harness to Rear of Cylinder Head Bolt 35 N·m (26 lb·ft)
96-pin E1 Engine Harness to Front of Cylinder Head Bolt 31 N·m (23 lb·ft)
Figure 890 96-pin E1 Engine Wiring Harness (Engine Block)

1. Bolts (2) 2. 96-pin E1 engine harness 3. Crankcase
1. Install 96-pin E1 engine harness (2) to crankcase (3) and secure with 2 bolts (1). Torque bolts to 35 N·m
(26 lb·ft).
Figure 891 96-pin E1 Engine Harness (Rear of Cylinder Head)

1. Bolt 2. Cylinder head 3. 96-pin E1 engine harness
See 96-pin E1 Engine Harness (Rear of Cylinder Head) (Figure 891) to perform step 2.
2. Secure 96-pin E1 engine harness (3) to rear of cylinder head (2) with bolt (1). Torque bolt to 35 N·m (26
lb·ft).
Figure 892 96-pin E1 Engine Harness (Front of Cylinder Head)

1. Bolt 2. 96-pin E1 engine harness 3. Cylinder head
See 96-pin E1 Engine Harness (Front of Cylinder Head) (Figure 892) to perform step 3.
3. Secure 96-pin E1 engine harness to left front of cylinder head with bolt. Torque bolt to 31 N·m (23 lb·ft).
Figure 893 Fuel Rail Pressure (FRP) Sensor

1. FRP sensor 96-pin E1 engine
harness connector
2. FRP sensor
See Fuel Rail Pressure (FRP) Sensor (Figure 893) to perform step 4.
4. Connect FRP sensor 96-pin E1 engine harness connector (1) to FRP sensor (2).
Figure 894 Intake Manifold Temperature (IMT) Sensor

1. IMT sensor 96-pin E1 engine
harness connector
2. IMT sensor
See Intake Manifold Temperature (IMT) Sensor (Figure 894) to perform step 5.
5. Connect IMT sensor 96-pin E1 engine harness connector (1) to IMT sensor (2).
Figure 895 Fuel Delivery Pressure (FDP) Sensor and High-Pressure Fuel Pump (HPFP)
1. HPFP 3. FDP sensor
2. HPFP 96-pin E1 engine harness 4. FDP sensor 96-pin E1 engine
connector harness connector
See Fuel Delivery Pressure (FDP) Sensor and High-Pressure Fuel Pump (HPFP) (Figure 895) to perform steps
6 and 7.
6. Connect FDP sensor 96-pin E1 engine harness connector (4) to FDP sensor (3).
7. Connect HPFP sensor 96-pin E1 engine harness connector (2) to HPFP (1).
Figure 896 Intake Air Heater (IAH) Fuel Solenoid

1. IAH fuel solenoid 96-pin E1
engine harness connector
2. IAH fuel solenoid
See IAH Fuel Solenoid (Figure 896) to perform step 8.

8. Connect IAH fuel solenoid 96-pin E1 engine harness connector (1) to IAH fuel solenoid (2).
Figure 897 Engine Coolant Temperature 1 (ECT1) Sensor

1. ECT1 sensor 96-pin E1 engine
harness connector
2. ECT1 sensor
See Engine Coolant Temperature 1 (ECT1) Sensor (Figure 897) to perform step 9.
9. Connect ECT1 sensor 96-pin E1 engine harness connector (1) to ECT1 sensor (2).
Figure 898 Crankcase Oil Separator Speed (CCOSS) and Engine Oil Temperature (EOT) Sensors
1. CCOSS sensor 3. EOT sensor
2. CCOSS sensor 96-pin E1 4. EOT sensor 96-pin E1 engine
engine harness connector harness connector
See Crankcase Oil Separator Speed (CCOSS) and Engine Oil Temperature (EOT) Sensors (Figure 898) to
perform steps 10 and 11.
10. Connect CCOSS sensor 96-pin E1 engine harness connector (2) to CCOSS sensor (1).
11. Connect EOT sensor 96-pin E1 engine harness connector (4) to EOT sensor (3).
Figure 899 Crankshaft Position (CKP) and Camshaft Position (CMP) Sensors
1. CMP sensor 96-pin E1 engine 3. CKP sensor 96-pin E1 engine
harness connector harness connector
2. CMP sensor 4. CKP sensor
See Crankshaft Position (CKP) and Camshaft Position (CMP) Sensors (Figure 899) to perform steps 12 and 13.
12. Connect CKP sensor 96-pin E1 engine harness connector (3) to CKP sensor (4).
13. Connect CMP sensor 96-pin E1 engine harness connector (1) to CMP sensor (2).
14. Install tie straps as necessary.
Perform Injector Installation (page 1078) procedure.
Injector Installation
96-pin E1 Engine Harness Installed (page 1068).

• Injector Installer ZTSE4777
Torques
High-pressure Connector Body Retaining Nuts See special torque sequence. Steps 7 -
15 of Installation Procedure (page 1083)
High-pressure Connector Body Retaining Nuts See special torque sequence. Steps 7 -
15 of Installation Procedure (page 1083)
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.
CAUTION: To prevent engine damage, verify all thrust washers are properly installed in cylinder head.
Figure 900 Thrust Washers

1. Thrust washers (6) 2. Cylinder head
See Thrust Washers (Figure 900) to perform step 1.

1. Install 6 thrust washers (1) onto cylinder head (2).
Figure 901 Injection Quantity Adjustment (IQA) Code
See Injection Quantity Adjustment (IQA) Code (Figure 901) to perform step 2.
2. Record the IQA code of each new fuel injector and its corresponding cylinder number so the new code can
be programed into the ECM after fuel injectors are installed.
Figure 902 Injector Seals

1. Injector (6) 2. Combustion washer 3. O-ring
See Injector Seals (Figure 902) to perform steps 3 and 4.

CAUTION: To prevent engine damage, install new injector O-ring and combustion washer before installing
injector.
3. Install a new combustion washer (2) onto injector (1).
4. Lubricate a new O-ring (3) with clean engine oil and install in recess at mid-point of injector (1).
Figure 903 Injector And Injector Hold-Down Clamp Orientation

1. injector hold-down clamp (6) 2. Injector fuel inlet opening
See Injector And Injector Hold-Down Clamp Orientation (Figure 903) to perform step 5.
5. Slide injector hold-down clamp (1) on fuel injector with injector fuel inlet opening (2) on opposite side of
hold-down clamps.
CAUTION: To prevent engine damage, align injector and hold-down clamp correctly with cylinder head. Do not
twist injector when inserting injector into cylinder head.
6. Ensure injector bore in cylinder head is clean and no old combustion washer remains inside the bore.
Figure 904 Injectors and Hold-Down Clamps

1. Injector hold-down clamps (6) 2. Cylinder head 3. Fuel injectors (6)
See Injectors and Hold-Down Clamps (Figure 904) to perform steps 7 through 9.
7. Install fuel injector (3) by lowering fuel injector and injector hold-down clamp (1) as one unit into cylinder
head (2).
8. Using Injector Installer ZTSE4777, firmly press fuel injector (3) and injector hold-down clamp (1) to make
sure injector is fully seated into cylinder head (2).
9. Repeat steps 3 through 8 until all fuel injectors (3) have been seated in cylinder head (2)
CAUTION: To prevent engine damage, 6 new high-pressure connector bodies must be installed and aligned
before tightening M8 x 50 bolts for six fuel injectors.
Figure 905 Alignment of High-Pressure (HP) Connector Body

1. Notch in cylinder head 2. Locating ball 3. HP connector body (6)
See Alignment of High-pressure Connector Body (Figure 905) to perform step 10.
10. Using 6 new high-pressure connector bodies (3), align locating ball (2) with notch in cylinder head (1) and
install new high-pressure connector bodies.
Figure 906 Injector Hold-Down Clamp Bolts

1. Injector hold-down clamp bolts 2. Cylinder head
(6) 3. Fuel injectors (6)
See Injector Hold-Down Clamp Bolts (Figure 906) to perform step 10.
11. Secure 6 fuel injectors (3) by installing 6 injector hold-down clamp bolts (1) into cylinder head (2). Tighten
injector hold-down clamp bolts finger tight.
Figure 907 HP Connector Bodies

1. HP connector body retaining 2. Cylinder head 3. High-pressure connector bodies
nuts (6) (6)
See HP Connector Bodies (Figure 907) to perform steps 12 through 14.

12. Secure high-pressure connector bodies (3) to cylinder head (2) with 6 high-pressure connector retaining
nuts (1). Torque high-pressure connector body retaining nuts to 55 N·m (41 lb·ft).
13. Completely loosen 6 high-pressure retaining nuts (1).
14. Torque 6 high-pressure retaining nuts (1) to 10 N·m (89 lb·in).
Figure 908 Injector Hold-Down Clamp Bolt Final Torque

1. Injector hold-down clamp bolts 2. Cylinder head
(6) 3. Fuel injectors (6)
See Injector Hold-Down Clamp Bolt Final Torque (Figure 908) to perform steps 15 and 16.
15. Secure 6 fuel injectors (3) by torquing 6 injector hold-down clamp bolts (1) to 25 N·m (18 lb·ft).
16. Rotate 6 injector hold-down clamp bolts (1) an additional 90 degrees clockwise in cylinder head (2).
Figure 909 High-Pressure Connector Retaining Nut Final Torque

1. HP connector body retaining 2. Cylinder head
nuts (6) 3. HP connector bodies (6)
See High-Pressure Connector Retaining Nut Final Torque (Figure 909) to perform steps 17 and 18.
17. Secure 6 HP connector bodies (3) by torquing 6 high-pressure connector retaining nuts (1) to 20 N·m (15
lb·ft).
18. Rotate 6 high-pressure connector body retaining nuts (1) an additional 32 degrees clockwise in cylinder
head (2).
Perform Rocker Arm Assembly Installation (page 1091) procedure.
Lower Valve Cover and 16-pin E2 Engine Harness Installation
Rocker Arm Assemblies and Engine Brake Assemblies Installed (page 1091).

• Loctite® 5127
Torques
Lower Valve Cover Screws With Dampers 11 N·m (97 lb·in)
Injector Electrical Connection Nuts 2 N·m (16 lb·in)
Engine Brake Solenoid Electrical Connection Nuts 4 N·m (31 lb·in)
1. Apply Loctite® 5127 sealant at sharp corners and curved surfaces to joining surfaces of cylinder head and
lower valve cover gasket.

1. Screws with dampers (18) 2. Lower valve cover 3. Cylinder head

2. Secure lower valve cover (2) to cylinder head (3) with 18 screws with dampers (1). Tighten screws with
dampers finger-tight.
Figure 911 Lower Valve Cover Torque Pattern

3. Tighten 18 screws with dampers (1-18) in sequence to 11 N·m (97 lb·in).
Figure 912 Fuel Injector Electrical Connections (front of cylinder head engine brake removed for
clarity)
1. Fuel injectors (6) 2. Injector electrical connection 3. 16-pin E2 engine harness
nuts (12) 4. Lower valve cover
See Fuel Injector Electrical Connections (front of cylinder head engine brake removed for clarity) (Figure 784)
to perform steps 4 and 5.
4. Install 12 injector electrical connection nuts (2) securing 16-pin E2 engine harness (3) to fuel injectors (1).
Torque injector electrical connection nuts to 2 N·m (16 lb·in).
5. Secure 16-pin E2 engine harness (3) to lower valve cover (4) with tie straps as needed.
Figure 913 Engine Brake Solenoid Electrical Connections (Front of Cylinder Head)
1. Engine brake solenoid electrical 2. 16-pin E2 engine harness
connection nuts (40 3. Engine brake solenoid
See Engine Brake Solenoid Electrical Connections (Front of Cylinder Head) (Figure 913) to perform step 6.
6. Install 4 engine brake solenoid electrical connection nuts (1) securing 16-pin E2 engine harness (2) to engine
brake solenoid (3). Torque engine brake solenoid electrical connection nuts to 4 N·m (31 lb·in).
Perform Upper Valve Cover Installation (page 1095) procedure.
Rocker Arm Assembly and Engine Brake Assembly Installation
Injectors Installed (page 1078).

None
Torques
Rocker Arm Assembly Bolts 105 N·m (77 lb-ft)
Engine Brake Housing Bolts 75 N·m (55 lb·ft)

1. Rocker bearing block (6) 2. Valve bridge (12)
See Rocker Bearing Block and Valve Bridges (Figure 914) to perform steps 1 and 2.
1. Install 6 new or previously marked rocker bearing blocks (1).
2. Place 12 new or previously marked valve bridges (2) on intake and exhaust valves with milled end oriented
toward rocker bearing block (1).
Figure 915 Rocker Arm Assemblies

1. Rocker arm assembly (6) 2. Cylinder head 3. Rocker arm assembly bolt (12)
See Rocker Arm Assemblies (Figure 915) to perform steps 3 and 4.

3. Install 6 new or previously marked rocker arm assemblies (1).
4. Install 12 rocker arm assembly bolts (3) to secure rocker arm assemblies (1) to cylinder head (2) (if engine
is equipped with engine brake, only install 6 rocker arm assembly bolts at this time).
Figure 916 Front and Rear Engine Brake

1. Rocker arm assembly bolts (12) 3. Front engine brake housing 5. Cylinder Head
2. Rear engine brake housing assembly 6. Camshaft
assembly 4. Engine brake housing bolts (6)
See Front and Rear Engine Brake (Figure 916) to perform steps 5 through 12.
5. If equipped with engine brake, carefully place previously marked front engine brake housing assembly (3)
into position over camshaft (6) and valve train.
6. If equipped with engine brake, install 3 rocker arm assembly bolts (1) to secure front engine brake housing
assembly (3) to cylinder head (5).
7. If equipped with engine brake, install 3 Engine brake housing bolts (4) to secure front engine brake housing
8. If equipped with engine brake, carefully place previously marked rear engine brake housing assembly (2)
into position over camshaft (6) and valve train.
9. If equipped with engine brake, install 3 rocker arm assembly bolts (1) to secure rear engine brake housing
10. If equipped with engine brake, install 3 Engine brake housing bolts (4) to secure rear engine brake housing
11. Torque 12 rocker arm assembly bolts (1) to 105 N·m (77 lb-ft).
12. If equipped with engine brake, torque engine brake housing bolts (4) to 75 N·m (55 lb·ft).
13. Perform Valve Lash Adjustment (page 63) procedure.
14. If equipped with engine brake, perform Engine Brake Lash Adjustment procedure.
Perform Lower Valve Cover and 16-pin E2 Engine Harness Installation (page 1086) procedure.
Upper Valve Cover Installation
Lower valve cover and 16-pin E2 engine harness installed (page 1086).

None
Torques
Upper Valve Cover Bolts 31 N·m (23 lb·ft)

1. Bolts (18) 2. Upper valve cover 3. Lower valve cover
See Upper Valve Cover (Figure 917) to perform step 1.

1. Secure upper valve cover (2) to lower valve cover (3) with 18 bolts (1). Torque bolts to 31 N·m (23 lb·ft).
Perform Coolant Outlet Manifold and Thermostat Housing Installation (page 1097) procedure.
Coolant Outlet Manifold and Thermostat Housing Installation
Upper valve cover installed (page 1095).

• P-80® rubber lubricant or equivalent Obtain locally
• Extension Tube Installer Small ZTSE6047
• Extension Tube Installer Large ZTSE6046
Torque
Thermostat Housing Bolts 35 N·m (26 lb·ft)
96-pin E1 Engine Harness to Exhaust Gas Recirculation (EGR)
31 N·m (23 lb·ft)
Cooler Return Manifold Bolt
96-pin E1 Engine Harness to Coolant Outlet Manifold Bolt 13 N·m (10 lb·ft)
Figure 918 Thermostat Housing Assembly (Some Items Removed for Clarity)
1. Cylinder head 4. Bolts (2) 7. Front cover
2. Extension tubes (2) 5. Gaskets (2)
3. Thermostat housing assembly 6. Spacer plate
See Thermostat Housing Assembly (Some Items Removed for Clarity) (Figure 918) to perform steps 1 through
3.
1. Lubricate sealing surfaces of two extension tubes (2) with P-80® rubber lubricant or equivalent and install
into thermostat housing assembly (3) using Extension Tube Installer Small ZTSE6047.
2. Position thermostat housing assembly (3), gaskets (5), and spacer plate (6) in place on front cover (7) and
cylinder head (1).
3. Secure thermostat housing (3) to front cover (7) with two bolts (4). Tighten bolts finger-tight.
Figure 919 Thermostat Housing Bolts

1. Extension tube 2. Thermostat housing assembly 3. Thermostat housing bolts (4)
See Thermostat Housing Bolts (Figure 919) to perform step 4 and 5.

