Detroit Diesel DD13, DD15, DD16 GHG17 Engine Workshop Manual

$149.95 $129.95

Covers: Detroit DD13, DD15, DD16 GHG17 Heavy Duty Diesel Engines
Pages: 1,226
Format: PDF
File size: 220mb
Compatibility: Windows/Mac/Tablet
Notes: Instant digital download only – no printed copy or CD-ROM media.

This workshop manual contains detailed inspection, testing, adjusting, disassembly/assembly and removal/installation procedures for the Detroit Diesel DD13, DD15, DD16 engines with GHG17 emissions. This manual is recommended for Detroit Diesel DD13, DD15, DD16 GHG17 diesel engine technicians overhauling or repairing the engine to the manufacturer’s standards. Print off pages, including the detailed diagrams and accurate illustrations you need, at any time and save time and money on repairs. This workshop manual is also referred to as the service manual or repair manual.

Electronic troubleshooting & wiring diagrams sold separately.

Topics in the Detroit Diesel DD13, DD15, DD16 GHG17 Engine Workshop Manual:

1 Aftertreatment System
1.1 Aftertreatment System Overview
Aftertreatment Variances
Description and Operation of the Diesel Particulate Filter
Description and Operation of the Selective Catalytic Reduction (SCR) Catalyst
Description and Operation of the Diesel Exhaust Fluid Flow
Description and Operation of the Diesel Exhaust Fluid Heating
Aftertreatment Exhaust Flow
Aftertreatment Regeneration Strategy
Parked Regeneration
Performing a Parked Regeneration – GHG17
Aftertreatment Diesel Exhaust Fluid Gauge/Lamps
Instrument Panel Lamps
1.2 1-BOX™ Aftertreatment Control Module
Description and Operation of the 1-BOX™ Aftertreatment Contol Module
Removal of the 1-BOX™ Aftertreatment Control Module
Installation of the 1-BOX™ Aftertreatment Control Module
1.3 1-BOX™ Aftertreatment Harness
Removal of the 1-BOX™ Aftertreatment Harness
Installation of the 1-BOX™ Aftertreatment Harness
1.4 1-BOX™ Aftertreatment Sensors
1-BOX™ Aftertreatment Device Sensor Locations
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube
Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Removal of the Diesel Particulate Filter Outlet Temperature Sensor
Installation of the Diesel Particulate Filter Outlet Temperature Sensor
Removal of the Selective Catalytic Reduction Inlet NOx Sensor
Installation of the Selective Catalytic Reduction Inlet NOx Sensor
Removal of the Selective Catalytic Reduction Outlet NOx Sensor
Installation of the Selective Catalytic Reduction Outlet NOx Sensor
Removal of the Selective Catalyst Reduction Outlet Temperature Sensor
Installation of the Selective Catalyst Reduction Outlet Temperature Sensor
Removal of the Soot Sensor
Installation of the Soot Sensor
1.5 1-BOX™ Diesel Oxidation Catalyst – Diesel Particulate Filter – SCR Catalyst
Inspection of the Diesel Oxidation Catalyst
Removal of the 1-BOX™ Diesel Particulate Filter
Inspection of the Diesel Particulate Filter
Installation of the 1-BOX™ Diesel Particulate Filter
GHG17 Diesel Particulate Filter Re-Fit Procedure
1.6 1-BOX™ Removal and Installation from the Vehicle
Removal of the 1-BOX™ from the Vehicle
Installation of the 1-BOX™ to the Vehicle
Removal of the 1-BOX™ from the Vehicle
Installation of the 1-BOX™ to the Vehicle
1.7 2-Box (2V2) Aftertreatment Control Module
Description and Operation of the Two-BOX (2V2) Aftertreatment Control Module
Removal of the Two-BOX (2V2) Aftertreatment Control Module
Installation of the Two-BOX (2V2) Aftertreatment Control Module
Description and Operation of the Two-BOX (2V2) Aftertreatment Control Module
Removal of the Two-BOX (2V2) Aftertreatment Control Module
Installation of the Two-BOX (2V2) Aftertreatment Control Module
1.8 2-Box (2V2) Aftertreatment Sensors
2-BOX (2V2) Aftertreatment Device Sensor Locations
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Removal of the Diesel Particulate Filter Outlet Pressure Sensor
Installation of the Diesel Particulate Filter Outlet Pressure Sensor
Removal of the Diesel Particulate Filter Outlet Temperature Sensor
Installation of the Diesel Particulate Filter Outlet Temperature Sensor
Removal of the Selective Catalytic Reduction Inlet Temperature Sensor
Installation of the Selective Catalytic Reduction Inlet Temperature Sensor
Removal of the Selective Catalytic Reduction Outlet Temperature Sensor
Installation of the Selective Catalytic Reduction Outlet Temperature Sensor
Removal of the Selective Catalytic Reduction Inlet NOx Sensor
Installation of the Selective Catalytic Reduction Inlet NOx Sensor
Removal of the Selective Catalytic Reduction Outlet NOx Sensor
Installation of the Selective Catalytic Reduction Outlet NOx Sensor
Removal of the Soot Sensor
Installation of the Soot Sensor
2-BOX (2V2) Aftertreatment Device Sensor Locations
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor
Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Inlet Temperature Sensor
Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Installation of the Diesel Oxidation Catalyst Outlet Temperature Sensor
Removal of the Diesel Particulate Filter Outlet Pressure Sensor
Installation of the Diesel Particulate Filter Outlet Pressure Sensor
Removal of the Diesel Particulate Filter Outlet Temperature Sensor
Installation of the Diesel Particulate Filter Outlet Temperature Sensor
Removal of the Selective Catalytic Reduction Inlet Temperature Sensor
Installation of the Selective Catalytic Reduction Inlet Temperature Sensor
Removal of the Selective Catalytic Reduction Outlet Temperature Sensor
Installation of the Selective Catalytic Reduction Outlet Temperature Sensor
Removal of the Selective Catalytic Reduction Inlet NOx Sensor
Installation of the Selective Catalytic Reduction Inlet NOx Sensor
Removal of the Selective Catalytic Reduction Outlet NOx Sensor
Installation of the Selective Catalytic Reduction Outlet NOx Sensor
Removal of the Soot Sensor
Installation of the Soot Sensor
1.9 2-Box (2V2) Diesel Oxidation Catalyst – Diesel Particulate Filter – Selective Catalytic Reduction
(SCR) Catalyst
Diesel Oxidation Catalyst – Diesel Particulate Filter Additional Removal Information
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel Particulate Filter From the Stanchion
Installation of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel Particulate Filter onto the
Stanchion
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst
Installation of the 2-BOX (2V2) Diesel Oxidation Catalyst
Removal of the 2-BOX (2V2) Diesel Particulate Filter
Installation of the 2-BOX (2V2) Diesel Particulate Filter
Selective Catalytic Reduction Catalyst Additional Removal Information
Removal of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst From the Stanchion
Installation of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst Onto the Stanchion
Removal of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst
Installation of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst
Diesel Oxidation Catalyst – Diesel Particulate Filter Additional Removal Information
