EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
TABLE OF CONTENTS
1 ROCKER COVER
1.1 DESCRIPTION AND OPERATIONOFROCKER COVER AND RELATED
PARTS ...................................................................................................... 1-3
1.2 REMOVAL OF THE ROCKER COVER .................................................... 1-4
1.3 CLEANING AND INSPECTION OF THE ROCKER COVER ................... 1-6
1.4 INSTALLATION OF THE ROCKER COVER ............................................ 1-7
2 CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY
2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER
SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS ............... 2-3
2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE B
ASSEMBLY .............................................................................................. 2-7
2.3 INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE
BRAKE ASSEMBLY ................................................................................. 2-15
2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE
BRAKE ASSEMBLY ................................................................................. 2-16
2.5 DD13 EGR COOLER CLEANING PROCEDUR
ETOREMOVEEXCESS
FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2-26
2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGIN
E BRAKE SOLENOID FAILURE
RAKE
2-31
3 CAMSHAFT HOUSING
3.1 REMOVAL OF THE CAMSHAFT HOUSING ........................................... 3-3
3.2 INSPECTION OF CAMSHAF
T HOUSING ...............................................
3-8
3.3 INSTALLATION OF THE CAMSHAFT HOUSING ................................... 3-9
4 CAMSHAFT TIMING
4.1 CAMSHAFT TIMING VER
IFICATION ......................................................
4-3
4.2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED ........ 4-6
5 GEARTRAINANDENGINETIMING
5.1 DESCRIPTION AN
D OPERATION OF GEAR TRAIN AND RELATED
PARTS ...................................................................................................... 5-3
5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING ............................ 5-8
5.3 CHECKING AND
ADJUSTING GEAR LASH W ITH CAMSHAFT
HOUSING REMOVED ............................................................................. 5-16
6 WATER MANIFOLD
6.1 DESCRIPT
IONANDOPERATIONOFDD15&DD16WATER
MANIFOLD AND RELATED COMPONENTS .......................................... 6-3
6.2 REMOVAL OF THE DD15 & DD16 WATER M AN IFOLD ......................... 6-5
6.3 CLEAN
ING AND INSPECTION OF THE DD15 & DD16 WATER
MANIFOLD ............................................................................................... 6-7
6.4 INSTALLATION OF THE DD15 & DD16 WATER
MANIFOLD ................. 6
-8
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6.5 DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD
ASSEMBLY .............................................................................................. 6-10
7 COLD BOOST PIPE (C HA RGE AIR PIPE)
7.1 DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE
AIR PIPE) AND RELATED COMPONENTS ............................................ 7-3
7.2 REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ............. 7-4
7.3 INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) ................ 7-5
7.4 INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) .... 7-6
8 AIR INTAKE MANIFOLD
8.1 DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND
RELATED PARTS .................................................................................... 8-3
8.2 REMOVAL OF AIR INTAKE MANIFOLD .................................................. 8-6
8.3 CLEANING OF THE AIR INTAKE MANIFOLD ........................................ 8-7
8.4 INSPECTION OF THE AIR INTAKE MANIFOLD ..................................... 8-8
8.5 INSTALLATION OF AIR INTAKE MANIFOLD .......................................... 8-9
9 DD13 TURBOCHARGER
9.1 DESCRIPTION AND OPERATION OF THE DD13 TU
RBOCHARGER
AND RELATED PARTS ............................................................................ 9-3
9.2 REMOVAL OF THE DD13 TURBOCHARGER ........................................ 9-5
9.3 INSPECTION O F THE DD13 TURBOCHARGER
...................................
9.4 INSTALLATION OF THE DD13 TURBOCHARGER ................................ 9-10
9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCH
ARGER FAILURE ................
9-9
9-12
10 DD13 WASTEGATE SOLENOID
10.1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE
SOLENOID ............................................................................................... 10-3
10.2 REMOVAL OF THE DD13 WASTEGATE SOLENOID ............................. 10-4
10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID ..................... 10-6
11 DD15 TURBOCHARGER
11.1 DESCRIPTION AND OPERATION OF TURBOCHARGER AND
RELATED PARTS .................................................................................... 11-3
11.2 REMOVAL OF DD15 TU
RBOCHARGER ................................................