4. Install 4 thermostat housing bolts (3). Torque thermostat housing bolts to 35 N·m (26 lb·ft)
5. Lubricate sealing surfaces of extension tube (1) with P-80® rubber lubricant or equivalent and install into
thermostat housing assembly (2) using Extension Tube Installer Large ZTSE6046.
Figure 920 Lower Thermostat Housing Assembly Bolts

1. Bolts (2) 2. Thermostat housing assembly 3. Front cover
See Lower Thermostat Housing Assembly Bolts (Figure 778) to perform step 6.
6. Using 2 bolts (1), secure thermostat housing assembly (2) to front cover (3). Torque bolts to 35 N·m (26
lb·ft).

1. Exhaust Gas Recirculation 2. 96-pin E1 engine harness
(EGR) cooler return manifold 3. Thermostat housing assembly
bolt 4. Coolant outlet manifold bolt
See 96-pin E1 Engine Harness (Figure 921) to perform steps 7 through 9.

7. Position 96-pin E1 engine harness (2) on thermostat housing assembly (3).
8. Secure 96-pin E1 engine harness (2) to thermostat housing assembly (3) with EGR cooler return manifold
bolt (1). Torque EGR cooler return manifold bolt to 31 N·m (23 lb·ft).
9. Secure 96-pin E1 engine harness (2) to thermostat housing assembly (3) with coolant outlet manifold bolt
(4). Torque coolant outlet manifold bolt to 13 N·m (10 lb·ft).
Perform Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Installation (page 1102) procedure.
Engine Throttle Valve (ETV) and Air Intake Throttle Duct Assembly Installation
Coolant outlet manifold and thermostat housing installed (page 1097).

None
Torques
Intake Throttle Duct Mounting Bolts 31 N·m (23 lb·ft)
IAH Igniter Fuel Supply line 10 N·m (89 lb·in)
Figure 922 Air Intake Throttle Duct Bolts (Some Items Removed For Clarity)
1. Cylinder head 2. Air intake throttle duct 3. Bolts (3)
See Air Intake Throttle Duct Bolts (Some Items Removed For Clarity) (Figure 922) to perform steps 1 and 2.
1. Position air intake throttle duct (2) on cylinder head (1) with new gasket.
2. Secure intake throttle duct (2) to cylinder head (1) with 3 bolts (3). Torque bolts to 31 N·m (23 lb·ft).

1. IAH Igniter fuel supply line 5. EGRGT sensor 10. IAH Igniter
2. Intake Manifold Pressure (IMP) 6. ETV engine harness connector
sensor 7. ETV
3. IMP engine harness connector 8. Charge Air Cooler Outlet
4. Exhaust Gas Recirculation Gas Temperature (CACOT) sensor
Temperature (EGRGT) sensor engine harness connector
engine harness connector 9. CACOT sensor
See Engine Wiring Harness (Figure 923) to perform steps 3 and 4.

3. Connect CACOT sensor engine harness connector (8) to CACOT sensor (9), IMP engine harness connector
(3) to IMP sensor (2), ETV engine harness connector (6) to ETV (7), and EGRGT engine harness connector
(4) to EGRGT sensor (5).
4. Install IAH igniter fuel supply line (1) onto IAH Igniter (10). Torque IAH igniter fuel supply line to 10 N·m (89
lb·in).
Perform HP Fuel Line Installation (page 1105) procedure.
High-Pressure (HP) Fuel Line Installation
Engine Throttle Valve (ETV) and air intake throttle duct assembly installed (page 1102).

• Crowfoot wrench (obtain locally)
Torques
Banjo Bolts 30 N·m (22 lb·ft)
Fuel Rail Mounting Bolts 35 N·m (26 lb·ft)
Injector High-Pressure (HP) Line Tube Nuts See special torque procedure. Steps
7 and 8 of installation procedure (page
1109)
Fuel Rail Supply Lines See special torque procedure. Steps 9
through 11 of installation procedure (page
1110)
21-way Connector Bracket Bolts 31 N·m (23 lb·ft)
Figure 924 Fuel Drain Tube

1. Fuel rail 3. Banjo bolts (2) 5. Cylinder head
2. Fuel drain tube 4. Seal rings (4)
See Fuel Drain Tube (Figure 924) to perform steps 1 through 3.

1. Position fuel drain tube (2) on fuel rail (1) and secure with banjo bolt (3) and 2 new seal rings (4). Tighten
banjo bolt to finger tight.
2. Position fuel drain tube (2) on cylinder head (5) and secure with banjo bolt (3) and 2 new seal rings (4).
Torque banjo bolt to 30 N·m (22 lb·ft).
3. Torque banjo bolt (3) that secures fuel drain tube (2) to fuel rail (1) to 30 N·m (22 lb·ft).
Figure 925 HP Lines

1. Tube nuts (2) 4. Injector 3 high-pressure line 7. Injector 6 high-pressure line
2. Injector 1 high-pressure line 5. Injector 4 high-pressure line 8. Cylinder head
3. Injector 2 high-pressure line 6. Injector 5 high-pressure line 9. Fuel rail
See HP Lines (Figure 925) to perform steps 4 and 5.
4. Install new injector 1 high-pressure line (2) to fuel rail (9) and cylinder head (8). Tighten tube nuts (1)
finger-tight.
5. Repeat Step 4 for injector 2 high-pressure line (3), injector 3 high-pressure line (4), injector 4 high-pressure
line (5), injector 5 high-pressure line (6), and injector 6 high-pressure line (7).

1. Fuel rail 2. Cylinder head 3. Bolts (3)
See Fuel Rail (Figure 926) to perform step 6.

6. Secure fuel rail (1) to cylinder head (2) by torquing 3 bolts (3) to 35 N·m (26 lb·ft).
Figure 927 HP Lines Torque

1. Tube nuts (12)
2. Injector 1 HP line
8. Cylinder head
9. Fuel rail
See HP Lines Torque (Figure 927) to perform steps 7 and 8.

7. Using a crowfoot wrench, secure all injector HP lines (2-7) to fuel rail (9) and cylinder head (8) with 12 tube
nuts(1). Torque tube nuts to 23 N·m (17 lb·ft). See Using a Torque Wrench Extension to calculate the torque
compensation to match specific wrench configuration.
8. Tighten tube nuts (1) an additional 60 degrees.
Figure 928 Fuel Rail Supply Lines

1. Fuel rail supply lines 3. Fuel rail 4. High-Pressure Fuel Pump
2. Tube nuts (4) (HPFP)
See Fuel Rail Supply Lines (Figure 928) to perform step 9 through 11.
9. Secure fuel rail supply lines (1) to HPFP (4) and fuel rail (3) with 4 tube nuts (2). Hand tighten tube nuts.
10. Using a crowfoot wrench secure fuel rail supply lines (1) to fuel rail (3) and HPFP (4) with 4 tube nuts
(2). Torque tube nuts to 23 N·m (17 lb·ft). See Using a Torque Wrench Extension to calculate the torque
compensation to match specific wrench configuration.
11. Tighten tube nuts (2) an additional 60 degrees.
Figure 929 21-Way Connector and Connector Bracket

1. Air supply line 3. 21-way connector bracket bolts 5. 21-way connector bolts (4)
2. 21-way connector bracket (3) 6. 21-way connector
4. Cylinder head
See 21-Way Connector and Connector Bracket (Figure 929) to perform steps 12 through 15.
12. Secure 21-way connector bracket (2) to cylinder head (4) with 2 21-way connector bracket bolts (3). Torque
21-way connector bracket bolts to 31 N·m (23 lb·ft).
13. Connect air supply line (1) to 21-way connector bracket (2).
14. Secure 21-way connector (6) to 21-way connector bracket (2) with 4 21-way connector bolts (5).
15. Connect 21-way connector.
Perform Engine Control Module (ECM) and ECM Mounting Bracket Installation (page 1112) procedure.
Engine Control Module (ECM) and ECM Mounting Bracket Installation
High-Pressure (HP) fuel lines installed (page 1105).
Torques
ECM Bracket Mounting Bolts with Rubber Insulators. 31 N·m (23 lb·ft)
96-Pin E1 Engine Harness to ECM Mounting Bracket Bolt 10 N·m (89 lb·in)
ECM Mounting Bolts 10 N·m (89 lb·in)
IAH Solenoid Bolts 6 N·m (53 lb·in)

1. Bolts with rubber insulators (3) 2. ECM mounting bracket 3. Cylinder head

1. Secure ECM mounting bracket (2) to cylinder head (3) with 3 bolts with rubber insulators (1). Torque bolts
with rubber insulators to 13 N·m (115 lb·in).

1. Bolt 2. ECM mounting bracket
See 96-pin E1 Engine Harness (Figure 931) to perform step 2.

2. Secure 96-pin E1 engine harness to ECM mounting bracket (2) with bolt (1). Torque bolt to 10 N·m (89 lb·in).

1. Intake Air Heater (IAH) solenoid
2. IAH solenoid bolts (2)
3. ECM mounting bolts (8)
4. ECM mounting bracket
5. ECM
6. Air Control Valve (ACV) supply line
7. Engine wiring harness
8. Chassis connector sockets
9. 96-pin E1 engine harness connector
10. 16-pin E2 engine harness connector
3. Secure ECM (5) to ECM mounting bracket (4) with 8 ECM mounting bolts (3). Torque ECM mounting bolts
to 10 N·m (89 lb·in).
4. Secure IAH solenoid (1) to ECM mounting bracket (4) with 2 IAH solenoid bolts (2). Torque IAH solenoid
bolts to 53 lb·in (6 N·m).
5. Connect IAH relay connector to IAH solenoid (1).

8. Install clips and tie straps as needed to secure engine wiring harness (7) to ECM mounting bracket (4).
9. Install tie straps as needed to secure ACV supply line (6) to ECM mounting bracket (4).
Perform Exhaust Manifold Installation (page 1117) procedure.
Exhaust Manifold Assembly Installation
Exhaust Manifold Installed (page 1117).

None
Torques
Exhaust-Manifold Bolts and Spacers See special torque procedure. Steps 2
through 4 of installation procedure (page
1119)
Exhaust Manifold Heat Shield Bolts 31 N·m (22 lb·ft)

See Exhaust Manifold (Figure 933) to perform step 1.

1. Position exhaust manifold sections (2) and new exhaust manifold gaskets on cylinder head (3) and secure
with 18 exhaust manifold bolts and spacers (1). Tighten exhaust manifold bolts and spacers finger-tight.
Figure 934 Exhaust Manifold Torque Sequence

See Exhaust Manifold Torque Sequence (Figure 934) to perform steps 2 through 4.
2. Torque 18 exhaust-manifold bolts and spacers in sequence to 20 N·m (15 lb·ft).
3. Following the same torque sequence, verify all bolts are torqued to 20 N·m (15 lb·ft).
4. Following the torque sequence used in steps 15 and 16, torque bolts an additional 90 degrees.

bolts (4) shield
5. Using 4 exhaust manifold heat shield bolts (1), install rear exhaust manifold heat shield (2) onto rear exhaust
manifold (3). Torque bolts to 18 N·m (13 lb·ft).
Perform Rear Coolant Manifold Installation (page 1122) procedure.
Rear Coolant Manifold Installation
Rear Coolant Manifold installed (page 1122).

• P-80® rubber lubricant or equivalent (obtain locally)
• Extension Tube Installer Small ZTSE6047
• Extension Tube Installer Large ZTSE6046
Torques
Rear Coolant Manifold Mounting Bolts 31 N·m (23 lb·ft)
Figure 936 Rear Coolant Manifold Extension Tubes

2. Small extension tube
3. Large extension tube
See Rear Coolant Manifold Extension Tubes (Figure 936) to perform steps 1 and 2.
1. Lubricate sealing surfaces of large extension tube (3) with P-80® rubber lubricant or equivalent and install
into rear coolant manifold (1) using Extension Tube Installer Large ZTSE6046.
2. Lubricate sealing surfaces of small extension tube (2) with P-80® rubber lubricant or equivalent and install
into rear coolant manifold (1) using Extension Tube Installer Small ZTSE6047.

1. Bolts (3)
2. Aftertreatment Fuel Injector (AFTFI) fuel supply line
3. AFTFI fuel supply tube
5. Cylinder head
See Rear Coolant Manifold (Figure 937) to perform steps 3 and 4.

3. Secure rear coolant manifold (4) to cylinder head (5) with 3 bolts (1). Torque bolts to 31 N·m (23 lb·ft).
4. Connect AFTFI fuel supply line (2) to AFTFI fuel supply tube (3).
5. Install tie straps as needed.
Perform Oil Module Installation (page 1126) procedure.
Oil Module Installation
Rear Coolant Manifold installed (page 1122).

None
Torques
M10 oil module bolts 65 N·m (48 lb·ft)

M8 x 150 oil module bolt 35 N·m (26 lb·ft)
Oil module flange bolts 24 N·m (18 lb·ft)
1. Position new gasket onto oil module assembly.

1. M10 x 80 oil module bolt (7)
2. M10 x 170 oil module bolt
3. M10 x 110 oil module bolt (3)
4. M8 x 150 oil module bolt location (from water pump) includes 9 x 16 x 15 spacer
CAUTION: To prevent engine damage, do not use any silicone or other sealant when installing oil module
assembly.
2. Position oil module assembly and install 7 M10 x 80 bolts, M10 x 170 bolt, and 3 M10 x 110 bolts. Tighten
M10 oil module bolts to 65 N·m (48 lb·ft).
3. Place 9 x 16 x 15 spacer between water distribution housing and oil module assembly.
4. 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 oil module bolt to 35 N·m (26 lb·ft).

4. Oil module flange bolt (3)
5. Lubricate sealing surfaces of DMR20 x DN14 and DMR37 x DN29 extension tubes with P-80® rubber
lubricant or equivalent (page 1232) and insert into oil module flange.
6. Install extension tubes into oil module flange using Extension Tube Installer Large and Extension Tube
Installer Small (page 1232).
7. Position oil module with new formed seal onto oil module while gently pushing extension tubes into cylinder
head. Install 3 oil module flange bolts. Tighten bolts oil module flange bolts to 24 N·m (18 lb·ft).
Perform High-Pressure (HP) Turbocharger Installation (page 1129) procedure.
High-Pressure (HP) Turbocharger Installation
Oil Filter installed (page 1126).

None
Torques


See HP Turbocharger Upper Mounting Nuts (Figure 940) to perform steps 1 and 2.
1. With help from assistant, move HP turbocharger (3) into place for installation.
2. Using 2 new HP turbocharger upper-mounting nuts (2) and new turbocharger to exhaust manifold gasket,
install HP turbocharger (3) onto exhaust manifold (1). Torque HP turbocharger upper-mounting nuts to finger
tight.


3. Install new HP turbocharger lower-mounting nut (3) to secure HP turbocharger (1) to exhaust manifold (2).
Torque HP turbocharger lower-mounting nut to finger tight.