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel Particulate Filter From the Stanchion
Installation of the 2-BOX (2V2) Diesel Oxidation Catalyst/Diesel Particulate Filter onto the
Stanchion
Removal of the 2-BOX (2V2) Diesel Oxidation Catalyst
Installation of the 2-BOX (2V2) Diesel Oxidation Catalyst
Removal of the 2-BOX (2V2) Diesel Particulate Filter
Installation of the 2-BOX (2V2) Diesel Particulate Filter
Selective Catalytic Reduction Catalyst Additional Removal Information
Removal of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst From the Stanchion
Installation of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst Onto the Stanchion
Removal of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst
Installation of the 2-BOX (2V2) Selective Catalytic Reduction (SCR) Catalyst
1.10 2-Box (2V2) Removal and Installation from the Vehicle
Removal of the 2-Box (2V2) from the Vehicle
Installation of the 2-Box (2V2) to the Vehicle
Removal of the 2-Box (2V2) from the Vehicle
Installation of the 2-Box (2V2) to the Vehicle
1.11 Diesel Exhaust Fluid Dosing System
Description and Operation of the Diesel Exhaust Fluid Dosing System
Removal of the Diesel Exhaust Fluid Dosing Unit
Installation of the Diesel Exhaust Fluid Dosing Unit
Removal of the Diesel Exhaust Fluid Dosing Unit Inlet Screen
Installation of the Diesel Exhaust Fluid Dosing Unit Inlet Screen
Description and Operation of the Diesel Exhaust Fluid Dosing System
Removal of the Diesel Exhaust Fluid Dosing Unit
Installation of the Diesel Exhaust Fluid Dosing Unit
Removal of the Diesel Exhaust Fluid Dosing Unit Inlet Screen
Installation of the Diesel Exhaust Fluid Dosing Unit Inlet Screen
1.12 Diesel Exhaust Fluid Lines
Removal of the Diesel Exhaust Fluid Lines
Installation of the Diesel Exhaust Fluid Lines
Removal of the Diesel Exhaust Fluid Lines
Installation of the Diesel Exhaust Fluid Lines
1.13 Diesel Exhaust Fluid Pump Module and Components
Description and Operation of the Airless Dosing System Diesel Exhaust Fluid Pump
Removal of the Diesel Exhaust Fluid Pump Module
Inspection of the Diesel Exhaust Fluid Pump Module
Installation of the Diesel Exhaust Fluid Pump Module
Flushing of the Diesel Exhaust Fluid System
Removal of the Diesel Exhaust Fluid Pump Pressure Relief Valve
Installation of the Diesel Exhaust Fluid Pump Pressure Relief Valve
Removal of the Diesel Exhaust Fluid Pump Module Inlet Screen
Installation of the Diesel Exhaust Fluid Pump Module Inlet Screen
Removal of the Diesel Exhaust Fluid Pump Module Coolant Line Connector Fitting
Installation of the Diesel Exhaust Fluid Pump Module Coolant Connector Fitting
Removal of the Diesel Exhaust Fluid Pump Module Filter
Installation of the Diesel Exhaust Fluid Pump Module Filter
Description and Operation of the Airless Dosing System Diesel Exhaust Fluid Pump
Removal of the Diesel Exhaust Fluid Pump Module
Inspection of the Diesel Exhaust Fluid Pump Module
Installation of the Diesel Exhaust Fluid Pump Module
Flushing of the Diesel Exhaust Fluid System
Removal of the Diesel Exhaust Fluid Pump Pressure Relief Valve
Installation of the Diesel Exhaust Fluid Pump Pressure Relief Valve
Removal of the Diesel Exhaust Fluid Pump Module Inlet Screen
Installation of the Diesel Exhaust Fluid Pump Module Inlet Screen
Removal of the Diesel Exhaust Fluid Pump Module Coolant Line Connector Fitting
Installation of the Diesel Exhaust Fluid Pump Module Coolant Connector Fitting
Removal of the Diesel Exhaust Fluid Pump Module Filter
Installation of the Diesel Exhaust Fluid Pump Module Filter
1.14 Diesel Exhaust Fluid Tank
Description and Operation of the Diesel Exhaust Fluid Tank
Removal of the Six-Gallon Diesel Exhaust Fluid Tank
Installation of the Six-Gallon Diesel Exhaust Fluid Tank
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank
Description and Operation of the Diesel Exhaust Fluid Tank
Removal of the Six-Gallon Diesel Exhaust Fluid Tank
Installation of the Six-Gallon Diesel Exhaust Fluid Tank
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank
1.15 Diesel Exhaust Fluid Tank Header Unit
Description and Operation of the Diesel Exhaust Fluid Tank Header Unit
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit
Removal of the Six-Gallon Diesel Exhaust Fluid Tank Header
Installation of the Six-Gallon Diesel Exhaust Fluid Tank Header
Description and Operation of the Diesel Exhaust Fluid Tank Header Unit
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit
Removal of the Six-Gallon Diesel Exhaust Fluid Tank Header
Installation of the Six-Gallon Diesel Exhaust Fluid Tank Header
1.16 Diesel Particulate Filter Ash Accumulators
Resetting the Diesel Particulate Filter Ash Accumulators
Resetting the Diesel Particulate Filter Ash Accumulators
1.17 Hydrocarbon Doser Coolant Lines
Removal of the Hydrocarbon Doser Coolant Lines – DD13 and DD15AT
Installation of the Hydrocarbon Doser Coolant Lines – DD13 and DD15AT
Removal of the Hydrocarbon Doser Coolant Lines – DD15TC and DD16
Installation of the Hydrocarbon Doser Coolant Lines – DD15TC and DD16
Removal of the Hydrocarbon Doser Coolant Lines – DD13 and DD15AT
Installation of the Hydrocarbon Doser Coolant Lines – DD13 and DD15AT
Removal of the Hydrocarbon Doser Coolant Lines – DD15TC and DD16
Installation of the Hydrocarbon Doser Coolant Lines – DD15TC and DD16
1.18 Hydrocarbon Fuel Doser Injector Valve
Description and Operation of the Hydrocarbon Fuel Doser Injector Valve
Removal of the Hydrocarbon Fuel Doser Injector Valve
Installation of the Hydrocarbon Fuel Doser Injector Valve
Description and Operation of the Hydrocarbon Fuel Doser Injector Valve
Removal of the Hydrocarbon Fuel Doser Injector Valve
Installation of the Hydrocarbon Fuel Doser Injector Valve
1.19 Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Removal of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Inspection of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Installation of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Removal of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Inspection of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
Installation of the Hydrocarbon Fuel Doser Injector Valve Fuel Supply Line
1.20 Hydrocarbon Fuel Doser Block
Description and Operation of the Hydrocarbon Fuel Doser Block
Removal of the Hydrocarbon Fuel Doser Block
Installation of the Hydrocarbon Fuel Doser Block
Description and Operation of the Hydrocarbon Fuel Doser Block
Removal of the Hydrocarbon Fuel Doser Block
Installation of the Hydrocarbon Fuel Doser Block
1.21 Hydrocarbon Fuel Doser Block Feed Line
Removal of the Hydrocarbon Doser Block Feed Line
Installation of the Hydrocarbon Doser Block Feed Line
Removal of the Hydrocarbon Doser Block Feed Line
Installation of the Hydrocarbon Doser Block Feed Line
1.22 Hydrocarbon Fuel Doser Housing
Removal of the Hydrocarbon Fuel Doser Housing
Installation of the Hydrocarbon Fuel Doser Housing
Removal of the Hydrocarbon Fuel Doser Housing
Installation of the Hydrocarbon Fuel Doser Housing