11-5
11.3 INSPECTION OF DD15 TURBOCHARGER ........................................... 11-7
11.4 INSTALLATION OF DD15 TURBOCHARGER ........................................ 11-8
11.5 EGR COOLER CLEA
NING PROCEDURE TO REMOVE EXCESS OIL
FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE ....... 11-10
12 DD15 AXIAL POWER TURBINE
12.1 DESCRIPTI
AND OPERATION O
ON
F DD15 AXIAL POWER TURBINE
AND RELATED PARTS ............................................................................ 12-3
12.2 REMOVAL OF DD15 AXIAL POWER TURBINE ..................................... 12-5
12.3 INSPECT
ION OF THE DD15 AXIAL POWER TURBINE ........................
12-6
12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE ............................. 12-7
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13 DD15 AXIAL POWER TURBINE GEAR BOX
13.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE
GEAR BOX AND RELATED PARTS ........................................................ 13-3
13.2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX ......... 13-5
13.3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX ............. 13-6
13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX ............ 13-7
14 CYLINDER HEAD
14.1 DESCRIPTION AND OPERATIONOF CYLINDER HEAD AND RELATED
PARTS ...................................................................................................... 14-3
14.2 REMOVAL OF THE DD13 CYLINDER HEAD ......................................... 14-10
14.3 INSTALLATION OF THE DD13 CYLINDER HEAD .................................. 14-12
14.4 REMOVAL OF THE DD15 CYLINDER HEAD ......................................... 14-15
14.5 CLEANING OF THE CYLINDER HEAD .................................................. 14-17
14.6 ASSEMBLY OF CYLINDER HEAD .......................................................... 14-18
14.7 INSTALLATION OF THE DD15 CYLINDER HEAD .................................. 14-19
14.8 REMOVAL OF VALVE SPRING (CYLINDER HEAD IN
STALLED) ..........
14-22
14.9 REMOVAL OF THE VALVE SPRING (CYLINDER HEAD REMOVED) ... 14-24
14.10 REMOVAL OF INTAKE AND EXHAUST VALVES ................................... 14-25
14.11 CLEANING OF VALVES AND RELATED PARTS .................................... 14-26
14.12 INSPECTION OF VALVE SPRINGS ........................................................ 14-27
14.13 INSPECTION OF VALVE ......................................................................... 14-28
14.14 INSTALLATION OF VALVE, SPRING,
SEAL AND VALVE CAP ..............
14-29
14.15 VALVE LASH ADJUSTMENTS ................................................................ 14-31
14.16 SETTING THE ENGINE BRAKE LASH ................................................... 14-33
15 PISTON AND CONNECTING ROD ASSEMBLY
15.1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING
ROD AND RELATED PARTS ................................................................... 15-3
15.2 REMOVAL OF PISTON AND CO
NNECTING ROD ASSEMBLY .............
15-5
15.3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY ..... 15-7
15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY ........ 15-8
15.5 ASSEMBLY OF PISTON AN
D CONNECTING ROD ASSEMBLY ...........
15-9
15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY ..... 15-11
16 CYLINDER LINER
16.1 DESCRIPTION AND
OPERATION OF CYLINDER LINER AND
RELATED PARTS .................................................................................... 16-3
16.2 REMOVAL OF CYLINDER LINER ........................................................... 16-4
16.3 INSPECTION OF
CYLINDER LINER ......................................................
16-5
16.4 CLEANING OF THE CYLINDER LINER .................................................. 16-7
16.5 INSTALLATION OF THE CYLINDER LINER ........................................... 16-8
17 CRANKSHAFT
17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED
PARTS ..................................
17.2 REMOVA
......................
L OF CRANKSHAFT .................................................................
