Detroit Diesel Engine DD15 Service Manual

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

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

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

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

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

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

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

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

All information subject to change without notice.

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 ..................

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

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

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

All information subject to change without notice.

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

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

All information subject to change without notice.

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

All information subject to change without notice.

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

All information subject to change without notice.

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.

All information subject to change without notice.

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

3. Loosen the bolts (1) or stud bolts (2) (if equipped) and isolators (3); remove rocker cover.

NOTE:

Mark the location of the stud bolts. The stud bolts must be replaced in their original location during installation.

4. Remove rocker cover gasket from the

rocker cover.

All information subject to change without notice.

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.

All information subject to change without notice.

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).

All information subject to change without notice.

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.

All information subject to change without notice.

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

All information subject to change without notice.

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

All information subject to change without notice.

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.

All information subject to change without notice.

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.

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

All information subject to change without notice.

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

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.

All information subject to change without notice.

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.

All information subject to change without notice.

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).

All information subject to change without notice.

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.

All information subject to change without notice.

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.

All information subject to change without notice.

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.

All information subject to change without notice.

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