2 Air Compressor
2.1 Air Compressor
Description and Operation of the Air Compressor
Removal of the Air Compressor
Inspection of the Air Compressor
Installation of the Air Compressor
2.2 Air Compressor Coolant Lines
Removal of the Air Compressor Coolant Supply Line
Installation of the Air Compressor Coolant Supply Line
Removal of the Air Compressor Coolant Return Line
Installation of the Air Compressor Coolant Return Line
2.3 Unloader Valve
Description and Operation of the Unloader Valve
Removal of the Air Compressor Unloader Valve
Inspection of the Air Compressor Unloader Valve
Installation of the Air Compressor Unloader Valve

3 Air System and Turbocharger
3.1 Air Intake Manifold
Description and Operation of the DD13/DD15 Air Intake Manifold
Description and Operation of the DD16 Air Intake Manifold
Removal of the Air Intake Manifold
Cleaning of the Air Intake Manifold
Inspection of the Air Intake Manifold
Installation of the Air Intake Manifold
3.2 Cold Boost Pipe (Charge Air Pipe)
Description and Operation of the Composite Cold Boost Pipe (Charge Air Pipe)
Removal of the Composite Cold Boost Pipe (Charge Air Pipe)
Inspection of Cold Boost Pipe (Charge Air Pipe)
Installation of the Composite Cold Boost Pipe (Charge Air Pipe)
3.3 Intake Mixer Assembly
Description and Operation of the Intake Mixer Assembly
Removal of the Intake Mixer Assembly
Installation of the Intake Mixer Assembly
3.4 Intake Throttle Valve and Adaptor
Description and Operation of the Intake Throttle Valve and Adaptor
Removal of the Intake Throttle Valve and Adaptor
Installation of the Intake Throttle Valve and Adaptor
3.5 Turbocharger
Description and Operation of the DD13 and DD15 Turbocharger
Removal of the DD13 and DD15 Turbocharger
Inspection of the DD13 and DD15 Turbocharger
Installation of the DD13 and DD15 Turbocharger
Description and Operation of the DD16 Turbocharger
Removal of the DD16 Turbocharger
Inspection of the DD16 Turbocharger
Installation of the DD16 Turbocharger