4. Install new HP turbocharger air supply duct O-ring seal onto HP turbocharger (1). Apply P-80® lubricant to
HP turbocharger air supply duct O-ring seal.
slide HP turbocharger air supply duct over inlet of HP turbocharger (1).
6. To secure HP turbocharger air supply duct (3) to HP turbocharger (1), torque HP turbocharger air supply
duct V-band clamp to 6 N·m (4 lb·ft).
Figure 943 HP Turbocharger Upper Mounting Nuts Final Torque

See HP Turbocharger Upper Mounting Nuts Final Torque (Figure 943) to perform step 7.
7. To secure HP turbocharger (3) onto exhaust manifold (1), torque 2 HP turbocharger upper-mounting nuts
(2) to 62 N·m (46 lb·ft).
Figure 944 HP Turbocharger Lower Mounting Nut Final Torque

See HP Turbocharger Lower Mounting Nut Final Torque (Figure 944) to perform step 8.
8. To secure HP turbocharger (1) to exhaust manifold (2), torque HP turbocharger lower-mounting nut (3) to
62 N·m (46 lb·ft).
Figure 945 HP Turbocharger Air Supply Duct Final Torque

See HP Turbocharger Air Supply Duct Final Torque (Figure 945) to perform steps 9 and 10.
9. To secure HP turbocharger air supply duct (3) to oil module assembly (6), torque HP turbocharger air supply
duct bolt (5) to 62 N·m (46 lb·ft).
10. Install wiring harness and 2 wiring harness clips (4) onto HP turbocharger air supply duct (3).
Figure 946 Low-Pressure Charge Air Cooler (LPCAC) Coolant Supply Tube
1. LPCAC coolant supply tube to 2. Water distribution housing
water distribution housing bolt 3. LPCAC coolant supply tube
See LPCAC Coolant Supply Tube (Figure 946) to perform steps 11 and 12.
11. Install new O-ring onto LPCAC coolant supply tube (3) and lubricate O-ring with P-80® lubricant.
12. Using LPCAC coolant supply tube to water distribution housing bolt (1), install LPCAC coolant supply tube
(3) into water distribution housing (2). Torque LPCAC coolant supply tube to water distribution housing bolt
to 13 N·m (10 lb·ft).
Figure 947 HP Turbocharger Air Supply Duct Connections

bolt bolts (2) 8. Coolant return hose clamp
2. Cab heater coolant return tube 5. HP turbocharger air supply duct 9. Coolant return hose
3. LPCAC coolant supply tube 6. Cab heater coolant return tube
stud bolt
See High-Pressure (HP) Turbocharger Air Supply Duct Connections (Figure 947) to perform steps 13 through
16.
13. Using 2 LPCAC coolant supply tube bolts (4), install LPCAC coolant supply tube (3) onto HP turbocharger
air supply duct (5). Torque LPCAC coolant supply tube bolts to 31 N·m (23 lb·ft).
14. Using coolant return hose clamp (8), install coolant return hose (9) onto water distribution housing (7). Torque
coolant return hose clamp to 4 N·m (35 lb·in).
15. Install 2 new O-rings onto cab heater coolant return tube (2) and apply P-80® lubricant to O-rings.
16. Using cab heater return tube bolt (1) and cab heater coolant return tube stud bolt (6), install cab heater
return tube (2) into HP turbocharger air supply duct (5). Torque both the cab heater coolant return tube bolt
and stud bolt to 13 N·m (10 lb·ft).

1. Cab heater coolant return tube 3. HP turbocharger air supply duct 5. Engine harness connector
bolt Inlet Sensor (TC2CIS)
17. Connect engine harness connector (5) onto TC2CIS (4).
18. Using cab heater coolant return tube bolt (2), install cab heater coolant return tube (1) onto HP turbocharger
air supply duct (3). Torque cab heater coolant return tube bolt to 31 N·m (23 lb·ft).
Perform Low-Pressure (LP) Turbocharger Installation (page 1138) procedure.
Low-Pressure (LP) Turbocharger Installation
HP turbocharger installed (page 1129).

• P-80® lubricant (obtain locally)
Torques


1. LP turbocharger 2. LP turbocharger to HP 3. HP turbocharger
turbocharger mounting bolts (5)
See LP Turbocharger (Figure 949) to perform steps 1 through 3.

1. Remove all disposable air and fuel caps ZTSE4891 from LP turbocharger inlet and outlet ports prior to
installation.
2. With help from an assistant, move LP turbocharger into place for installation. Ensure alignment dowels are
properly aligned.
3. Using 5 new LP turbocharger to HP turbocharger mounting bolts (2), install LP turbocharger (1) onto HP
turbocharger (3). Torque LP turbocharger to HP turbocharger mounting bolts to 47 N·m (35 lb·ft).
Figure 950 LP Turbocharger Mounting Bracket

1. LP turbocharger mounting 3. LP turbocharger mounting 4. LP turbocharger mounting
bracket bolt bracket stud bolts with spacers bracket
2. LP turbocharger (2) 5. Crankcase
See LP Turbocharger Mounting Bracket (Figure 950) to perform steps 4 through 6.

4. Using 2 LP turbocharger mounting bracket stud bolts with spacers (3), install LP turbocharger mounting
bracket (4) to crankcase (5). Torque bolts to finger tight.
5. Using LP turbocharger mounting bracket bolt (1), secure LP turbocharger mounting bracket (4) to LP
turbocharger (2). Torque bolt finger-tight.
6. Torque 2 LP turbocharger mounting bracket stud bolts with spacers and LP turbocharger mounting bracket
bolt to 31 N·m (23 lb·ft).

1. Turbocharger oil drain tube bolts 2. HP turbocharger 4. LP turbocharger
(4) 3. Turbocharger oil drain tube
See Turbocharger Oil Drain Tube (Figure 951) to perform steps 7 through 9.
7. Install new O-rings onto new turbocharger oil drain tube (3) and lubricate O-rings with P-80® lubricant.
8. Install bottom of new oil drain tube (3) into crankcase.
9. Using 4 turbocharger oil drain tube bolts (1), install turbocharger oil drain tube (3) into HP and LP
turbochargers (2 and 4). Torque turbocharger oil drain tube bolts to 31 N·m (23 lb·ft).

1. Turbocharger oil supply line 2. Turbocharger oil supply line 3. HP turbocharger
bolts (2) 4. LP turbocharger
10. Lubricate O-rings on new turbocharger oil supply line (1) with P-80® lubricant.
11. Using 2 turbocharger oil supply line bolts (2), install turbocharger oil supply line (1) into HP and LP
turbochargers (3 and 4). Torque turbocharger oil supply line bolts to 26 N·m (19 lb·ft).
1. LPCAC coolant supply line 2. LPCAC coolant supply line bolts 3. HP turbocharger air supply duct
(2)
12. Using 2 LPCAC coolant supply line bolts (2), install LPCAC coolant supply line (1) to HP turbocharger air
supply duct (3). Torque LPCAC coolant supply line bolts to 31 N·m (23 lb·ft).

1. Oil supply line 4. EOP sensor engine harness 7. Oil supply t-fitting stud bolt
2. Oil supply line tube nut connector
3. Engine Oil Pressure (EOP) 5. Oil supply t-fitting
sensor 6. Oil supply t-fitting nut
CAUTION: To prevent damage to EOP sensor (3), do not grip sensor by connector housing.
13. Install new O-rings onto oil supply t-fitting (5) and lubricate with P-80® lubricant.
14. Using oil supply t-fitting nut (6), install oil supply t-fitting (5) into engine. Torque oil supply t-fitting nut onto
oil supply t-fitting stud bolt (7) to 13 N·m (10 lb·ft).
15. Using oil supply line tube nut (2), install oil supply line (1) onto oil supply t-fitting (5). Torque oil supply line
tube nut to 26 N·m (19 lb·ft).
16. Connect EOP sensor engine harness connector (4) to EOP sensor (3).
Figure 955 HP Turbocharger Heat Shield

1. HP turbocharger heat shield 3. HP turbocharger heat-shield 4. HP turbocharger
2. HP turbocharger heat-shield bolt stud bolt
See HP Turbocharger Heat Shield (Figure 955) to perform step 17.

17. Using HP turbocharger heat-shield bolt (2) and HP turbocharger heat-shield stud bolt (3), install HP
turbocharger heat shield (1) onto HP turbocharger (4). Torque HP turbocharger heat-shield stud bolt and
HP turbocharger heat-shield bolt to 31 N·m (23 lb·ft).
Figure 956 Exhaust Back-Pressure (EBP) Sensor Line

1. LP turbocharger 2. EBP sensor line tube nut 3. EBP sensor line

18. Using EBP sensor line tube nut (2), install EBP sensor line (3) onto LP turbocharger (1). Torque EBP sensor
Perform Low-Pressure Charge Air Cooler (LPCAC) Installation (page 1147) procedure.
Low-Pressure Charge Air Cooler (LPCAC) Installation
Low-Pressure (LP) turbocharger installed (page 1138).

Torques

Figure 957 LPCAC Tube Seal and O-ring

1. LPCAC air inlet O-ring seal 3. Tube seal (extension tube) 5. LPCAC
2. LPCAC air inlet 4. LPCAC air outlet
See LPCAC Tube Seal and O-ring (Figure 957) to perform steps 1 and 2.
1. Lubricate new tube seal (3) with P-80® lubricant or equivalent and install into LPCAC (5) using Extension
Tube Installer ZTSE6043.
2. Install new LPCAC air inlet O-ring seal (1) onto LPCAC air outlet (4) and lubricate with P-80® lubricant or
equivalent.
Figure 958 LPCAC

1. LPCAC 3. Coolant return hose 5. LPCAC mounting bolt
2. Hose clamp 4. Coolant supply hose 6. LPCAC stud bolts (2)

3. Install LPCAC (1) into LP turbocharger and High-Pressure (HP) turbocharger air supply duct.
4. Using LPCAC mounting bolt (5) and 2 LPCAC stud bolts (6), install LPCAC onto engine. Torque LPCAC
mounting bolt and 2 LPCAC stud bolts to 62 N·m (46 lb·ft).
5. Using hose clamp (2), install coolant return hose (3) onto LPCAC (1). Torque hose clamp to 3.5 N·m (31
lb·in).
6. Using hose clamp (2), install coolant supply hose (4) onto LPCAC (1). Torque hose clamp to 3.5 N·m (31
lb·in).

1. Open breather tube assembly 2. Open breather tube assembly 3. CCOS assembly
spring clamp
7. Using open breather tube assembly spring clamp (2), install open breather tube assembly (1) to the CCOS
assembly (3).

1. Air inlet duct 3. Lower air inlet duct bolt
2. Upper air inlet duct bolt 4. LP turbocharger
See Air Inlet Duct (Figure 960) to perform steps 8 through 11.
8. Install new O-ring seal onto LP turbocharger (4) and lubricate with P-80® lubricant.
9. Slide end of air inlet duct (1) onto LP turbocharger (4).
10. Using upper inlet duct bolt (2), secure air inlet duct (1) to engine. Torque upper air inlet duct bolt to 31 N·m
(23 lb·ft).
11. Using lower inlet duct bolt (3), secure air inlet duct (1) to engine. Torque lower air inlet duct bolt to 62 N·m
(46 lb·ft).
Figure 961 EBP Sensor

1. EBP sensor engine harness 3. EBP sensor 6. EBP sensor line nut
connector 4. EBP sensor line stud bolt 7. HP turbocharger heat shield
2. Air inlet duct 5. EBP sensor line stud bolt
See EBP Sensor (Figure 961) to perform steps 12 through 15.

12. Using EBP sensor line nut (6), secure EBP sensor line (5) to HP turbocharger heat shield stud bolt (7).
Torque EBP sensor line nut to 31 N·m (23 lb·ft).
13. Using EBP sensor line stud bolt (4), secure EBP sensor line (5) to air inlet duct (2). Torque EBP sensor line
stud bolt to 13 N·m (20 lb·ft).
14. Using new tie straps and tie-strap clips, install EBP sensor engine harness connector (1) into place on air
inlet duct (2).
15. Connect EBP sensor engine harness connector (1) to EBP sensor (3).
Figure 962 HP Turbocharger Outlet Duct

1. HP turbocharger wastegate 3. HP turbocharger 6. HP turbocharger wastegate
hose crimp clamp 4. HP turbocharger outlet duct actuator
2. HP Turbocharger wastegate 5. HP turbocharger outlet duct stud
hose bolts (2)
See HP Turbocharger Outlet Duct (Figure 962) to perform steps 16 through 21.
16. Install new O-ring seal on HP turbocharger outlet duct (4). Lubricate seal with P-80® lubricant.
17. Slide end of HP turbocharger outlet duct (4) into outlet of HP turbocharger (3).
18. Using 2 HP turbocharger outlet duct stud bolts (5), install HP turbocharger outlet duct (4) to engine. Torque
HP turbocharger outlet duct stud bolts to 62 N·m (46 lb·ft).
19. Position HP turbocharger wastegate hose (2) for installation.
20. Install new tie straps and tie-strap clips.
21. Using new HP turbocharger wastegate hose crimp clamp (1), install HP turbocharger wastegate hose (2)
onto HP turbocharger wastegate actuator (6).

1. Open breather tube assembly 2. Open breather tube assembly
stud bolts (2) 3. LPCAC
22. Using 2 open breather tube assembly stud bolts (1) install open breather tube assembly (2) onto LPCAC
(3). Torque open breather tube assembly stud bolts to 31 N·m (23 lb·ft).

1. LPCAC 3. Heater hose return tube
2. Heater hose return tube 4. Spring clamp
mounting bolt 5. Open breather tube assembly
23. Using heater hose return tube mounting bolt (2), install heater hose return tube (3) onto LPCAC (1).
24. Using spring clamp (4), install heater hose return tube (3) onto open breather tube assembly (5).

See AFTFI Coolant Return Tube Hold-Down Clips (Figure 965) to perform steps 25 and 26.
25. Using spring clamp (3), install AFTFI coolant return tube (1) onto open breather tube assembly (4).
26. Install AFTFI coolant return tube (1) into hold-down clips (2).

1. AFTFI coolant return tube mounting bolt
2. AFTFI coolant return tube
3. Crankcase
See Aftertreatment Fuel Injector (AFTFI) Coolant Return Tube (Figure 966) to perform step 27.
27. Using AFTFI coolant return tube mounting bolt (1) secure AFTFI coolant return tube (2) to crankcase (3).
Torque AFTFI coolant return tube mounting bolt to 31 N·m (23 lb·ft).
Perform Exhaust Back-Pressure Valve (EBPV) Installation (page 1158) procedure.
Exhaust Back-Pressure Valve (EBPV) Installation
Low-Pressure Charge Air Cooler (LPCAC) installed (page 1147).

• Torque Wrench (Obtain Locally)
Torques
Lower EBPV mounting bolts with spacers 107 N·m (79 lb·ft)
Upper EBPV mounting bolts with spacers 107 N·m (79 lb·ft)
Lower EBPV support bracket stud bolts 62 N·m (46 lb·ft)
Upper EBPV assembly support bracket bolts 62 N·m (46 lb·ft)
EBPV air supply line tube nut 15 N·m (133 lb·in)
2
Heat shield mounting bolt and nut 31 N·m (23 lb·ft)

1. Upper EBPV mounting bolts with 2. LP turbocharger
spacers (3) 3. EBPV assembly

1. Using 3 upper EBPV mounting bolts with spacers (1) and new gasket, install EBPV assembly (3) to LP
turbocharger (2). Torque 3 upper EBPV mounting bolts to finger-tight.

1. EBPV assembly 3. Lower EBPV mounting bolts with
2. LP turbocharger spacers (3)

2. Install 3 lower EBPV mounting bolts with spacers (3) to secure EBPV assembly (1) to LP turbocharger (2).
Torque 3 lower EBPV mounting bolts with spacers to 107 N·m (79 lb·ft).
Figure 969 Upper EBPV Mounting Bolt Torque

1. Upper EBPV mounting bolts with 2. LP turbocharger
spacers (3) 3. EBPV assembly
See Upper EBPV Mounting Bolt Torque (Figure 969) to perform step 3.
3. To secure EBPV assembly (3) to LP turbocharger (2), torque 3 upper EBPV mounting bolts with spacers (1)
to 107 N·m (79 lb·ft).
Figure 970 Lower EBPV Assembly Support Bracket Stud Bolts

1. Lower EBPV assembly support 2. Lower EBPV support bracket 3. Engine bell housing
bracket stud bolts (2)
See Lower EBPV Assembly Support Bracket Stud Bolts (Figure 970) to perform step 4.
4. Using 2 lower EBPV assembly support bracket stud bolts (2), install lower EBPV assembly support bracket
onto engine bell housing. Torque lower EBPV assembly support bracket stud bolts to 62 N·m (46 lb·ft).
Figure 971 Upper EBPV Assembly Support Bracket Bolts

1. Upper EBPV assembly support 2. Upper EBPV assembly support 3. EBPV assembly
bracket bracket bolts (2)
See Upper EBPV Assembly Support Bracket Bolts (Figure 971) to perform step 5.
5. Using 2 upper EBPV assembly support bracket bolts (2), secure upper EBPV assembly support bracket (1)
to EBPV assembly (3). Torque upper EBPV assembly support bracket bolts to 62 N·m (46 lb·ft).

1. EBPV actuator 2. EBPV air supply line tube nut
See Air Supply Line (Figure 972) to perform step 6.

6. Using EBPV air supply line tube nut (2), install EBPV air supply line onto EBPV actuator (1). Torque EBPV
air supply line tube nut to 15 N·m (133 lb·in).