.............................................. 17-3
17-6
17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS ............. 17-9
17.4 INSTALLATION OF CRANKSHAFT ......................................................... 17-10
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17.5 REMOVAL OF CRANKSHAFT REAR OIL SEAL ..................................... 17-14
17.6 INSTALLATION OF THE REAR OIL SEAL .............................................. 17-15
17.7 REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL .......................... 17-17
17.8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL .................. 17-18
18 LUBRICATION SYSTEM
18.1 DESCRIPTIONANDOPERATIONOFTHELUBRICATIONSYSTEM
AND RELATED COMPONENTS .............................................................. 18-3
19 OIL PAN
19.1 DESCRIPTIONANDOPERATIONOFOILPANANDRELATED
COMPONENTS ....................................................................................... 19-3
19.2 REMOVAL OF OIL PAN ........................................................................... 19-4
19.3 CLEANING OF OIL PAN .......................................................................... 19-5
19.4 INSPECTION OF OIL PAN ...................................................................... 19-6
19.5 REMOVAL OF THREADED INSERT — PLASTIC OIL PAN ONLY
.........
19.6 INSTALLATION OF THREADED INSERT — PLASTIC OIL PAN ONLY . 1 9-8
19.7 INSTALLATION OF OIL PAN ................................................................... 19-9
20 OIL DIPSTICK TUBE
20.1 DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND
RELATED COMPONENTS ...................................................................... 20-3
20.2 REMOVAL OF THE OIL DIPSTICK TUBE ............................................... 20-4
20.3 INSTALLATION OF THE OIL DIPSTICK TUBE ....................................... 20-5
19-7
21 OIL PUMP
21.1 DESCRIPTION AND OPERATION OF
OIL PUMP AND RELATED
COMPONENTS ....................................................................................... 21-3
21.2 REMOVAL OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL
LINES ....................................................................................................... 21-4
21.3 INSPECTION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL
LINES ....................................................................................................... 21-5
21.4 INSTALLATION OF THE OI
L PUMP, OIL SUCTION MANIFOLD, AND
OIL L INES ................................................................................................ 21-6
22 CRANKCASE BREATHER
22.1 DESCRIPTION AND O
PERATION OF CRANKCASE BREATHER ........
22-3
22.2 REMOVAL O F THE CRANKCASE BREATHER ...................................... 22-5
22.3 INSPECTION OF THE CRANKCASE BREATHER
22.4 INST
ALLATION O
F THE CRANKCASE BREATHER ..............................
................................. 22-6
22-7
23 OIL FILTER
23.1 REPLACEMENT OF THE OIL FILTER .................................................... 23-3
24 OIL SAMPLE VALVE
24.1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE .............................. 24-3
24.2 REMOVAL OF OIL SAMPLE VALVE ....................................................... 24-4
24.3 INSTALL
ATION OF OIL SAMPLE VALVE ................................................
24-5
25 OIL FIL
LER NECK
25.1 REMOVAL OF THE OIL FILLER NECK ................................................... 25-3
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
25.2 INSTALLATION OF THE OIL FILLER NECK ........................................... 25-4
26 OIL COOLANT MODULE
26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE .. 26-3
26.2 REMOVAL OF THE OIL COOLANT M OD ULE ........................................ 26-5
26.3 INSTALLATION OF THE OIL COOLANT MODULE ................................ 26-7
26.4 REMOVAL OF THE OIL THERMOSTAT .................................................. 26-9
26.5 INSTALLATION OF THE OIL THERMOSTAT .......................................... 26-11
27 PRIMING THE LUBRICATION SYSTEM
27.1 PRIMING THE ENGINE LUBRICATION SYSTEM .................................. 27-3
28 COOLING SYSTEM
28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND
RELATED COMPONENTS ...................................................................... 28-3
29 ENGINE WATER PUMP
29.1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP
............
29-3
29.2 REMOVAL OF THE WATER PUMP ......................................................... 29-4
29.3 INSPECTION OF THE WATER PUMP .................................................... 29-5
29.4 INSTALLATION OF THE WATER PUMP ................................................. 29-6
30 COOLANT THERMOSTAT
30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT ........ 30-3
30.2 REMOVAL OF COOLANT THERMOSTAT AN
D SEAL ...........................