4 Belt Drive
4.1 Accessory Mounting Bracket
Removal of the Accessory Mounting Bracket
Installation of the Accessory Mounting Bracket
4.2 Belt Drive Tensioner System
Description and Operation of the Belt Drive Tensioner System
Removal of the Belt Tensioner
Installation of the Belt Tensioner
4.3 Idler Pulley and Idler Pulley Bracket
Removal of the Idler Pulley and Idler Pulley Bracket
Inspection of the Idler Pulley Bracket
Installation of the Idler Pulley and Idler Pulley Bracket
4.4 Non-Bracketed Idler Pulley
Removal of the Non-Bracketed Idler Pulley
Installation of the Non-Bracketed Idler Pulley
4.5 Poly-V-Belts
Description and Operation of the Poly-V Belts
Removal of the Poly-V-Belts
Inspection of the Poly-V-Belts
Installation of the Poly-V-Belts

5 Cooling System
5.1 Description and Operation of the Cooling System and Related Components
Description and Operation of the Cooling System and Related Components
5.2 Coolant Requirements
Coolant Requirements
5.3 Cooling System Drain Procedure
Cooling System Drain Procedure
5.4 Cooling System Flushing Procedure
Inspecting and Flushing the Cooling System
5.5 Cooling System Fill Procedure
Cooling System Fill Procedure
5.6 Coolant Crossover Pipe
Description and Operation of the Coolant Crossover Pipe
Removal of the Coolant Crossover Pipe
Installation of the Coolant Crossover Pipe
5.7 Coolant Inlet Elbow
Removal of the Coolant Inlet Elbow
Installation of the Coolant Inlet Elbow
5.8 Coolant Outlet Elbow
Removal of the Coolant Outlet Elbow
Installation of the Coolant Outlet Elbow
5.9 Coolant Thermostat
Description and Operation of the Coolant Thermostat
Removal of the Engine Coolant Thermostat and Seal
Inspection of the Coolant Thermostat and Seal
Installation of the Coolant Thermostat and Seal
5.10 Engine Water Pump
Description and Operation of the Engine Water Pump
Removal of the Water Pump
Inspection of the Water Pump
Installation of the Water Pump
5.11 Variable Speed Engine Water Pump
Description and Operation of the Variable Speed Water Pump
Removal of the Variable Speed Water Pump
Inspection of the Variable Speed Water Pump
Installation of the Variable Speed Water Pump
Removal of the Variable Speed Water Pump Pulley
Installation of the Variable Speed Water Pump Pulley