1. Oxygen (O2) sensor harness 4. O2 sensor harness bolt 6. NOxin sensor module
connector 5. Nitrogen Oxides in (NOxin) 7. NOxin sensor module bolts (2)
2. Rear coolant manifold sensor module engine harness
3. Tie straps connector
7. Using O2 sensor harness bolt (4), install O2 sensor harness connector (1) to rear coolant manifold (2). Torque
O2 sensor harness bolt to 31 N·m (23 lb·ft).
8. Using 2 NOxin sensor module bolts (7), install NOx in sensor module (6) to rear coolant manifold (2). Torque
NOxin sensor module bolts to 31 N·m (23 lb·ft).
9. Connect NOxin sensor module engine harness connector (5) to NOxin sensor module (6).
10. Install O2 sensor harness connector (1) clips into rear coolant manifold (2).
11. Connect O2 sensor harness connector (1) to engine harness.
12. Using tie straps (3), secure NOxin sensor module wiring and O2 sensor wiring to rear coolant manifold (2).

1. Heat shield mounting bolt 3. Heat shield mounting nut
See EBPV Heat Shield (Figure 974) to perform step 13.

13. Using heat shield mounting bolt and nut (1 and 3), install heat shield with spacer (2) onto EBPV assembly
(4). Torque heat shield mounting bolt and nut to 31 N·m (23 lb·ft).
Perform Aftertreatment Fuel Injector (AFTFI) Installation (page 1170) procedure.
Aftertreatment Fuel Injector (AFTFI) Installation
Exhaust Back-Pressure Valve (EBPV) installed (page 1158).

None
Torques
AFTFI mounting bolts 13 N·m (115 lb·in)

AFTFI coolant return line straight fitting 15 N·m (11 lb·ft )
AFTFI coolant supply line straight fitting 15 N·m (11 lb·ft )
AFTFI fuel supply tube fitting 15 N·m (11 lb·ft )
Figure 975 AFTFI Connections

1. AFTFI electrical connector 3. AFTFI fuel supply tube 6. EBPV assembly
2. AFTFI connector mounting 4. AFTFI mounting bolts (2) 7. AFTFI assembly
bracket 5. AFTFI coolant supply line 8. AFTFI coolant return line
See AFTFI Connections (Figure 975) to perform steps 1 through 8.

passage. If protection caps are used, they should be new or ultrasonically cleaned before using.
1. Using 2 AFTFI mounting bolts (4), install new metal gasket and fibrous insulator with AFTFI assembly (7)
onto EBPV assembly (6). Torque AFTFI mounting bolts to 13 N·m (115 lb·in).
2. Using new O-ring, connect AFTFI coolant return line (8) to AFTFI assembly. Torque AFTFI coolant return
line straight fitting to 15 N·m (11 lb·ft ).
3. Using new O-ring, connect AFTFI coolant supply line (5) to AFTFI assembly. Torque AFTFI coolant supply
line straight fitting to 15 N·m (11 lb·ft ).
4. Using new O-ring, connect AFTFI fuel supply tube (3) to AFTFI assembly (7). Torque AFTFI fuel supply
tube fitting to 15 N·m (11 lb·ft ).
5. Install new tie straps and fasteners that secure AFTFI harness as necessary.
6. Connect AFTFI electrical connector (1) to AFTFI connector mounting bracket (2).
7. Install all necessary tie straps.
8. Connect AFTFI electrical connector (1) to AFTFI assembly (7).
Perform Exhaust Gas Recirculation (EGR) Valve Installation (page 1170) procedure.
Aftertreatment Fuel Injector (AFTFI) installed (page 1158).

None
Torques
Upper EGR valve mounting bracket bolts 31 N·m (23 lb·ft)

Lower EGR valve mounting bracket bolts 62 N·m (46 lb·ft)
M8 X 30 EGR heat shield bolts 18 N·m (13 lb·ft)
M10 X 16 EGR heat shield bolts 62 N·m (46 lb·ft)
M8 X 25 heat shield bolt 18 N·m (13 lb·ft).
Figure 976 EGR Valve Mounting Bracket

1. Upper EGR valve mounting 2. EGR valve mounting bracket 3. Lower EGR valve mounting
bracket bolts (2) bracket bolts (3)
See EGR Valve Mounting Bracket (Figure 976) to perform steps 1 through 3.
1. Using 2 upper EGR valve mounting bracket bolts (1) and 3 lower EGR valve mounting bracket bolts (3),
install EGR valve mounting bracket (2) onto engine. Torque all bolts to finger-tight.
2. Torque 2 upper EGR valve mounting bracket bolts (1) to 31 N·m (23 lb·ft).
3. Torque 3 lower EGR valve mounting bracket bolts (3) to 62 N·m (46 lb·ft).
Figure 977 Inner EGR Heat Shield

1. Inner EGR heat shield 2. M8 X 30 EGR heat shield bolts 3. M10 X 16 EGR heat shield bolts
(3) (2)
See Inner EGR Heat Shield (Figure 977) to perform steps 4 through 6.
4. Using 3 M8 X 30 EGR heat shield bolts (2) and 2 M10 X 16 EGR heat shield bolts (3), install inner EGR
heat shield (1) onto engine. Torque bolts to finger-tight.
5. Torque 3 M8 X 30 EGR heat shield bolts (2) to 18 N·m (13 lb·ft).
6. Torque 2 M10 X 16 EGR heat shield bolts (3) to 62 N·m (45 lb·ft).
Figure 978 Inner EGR Valve Heat Shield Bolt

1. M8 X 25 heat shield bolt 2. Inner EGR valve heat shield
See Inner EGR Valve Heat Shield Bolt (Figure 978) to perform step 7.
7. Use M8 X 25 heat shield bolt (1) to secure inner EGR valve heat shield (2). Torque M8 X 25 heat shield bolt
(1) to 18 N·m (13 lb·ft).

1. EGR valve bellows V-band 2. EGR valve bellows tube 4. EGR valve
clamp 3. EGR valve bolts (4) 5. Rear exhaust manifold
See EGR Valve (Figure 979) to perform steps 8 through 10.

NOTE: Ensure that V-band clamp orientation is 90 degrees from horizontal (stud of V-band clamp should be
pointing vertically).
8. Using 4 EGR valve bolts (3), install EGR valve (4) onto EGR valve mounting bracket. Torque bolts to finger
tight.
9. Using EGR valve bellows V-band clamp (1) and new EGR valve bellows gasket, secure EGR valve bellows
tube (2) to rear exhaust manifold (5). Torque EGR valve bellows V-band clamps to 14.5 N·m (11 lb·ft).
10. Torque 4 EGR valve bolts (3) to 72 N·m (53 lb·ft).
Perform Exhaust Gas Recirculation (EGR) Cooler Installation (page 1175) procedure.
Exhaust Gas Recirculation (EGR) Cooler Installation
components.
Exhaust Gas Recirculation (EGR) valve installed (page 1170).

• Coolant Management Tool – KL5007NAV
• P-80 Lubricant – Obtained locally
Torques
EGR cooler exhaust outlet hose clamps 4 N·m (35 lb·in)

replaced.

1. Install new O-rings onto EGR coolant supply tube (3) and lube O-rings with P-80® lubricant.
2. Apply P-80® lubricant in rear coolant manifold bore.
3. Install EGR coolant supply tube (3) into rear coolant manifold.
4. Using 4 EGR coolant supply tube bracket bolts (2), install EGR coolant supply tube bracket (4) and EGR
coolant supply tube (3) onto cylinder head (1). Torque bolts to finger-tight.

See Lower EGR Cooler Mounting Points (Figure 982) to perform steps 5 and 6.
5. Install new EGR cooler outlet seal onto EGR cooler (3).
NOTE: Insert coolant manifold pipe into EGR cooler during installation of EGR cooler.
6. Using 5 lower EGR cooler support bracket mounting bolts (1), install EGR cooler support bracket (2) with
EGR cooler (3) onto cylinder head. Torque bolts to finger-tight.

7. Using 2 upper EGR cooler support bracket mounting bolts (1), secure EGR cooler support bracket (3) to
cylinder head (2). Torque bolts to 8 N·m (6 lb·ft).
Figure 984 Lower EGR Cooler Mounting Bolt Torque Procedure

See Lower Exhaust Gas Recirculation (EGR) Cooler Mounting Bolt Torque Procedure (Figure 984) to perform
step 8.
8. Torque 5 lower EGR cooler support bracket mounting bolts (1) that secure EGR cooler (3) and EGR cooler
support bracket (2) to cylinder head to 62 N·m (46 lb·ft).
Figure 985 Upper EGR Cooler Mounting Bolt Torque Procedure

See Upper EGR Cooler Mounting Bolt Torque Procedure (Figure 985) to perform step 9.
9. Torque 2 upper EGR cooler support bracket mounting bolts (1) that secure EGR cooler support bracket (3)
to cylinder head (2) to 31 N·m (23 lb·ft).
Figure 986 Coolant Manifold Pipe Support Bracket Torque Procedure

1. Coolant manifold pipe support 3. Coolant manifold pipe 6. Coolant manifold pipe support
bracket bolt 1 4. Coolant manifold pipe to EGR bracket bolt 3
2. Coolant manifold pipe support cooler mounting bolts (2) 7. Coolant manifold pipe support
bracket bolt 2 5. EGR cooler bracket bolt 4
See Coolant Manifold Pipe Support Bracket Torque Procedure (Figure 986) to perform steps 10 through 13.
10. Using 2 coolant manifold pipe to EGR cooler mounting bolts (4), secure coolant manifold pipe (3) to EGR
cooler (5). Torque bolts to 31 N·m (23 lb·ft).

1. LTR hose 2. Hose clamp 3. LTR thermostat housing
14. Using hose clamp (2), install LTR hose (1) onto LTR thermostat housing (3).

15. Install deaeration hose (3) onto EGR cooler (1).
16. Install rear bunk heater coolant supply line (2) onto EGR cooler (1) if equipped. Torque bolt to 13 N·m (10
lb·ft).
17. Install heater hose (4) onto EGR cooler (1).

tube nut

spring clamp

20. Using EGR valve coolant supply line spring clamp (2), install EGR valve coolant supply line (1) onto T-fitting
(3).
Figure 991 Supply Line Installation

1. EGR valve coolant supply line 3. EGR cooler
2. EGR valve coolant supply line 4. EBPV air supply line
stud bolts (2) 5. EBPV air supply line bolts (3)
See Supply Line Installation (Figure 991) to perform steps 21 and 22.
21. Using 3 EBPV air supply line bolts (5), install EBPV air supply line (4) onto EGR cooler (3). Torque bolts to
13 N·m (10 lb·ft).
22. Using 2 EGR valve coolant supply line stud bolts (2), install EGR valve coolant supply line (1) to EGR cooler
(3). Torque bolts to 31 N·m (23 lb·ft).

NOTE: Ensure that V-band clamp orientation is 90 degrees from horizontal (stud of V-band clamp should be
pointing vertically).
23. Using 2 new EGR valve bellows tube V-band clamps (2) and 2 new EGR valve bellows gaskets, install
EGR valve bellows tube (3) between EGR valve (1) and EGR cooler (4). Torque EGR valve bellows V-band
clamps to 15 N·m (11 lb·ft).
24. Install EGR valve jumper harness clips as necessary.



See EGR Cooler Exhaust Outlet Hose (Figure 994) to perform steps 26 and 27.
26. Apply P-80® lubricant to both ends of EGR cooler exhaust outlet hose (3).
27. Using 2 EGR cooler exhaust outlet hose clamps (2), install EGR cooler exhaust outlet hose (3) between
EGR cooler exhaust outlet (1) and EGR outlet manifold (4). Torque EGR cooler outlet hose clamps to 4 N·m
(2.95 lb·ft).
SPECIFICATIONS 1191
Table of Contents
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1193

Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1193
Engine Brake....................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1193
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1193
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1193
Oil Pump, Low Mount Fan Drive, and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1194
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1194
Crankcase and Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1195
1192 SPECIFICATIONS
SPECIFICATIONS 1193
Fuel System
Fuel strainer filtration 300 microns

Fuel filter element filtration 3-5 microns
Air Inlet Duct and Exhaust Manifolds
Exhaust manifold maximum allowable warpage 0.1 mm (0.003 in)
Engine Brake
Solenoid resistance:
Cold — 25° C (77° F) 8.7–10 ohms
Hot — 121° C (250° F) 12–15.5 ohms
Table 2
Camshaft
Camshaft bearing inside diameter 39.925 – 39.950 mm (1.57185 – 1.57283 in)
Camshaft end play 0.25 – 0.85 mm (0.0098 – 0.0334 in)
Exhaust valve clearance 0.8 mm (0.0315 in)
Intake valve clearance 0.5 mm (0.0197 in)
Cylinder Head Idler Gear Cup Plug
Cup plug, DMR 63.10 Recess 2.3 mm (0.9 in)
Flywheel minimum thickness (dimension “A”) 46 mm (1.811 in)
Flywheel maximum surface runout 0.20 mm (0.0079 in)

1194 SPECIFICATIONS
Oil Pump, Low Mount Fan Drive, and Timing Gears
Front Timing Gears
Front intermediate gear backlash 0.057 - 0.183 mm (0.0022 - 0.0072 in)

Oil Pump
Oil pump pinion and oil pump ring gear end play 0.0030 - 0.120 mm (0.0012 - 0.0047 in)
Rear Timing Gears
Big intermediate gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Crankcase intermediate gear backlash 0.052 - 0.176 mm (0.0020 - 0.0069 in)
Power Cylinders
Connecting Rods
Piston pin bore inside diameter 52.06 ± 0.005 mm (2.0496 ± 0.0001 in)
Connecting rod bearing bore diameter

95.000 to 95.022 mm (3.7402 to 3.7402 in)
(crankshaft end)
Pistons — N13
Skirt diameter measured 26.9 mm from piston
bottom edge, 90° to piston pin axis in “window” 125.950 ± 0.013 mm (4.9587 ± 0.0005 in)
on skirt graphite layer, where applicable
Piston protrusion measured from crankcase
0.3 ± 0.22 mm (0.0118 ± 0.009 in)
deck to piston
Piston pin bore inside diameter, measured
52.04 - 52.05 mm (2.0490 - 2.0492 in)
horizontally 26 mm from piston center
Piston pin running clearance 0.040 - 0.058 mm (0.0016 - 0.0023 in)
Piston Pins
Outside diameter 51.992 - 52.000 mm (2.0469 - 2.0472 in)
Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Ring gap 1.00 - 1.20 mm (0.0393 - 0.0472 in)

Bevelled oil ring
SPECIFICATIONS 1195
Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)

Ring gap 0.4 - 0.55 mm (0.0157 - 0.0217 in)
Ring gap 1.00 - 1.20 mm (0.0394 - 0.0472 in)
Bevelled oil ring
Ring gap 0.25 - 0.50 mm (0.0098 - 0.0197 in)

Cylinder sleeve dimensions — N13
Sleeve protrusion 0.050 - 0.085 mm (0.0019 - 0.0033 in)
Sleeve inside diameter (bore) 126 ± 0.01 mm (4.9606 ± 0.0004 in)
Crankshaft
Main Bearing:
Installed bearing inside diameter 104.044 - 104.09 mm (4.0962 - 4.0980 in)
Uninstalled bearing outside diameter (free
111.20 - 112.40 mm (4.3779 - 4.4252 in)
spread)
Connecting Rod Bearing:
Crankshaft end play:
Maximum service 0.200 - 0.401 mm (0.0079 - 0.0158 in)
1196 SPECIFICATIONS
STANDARD TORQUE 1197
Table of Contents
Bolt Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1199
General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1200
Standard Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1201
Using a Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1202

1198 STANDARD TORQUE
Bolt Identification
Figure 995 Metric fasteners – Classification and identification
Figure 996 Special fasteners – Classification and identification