30-5
30.3 INSPECTION OF COOLANT THERMOSTAT AND SEAL ....................... 30-6
30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL .................... 30-7
31 COOLANT FILTER
31.1 DESCRIPTION AND OPERATION OF COOLANT FILTER ..................... 31-3
31.2 REMOVAL OF THE COOLANT FILTER .................................................. 31-4
31.3 INSTALLATION OF THE COO
32 COOLANT FILTER SERVIC
LANT FILTER ..........................................
EMODULE
31-5
32.1 REMOVAL OF COOLANT FILTER SERVICE MODULE ......................... 32-3
32.2 INSTALLATION OF COOL
33 COOLANT INLET ELB
ANT FILTER SERVICE MODULE ..................
OW
32-4
33.1 REMOVAL OF THE COOLANT INLET ELBOW ...................................... 33-3
33.2 INSTALLATION OF
34 FLYWHEEL AND FL
THE COOLANT INLET ELBOW ..............................
YWHEEL HOUSING
33-4
34.1 DESCRIPTION AND OPER ATION OF FLYWHEEL, FLYWHEEL HOUSING AND R
ELATED PARTS ..........................................................
34-3
34.2 REMOVAL OF FLYWHEEL HOUSING .................................................... 34-6
34.3 INSTALLATION OF FLYWHEEL HOUSING ............................................ 34-7
34.4 REMOVAL OF
34.5
INSPECTION OF FL
THE FLYWHEEL ..............................................................
YWHEEL ................................................................. 34-10
34-9
34.6 INSTALLATION OF FLYWHEEL .............................................................. 34-11
34.7 INSPEC
TION OF FLYWHEEL HOUSING AND REAR OIL SEAL AREA
OF CRANKSHAFT ................................................................................... 34-12
34.8 REMOVAL OF RING GEAR ..................................................................... 34-13
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34.9 INSTALLATION OF RING GEAR ............................................................. 34-14
35 FRONT ENGINE MOUNT/RADIATOR SUPPORT
35.1 DESCRIPTION AND OPERATION OF FRONT ENGINE
MOUNT/RADIATOR SUPPORT AND RELATED PARTS ........................ 35-3
35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT .. 35-4
35.3 INSPECTION OF THE FRONT ENGINE MOUNT/RADIATOR
SUPPORT ................................................................................................ 35-5
35.4 INSTALLATION OF THE FRONT ENGINE MOUNT/RADIATOR
SUPPORT ................................................................................................ 35-6
36 VIBRATION DAMPER
36.1 REMOVAL OF THE VIBRATION DAMPER ............................................. 36-3
36.2 INSTALLATION OF THE VIBRATION DAMPER ..................................... 36-4
37 FRONT ENGINE COVER
37.1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE CO
VER ..
37.2 REMOVAL OF THE FRONT ENGINE COVER ........................................ 37-4
37.3 INSPECTION OF THE FRONT ENGINE COVER ................................... 37-5
37.4 INSTALLATION OF THE FRONT ENGINE COVER ................................ 37-6
37-3
38 ENGINE LIFTER BRACKETS
38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS
AND RELATED PARTS ............................................................................ 38-3
38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT
FRONT ENGINE POWER TAKE-OFF ..................................................... 38-8
38.3 REMOVAL OF THE FRONT ENGINE LI
FTER BRACKET WITH FRONT
ENGINE POWER TAKE-OFF .................................................................. 38-9
38.4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS ...................... 38-10
38.5 INSPECTION OF THE ENGINE
LIFTER BRACKETS ............................
38-11
38.6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS .............. 38-12
38.7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAK
E-OFF .....................................................
38-13
38.8 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITH
FRONT ENGINE POWER TAKE-OFF ..................................................... 38-14
39 BELT DRIVE TENSIONER SYSTEM
39.1 DESCRIPTION AND OPERATIONOFBELTDRIVETENSIONERAND
RELATED PARTS .................................................................................... 39-3
39.2 REMOVAL OF THE B
39.3 INSTALLATION OF THE B ELT TENSIONER ...........
4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET .. 39-7
39.
39.5 INSTALLATI
ON OF THE IDLER PULLEY AND IDLER PULLEY
ELT TENSIONER ..................................................