6 Engine Mechanical
6.1 California Proposition 65 Warning and Engine Idle Notice
6.2 General Information and Specifications
General Cleaning and Gasket Preparation Guidelines
DD Platform Engine Views
Engine Model and Serial Number Designation
Enhanced Steam Clean
General Steam Clean
General Engine Information
Engine Mechanical Specifications
Safety Precautions
Temporary Storage (30 Days or Less)
Extended Storage (More than 30 Days)
Procedure for Restoring an Engine to Service that Has Been in Extended Storage
6.3 Camshafts, Rocker Arms and Engine Brakes
Description and Operation of the Camshafts and Rocker Arms
Removal of the Camshafts
Inspection of the Camshafts and Rocker Shaft Assemblies
Installation of the Camshafts
Removal of the Intake Rocker Shaft Assembly
Installation of the Intake Rocker Shaft Assembly
Removal of the Exhaust Rocker Shaft Assembly
Installation of the Exhaust Rocker Shaft Assembly
Description and Operation of the Engine Braking
Description and Operation of the Engine Brake Solenoids
Removal of the Engine Brake Solenoid
Inspection of the Engine Brake Solenoid
Installation of the Engine Brake Solenoid
Setting the Valve and Engine Brake Lash
Camshaft Timing Verification
6.4 Camshaft Housing
Description and Operation of the Camshaft Housing
Removal of the Camshaft Housing
Inspection of the Camshaft Housing
Installation of the Camshaft Housing
Removal of the Camshaft Housing Assembly
Installation of the Camshaft Housing Assembly
6.5 Crankshaft and Bearings
Description and Operation of the Crankshaft
Removal of the Crankshaft
Inspection of the Crankshaft
Installation of the Crankshaft
Inspection of the Main and Connecting Rod Bearings in Chassis
6.6 Cylinder Block
Description and Operation of the Cylinder Block
Cleaning of the Cylinder Block
Inspection of the Cylinder Block
Cylinder Block Oil Gallery Cup Plug Replacement
Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump
6.7 Cylinder Block Cover Plate
Removal of the DD13 and DD15 Cylinder Block Cover Plate
Installation of the DD13 and DD15 Cylinder Block Cover Plate
6.8 Cylinder Head and Valves
Description and Operation of the Cylinder Head
Removal of the DD13 Cylinder Head Assembly
Removal of the DD15 and DD16 Cylinder Head Assembly
Cleaning of the Cylinder Head
Inspection of the Cylinder Head
Installation of the DD13 Cylinder Head Assembly
Installation of the DD15 and DD16 Cylinder Head Assembly
DD Platform Cylinder Head Replacement
Removal of the Valve Spring (Cylinder Head Installed)
Removal of the Valve Spring and Valve (Cylinder Head Removed)
Inspection of the Intake and Exhaust Valves
Installation of the Valve, Valve Spring and Retainer
6.9 Cylinder Liner
Description and Operation of the Cylinder Liner
Removal of the Cylinder Liner
Cleaning of the Cylinder Liner
Inspection of the Cylinder Liner
Installation of the Cylinder Liner
Testing of the Cylinder Liner Upper O-Ring
6.10 Engine Lifting Brackets
Description and Operation of the Front Engine Lifting Bracket
Removal of the Front Engine Lifting Bracket
Inspection of the Front Engine Lifting Bracket
Installation of the Front Engine Lifting Bracket
Description and Operation of the Rear Engine Lifting Brackets
Removal of the Rear Engine Lifting Brackets
Inspection of the Rear Engine Lifting Brackets
Installation of the Rear Engine Lifting Brackets
Description and Operation of the Front Engine Lifting Bracket (New Cascadia)
Removal of the Front Engine Lifting Bracket (New Cascadia)
Inspection of the Front Engine Lifting Bracket (New Cascadia)
Installation of the Front Engine Lifting Bracket (New Cascadia)
6.11 Flywheel and Ring Gear
Description and Operation of the Flywheel and Ring Gear
Removal of the Flywheel
Inspection and Machining of the Flywheel
Installation of the Flywheel
Removal of the Ring Gear
Installation of the Ring Gear
6.12 Flywheel Housing and Rear Crankshaft Oil Seal
Description and Operation of the Flywheel Housing and Rear Crankshaft Oil Seal
Removal of the Flywheel Housing
Inspection of the Flywheel Housing and Cylinder Block Mounting Surface
Installation of the Flywheel Housing
Removal of the Rear Crankshaft Oil Seal
Installation of the Rear Crankshaft Oil Seal
6.13 Front Engine Cover and Front Crankshaft Oil Seal
Description and Operation of the Front Engine Cover and Front Crankshaft Oil Seal
Removal of the Front Engine Cover
Inspection of the Front Engine Cover
Installation of the Front Engine Cover
Removal of the Front Crankshaft Oil Seal
Installation of the Front Crankshaft Oil Seal
6.14 Front Engine Mount/Radiator Support
Description and Operation of the Front Engine Mount/Radiator Support
Removal of the Front Engine Mount/Radiator Support
Inspection of the Front Engine Mount/Radiator Support
Installation of the Front Engine Mount/Radiator Support
6.15 Gear Train
Description and Operation of Gear Train and Related Parts
Removal of the Gear Train
Installation of the Gear Train
Checking and Adjusting Gear Lash with Camshaft Housing Removed
6.16 Piston and Connecting Rod Assembly
Description and Operation of the Piston and Connecting Rod
Removal of the Piston and Connecting Rod Assembly
Disassembly of the Piston and Connecting Rod
Cleaning of the Piston and Connecting Rod
Inspection of the Piston, Piston Rings and Connecting Rod
Assembly of the Piston and Connecting Rod
Installation of the Piston and Connecting Rod Assembly
6.17 Rocker Cover
Description and Operation of the Rocker Cover
Removal of the Rocker Cover
Inspection of the Rocker Cover
Installation of the Rocker Cover
6.18 Vibration Damper
Description and Operation of the Vibration Damper
Removal of the Vibration Damper
Inspection of the Vibration Damper
Installation of the Vibration Damper

7 Engine Electrical
7.1 Engine Wiring Harness
Removal of the Engine Wiring Harness
Installation of the Engine Wiring Harness
7.2 Engine Sensors
DD13 Engine Sensors
DD15 Engine Sensors
DD16 Engine Sensors
Description and Operation of the Camshaft Position Sensor
Removal of the Camshaft Position Sensor
Installation of the Camshaft Position Sensor
Removal of the Crankcase Breather Speed Sensor
Installation of the Crankcase Breather Speed Sensor
Description and Operation of the Crankshaft Position Sensor
Removal of the Crankshaft Position Sensor
Installation of the Crankshaft Position Sensor
Description and Operation of the Delta P Sensor
Removal of the Delta P Sensor
Installation of the Delta P Sensor
Calibration of the Delta P Sensor
Description and Operation of the Engine Coolant Inlet Temperature Sensor
Removal of the Engine Coolant Inlet Temperature Sensor
Inspection of the Engine Coolant Inlet Temperature Sensor
Installation of the Engine Coolant Inlet Temperature Sensor
Description and Operation of the Engine Coolant Level Sensor
Description and Operation of the Engine Coolant Outlet Temperature Sensor
Removal of the Engine Coolant Outlet Temperature Sensor
Inspection of the Engine Coolant Outlet Temperature Sensor
Installation of the Engine Coolant Outlet Temperature Sensor
Description and Operation of the Fuel Rail Pressure Sensor
Removal of the Fuel Rail Pressure Sensor
Installation of the Fuel Rail Pressure Sensor
Description and Operation of the Intake Manifold Air Temperature Sensor
Removal of the Intake Manifold Air Temperature Sensor
Installation of the Intake Manifold Air Temperature Sensor
Description and Operation of the Intake Pressure/Temperature Sensor
Removal of the Intake Pressure/Temperature Sensor
Installation of the Intake Pressure/Temperature Sensor
Description and Operation of the Low Pressure Fuel Sensor
Removal of the Low Pressure Fuel Sensor
Installation of the Low Pressure Fuel Sensor
Description and Operation of the Engine Oil Pressure Sensor
Removal of the Engine Oil Pressure Sensor
Installation of the Engine Oil Pressure Sensor
Description and Operation of the Engine Oil Temperature Sensor
Removal of the Engine Oil Temperature Sensor
Installation of the Engine Oil Temperature Sensor
Description and Operation of the Supply Fuel Temperature Sensor
Removal of the Supply Fuel Temperature Sensor
Installation of the Supply Fuel Temperature Sensor
Description and Operation of the Turbocharger Speed Sensor
Removal of the Turbocharger Speed Sensor
Installation of the Turbocharger Speed Sensor
Description and Operation of the Turbocharger Compressor Inlet Temperature Sensor
Description and Operation of the Water-in-Fuel Sensor
Removal of the Water-in-Fuel Sensor
Installation of the Water-in-Fuel Sensor
7.3 Motor Control Module (MCM)
Description and Operation of the Motor Control Module
Removal of the Motor Control Module
Inspection of the Motor Control Module
Installation of the Motor Control Module