General Torque Guidelines

CAUTION: To prevent engine damage, do not substitute fasteners. All original equipment fasteners are
hardened and phosphate coated.
NOTE: Inspect parts for cleanliness and defects before assembly.
Many conditions affect torque and the results of torque applications. The major purpose in tightening a fastener
to a specified torque is to obtain a clamping load which exceeds any possible loading imposed on parts.
New phosphate coated fasteners do not require oil lubrication during assembly and torque application. Reused
fasteners (even if originally phosphate coated) do require oil lubrication to threads and under head area for
correct torque application.
Threads that are dry, excessively rough, battered, or filled with dirt require considerable effort just to rotate. Then
when the clamping load is developed or the bolt tension is applied, the torque reading mounts rapidly (due to
thread friction) to the specified torque value. However, the desired bolt tension and correct clamping load is not
achieved. This condition can lead to failure of the fastener to maintain component integrity. The correct bolt
tension and clamping effect can never be attained if the fastener is dry. Fastener threads must be new condition
phosphate coated or have a film of clean lubricant (engine oil) to be considered lubricated.
Standard Torque Charts

CAUTION: To prevent engine damage, do not use this standard torque chart with other International brand
engines or engines made by other manufacturers.
Standard torque chart provides tightening values for all hardware that do not require special torque.
Standard Torque Values - Class 10.9 Metric Flange Head Bolts and Studs
Thread Diameter (mm) Thread Pitch (mm) Torque
6 1 13 N·m (115 lb·in)
8 1.25 31 N·m (23 lb·ft)
10 1.5 62 N·m (45 lb·ft)
12 1.75 107 N·m (79 lb·ft)
14 2 172 N·m (127 lb·ft)
15 2 216 N·m (159 lb·ft)
16 2 266 N·m (196 lb·ft)
18 2.5 368 N·m (272 lb·ft)
20 2.5 520 N·m (384 lb·ft)
Example: Tighten four M6 x 12 pulley bolts to standard torque. What is the size and standard torque for these
four bolts?
M6 x 12 refers to the bolts thread diameter and length. These bolts have a thread diameter of 6 mm and are 12
mm long.
To find the standard torque for a M6 x 12 bolt look at the torque chart above. We see the standard torque for a
6 mm thread diameter class 10.9 bolt should be 13 N·m (115 lb·in).
Using a Torque Wrench Extension

Occasionally an extension, crowfoot, or other adapter is necessary to use with a torque wrench to torque a bolt
or line fitting. Adding adapters or extensions will alter the torque on the fastener from what the torque wrench
reads. Use the following formula to calculate the correct torque wrench setting to achieve a specific torque value.
Figure 997 Torque wrench and extension
• F - Force applied by technician

• L - Total length through which force is applied to fastener
• TW - Torque applied at end of torque wrench
TS = TE (LW / (LW + LE))
• TS - Torque wrench setting
• TE - Torque specified at fastener
• LW - Length of torque wrench
• LE - Length of extension
Example: A component requires a specified torque value of 65 lb·ft and a 6 inch extension is required to reach
it. What should the torque wrench setting (TS) be to compensate for the extension?
• Torque specified at fastener (TE) = 65 lb·ft
• Length of torque wrench (LW) = 12 inches
• Length of extension (LE) = 6 inches
TS = TE (LW / (LW + LE))
TS = 65 lb·ft (12 inches / (12 inches + 6 inches)
TS = 65 lb·ft (12 inches / (18 inches)
TS = 65 lb·ft (0.666)
TS = 43.33 lb·ft
ABBREVIATIONS AND ACRONYMS 1203
Table of Contents
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1205

1204 ABBREVIATIONS AND ACRONYMS
Abbreviations and Acronyms

A or amp – Ampere
AAT – Ambient Air Temperature
ABDC – After Bottom Dead Center
ABS – Antilock Brake System
AC – Alternating Current
A/C – Air Conditioner
ACC – Air Conditioner Control
ACCEL – Accelerator
ACD – Air Conditioner Demand
ACM – Aftertreatment Control Module
ACV – Air Control Valve
AFTFI – Aftertreatment Fuel Injector
AFT – Aftertreatment
AFTFP1 – Aftertreatment Fuel Pressure 1
AFTFSV – Aftertreatment Fuel Shutoff Valve
AFTPAV – Aftertreatment Purge Air Valve
Amb – Ambient
amp or A – Ampere
AMS – Air Management System
API – American Petroleum Institute
APP – Accelerator Pedal Position
APP1 – Accelerator Pedal Position 1
APP2 – Accelerator Pedal Position 2
APS – Accelerator Position Sensor
APS/IVS – Accelerator Position Sensor / Idle Validation Switch
ASTM – American Society for Testing and Materials
ATA – American Trucking Association
ATAH – American Trucking Association Link High
ATAL – American Trucking Association Link Low
ATDC – After Top Dead Center
AWG – American Wire Gauge
AWL – Amber Warning Lamp
B+ or VBAT – Battery Voltage

BAP or BARO – Barometric Absolute Pressure
BARO or BAP – Barometric Absolute Pressure
BBDC – Before Bottom Dead Center
BC – Body Controller
BCP – Brake Control Pressure
BCS – Boost Control Solenoid
BDC – Bottom Dead Center
bhp – Brake Horsepower
BNO – Brake Normally Open
BOO – Brake On / Off
BPP – Brake Pedal Position
BPS – Brake Pressure Switch
BSV – Brake Shut-off Valve
BTDC – Before Top Dead Center
BTU – British Thermal Unit
C – Celsius
CAC – Charge Air Cooler
CACOT – Charge Air Cooler Outlet Temperature
CAN – Controller Area Network
CAP – Cold Ambient Protection
CARB – California Air Resources Board
cc – Cubic centimeter
CCA – Cold Cranking Ampere
CCV – Coolant Control Valve
CCOSS – Crankcase Oil Separator Speed
CCPS – Crankcase Pressure Sensor
CCS – Cruise Control Switches
CDR – Crankcase Depression Regulator
cfm – Cubic feet per minute
cfs – Cubic feet per second
CFV – Coolant Flow Valve
CID – Cubic Inch Displacement
CKP – Crankshaft Position
CKPH – Crankshaft Position High
CKPL – Crankshaft Position Low
CKPO – Crankshaft Position Out
cm – Centimeter
CMP – Camshaft Position
CMPH – Camshaft Position High
CMPL – Camshaft Position Low
CMPO – Camshaft Position Out
CMV – Coolant Mixer Valve
CO – Carbon Monoxide
COO – Cruise On / Off switch
CPU – Central Processing Unit
CTC – Coolant Temperature Compensation
Cyl – Cylinder
DB – Decibel
DC – Direct Current
DCA – Diesel Coolant Additive
DDI – Digital Direct Fuel Injection
DDS – Driveline Disengagement Switch
DEF – Diesel Exhaust Fluid
DEFDUH – Diesel Exhaust Fluid Dosing Unit Heater
DEFDV – Diesel Exhaust Fluid Doser Valve
DEFLHR – Diesel Exhaust Fluid Line Heater Relay
DEFLP – Diesel Exhaust Fluid Line Pressure
DEFLT – Diesel Exhaust Fluid Line Temperature
DEFPLH – Diesel Exhaust Fluid Pressure Line Heater
DEFRLH – Diesel Exhaust Fluid Return Line Heater
DEFRV – Diesel Exhaust Fluid Return Valve
DEFSLH – Diesel Exhaust Fluid Suction Line Heater
DEFSP – Diesel Exhaust Fluid Supply Pump
DEFTHV – Diesel Exhaust Fluid Tank Heater Valve
DEFTL – Diesel Exhaust Fluid Tank Level
DEFTLT – Diesel Exhaust Fluid Tank Level and Temperature

DEFTT – Diesel Exhaust Fluid Tank Temperature
DEFUHR – Diesel Exhaust Fluid Unit Heater Relay
DLC – Data Link Connector
DME – Dimethyl Ether
DMM – Digital Multimeter
DOC – Diesel Oxidation Catalyst
DOCIT – Diesel Oxidation Catalyst Inlet Temperature
DOCOT – Diesel Oxidation Catalyst Outlet Temperature
DPF – Diesel Particulate Filter
DPFDP – Diesel Particulate Filter Differential Pressure
DPFOP – Diesel Particulate Filter Outlet Pressure
DPFIT – Diesel Particulate Filter Inlet Temperature
DPFOT – Diesel Particulate Filter Outlet Temperature
DSI – Down Stream Injection
DT – Diesel Turbocharged
DTC – Diagnostic Trouble Code
DTCs – Diagnostic Trouble Codes
DTRM – Diesel Thermo Recirculation Module
EBC – Exhaust Brake Controller

EBP – Exhaust Back Pressure
EBPD – Exhaust Back Pressure Desired
EBPV – Exhaust Back Pressure Valve
ECB – Engine Compression Brake
ECB1 – Engine Compression Brake 1
ECBP – Engine Compression Brake Pressure
ECI – Engine Crank Inhibit
ECL – Engine Coolant Level
ECM – Engine Control Module
ECM GND – Engine Control Module Ground
ECM PWR – Engine Control Module Power
ECS – Engine Coolant System
ECSR – Engine Controlled Shutdown Request
ECT – Engine Coolant Temperature
ECT1 – Engine Coolant Temperature 1
ECT2 – Engine Coolant Temperature 2
EFAN – Engine Fan
EFANS – Engine Fan Speed
EFC – Engine Fan Control
EFP – Engine Fuel Pressure
EFRC – Engine Family Rating Code
EFS – Engine Fan Speed
EFT – Engine Fuel Temperature
EG – Ethylene Glycol
EGC – Electronic Gauge Cluster
EGBP – Exhaust Gas Back Pressure
EGDP – Exhaust Gas Differential Pressure
EGR – Exhaust Gas Recirculation
EGRC – Exhaust Gas Recirculation Control

EGRH – Exhaust Gas Recirculation High control
EGRL – Exhaust Gas Recirculation Low control
EGROT – Exhaust Gas Recirculation Outlet Temperature
EGRP – Exhaust Gas Recirculation Position
EGRT – Exhaust Gas Recirculation Temperature
EGT – Exhaust Gas Temperature
EGT1 – Exhaust Gas Temperature 1
ELS – Exhaust Lambda Sensor
EMI – Electromagnetic Interference
EMP – Exhaust Manifold Pressure
EMT – Exhaust Manifold Temperature
EOL – Engine Oil Level
EOP – Engine Oil Pressure
EOT – Engine Oil Temperature
EOT2 – Engine Oil Temperature 2
EPA – Environmental Protection Agency
EPR – Engine Pressure Regulator
ESC – Electronic System Controller
ESN – Engine Serial Number
EST – Electronic Service Tool
ETC – Engine Throttle Control
ETCH – Engine Throttle Control High
ETCL – Engine Throttle Control Low
ETP – Engine Throttle Position
ETV – Engine Throttle Valve
EVB – Exhaust Valve Brake
EWPS – Engine Warning Protection System
F – Fahrenheit
FCV – Fuel Coolant Valve
FDP – Fuel Delivery Pressure
FEL – Family Emissions Limit
fhp – Friction horsepower
FMI – Failure Mode Indicator
FPC – Fuel Pump Control
FPCV – Fuel Pressure Control Valve
fpm – Feet per minute
FPM – Fuel Pump Monitor
fps – Feet per second
FRP – Fuel Rail Pressure
ft – Feet
FVCV – Fuel Volume Control Valve
GND – Ground (electrical)

gal – Gallon
gal/h – U.S. Gallons per hour
gal/min – U.S. Gallons per minute
GCW – Gross Combined Weight
GCWR – Gross Combined Weight Rating

GVW – Gross Vehicle Weight
H2O – Water
HC – Hydrocarbons
HCI – Hydrocarbon Injection
HEST – High Exhaust System Temperature
HFCM – Horizontal Fuel Conditioning Module
Hg – Mercury
hp – Horsepower
HPCAC – High-Pressure Charge Air Cooler
HPCR – High-Pressure Common Rail
HPFP – High-Pressure Fuel Pump
hr – Hour
HS – Humidity Sensor
Hyd – Hydraulic
IAH – Inlet Air Heater

IAHC – Inlet Air Heater Control
IAHD – Inlet Air Heater Diagnostic
IAHFI – Inlet Air Heater Fuel Igniter
IAHFS – Inlet Air Heater Fuel Solenoid
IAHR – Inlet Air Heater Relay
IAHS – Inlet Air Heater Solenoid
IAT – Inlet Air Temperature
IC – Integrated Circuit
ICP – Injection Control Pressure
ICPR – Injection Control Pressure Regulator
ICG1 – Injector Control Group 1
ICG2 – Injector Control Group 2
ID – Inside Diameter
IGN – Ignition
ILO – Injector Leak Off
IMP – Intake Manifold Pressure
IMT – Intake Manifold Temperature
in – Inch
inHg – Inch of mercury
inH2O – Inch of water
INJs – Injectors
IPR – Injection Pressure Regulator
IPR PWR – Injection Pressure Regulator Power
ISC – Interstage Cooler
IST – Idle Shutdown Timer
ITP – Internal Transfer Pump
ITV – Intake Throttle Valve
ITVH – Intake Throttle Valve High control
ITVL – Intake Throttle Valve Low control
ITVP – Intake Throttle Valve Position
IVS – Idle Validation Switch
J1939H – J1939 Data Link High

J1939L – J1939 Data Link Low

JCT – Junction (electrical)
kg – Kilogram
km – Kilometer
km/h – Kilometers per hour
km/l – Kilometers per liter
KOEO – Key-On Engine-Off
KOER – Key-On Engine-Running
kPa – Kilopascal
L – Liter
L/h – Liters per hour
L/m – Liters per minute
L/s – Liters per second
lb – Pound
lbf – Pounds of force
lb/s – Pounds per second
lbf ft – Pounds of force per foot
lb in – Pounds of force per inch
lbm – Pounds of mass
LPCAC – Low-pressure Charge Air Cooler
LSD – Low Sulfur Diesel
m – Meter
m/s – Meters per second
MAF – Mass Air Flow
MAF GND – Mass Air Flow Ground
MAG – Magnetic
MAP – Manifold Absolute Pressure
MAP/IAT – Manifold Absolute Pressure / Inlet Air Temperature
MAT – Manifold Air Temperature
mep – Mean effective pressure
mi – Mile
MIL – Malfunction Indicator Lamp
mm – Millimeter
mpg – Miles per gallon
mph – Miles per hour
MPR – Main Power Relay
MSDS – Material Safety Data Sheet
MSG – Micro Strain Gauge
MSM – Multiplex System Module
MY – Model Year
NC – Normally Closed (electrical)

NETS – Navistar Electronics Technical Support
NH3 – Ammonia sensor
Nm – Newton meter
NO – Normally Open (electrical)
NOX – Nitrogen Oxides
NOX IN – Nitrogen Oxides Inlet sensor
NOX OUT – Nitrogen Oxides Outlet sensor

O2S – Oxygen Sensor
O2SH – Oxygen Sensor Heater
OAT – Organic Acid Technology
OCC – Output Circuit Check
OCP – Overcrank Protection
OD – Outside Diameter
OL – Over Limit
ORH – Out-of-Range High
ORL – Out-of-Range Low
OSHA – Occupational Safety and Health Administration
OWL – Oil/Water Lamp
PID – Parameter Identifier

P/N – Part Number
ppm – Parts per million
PROM – Programmable Read Only Memory
psi – Pounds per square inch
psia – Pounds per square inch absolute
psig – Pounds per square inch gauge
pt – Pint
PTO – Power Takeoff
PWM – Pulse Width Modulate
PWR – Power (voltage)
qt – Quart
RAM – Random Access Memory

RAPP – Remote Accelerator Pedal Position
RAS – Resume / Accelerate Switch (speed control)
REPTO – Rear Engine Power Takeoff
RFI – Radio Frequency Interference
rev – Revolution
rpm – Revolutions per minute
RPRE – Remote Preset
RSE – Radiator Shutter Enable
RVAR – Remote Variable
SAE – Society of Automotive Engineers

SART – Stand Alone Real Time Clock
SCA – Supplemental Cooling Additive
SCCS – Speed Control Command Switches
SCR – Selective Catalyst Reduction
SCRIT – Selective Catalyst Reduction Inlet Temperature
SCROT – Selective Catalyst Reduction Outlet Temperature
SCS – Speed Control Switch
SHD – Shield (electrical)
SID – Subsystem Identifier
SIG GND – Signal Ground
SIG GNDB – Signal Ground Body
SIG GNDC – Signal Ground Chassis
SIG GNDE – Signal Ground Engine

S/N – Serial Number
SPEEDO – Speedometer
SPN – Suspect Parameter Number
SW – Switch (electrical)
SWBAT – Switch Battery
SYNC – Synchronization
TACH – Tachometer output signal