............................... 39-6
39-5
BRACKET ................................................................................................ 39-8
39.6 REMOVAL OF NON-BRACKETED IDLER PULLEY .............................. 39-9
39.7 INSTALLA
TION OF NON-BRACKETED IDLER PULLEY ........................
39-10
39.8 REMOVAL OF THE ACCESSORY MOUNTING BRACKET .................... 39-11
39.9 INSTALLATION OF THE ACCESSORY MOUNTING BRACKET ............ 39-12
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
40 POLY-V-BELTS
40.1 REMOVAL OF THE POLY-V-BELTS ....................................................... 40-3
40.2 INSPECTION OF THE POLY-V-BELTS ................................................... 40-6
40.3 INSTALLATION OF THE POLY-V-BELTS ................................................ 40-9
41 AIR COMPRESSOR
41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR .......... 41-3
41.2 REMOVAL OF THE AIR COMPRESSOR ................................................ 41-5
41.3 INSPECTION OF THE AIR COMPRESSOR ........................................... 41-6
41.4 INSTALLATION OF THE AIR COMPRESSOR ........................................ 41-8
42 CYLINDER BLOCK
42.1 DESCRIPTION AND OPER ATION OF CYLINDER BLOCK AND
RELATED PARTS .................................................................................... 42-3
42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICL
E....
42-9
42.3 CLEANING THE CYLINDER BLOCK ...................................................... 42-12
42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK ................ 42-16
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1 ROCKER COVER
Section Page
1.1 DESCRIPTION AND OPERATIONOF ROCKER COVERAND RELATED
PARTS ...................................................................................................... 1-3
1.2 REMOVAL OF THE ROCKER COVER .................................................... 1-4
1.3 CLEANING AND INSPECTION OF THE ROCKER COVER ................... 1-6
1.4 INSTALLATION OF THE ROCKER COVER ............................................ 1-7
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
1.1 DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PART S
The rocker cover (2) is made of an aluminum or plastic material and uses an elastome
r seal (1) which completely encloses the valve operating mechanism including the overhead camshafts, brake assemblies and the injector harness.
1. Gasket 4. Air Cleaner Bracket
2. Rocker Cover 5. Stud (Bolt)
3. Bolt
Figure 1-1 Rocker Cover
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1.2 REMOVAL OF THE ROCKER COVER
1.2 REMOVAL OF THE ROCKER COVER
Remove as follows:
1. Steam clean the engine.
2. Remove bolts (1) or nuts (if equipped) from the two air filter housing brackets (2) and remove housings from the rocker cover.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
3. Loosen the bolts (1) or stud bolts (2) (if equipped) and isolators (3); remove rocker cover.
NOTE:
Mark the location of the stud bolts. The stud bolts must be replaced in their original location during installation.
4. Remove rocker cover gasket from the
rocker cover.
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1.3 CLEANING AND INSPECTION OF THE ROCKER COVER
1.3 CLEANING AND INSPECTION OF THE ROCKER COVER
Clean as follows:
1. Clean cover in clean solvent or fuel.
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
2. Blow dry with compressed air.
3. Check the rocker cover, breather passage and seal for damage. Replace as necessary.
4. Inspect the bolts. Replace if damaged.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
1.4 INSTALLATION OF THE ROCKER COVER
Install as follow s:
1. Install rocker cover gasket into groove in rocker cover.
2. Install bolts (1) or stud bolts (2) (if removed) and isolators (3) into rocker cover.
3. Install roc
ker c over onto camshaft housing.
4. Finger tighten all bolts (1) and stud bolts; then torque to 20 N·m (14 lb·ft).
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1.4 INSTALLATION OF THE ROCKER COVER
5. Install the two air filter brackets (2) (if equipped), onto the rocker cover and torque the eight nuts to 20 N·m (14 lb·ft).
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-venti exhaust is toxic.
6. Start the engine and check f
lated area. Engine
or leaks.