8 Exhaust and Exhaust Gas Recirculation
8.1 Axial Power Turbine
Description and Operation of the Axial Power Turbine
Removal of the Axial Power Turbine
Inspection of the Axial Power Turbine
Installation of the Axial Power Turbine
8.2 Axial Power Turbine Gear Box
Description and Operation of the Axial Power Turbine Gear Box
Removal of the Axial Power Turbine Gear Box
Inspection of the Axial Power Turbine Gear Box
Installation of the Axial Power Turbine Gear Box
8.3 Exhaust Gas Recirculation Valve Actuator
Description and Operation of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator
Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator
Inspection of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator
Installation of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator
Description and Operation of the DD16 Exhaust Gas Recirculation Valve Actuator
Removal of the DD16 Exhaust Gas Recirculation Valve Actuator
Inspection of the DD16 Exhaust Gas Recirculation Valve Actuator
Installation of the DD16 Exhaust Gas Recirculation Valve Actuator
8.4 Exhaust Gas Recirculation Actuator Coolant Lines
Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Coolant Return Line
Installation of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Coolant Return Line
Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Coolant Supply Line
Installation of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Coolant Supply Line
Removal of the DD16 Exhaust Gas Recirculation Valve Actuator Coolant Return Line
Installation of the DD16 Exhaust Gas Recirculation Valve Actuator Coolant Return Line
Removal of the DD16 Exhaust Gas Recirculation Valve Actuator Coolant Supply Line
Installation of the DD16 Exhaust Gas Recirculation Valve Actuator Coolant Supply Line
8.5 Exhaust Gas Recirculation Valve Actuator Pull Rod
Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Pull Rod
Installation of the DD13 and DD15 Exhaust Gas Recirculation Valve Actuator Pull Rod
Removal of the DD16 Exhaust Gas Recirculation Valve Actuator Pull Rod
Installation of the DD16 Exhaust Gas Recirculation Valve Actuator Pull Rod
8.6 Exhaust Gas Recirculation Actuator Lever
Removal of the DD13 and DD15 Exhaust Gas Recirculation Actuator Lever
Installation of the DD13 and DD15 Exhaust Gas Recirculation Actuator Lever
Removal of the DD16 Exhaust Gas Recirculation Actuator Lever
Installation of the DD16 Exhaust Gas Recirculation Actuator Lever
8.7 Exhaust Gas Recirculation Cooler – DD15 and DD16
Description and Operation of the DD15 and DD16 Exhaust Gas Recirculation Cooler
Removal of the DD15 and DD16 Exhaust Gas Recirculation Cooler
Cleaning of the DD15 Exhaust Gas Recirculation System
Cleaning of the DD16 Exhaust Gas Recirculation System
Testing of the DD15 and DD16 Exhaust Gas Recirculation Cooler – In Chassis
Installation of the DD15 and DD16 Exhaust Gas Recirculation Cooler
8.8 Exhaust Gas Recirculation Hot Pipe
Removal of the Exhaust Gas Recirculation Hot Pipe
Installation of the Exhaust Gas Recirculation Hot Pipe
8.9 Exhaust Gas Recirculation Valve
Description and Operation of the DD13 and DD15 Exhaust Gas Recirculation Valve
Removal of the DD13 and DD15 Exhaust Gas Recirculation Valve
Inspection of the DD13 and DD15 Exhaust Gas Recirculation Valve
Installation of the DD13 and DD15 Exhaust Gas Recirculation Valve
Description and Operation of the DD16 Exhaust Gas Recirculation Valve
Removal of the DD16 Exhaust Gas Recirculation Valve
Inspection of the DD16 Exhaust Gas Recirculation Valve
Installation of the DD16 Exhaust Gas Recirculation Valve
8.10 Exhaust Gas Recirculation Venturi
Description and Operation of the Exhaust Gas Recirculation Venturi
Removal of the Exhaust Gas Recirculation Venturi
Cleaning of the Exhaust Gas Recirculation Venturi
Installation of the Exhaust Gas Recirculation Venturi
8.11 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Cleaning of the DD13 Exhaust Gas Recirculation System
Testing of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly – In Chassis
Installation of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Removal of the DD15 and DD16 Water Manifold
Installation of the DD15 and DD16 Water Manifold
8.12 Exhaust Flanged Manifold/Exhaust S-Pipe
Description and Operation of the DD13 and DD15 Exhaust Flanged Manifold
Removal of the DD13 and DD15 Exhaust Flanged Manifold
Installation of the DD13 and DD15 Exhaust Flanged Manifold
Description and Operation of the DD16 Exhaust S-Pipe (Elbow)
Removal of the DD16 Exhaust S-pipe
Installation of the DD16 Exhaust S-pipe
8.13 Exhaust Manifold – DD13 and DD15
Description and Operation of the DD13 and DD15 Exhaust Manifold
Removal of the DD13 and DD15 Exhaust Manifold
Inspection of the DD13 and DD15 Exhaust Manifold
Cleaning of the DD13 and DD15 Exhaust Manifold
Installation of the DD13 and DD15 Exhaust Manifold
8.14 Exhaust Manifold – DD16
Description and Operation of the DD16 Exhaust Manifold
Removal of the DD16 Exhaust Manifold
Inspection of the DD16 Exhaust Manifold
Cleaning of the DD16 Exhaust Manifold
Installation of the DD16 Exhaust Manifold
8.15 Mixer Pipe
Description and Operation of the Mixer Pipe
Removal of the Mixer Pipe
Inspection of the Mixer Pipe
Installation of the Mixer Pipe
8.16 Water Manifold
Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Installation of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly

9 Fuel System
9.1 Fuel System Overview
Fuel System (Without MCM Heat Exchanger) –Two-Filter System
Description and Operation of the Fuel System
Normal Fuel System Pressures – Two-Filter System
9.2 Fuel System Draining Procedure
Draining the Fuel System Using J-48710 Prior to Repairs – Two-Filter System
9.3 Fuel System Priming
Priming the Fuel System – KM63 GEN2 – Two-Filter System
9.4 Amplified Pressure Common Rail System
Fuel System – Two-Filter System
9.5 Fuel Filters
Description and Operation of the Fuel Prefilter – Two-Filter System
Removal of the Fuel Prefilter – Two Filter System
Installation of the Fuel Prefilter – Two Filter System
Description and Operation of the Coalescer/Final Filter – Two-Filter System
Removal of the Coalescer/Final Filter – Two Filter System
Installation of the Coalescer/Final Filter – Two Filter System
Removal of the Coalescer/Final Filter Stand Pipe – Two-Filter System
Installation of the Coalescer/Final Filter Stand Pipe – Two-Filter System
9.6 Fuel Filter Module
Description and Operation of the Fuel Filter Module and Related Parts – Two-Filter System
Removal of the Fuel Filter Module – Two-Filter System
Disassembly of the Fuel Filter Module – Two-Filter System
Assembly of the Fuel Filter Module – Two Filter System
Installation of the Fuel Filter Module – Two-Filter System
Description and Operation of the Hand Primer- Two-Filter System
Removal of the Hand Primer – Two-Filter System
Inspection of the Hand Primer – Two- Filter System
Installation of the Hand Primer – Two-Filter System
9.7 Fuel Injectors
Fuel Injection with Amplification – Two-Filter System
Fuel Injection without Amplification – Two-Filter System
Description and Operation of the Fuel Injector – Two-Filter System
Removal of the Fuel Injector – Two-Filter System
Installation of the Fuel Injector – Two-Filter System
9.8 Fuel Injector Cup
Description and Operation of the Fuel Injector Cup – Two-Filter System
Removal of the Fuel Injector Cup – Two-Filter System
Inspection of the Fuel Injector Cup – Two-Filter System
Installation of the Fuel Injector Cup – Two-Filter System
9.9 Fuel Injector Wiring Harness
Description and Operation of the Two-Piece Fuel Injector Wiring Harness – Two-Filter System
Removal of the Two-Piece Fuel Injector Wiring Harness – Two-Filter System
Inspection of the Two-Piece Fuel Injector Wiring Harness – Two-Filter System
Installation of the Two-Piece Fuel Injector Wiring Harness – Two-Filter System
9.10 Fuel Rail
Description and Operation of the Fuel Rail and Related Parts – Two-Filter System
Removal of the Fuel Rail – Two-Filter System
Inspection of the Fuel Rail – Two-Filter System
Installation of the Fuel Rail – Two-Filter System
9.11 High Pressure Fuel Flange
Description and Operation of the High Pressure Fuel Flange – Two-Filter System
Removal of the High Pressure Fuel Flange – Two-Filter System
Inspection of the High Pressure Flange – Two-Filter System
Installation of the High Pressure Fuel Flange – Two-Filter System
9.12 High Pressure Fuel Injector Lines
Description and Operation of the High Pressure Fuel Injector Lines – Two-Filter System
Removal of the High Pressure Fuel Injector Lines – Two-Filter System
Inspection of the High Pressure Fuel Injector Lines- Two-Filter System
Installation of the High Pressure Fuel Injector Lines – Two-Filter System
9.13 High Pressure Fuel Pump
Description and Operation of the High Pressure Fuel Pump and Related Parts – Two-Filter System
Removal of the High Pressure Fuel Pump – Two-Filter System
Inspection of the High Pressure Fuel Pump – Two-Filter System
Installation of the High Pressure Fuel Pump – Two Filter System
Removal of the High Pressure Fuel Pump Drive Gear – Two-Filter System
Installation of the High Pressure Fuel Pump Drive Gear – Two-Filter System
Removal of the High Pressure Fuel Pump Camshaft Oil Seal – Two-Filter System
Installation of the High Pressure Fuel Pump Camshaft Oil Seal – Two-Filter System
Removal of the High Pressure Fuel Pump Locating Pin – Two-Filter System
Installation of the High Pressure Fuel Pump Locating Pin – Two-Filter System
9.14 High Pressure Fuel Rail Feed Lines
Description and Operation of the High Pressure Fuel Rail Feed Lines and Related Parts – Two-Filter
System
Removal of the High Pressure Fuel Rail Feed Lines – Two-Filter System
Inspection of the High Pressure Fuel Rail Feed Lines – Two Filter System
Installation of the High Pressure Fuel Rail Feed Lines – Two-Filter System
9.15 Low Pressure Fuel Pump
Description and Operation of the Low Pressure Fuel Pump and Related Parts – Two-Filter System
Removal of the Low Pressure Fuel Pump – Two-Filter System
Inspection of the Low Pressure Fuel Pump – Two-Filter System
Installation of the Low Pressure Fuel Pump – Two-Filter System
9.16 Low Pressure Fuel Pump Lines
Description and Operation of Low Pressure Fuel Pump Lines – Two-Filter System
Removal of the Low Pressure Fuel Pump Lines – Two-Filter System
Inspection of the Low Pressure Fuel Pump Lines – Two-Filter System
Installation of the Low Pressure Fuel Pump Lines – Two-Filter System
9.17 Needle, Amplifier and Pressure Limiting Valve Return Lines
Description and Operation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines –
Two-Filter System
Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines – Two-Filter System
Inspection of the Needle, Amplifier, Pressure Limiting Valve Return Lines – Two-Filter System
Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines – Two-Filter System
9.18 Needle Return Pressure Control Valve
Description and Operation of the Needle Control Pressure Valve – Two-Filter System
Removal of the Needle Return Pressure Control Valve – Two-Filter System
Inspection of the Needle Return Pressure Control Valve – Two-Filter System
Installation of the Needle Return Pressure Control Valve – Two-Filter System
9.19 Pressure Limiting Valve
Description and Operation of the Pressure Limiting Valve – Two-Filter System
Removal of the Pressure Limiting Valve – Two-Filter System
Inspection of the Pressure Limiting Valve – Two-Filter System
Installation of the Pressure Limiting Valve – Two-Filter System
Resetting the Pressure Limiting Valve Counter – Two-Filter System
9.20 Pressure Relief Valve
Description and Operation of the Pressure Relief Valve – Two-Filter System
Removal of the Pressure Relief Valve – Two-Filter System
Inspection of the Pressure Relief Valve – Two-Filter System
Installation of the Pressure Relief Valve – Two-Filter System
9.21 Quantity Control Valve
Description and Operation of the Quantity Control Valve – Two-Filter System
Removal of the Quantity Control Valve – Two-Filter System
Inspection of the Quantity Control Valve and High Pressure Pump Housing – Two-Filter System
Installation of the Quantity Control Valve – Two-Filter System
Resetting Quantity Control Valve Adaptive Values – Two-Filter System
9.22 Two Stage Valve
Description and Operation of the Two Stage Valve – Two-Filter System
Removal of the Two-Stage Valve – Two-Filter System
Inspection of the Two-Stage Valve – Two-Filter System
Installation of the Two-Stage Valve – Two-Filter System
9.23 Water Drain Bowl
Removal of the Water Drain Bowl – Two-Filter System
Installation of the Water Drain Bowl – Two-Filter System