TBD – To Be Determined
TC2CIP – Turbocharger 2 Compressor Inlet Pressure
TC2CIS – Turbocharger 2 Compressor Inlet Sensor
TC2CIT – Turbocharger 2 Compressor Inlet Temperature
TC1TOP – Turbocharger 1 Turbine Outlet Pressure
TC2TOP – Turbocharger 2 Turbine Outlet Pressure
TC2WC – Turbocharger 2 Wastegate Control
TCAPE – Truck Computer Analysis of Performance and Economy
TCM – Transmission Control Module
TDC – Top Dead Center
TDE – Transmission Driving Engaged
TOP – Transmission Oil Pressure
TOSS – Transmission Output Shaft Speed
TOT – Transmission Oil Temperature
TTS – Transmission Tailshaft Speed
ULSD – Ultra-Low Sulfur Diesel

UVC – Under Valve Cover
V – Volt
VBAT or B+ – Battery Voltage
VC – Volume Control
VEPS – Vehicle Electronics Programming System
VGT – Variable Geometry Turbo
VIGN – Ignition Voltage
VIN – Vehicle Identification Number
VOP – Valve Opening Pressure
VRE – Vehicle Retarder Enable
VREF – Reference Voltage
VREFB – Reference Voltage Body
VREFC – Reference Voltage Chassis
VREFE – Reference Voltage Engine
VSO – Vehicle Speed Output
VSO or VSS_CAL – Vehicle Speed Output
VSS – Vehicle Speed Sensor
VSS_CAL or VSO – Vehicle Speed Output
VSSH – Vehicle Speed Sensor High
VSSL – Vehicle Speed Sensor Low
WTSL – Wait to Start Lamp

WEL – Warn Engine Lamp
WIF – Water In Fuel
WIFL – Water In Fuel Lamp

WTEC – World Transmission Electronically Controlled automatic transmissions (Allison)
XCS – Transfercase
XMSN – Transmission
TERMINOLOGY 1215
Table of Contents
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1217
Terms................................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1217
1216 TERMINOLOGY
TERMINOLOGY 1217
Terminology
Terms
Accelerator Pedal Position (APP) sensor – A potentiometer sensor that indicates the position of the throttle
pedal.
Accessory work – The work per cycle required to drive engine accessories (normally, only those essential to
engine operation).
Actuator – A device that performs work in response to an input signal.
Actuator Control – The ECM controls the actuators by applying a low-level signal (low-side driver) or a high-level
signal (high side driver). When switched on, both drivers complete a ground or power circuit to an actuator.
Aeration – The entrainment of air or combustion gas in coolant, lubricant, or fuel.
Aftercooler (Charge Air Cooler) – A heat exchanger mounted in the charge air path between the turbocharger
and engine intake manifold. The aftercooler reduces the charge air temperature by transferring heat from the
charge air to a cooling medium (usually air).
Aftertreatment Fuel Doser (AFTFD) – A part of the Downstream Injection (DSI) unit that sends pressurized
fuel to the Hydrocarbon Injector (HCI) assembly to inject fuel into the exhaust pipe.
Aftertreatment (AFT) system – A part of the exhaust system that processes engine exhaust to meet emission
requirements and traps particulate matter (soot) to prevent it from leaving the tailpipe.
Air Control Valve (ACV) – Contains the LP turbocharger wastegate control port, HP turbocharger wastegate
control port, the EBPV control port, and the TC1TOP port. Although these components are integral to the ACV,
each circuit is controlled by the ECM. The ACV controls compressed air for each control valve.
Ambient temperature – The environmental air temperature in which a unit is operating. In general, the
temperature is measured in the shade (no solar radiation) and represents the air temperature for other engine
cooling performance measurement purposes. Air entering the radiator may or may not be the same ambient
due to possible heating from other sources or recirculation. (SAE J1004 SEP81)
Ampere (amp) – The standard unit for measuring the strength of an electrical current. The flow rate of a charge
in a conductor or conducting medium of one coulomb per second. (SAE J1213 NOV82)
Analog – A continuously variable voltage.
Analog to digital converter (A/D) – A device in the ECM that converts an analog signal to a digital signal.
American Trucking Association (ATA) Datalink – A serial datalink specified by the American Trucking
Association and the SAE.
Boost pressure – 1. The pressure of the charge air leaving the turbocharger.
2. Inlet manifold pressure that is greater than atmospheric pressure. Obtained by turbocharging.
Bottom Dead Center (BDC) – The lowest position of the piston during the stroke.
Brake Horsepower (bhp) – The power output from an engine, not the indicated horsepower. The power output
of an engine, sometimes-called flywheel horsepower, is less than the indicated horsepower by the amount of
friction horsepower consumed in the engine.
Brake Horsepower (bhp) net – Net brake horsepower is measured with all engine components. The power of
an engine when configured as a fully equipped engine. (SAE J1349 JUN90)
Calibration – ECM programming strategy to solve engine performance equations and make decisions.
Calibration values are stored in ROM and put into the processor during programming to allow the engine to
operate within certain parameters.
1218 TERMINOLOGY
Camshaft Position (CMP) sensor – A magnetic pickup sensor that provides the ECM with a camshaft speed
and position signal.
Carbon Monoxide (CO) – A colorless, odorless, highly poisonous gas that is formed by the incomplete
combustion of carbon burning diesel engine. It is present in the exhaust gases of diesel engines.
Catalyst – A substance that produces a chemical reaction without undergoing a chemical change itself.
Catalytic converter – An antipollution device in the exhaust system that contains a catalyst for chemically
converting some pollutants in the exhaust gases (carbon monoxide, unburned hydrocarbons, and oxides of
nitrogen) into harmless compounds.
Cavitation – A dynamic condition in a fluid system that forms gas-filled bubbles (cavities) in the fluid.
Cetane number – 1. The auto-ignition quality of diesel fuel.
2. A rating applied to diesel fuel similar to octane rating for gasoline.
3. A measure of how readily diesel fuel starts to burn (self-ignites) at high compression temperature.
Diesel fuel with a high cetane number self-ignites shortly after injection into the combustion chamber. Therefore,
it has a short ignition delay time. Diesel fuel with a low cetane number resists self-ignition. Therefore, it has a
longer ignition delay time.
Charge air – Dense, pressurized, heated air discharged from the turbocharger.
Charge Air Cooler (CAC) – See Aftercooler.
Charge Air Outlet Temperature (CACOT) sensor – A thermistor sensor that monitors the temperature of
charge air entering the intake air duct.
Closed crankcase – A crankcase ventilation that recycles crankcase gases through a breather, then back to
the clean air intake.
Closed loop operation – A system that uses sensors to provide feedback to the ECM. The ECM uses the
sensor input to continuously monitor variables and adjust actuators to match engine requirements.
Cloud point – The point when wax crystals occur in fuel, making fuel cloudy or hazy. Usually below -12 °C (10
°F).
Cold cranking ampere rating (battery rating) – The sustained constant current (in amperes) needed to
produce a minimum terminal voltage under a load of 7.2 volts per battery after 30 seconds.
Inlet Air Heater Fuel Igniter (IAHFI) – The IAHFI heats the intake air by vaporizing and igniting fuel in the air
inlet duct.
Inlet Air Heater Fuel Solenoid (IAHFS) – As the engine is cranked, the ECM energizes the IAHFS valve,
introducing fuel into the IAHFI, which ignites and warms the air being drawn into the engine.
Inlet Air Heater Relay (IAHR) – The IAHR provides voltage to the IAHFI, and is controlled by the ECM.
Controller Area Network (CAN) – A J1939 high speed communication link.
Coolant – A fluid used to transport heat from one point to another.
Coolant level switch – A switch sensor used to monitor coolant level.
Coolant Flow Valve (CFV) – The CFV is ECM controlled and redirects coolant through the fuel cooler, based
on EFT, when directed.
Coolant Mixer Valve (CMV) – Controls coolant flow through the low-temperature radiator.
TERMINOLOGY 1219
Continuous Monitor Test – An ECM function that continuously monitors the inputs and outputs to ensure that
readings are within set limits.
Crankcase – The housing that encloses the crankshaft, connecting rods, and allied parts.
Crankcase breather – A vent for the crankcase to release excess interior air pressure.
Crankcase Oil Separator Speed (CCOSS) sensor – The CCOSS sensor sends the ECM information about
the speed of the crankcase oil separator internal components.
Crankcase pressure – The force of air inside the crankcase against the crankcase housing.
Crankshaft Position (CKP) sensor – A magnetic pickup sensor that determines crankshaft position and speed.
Current – The flow of electrons passing through a conductor. Measured in amperes.
Damper – A device that reduces the amplitude of torsional vibration. (SAE J1479 JAN85)
Deaeration – The removal or purging of gases (air or combustion gas) entrained in coolant or lubricating oil.
Deaeration tank – A separate tank in the cooling system used for one or more of the following functions:
• Deaeration
• Coolant reservoir (fluid expansion and afterboil)
• Coolant retention
• Filling
• Fluid level indication (visible)
Diagnostic Trouble Code (DTC) – 2010 model year vehicles no longer utilize DTC identification by number.
DTCs are now identified using the Suspect Parameter Number (SPN) and Failure Mode Indicator (FMI) identifiers
only.
Diesel Particulate Filter (DPF) – A diesel particulate filter, sometimes called a DPF, is a device designed to
remove diesel particulate matter or soot from the exhaust gas of a diesel engine.
Diesel Oxidation Catalyst (DOC) – A DOC is part of the diesel exhaust Aftertreatment system. DOCs
are devices that use a chemical process to break down pollutants in the exhaust stream into less harmful
components. More specifically, DOCs utilize rare metals such as palladium and platinum to reduce hydrocarbon
based Soluble Organic Fraction (SOF) and carbon monoxide content of diesel exhaust by simple oxidation.
The DOC can be used during an active regeneration to create higher exhaust temperatures, thereby reducing
soot in the DPF.
Digital Multimeter (DMM) – An electronic meter that uses a digital display to indicate a measured value.
Preferred for use on microprocessor systems because it has a very high internal impedance and will not load
down the circuit being measured.
Disable – A computer decision that deactivates a system and prevents operation of the system.
Displacement – The stroke of the piston multiplied by the area of the cylinder bore multiplied by the number of
cylinders in the engine.
Downstream Injection (DSI) Unit – The DSI unit provides a metered amount of fuel to the Hydrocarbon Injector
(HCI) assembly.
Driver (high side) – A transistor within an electronic module that controls the power to an actuator circuit.
Driver (low side) – A transistor within an electronic module that controls the ground to an actuator circuit.
1220 TERMINOLOGY
Dual Stage Turbocharger – An assembly of two turbochargers (low-pressure and high-pressure) in series to
provide a wide range of charge air pressures efficiently.
Duty cycle – A control signal that has a controlled on/off time measurement from 0 to 100%. Normally used to
control solenoids.
EGR Cooler – A cooler that allows heat to dissipate from the exhaust gasses before they enter the intake
manifold.
Engine Control Module (ECM) – An electronic processor that monitors and controls the engine.
Engine Back Pressure Valve (EBPV) – The ECM commands the EBPV to control the Exhaust Brake.
Engine Compression Brake (ECB) valve – The ECB valve controls pressure entering the brake oil gallery
from the high-pressure oil rail gallery. This activates the brake actuator pistons and opens the exhaust valves.
Engine Compression Brake 1 (ECB1) solenoid – The ECB1 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake 2 (ECB2) solenoid – The ECB2 solenoid controls pressure entering the brake oil
gallery from the high-pressure oil rail gallery.
Engine Compression Brake Pressure (ECBP) sensor – A high-pressure sensor that provides a feedback
signal to the ECM indicating brake control pressure.
Engine Coolant Level (ECL) sensor – A switch sensor that monitors coolant level.
Engine Coolant Temperature 1 (ECT1) sensor – A thermistor sensor that detects engine coolant temperature.
Engine Coolant Temperature 2 (ECT2) sensor – A thermistor sensor that detects engine coolant temperature.
Engine Fuel Temperature (EFT) sensor – A thermistor sensor that measures fuel temperature.
Engine lamp – An instrument panel lamp that comes on when DTCs are set. DTCs can be read as flash codes
(red and amber instrument panel lamps).
Engine OFF tests – Tests that are done with the ignition switch ON and the engine OFF.
Engine Oil Pressure (EOP) sensor – A variable capacitance sensor that measures oil pressure.
Engine Oil Temperature (EOT) sensor – A thermistor sensor that measures oil temperature.
Engine rating – Engine rating includes Rated hp and Rated rpm.
Engine RUNNING tests – Tests done with the engine running.
Engine Throttle Valve (ETV) and Engine Throttle Position Sensor – The ETV valve is used to control airflow
during a regeneration process of the aftertreatment system. The ETV valve is also used to ensure a smooth
engine shut down by restricting airflow to the engine at shut down.
Engine Warning Protection System (EWPS) – Safeguards the engine from undesirable operating conditions
to prevent engine damage and to prolong engine life.
Exhaust Back Pressure (EBP) – The pressure present in the exhaust system during the exhaust period.
Exhaust Back Pressure Valve (EBPV) – A valve that regulates the amount of air pressure applied to the EBPV
pneumatic actuator.
Exhaust brake – A brake device using engine exhaust back pressure as a retarding medium.
Exhaust Gas Recirculation (EGR) – A system used to recirculate a portion of the exhaust gases into the power
cylinder in order to reduce oxides of nitrogen.
Exhaust Gas Temperature (EGT) – The temperature of exhaust gases.
TERMINOLOGY 1221
Exhaust Gas Recirculation Temperature (EGRT) sensor – A thermistor sensor that detects the exhaust gas
temperature entering the EGR cooler.
Exhaust Gas Recirculation (EGR) valve – The EGRV controls the flow of exhaust gases to the intake manifold.
The EGRV is integrated with an EGR Position (EGRP) sensor.
Exhaust manifold – Exhaust gases flow through the exhaust manifold to the turbocharger exhaust inlet and
are directed to the EGR cooler.
Exhaust Manifold Pressure (EMP) sensor – A variable capacitance sensor used to indicate air pressure in
the exhaust manifold.
Exhaust Manifold Temperature (EMT) sensor – A thermistor style sensor used to indicate air temperature in
the exhaust manifold.
Fault detection/management – An alternate control strategy that reduces adverse effects that can be caused
by a system failure. If a sensor fails, the ECM substitutes a good sensor signal or assumed sensor value in its
place. A lit amber instrument panel lamp signals that the vehicle needs service.
Failure Mode Indicator (FMI) – Identifies the fault or condition effecting the individual component.
Filter restriction – A blockage, usually from contaminants, that prevents the flow of fluid through a filter.
Flash code – See Diagnostic Trouble Code (DTC).
Fuel Delivery Pressure (FDP) sensor – A variable capacitance sensor that monitors fuel pressure coming from
the fuel tank and sends a signal to the ECM.
Fuel inlet restriction – A blockage, usually from contaminants, that prevents the flow of fluid through the fuel
inlet line.
Fuel pressure – The force fuel exerts on the fuel system as it is pumped through the fuel system.
Fuel Pressure Control Valve (FPCV) – The FPCV controls the fuel pressure to the fuel rails and is controlled
by the ECM. FPCV control depends on fuel pressure and fuel temperature.
Fuel Rail Pressure (FRP) – The amount of pressure in the fuel rail.
Fuel Rail Pressure (FRP) sensor – A variable capacitance sensor that monitors fuel pressure in the fuel rail
and sends a signal to the ECM.
Fuel strainer – A pre-filter in the fuel system that keeps larger contaminants from entering the fuel system.
Fuel Volume Control Valve (FVCV) – The FVCV regulates the volume of flow sent to the HPFP. The FVCV
allows a sufficient quantity of fuel to be delivered to the HPFP depending on engine load, speed, injector quantity,
fuel temperature, and number of injections per cycle.
Fully equipped engine – A fully equipped engine is an engine equipped with only those accessories necessary
to perform its intended service. A fully equipped engine does not include components that are used to power
auxiliary systems. If these components are integral with the engine or, for any reason are included on the test
engine, the power absorbed may be determined and added to the net brake power. (SAE J1995 JUN90)
Fusible link (fuse link) – A fusible link is a special section of low tension cable designed to open the circuit
when subjected to an extreme current overload. (SAE J1156 APR86)
Gradeability – The maximum percent grade, which the vehicle can transverse for a specified time at a specified
speed. The gradeability limit is the grade upon which the vehicle can just move forward. (SAE J227a)
Gross Combined Weight Rating (GCWR) – Maximum combined weight of towing vehicle (including
passengers and cargo) and the trailer. The GCWR indicates the maximum loaded weight that the vehicle is
allowed to tow.
1222 TERMINOLOGY
Gross brake horsepower – The power of a complete basic engine, with air cleaner, without fan, and alternator,
and air compressor not charging.
H-Bridge Circuit – An H-Bridge (bipolar) circuit operates like putting a power source on one side of a motor and
connecting the other side of the motor to a ground. This turns the motor. By shifting the leads on the motor, it
will turn in the opposite direction.
Hall effect – The development of a transverse electric potential gradient in a current-carrying conductor or
semiconductor when a magnetic field is applied.
Hall effect sensor – Transducer that varies its output voltage in response to changes in a magnetic field.
Commonly used to time the speed of wheels and shafts.
High-Pressure Fuel Pump (HPFP) assembly – The HPFP is a volumetric pump that supplies fuel at
high-pressure. The HPFP is mounted in the rear valley on the top of the engine and is driven by the camshaft.
High-pressure Piezo Common Rail (HPCR) – The HPFP pumps fuel through separate tubes to each fuel rail.
Each fuel rail has four fuel tubes, one for each injector, that maintain constant pressure from the high-pressure
pump to each injector.
High speed digital inputs – Inputs to the ECM from a sensor that generates varying frequencies (engine speed
and vehicle speed sensors).
Horsepower (hp) – Horsepower is the unit of work done in a given period of time, equal to 33,000 pounds
multiplied by one foot per minute. 1hp = 33,000 lb x 1 ft /1 min.
Humidity Sensor (HS) – A sensor that measures the moisture content of filtered air entering the intake system.
Hydrocarbons – Organic compounds consisting of hydrogen and carbon (fuel and oil).
Hydrocarbon Injector Assembly – Injects fuel into the exhaust system to increase temperature of the exhaust
gases.
Injection Pressure Regulator (IPR) valve – A valve that is used to maintain desired injection control pressure.
Injection Control Pressure (ICP) sensor – Provides a feedback signal to the ECM indicating injection control
pressure.
Inlet Air Heater (IAH) – The IAH is primarily used to assist in starting the engine during cold weather. In addition,
it helps to reduce white smoke emissions by heating the incoming air.
Inlet Air Temperature (IAT) sensor – A thermistor sensor that monitors intake air temperature.
Intake manifold – Engine component that evenly supplies air to each intake port in the cylinder head(s).
Intake Manifold Pressure (IMP) sensor – A variable capacitance sensor used to indicate air pressure in the
intake manifold.
Intake Manifold Temperature (IMT) sensor – A thermistor sensor used to indicate air temperature in the intake
manifold.
Internal Transfer Pump (ITP) – The ITP is part of the HPFP assembly and driven off the same shaft as the
HPFP assembly. The ITP supplies fuel at a slightly higher pressure and flow to the HPFP though the Fuel Volume
Control Valve (FVCV). The ITP also provides fuel for cooling and lubrication of the HPFP. Fuel is rerouted as
pump return flow through the HPFP cooling and lubrication valve. Pressure is maintained at the inlet of the
HPFP piston pump by an ITP regulator.
International NGV Tool Utilized for Next Generation Electronics (INTUNE) – The diagnostics software for
chassis related components and systems.
TERMINOLOGY 1223
Interstage Cooler (ISC) – Uses cooled coolant to lower the charged air temperature that exits from the
turbocharger low-pressure compressor and enters the turbocharger high-pressure compressor.
Low speed digital inputs – Switched sensor inputs that generate an on/off (high/low) signal to the ECM. The
input to the ECM from the sensor could be from a high input source switch (usually 5 or 12 volts) or from a
grounding switch that grounds the signal from a current limiting resistor in the ECM that creates a low signal (0
volts).
Low temperature radiator thermostat – Coolant flow to the low temperature radiator is regulated by the low
temperature radiator thermostat.
Lubricity – Lubricity is the ability of a substance to reduce friction between solid surfaces in relative motion
under loaded conditions.
Lug (engine) – A condition when the engine is run at an overly low RPM for the load being applied.
Manifold Absolute Pressure (MAP) – Boost pressure in the manifold that is a result of the turbocharger.
Manifold Absolute Pressure (MAP) sensor – A variable capacitance sensor that measures boost pressure.
Manometer – A double-leg liquid-column gauge, or a single inclined gauge, used to measure the difference
between two fluid pressures. Typically, a manometer records in inches of water.
Mass Air Flow – The intake airflow in an engine.
Mass Air Flow (MAF) sensor – The MAF sensor is used for closed loop control of the EGR valve and ITV. The
ECM monitors the MAF signal so that the ECM can control the EGR and intake throttle systems.
MasterDiagnostics® (MD) – Diagnostics software for engine related components and systems.
Magnehelic Gauge – A gauge that measures pressure in inches of water.
Magnetic Pickup Sensor – A magnetic pickup sensor generates an alternating frequency that indicates speed.
Magnetic pickups have a two-wire connection for signal and ground. This sensor has a permanent magnetic
core surrounded by a wire coil. The signal frequency is generated by the rotation of the gear teeth that disturb
the magnetic field.
Microprocessor – An integrated circuit in a microcomputer that controls information flow.
Micro Strain Gauge (MSG) Sensor – A MSG sensor measures pressure. Pressure exerts force on a pressure
vessel that stretches and compresses to change resistance of strain gauges bonded to the surface of the
pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage output.
Nitrogen Oxides (NOx) – Nitrogen oxides form by a reaction between nitrogen and oxygen at high temperatures
and pressures in the combustion chamber.
Normally closed – Refers to a switch that remains closed when no control force is acting on it.
Normally open – Refers to a switch that remains open when no control force is acting on it.
Ohm (Ω) – The unit of electrical resistance. One ohm is the value of resistance through which a potential of one
volt will maintain a current of one ampere. (SAE J1213 NOV82)
On demand test – A self-test the technician initiates using the EST that is run from a program in the software.
Output Circuit Check (OCC) – An on-demand test done during an Engine OFF self-test to check the continuity
of selected actuators.
Oxides of Nitrogen (NOx) – Nitrogen oxides formed by a reaction between nitrogen and oxygen at high
temperatures.
Oxygen Sensor (O2S) – A sensor that monitors oxygen levels in the exhaust.
1224 TERMINOLOGY
pH – A measure of the acidity or alkalinity of a solution.