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2 CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE
ASSEMBLY
Section Page
2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND
SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS ............... 2-3
2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE
ASSEMBLY .............................................................................................. 2-7
2.3 INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE
BRAKE ASSEMBLY ................................................................................. 2-15
2.4 INSTALLATION OF THE CAMSHAFT
BRAKE ASSEMBLY ................................................................................. 2-16
2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER E
2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2-31
ANDROCKERSHAFT/ENGINE
NGINE BRAKE SOLENOID FAILURE
ROCKER
2-26
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS
The engine uses a dual overhead camshaft and rocker shaft design. The intake and ex
haust camshafts are timed to each other, through a geartrain, to the crankshaft. The camshaft housing houses the camshafts and valve train. It has internal oil passages to supply oil from the block to the camshaft and rocker bearings along with pressurized oil to the engi
ne brake rockers via the engine
brake solenoids through the exhaust shaft. T he camshaft housing is made of aluminium material.
1. Camshaft Bearing Cap 6. Intake Rocker Arm
2. Bolt 120 mm 7. Exhaust Rocker Arm
3. Bolt 108 mm 8. Exhaust Camshaft and Gear
4. Bolt 63 mm 9. Intake Camshaft and Gear
5. Engine Brake Solenoid
10. Camshaft Housing 15. Intake Camshaft Tone Wheel
11. Gasket
12. Exhaust Camshaft Lobes
13. Exhaust Camshaft Brake Cam Lobe
14. Intake Camshaft Lobes
Figure 2-1 Camshaft Housing and Related Parts
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2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS
2.1.1 Engine Braking
The engine uses an integral engine brake. Engine braking is controlled electronica
llybythe engine control system with an electric solenoid. When activated, the solenoid allows oil pressure to activate a piston on the exhaust rocker arm. Engine braking is accomplished with a single exhaust valve in each cylinder. The exhaust camshaft uses a separate
engine brake-only lobe that allows for double valve activation for high efficiency braking. The exhaust valve is first operated toward the completion of the intake stroke, closed during the compression stroke and opened a second time when the compression stroke is completed. The engine
brake system is enabled using
the following components:
For EPA07 engines:
□ Engine brake solenoid valve in front of engine applies l
ow engine braking.
□ Engine brake solenoid valve in rear of engine applies medium engine braking. □ For high, both front and rear solenoids are activated. □ Six exhaust rocker arms with actuator pistons. □ Six brake rocker arms which are actuated by the brake cam lobes. □ Exhaust camshaft has one brake cam lobe per cylinder.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
For EPA07 engines, the exhaust rocker arm shaft lubricating oil passages direct pressurized oil to the rocker arms. The exhaust rocker arm has two additional oil passages to operate t
he engine brakes. Oil for cylinders 1 and 2 is supplied by the Front Engine Brake Solenoid Valve. Oil for cylinders3to6aresuppliedbytheRear Engine Brake Solenoid Valve.
1. Exhaust Rocker Arm 7. Exhaust Camshaft
2. Exhaust Rocker Arm with Actuator Piston 8. Actuator Piston
3. Brake Rocker Arm 9. Exhaust Valve
4. Oil Passage for Cylinders 1 and 2
5. Oil Passage for Cylinders 3, 4, 5 and 6
6. Exhaust Rocker Arm Sh aft
10. Brake Cam Lobe
11. Engine Brake Solenoid Valve, Front
12. Engine Brake Solenoid Valve, Rear
Figure 2-2 EPA07 Engine Brake
For EPA10 engines:
□ Engine brake solenoid valve in front of engine applies low engine braking. □ For medium engine braking, both front and rear solenoids are activated. □ For high, both front and rear solenoids are activated, along with EGR. □ Six exhaust rocker arms with actuator pistons. □ Six brake rocker arms which are actuated by the brake cam lobes. □ Exhaust camshaft has one brake cam lobe per cylinder.
All information subject to change without notice.
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2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS
For EPA10 engines, the exhaust rocker arm shaft lubricating oil passages direct pressurized oil to the rocker arms. The exhaust rocker arm has two additional oil passages to operate t
he engine brakes. Oil for cylinders 1 through 3 is supplied by the Front Engine Brake Solenoid Valve. Oil for cylinders 4 through 6 are supplied by the Rear Engine Brake Solenoid Valve.