10 Lubrication System
10.1 General Information and Specifications
Engine Oil Capacities
Engine Oil Flow
How to Replace the Lubricating Oil and Oil Filter
Monitoring the Lubricating Oil Level
Priming the Engine Lubrication System
10.2 Crankcase Breather Assembly
Description and Operation of the Crankcase Breather Assembly
Removal of the Crankcase Breather Assembly
Inspection of the Crankcase Breather Assembly
Installation of the Crankcase Breather Assembly
10.3 Oil Coolant Module
Description and Operation of the Oil Coolant Module
Removal of the Oil Coolant Module
Installation of the Oil Coolant Module
Removal of the Oil Coolant Module Plugs
Installation of the Oil Coolant Module Plugs
10.4 Oil Cooler
Removal of the Oil Cooler
Inspection and Pressure Testing of the Oil Cooler
Installation of the Oil Cooler
10.5 Oil Dipstick and Tube
Description and Operation of the Oil Dipstick and Tube
Removal of the Oil Dipstick and Tube
Installation of the Oil Dipstick and Tube
10.6 Oil Filler Neck
Removal of the Oil Filler Neck
Installation of the Oil Filler Neck
10.7 Oil Filter
Replacement of the Oil Filter
10.8 Oil Filter Stand Pipe
Description and Operation of the Oil Filter Stand Pipe
Removal of the Oil Filter Stand Pipe
Oil Filter Stand Pipe Inspection
Installation of the Oil Filter Stand Pipe
10.9 Oil Pan
Description and Operation of the Oil Pan
Removal of the Oil Pan
Cleaning of the Oil Pan
Inspection of the Oil Pan and Mounting Surfaces
Installation of the Oil Pan
Servicing the Oil Pan Threaded Insert (Plastic Oil Pan Only)
10.10 Oil Pump, Oil Suction Manifold and Oil Lines
Description and Operation of the Oil Pump, Oil Suction Manifold and Oil Lines
Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines
Inspection of the Oil Pump, Oil Suction Manifold, and Oil Lines
Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines
10.11 Oil Sample Valve
Replacing Oil Plug with Oil Sample Valve
Removal of Oil Sample Valve
Installation of the Oil Sample Valve
10.12 Oil Thermostat
Removal of the Oil Thermostat
Installation of the Oil Thermostat
10.13 Oil Thermostat Cover
Removal of the Oil Thermostat Cover
Installation of the Oil Thermostat Cover

11 Power Take-Off
11.1 Description and Operation of the Rear Engine Power Take-Off
11.2 Removal of the Rear Engine Power Take-Off
11.3 Inspection of the Rear Engine Power Take-Off
11.4 Installation of the Rear Engine Power Take-Off

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