Particulate matter – Particulate matter includes mostly burned particles of fuel and engine oil.
Piezometer – An instrument for measuring fluid pressure.
Power – Power is a measure of the rate at which work (force x distance) is done during a specific time. Compare
with Torque.
Power TakeOff (PTO) – Accessory output, usually from the transmission, used to power a hydraulic pump for
a special auxiliary feature (garbage packing, lift equipment, etc).
Pulse Width Modulation (PWM) – Succession of digital electrical pulses, rather than an analog signal. Efficient
method of providing power between fully on and fully off.
Random Access Memory (RAM) – Computer memory that stores information. Information can be written to and
read from RAM. Input information (current engine speed or temperature) can be stored in RAM to be compared
to values stored in Read Only Memory (ROM). All memory in RAM is lost when the ignition switch is turned off.
Rated gross horsepower – Engine gross horsepower at rated speed as declared by the manufacturer. (SAE
J1995 JUN90)
Rated horsepower – Maximum brake horsepower output of an engine as certified by the engine manufacturer.
The power of an engine when configured as a basic engine. (SAE J1995 JUN90)
Rated net horsepower – Engine net horsepower at rated speed as declared by the manufacturer. (SAE J1349
JUN90)
Rated speed – The speed, as determined by the manufacturer, at which the engine is rated. (SAE J1995
JUN90)
Rated torque – Maximum torque produced by an engine as certified by the manufacturer.
Ratiometric Voltage – In a Micro Strain Gauge (MSG) sensor, pressure to be measured exerts force on a
pressure vessel that stretches and compresses to change resistance of strain gauges bonded to the surface
of the pressure vessel. Internal sensor electronics convert the changes in resistance to a ratiometric voltage
output.
Reference voltage (VREF) – A 5 volt reference supplied by the ECM to operate the engine sensors.
Reserve capacity – Time in minutes that a fully charged battery can be discharged to 10.5 volts at 25 amperes.
Return Fuel System – The return fuel system moves unused fuel from the fuel injectors to the fuel cooler.
Excess fuel out of the FVCV and the FPCV mix with fuel from the fuel injectors on the way to the fuel cooler.
ServiceMaxx™ software – Diagnostics software for engine related components and systems.
Signal Conditioner – The signal conditioner in the internal microprocessor converts analog signals to digital
signals, squares up sine wave signals, or amplifies low-intensity signals to a level that the ECM microprocessor
can process.
Signal ground – The common ground wire to the ECM for the sensors.
Speed Control Command Switches (SCCS) – A set of switches used for cruise control, Power TakeOff (PTO),
and remote hand throttle system.
Steady state condition – An engine operating at a constant speed and load and at stabilized temperatures and
pressures. (SAE J215 JAN80)
Strategy – A plan or set of operating instructions that the microprocessor follows for a desired goal. Strategy
is the computer program itself, including all equations and decision making logic. Strategy is always stored in
ROM and cannot be changed during calibration.
TERMINOLOGY 1225
Stroke – The movement of the piston from Top Dead Center (TDC) to Bottom Dead Center (BDC).
Substrate – Material that supports the wash coating or catalytic materials.
Suspect Parameter Number (SPN) – A 19-bit number used to identify the item for which diagnostics are being
reported. The SPN is used for multiple purposes, some that are specific to diagnostics are as follows;
• Identify the least repairable subsystem that has failed.
• Identify subsystems or assemblies that may not have hard failures but may be exhibiting abnormal operating
performance.
• Identify a particular event or condition that will be reported.
• Report a component and non-standard failure mode.
System restriction (air) – The static pressure differential that occurs at a given airflow from air entrance through
air exit in a system. Usually measured in inches (millimeters) of water. (SAE J1004 SEP81)
Tachometer output signal – Engine speed signal for remote tachometers.
Thermistor – A semiconductor device. A sensing element that changes resistance as the temperature changes.
Thermistor Sensor – Changes electrical resistance with changes in temperature. Resistance in the thermistor
decreases as temperature increases, and increases as temperature decreases. Thermistors work with a resistor
that limits current to form a voltage signal matched with a temperature value.
Thrust load – A thrust load pushes or reacts through a bearing in a direction parallel to the shaft.
Top Dead Center (TDC) – The uppermost position of the piston during the stroke.
Torque – A force having a twisting or turning effect. For a single force, the cross product of a vector from some
reference point to the point of application of the force within the force itself. Also known as moment of force or
rotation moment. Torque is a measure of the ability of an engine to do work.
Truck Computer Analysis of Performance and Economy (TCAPE) – A computer program that simulates the
performance and fuel economy of trucks.
Turbocharger – A turbine driven compressor mounted on the exhaust manifold. The turbocharger increases
the pressure, temperature and density of intake air to charge air.
Turbocharger 1 Turbine Outlet Pressure (TC1TOP) sensor – A variable capacitance sensor that monitors
exhaust back-pressure.
Turbocharger 2 Compressor Inlet (TC2CIS) sensor – The TC2CIS sensor includes a thermistor sensor that
monitors the temperature of charge air entering the HP turbocharger. This sensor also monitors boost pressure
for the LP turbocharger.
Turbocharger Wastegate Control (TCWC) solenoid – Controls the TCWC actuator by regulating the amount
of charge air pressure supplied to the TCWC actuator. The TCWC solenoid is controlled by signals from the
ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
Turbocharger 1 Wastegate Control (TC1WC) solenoid – Controls the TC1WC actuator by regulating the
amount of charge air pressure supplied to the TC1WC actuator. The TC1WC solenoid is controlled by signals
from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
The TC1WC actuator is part of the turbocharger assembly.
Turbocharger 2 Wastegate Control (TC2WC) solenoid – Controls the TC2WC actuator by regulating the
amount of charge air pressure supplied to the wastegate actuator. The TC2WC solenoid is controlled by signals
from the ECM in response to engine speed, required fuel quantity, boost, exhaust back-pressure, and altitude.
The TC2WC actuator is part of the turbocharger assembly.
1226 TERMINOLOGY
Variable capacitance sensor – A variable capacitance sensor measures pressure. The pressure forces a
ceramic material closer to a thin metal disc in the sensor, changing the capacitance of the sensor.
Vehicle Electronic System Programming System – The computer system used to program electronically
controlled vehicles.
Vehicle Retarder Enable/Engage – Output from the ECM to a vehicle retarder.
Vehicle Speed Sensor (VSS) – Normally a magnetic pickup sensor mounted in the tailshaft housing of the
transmission, used to indicate ground speed.
Viscosity – The internal resistance to the flow of any fluid.
Viscous fan – A fan drive that is activated when a thermostat, sensing high air temperature, forces fluid through
a special coupling. The fluid activates the fan.
Volt (v) – A unit of electromotive force that will move a current of one ampere through a resistance of one Ohm.
Voltage – Electrical potential expressed in volts.
Voltage drop – Reduction in applied voltage from the current flowing through a circuit or portion of the circuit
current multiplied by resistance.
Voltage ignition – Voltage supplied by the ignition switch when the key is ON.
Washcoat – A layer of alumina applied to the substrate in a monolith-type converter.
Water In Fuel (WIF) sensor – A switch sensor that measures the amount of water in the fuel.
SPECIAL TOOLS 1227
Table of Contents
Contact Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1229
Engine Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1229
Mounting Engine On Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1229
Engine Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1230
Engine Individual Component............ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1230

1228 SPECIAL TOOLS
SPECIAL TOOLS 1229
Contact Information
For concerns or ordering information regarding special tools for N13 engines, refer to the Service Resource
Center on Service Portal, or call 1-800-365-0088.
Engine Removal From Chassis

Special Tools
Air and Fuel Cap and Plug Kit ZTSE4891
Coolant Management Tool KL 5007 NAV
Lifting Device Obtain locally
Transmission Jack and Support Straps Obtain locally
Mounting Engine On Stand
Special Tools
Engine Lifting Tool Kit 12-000-01-01 – 12-000-01-07
Engine Stand Adapter Plate 12-051-01
Engine Stand Adapter Plate Mounting Bolts 12-051-01-02
Engine Roll-Over Stand OTC1750A
1230 SPECIAL TOOLS
Engine Disassembly
Special Tools
EGR Cooler Pressure Test Kit 12-892-07
Straightedge Obtain locally
Mica Ring Assembly Tool
Digital Multimeter (DMM) Obtain locally
Piston Ring Expansion Pliers Obtain locally
Piston Ring Compressor Obtain locally
Engine Individual Component

Engine Electrical Special Tools
SPECIAL TOOLS 1231
Aftertreatment System Special Tools

Coolant Block Off Plug 12–559–02–01
Exhaust Back-Pressure Control System Special Tools

Crimping pliers Obtain locally
Superlub™ synthetic high heat lubricant Obtain locally
Air Compressor and Power Steering Special Tools

Coolant Line Release Tool ZTSE4778
P80® rubber lubricant or equivalent Obtain locally
1232 SPECIAL TOOLS
Fuel System Special Tools

Fan Hub/High Pressure Drive Seal Installer ZTSE6066
Forcing Screw 12-454-01-05
Forcing Screw Adapter 12-454-01-04
Forcing Screw Adapter Holding Plate 12-454-01-01
Fuel Injector Cups ZTSE4892
Fuel Injector Rack Holder ZTSE4299B
Fuel System Priming Tool 15-922-01
Guide Stud 12-454-01-02
High-Pressure Pump Removal Tool 12-454-01
Holding Plate ZTSE6044
P80® Rubber Lubricant or equivalent Obtain locally
Socket Head Bolt 12-454-01-03
Oil Cooler, Filter Housing, and Crankcase Ventilation System Special Tools
Air pressure regulator Obtain locally
Extension Tube Installer Large ZTSE6051-1
Extension Tube Installer Small ZTSE6051-2
Engine Oil Cooler Pressure Test Plate ZTSE6063
Exhaust Gas Recirculation (EGR) System Special Tools