1. Exhaust Rocker Arm 7. Exhaust Camshaft
2. Exhaust Rocker Arm with Actuator Piston 8. Actuator Piston
3. Brake Rocker Arm 9. Exhaust Valve
4. Oil Passage for Cylinders 1, 2 and 3
5. Oil Passage for Cylinders 4, 5 and 6
6. Exhaust Rocker Arm Shaft
10. Brake Cam Lobe
11. Engine Brake Solenoid Val
12. Engine Brake Solenoid Valve, Rear
Figure 2-3 EPA 10 Engine Brake
ve, Front
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY
Remove as follows:
1. Turn engine OFF, (key OFF, engine OFF).
2. Steam clean the engine.
3. Disconnect the battery power to the engine. Refer to OEM procedure
s.
4. Remove the air cleaner and the turbocharger inlet pipe and hose. Refer to OEM procedures.
5. Remove air cleaner housing. Refer to OEM procedures.
6. Remove the rocker cover. Refer to section 1.2.
7. Remove the two 14-pin fuel injector harness connectors (1) from the camshaft housing housing (2).
NOTE:
Top Dead Center (TDC) can be confirmed by installing camshaft timing tool. For the DD13 use Camshaft Timing Tool (W470589034000). For the EPA07 DD15 use Camshaft Timing Tool
(W470589054000). For the EPA10 DD15 use Camshaft Timing
Tool (W470589104000).
8. Using Engine Barring tool (J-46392), rotate the crankshaft to TDC on cylinder No. 1.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY
9. Remove the Crankshaft Position Sensor (CKP) (1) from t he rear of the flywheel housing. Refertosection.
10. To accurately locate TDC, install the flywheel housing crankshaft TDC Locating Pin (W470589001500) into the CKP sensor hole located in the rear of the flywheel housing. The plastic tip will protrude int
o the cutout in the tone wheel. TDC can be verified by the
proper installation of the camshaft timing tool.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
11. When the TDC dot (3) between two teeth on the flywheel aligns with the edge of pointer (2), the engine is at TDC firing stroke.
12. For EPA07 DD13:
[a] Disconnect both 14-pin injector harness connectors (8).
[b] Disconnect the 24 electrical te
rminals at the fuel injectors (7).
[c] Disconnect two wiring terminals at each engine brake solenoid (6).
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY
[d] Loosen the Allen screws holding the intermediate frame (5) to the camshaft housing
(1). Remove the intermediate frame .
13. For EPA10 engines:
[a] Remove the fuel injector electrical harness clips (2) from the 14-pin electrical
connectors.
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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE
[b] Remove the bolts securing the two-piece fuel injector electrical harness (1 and 3) and
remove the harness from the camshaft housing housing.
14. Remove the engine brake solenoids from the camshaft housing.
NOTICE:
Ensure when loosening the rocker shaft bolts that the bolts are loosened fro m the inside bolts outward in 1/2 turn increments. The increment procedure need
stobefollowedtopreventthe
rocker shaft from breaking.
15. Completely loosen all
of the adjusting screws on all of the rocker arms.
16. Loosen the seven bolts securing the intake rocker shaft to the camshaft bearing caps.
NOTICE:
Make sure that the camshaft housing housing is not damaged during removal of the intake/exhaust rocker shaft assemblies.
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2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY
17. Using Rocker Arm Lifter / Spacer tool (W470589044000) for the DD13, or Rocker Arm Lifter / Spacer Intake tool (W470589004000) for the DD15, remove the intake rocker shaft assembly.
NOTICE:
Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts outward in 1/2 turn increments. The increment procedure needs to be followed to prevent the rocker shaft from breaking.
18. Loosen the seven bolts securing the exhaust rocker
shaft to the camshaft caps.
19. Using Rocker Arm Lifter / Spacer Exhaust (W470589074000) for the DD13 or Rocker Arm Lifter / Spacer Exhaust (W470589004000) for the DD15, remove the exhaust rocker shaft assembly. When removing the EPA10 exhau
st rocker shaft, ensure the rockers are
in the up position.
NOTE:
The engine brake s
olenoids do not have to be removed unless damaged.
NOTE:
Mark cap position for proper reassembly.
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