EGR Cooler Pressure Test Kit 12-892-07
SPECIAL TOOLS 1233
Front Cover, Fan Drive, Cooling System, and Related Components Special Tools
Fan Seal Installer ZTSE6066
Front Crankshaft Seal Installer ZTSE4873
N13 Engine Brake Special Tools

Jacobs® Slave Piston Removal Tool ZTSE6068
Cylinder Head, Camshaft and Valve Train Special Tools

Bearing installer Obtain locally
Connecting Rod Bolt Torx® Socket ZTSE4835
Feeler gauge (Jacobs® 96-020949) Obtain from Jacobs
™
Loctite® 262 Threadlocker Obtain locally
Loctite® 5127 sealant Obtain locally
Loctite® 5900 sealant or equivalent Obtain locally
M8 x 20 class 10.9 bolts Obtain locally
Telescoping gauge set Obtain locally
1234 SPECIAL TOOLS
Flywheel and Flywheel Housing Special Tools

1-2 inch micrometer Obtain locally
Blind hole puller Obtain locally
Brake cleaner (non-caustic) Obtain locally
Loctite 5900® Obtain locally
Wacker® A–442 RTV sealant Obtain locally
Pilot Bearing Installation Tool ZTSE4898
Rear Oil Seal Installer ZTSE4875
Oil Pump and Timing Gears Special Tools

Gear puller Obtain locally
Power Cylinders Special Tools

Piston ring compressor Obtain locally
Piston ring expansion pliers Obtain locally
Sleeve Protrusion Hold Down Clamps ZTSE4825
Telescoping gauge Obtain locally
SPECIAL TOOLS 1235
Crankcase and Crankshaft Special Tools

Lifting sling Obtain locally
Main Bolt Bottoming Tap ZTSE4854
1236 SPECIAL TOOLS
SPECIAL TORQUES 1237
Table of Contents
Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1239
Engine Electrical............................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1239
Inlet Air Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1240
Aftertreatment System..................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1240
Exhaust Back Pressure Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1241
Turbochargers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1242
Air Compressor and Power Steering/Fuel Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1243
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1244
Oil Module Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1245
Air Inlet Duct and Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1246
Front Cover, High Mount Fan Drive, Cooling System, Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1247
Engine Brake. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1249
Cylinder Head, Camshaft and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1250
Flywheel and Flywheel Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1252
Oil Pan and Oil Suction Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1253
Oil Pump and Timing Gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1254
Power Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1254
Crankcase and Crankshaft................ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1254

1238 SPECIAL TORQUES

M14 x 50 engine front mount support bolts 225 N·m (166 lb·ft)
Oil drain plug 75 N·m (55 lb·ft)
Engine Electrical
Camshaft Position (CMP) sensor, M6 x 12 bolt 8 N·m (71 lb·in)

Charger Air Cooler Outlet Temperature (CACOT)
11 N·m (97 lb·in)
sensor
Crankcase Oil Separator Speed (CCOSS) sensor,
10 N·m (89 lb·in)
M6 x 14 bolt
Crankshaft Position (CKP) sensor, M6 x 16 bolt 8 N·m (71 lb·in)
10 N·m (89 lb·in)
Engine Control Module (ECM), M6 x 30 bolt
See procedure for tightening sequence
Engine Control Module (ECM) support, M8 x 40 bolt 13 N·m (115 lb·in)
Engine injector harness retainer clip, M6 x 30 bolt 10 N·m (89 lb·in)
Engine Oil Level (EOL) sensor 45 N·m (33 lb·ft)
Engine Oil Pressure (EOP) sensor 45 N·m (33 lb·ft)
Engine Oil Temperature (EOT) sensor 45 N·m (33 lb·ft)
Engine sensor harness bracket/clip, M8 x 16 bolt 35 N·m (26 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT)
14 N·m (10 lb·ft)
sensor
Fuel Delivery Pressure (FDP) sensor 45 N·m (33 lb·ft)
Humidity / Inlet Air Temperature (IAT) sensor, M6
9 N·m (80 lb·in)
x 16 bolt
Intake Manifold Temperature (IMT) sensor 45 N·m (33 lb·ft)
Intake Manifold Pressure (IMP) sensor 12 N·m (106 lb·in)
Mass Air Flow (MAF) sensor, M4 x 0.7 cap screw 0.36 N·m (3 lb·in)
Oxygen Sensor (O2S) 50 N·m (37 lb·ft)
NOx IN Sensor 50 N∙m (37 lb∙ft)
Fuel Rail Pressure (FRP) sensor 70 N·m (52 lb·ft)
Turbocharger 2 Compressor Inlet Sensor (TC2CIS),
9 N·m (80 lb·in)
M6 x 16 bolt
Inlet Air Heater
Banjo 6 (M10 x 1) and 8 (M12 x 1.5) bolts 15 N·m (132 lb·in)

Banjo M8 x 1 bolt 8 N·m (71 lb·in)
Fuel supply inlet air heater hose fitting nut 10 N·m (89 lb·in)
IAHFI locking nut 23 N·m (17 lb·ft)
IAHFI wiring harness nut 4 N·m (35 lb·in)
Relay assembly M6 x 20 bolts 10 N·m (89 lb·in)
Solenoid valve M6 x 20 bolts 6 N·m (53 lb·in)
Aftertreatment System
Coolant supply (straight) fitting at coolant manifold 35 N·m (26 lb·ft)

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

O2 sensor harness bolt 13 N·m (10 lb·ft)
Air supply tube (at bulkhead fitting) 17.5 N·m (13 lb·ft)
Air supply tube nut (at air control valve) 12 N·m (106 lb·in)
Exhaust back pressure valve tube nut (at air control valve) 15 N·m (11 lb·ft)
Flare M10 x M12 (24 degree) fitting 17.5 N·m (13 lb·ft)
TC1TOP sensor tube nut (at air control valve) 15 N·m (11 lb·ft)
TC1TOP sensor tube nut at flare M10 x M12 (24 degree) fitting 15 N·m (11 lb·ft)
TMV mounting bolts 31 N·m (23 lb·ft)
Turbochargers

Air Compressor and Power Steering/Fuel Pump
1-1/16" 90 degree elbow lock nut 55 N·m (40 lb·ft)

1/2" 90 degree tube elbow lock nut 45 N·m (33 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (one cylinder) 35 N·m (26 lb·ft)
Air compressor M8 x 40, M8 x 110 bolt (two cylinder) 31 N·m (23 lb·ft)
(Two cylinder) Air compressor M10 x 110 bolt 67 N·m (49 lb·ft)
High-pressure tube fitting nut 62 N·m (45 lb·ft)
M16 straight fitting 35 N·m (26 lb·ft)
M16 45° fitting 17.5 N·m (13 lb·ft)
M18 straight fitting 37.5 N·m (28 lb·ft)
Low-pressure tube fitting nut 164 N·m (120 lb·ft)
Power steering pump M10 x 40 bolt 67 N·m (49 lb·ft)
Fuel System
Banjo bolt, M14 30 N·m (22 lb·ft)

Check valve 35 N·m (26 lb·ft)
Closed (P) clamp and M6 x 16 bolt 13 N·m (115 lb·in)
Forcing Screw Adapter Holding Plate M10 x 40 bolts 27 N·m (20 lb·ft)
Fuel drain line fitting nut 26 N·m (19 lb·ft)
Fuel filter bracket M8 x 30 bolt 35 N·m (26 lb·ft)
Fuel filter housing assembly M8 x 45 bolt 35 N·m (26 lb·ft)
Fuel filter cap 25 N·m (18 lb·ft)
Fuel filter stand pipe 12 N·m (106 lb·in)
Fuel Pressure Control Valve (FPCV) screws 8 N·m (71 lb·in)
Fuel primer pump assembly M8 x 25 bolt 30 N·m (22 lb·ft)
Fuel rail M8 x 40 bolt 35 N·m (26 lb·ft)
Fuel strainer cover 10 N·m (89 lb·in)
Fuel supply adapter 30 N·m (22 lb·ft)
High-pressure connector (body) retaining nut See tightening steps in procedure
Drive housing M12 x 40, M12 x 90, M12 x 130 bolt 105 N·m (77 lb·ft)
High-pressure fuel pump M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure fuel pump M24 jam nut 285 N·m (210 lb·ft)
High-pressure fuel pump support M14 x 30 bolt 172 N·m (126 lb·ft)
High-pressure pump to rail tube assembly line fitting nuts See tightening steps in procedure
High-pressure rail to injector line fitting nut See tightening steps in procedure
High-pressure pump pulley housing M10 x 40 bolt 62 N·m (46 lb·ft)
High-pressure pump pulley M16 x 40 LH bolt 280 N·m (207 lb·ft)
Holding plate M12 bolts 47 N·m (35 lb·ft)
Injector harness nut 1.8 N·m (16 lb·in)
Injector hold-down clamp M8 x 50 bolt See tightening steps in procedure
Piston Overflow Valve (KUEV) 49 N·m (37 lb·ft)
Pressure limiting valve 110 N·m (81 lb·ft)
Quick-connect M16 x 1.5 connector 30 N·m (22 lb·ft)
Support bracket M12 x 30 bolts 107 N·m (79 lb·ft)
Threaded unions (M14 x 1.5) 30 N·m (22 lb·ft)
Oil Module Assembly
Heater return tube assembly bolt, M6 x 16 13 N·m (115 lb·in)

Heater return tube assembly tube nut 11 N·m (97 lb·in)
Oil cooler bolts, M8 x 45 and M8 x 90 25 N·m (18 lb·ft)
Oil filter cover 40 N·m (30 lb·ft)
Oil module assembly bolts, M10 x 80, M10 x 170 and M10 x 110 65 N·m (48 lb·ft)
Oil module flange bolts, M8 x 45 24 N·m (18 lb·ft)
Oil pressure relief valve 40 N·m (30 lb·ft)
Open breather tube assembly bolt, M6 x 16 13 N·m (115 lb·in)
Water pump bolt, M8 x 150 (front side of oil module) 35 N·m (26 lb·ft)
Exhaust Gas Recirculation (EGR) System
Air Inlet Duct and Exhaust Manifolds
Intake Manifold Pressure (IMP) sensor 14 N·m (10 lb·ft)

Exhaust Gas Recirculation (EGR) inlet manifold mounting bolts 31 N·m (23 lb·ft)
Exhaust Gas Recirculation Temperature (EGRT) sensor 14 N·m (10 lb·ft)
Exhaust manifold bolts 20 N·m (15 lb·ft) + 90°
Front Cover, High Mount Fan Drive, Cooling System, Related Components
Figure 998 High mount fan drive bolt tightening sequence

Automatic belt tensioner countersunk screw,

47 N·m (35 lb·ft)
M10 x 70
CCV assembly stud bolts (with lock washers),
35 N·m (26 lb·ft)
M8 x 60
Coolant heater 41 N·m (30 lb·ft)
Coolant outlet manifold bolts, M8 35 N·m (26 lb·ft)
Damper hub and fan drive pulley bolts to
45 N·m (33 lb·ft)
vibration damper, M10 x 35
EGR cooler return manifold bolts, M8 35 N·m (26 lb·ft)
Engine water inlet bolts, M10 x 30 29 N·m (21 lb·ft)
Front belt- or gear-driven fan cover bolts,
• M8 31 N·m (23 lb·ft)
• M12 x 75 115 N·m (85 lb·ft)
• M12 x 30 115 N·m (85 lb·ft)
High mount fan drive clutch assembly bolts,
M10
High mount fan drive tensioner countersunk
47 N·m (35 lb·ft)
screw, M10 x 70
High mount fan pulley assembly shoulder bolt 62 N·m (46 lb·ft)
Idler pulley bolt, M12 x 55 60 N·m (44 lb·ft)
Low mount fan drive bolt, M10 x 110 37 N·m (27 lb·ft)
Vibration damper socket-head cap screws,
M16 x 85
Water distribution housing bolts, M8 35 N·m (26 lb·ft)
Water pump assembly bolts, M8 35 N·m (26 lb·ft)
Water pump pulley bolts, M8 x 16 17 N·m (13 lb·ft)
Engine Brake
Brake housing M10 x 90 bolt 75 N·m (55 lb·ft)

Brake housing M12 x 100 (socket-head) screw 105 N·m (77 lb-ft)
Brake housing solenoid harness connector nut 3.5 N·m (31 lb·in)
Slave piston adjusting screw M10 (jam) nut 25 N·m (18 lb·ft)
Solenoid M6 x 10 socket-head cap screw 12.5 N·m (110 lb·in)
Figure 999 Cylinder Head Bolts Tightening Sequence
Figure 1000 Valve Cover Base Tightening Sequence

Camshaft gear M8 x 30 bolt See tightening steps in procedure

(Camshaft) bearing cap M8 x 35 bolt 25 N·m (18 lb·ft)
Cylinder head idler gear M8 x 30 socket-head cap screw 30 N·m (22 lb·ft)
Cylinder head M18 x 246 Torx® bolt See tightening steps in procedure
Rocker arm assembly M12 x 60 (socket-head) screw 105 N·m (77 lb·ft)
Upper valve cover M8 x 30 bolt 9 N·m (80 lb·in)
Valve cover base screw with damper 11 N·m (97 lb·in)
Valve lash adjustment M10 nut 45 N·m (33 lb·ft)
Figure 1001 Flywheel bolt tightening sequence
12PT flange bolts See tightening steps in procedure.

Flywheel housing bolts, M10 x 30 and M10 x 40 65 N·m (48 lb·ft)
Lifting eye bolts, M16 x 150 280 N·m (207 lb·ft)
Timing hole cover screws 2 N·m (18 lb·in)
Oil Pan and Oil Suction Tube
Figure 1002 Torque sequence
Drain plug, M27 x 2 75 N·m (55 lb·ft)

Oil pan bolts, M8 x 40 See tightening steps in procedure.
Oil pan heater element or replacement drain plug 75 N·m (55 lb·ft)
Oil Pump and Timing Gears
Air compressor coupled idler gear, M12 x 55 bolts 107 N·m (79 lb·ft)
Axle for pinion (oil pump), M10 x 35 socket-head cap screw 65 N·m (48 lb·ft)
Crankcase idler gear, M8 x 30 socket-head cap screws 30 N·m (22 lb·ft)
(Front) idler gear, M12 x 50 socket-head cap screws 105 N·m (77 lb·ft)
Idler large gear, M14 x 80 bolts 175 N·m (129 lb·ft)
Power Cylinders
Connecting rod bolts See tightening steps in procedure

Sleeve Protrusion Hold Down Clamp bolts 80 N·m (59 lb·ft)
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 lb·in)

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2015 N13 Engine

2015 N13 Engine

2701 Navistar Drive, Lisle, IL 60532 USA

Engine-to-Vehicle Connection Points... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Engine Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Service and Test Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Engine Component Replacement Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .81

Engine Disassembly Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .819

Standard Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1197

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1203

Special Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1227

Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1237

Technical Service Literature

• Clear the area before starting the engine.

• Check for frayed power cords before using power tools.

Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Engine Accessory Labels and Identification Plates. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Engine Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Aftertreatment Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Engine Serial Number

Figure 1 Engine serial number

Engine Serial Number Examples

Engine Serial Number Codes

Engine Emission Label

Engine Accessory Labels and Identification Plates

N13 Diesel Engine

• N13 126 mm (4.96 in)

Thermostat operating temperature

• Primary 83°C - 95°C (181°F - 203°F)

Chassis Mounted Equipment

Engine Component Locator

Component Description Top Front Left Left – Right Right Back

Component Description Top Front Left Left – Right Right Back

Component Description Top Front Left Left – Right Right Back

Figure 3 Top View

Figure 4 Front View

Figure 5 Left View

Left View – Closeup

Figure 6 Left View – Closeup

Figure 7 Right View

Right Front View

Figure 8 Right Front View

Figure 9 Back View

Aftertreatment Component Locator

SCR Switchback Assembly

Figure 10 SCR Switchback Assembly

Figure 11 DPF Components

Figure 12 SCR Components

Engine-to-Vehicle Connection Points... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Engine-to-Vehicle Connection Points

Figure 13 Engine to Vehicle Connection Points

Figure 14 Engine to Vehicle Connection Points (Continued)

Engine Removal From Chassis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Engine Removal From Chassis

Figure 15 Engine Removal From Chassis Manual References

1. Remove battery-box cover.

57. Remove fan from fan clutch.

88. Secure steering wheel to prevent rotation.

Mounting Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43