Engine Manual Navistar N9 and 10

ENGINESER

VICEMANUAL

0000004021N9and

N10

Revision

1EPA

10-U

S,C

anada,Mexico

July2014

ENGINE SERVICE MANUAL

N9 and N10

Navistar, Inc.2701 Navistar Drive, Lisle, IL 60532 USA

2014 Navistar, Inc. All rights reserved. All marks are trademarks of their respective owners.

ENGINE SERVICE MANUAL I

TABLE OF CONTENTSForeword.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Service Diagnosis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Safety Information.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Engine Identification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Mounting Engine on Engine Stand.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Down Stream Injection (DSI) & Related Components.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Dual Stage Turbocharger and Exhaust Brake.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

Exhaust Gas Recirculation (EGR) System.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

Intake, Inlet, and Exhaust Manifolds.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .141

Fuel and High-Pressure Oil Systems.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Engine Brake.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

Air Compressor and Power Steering Pump.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207

Oil System Module Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .217

Oil Pan and Oil Suction Tube.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235

Front Cover, Cooling System, and Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

Cylinder Head and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .297

Flywheel and Flywheel Housing.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347

Power Cylinders.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373

Crankcase, Crankshaft, and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411

Abbreviations and Acronyms.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .451

Terminology.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .459

Appendix A Specifications.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .471

Appendix B Torques.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .487

Appendix C Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .499

II ENGINE SERVICE MANUAL

ENGINE SERVICE MANUAL 1

ForewordNavistar, Inc. is committed to continuous researchand development to improve products and introducetechnological advances. Procedures, specifications,and parts defined in published technical serviceliterature may be altered.

This Engine Service Manual provides a generalsequence of procedures for out-of-chassis engineoverhaul (removal, inspection, and installation). Forin-chassis service of parts and assemblies, thesequence may vary.

NOTE: Photo illustrations identify specific partsor assemblies that support text and procedures;other areas in a photo illustration may not beexact.

See vehicle manuals and Technical ServiceInformation (TSI) bulletins for additional information.

N9 and N10 Engine Operations and MaintenanceManual

N9 and N10 Engine Service Manual

N9 and N10 Engine Diagnostic Manual

Navistar Electronic Control System Form

Technical Service Literature is revised periodically. Ifa technical publication is ordered, the latest revisionwill be supplied.

NOTE: To order technical service literature,contact your International dealer.

All marks are trademarks of their respective owners.

2 ENGINE SERVICE MANUAL

Service DiagnosisService diagnosis is an investigative procedure thatmust be followed to find and correct an engineapplication problem or an engine problem.

If the problem is engine application, see specificvehicle manuals for further diagnostic information.

If the problem is the engine, see specific EngineDiagnostic Manual for further diagnostic information.

Prerequisites for Effective Diagnosis

Availability of gauges, diagnostic test equipment,and diagnostic software.

Availability of current information for engineapplication and engine systems.

Knowledge of the principles of operation forengine application and engine systems.

Knowledge to understand and do procedures indiagnostic and service publications.

Technical Service Literature required for EffectiveDiagnosis

Engine Service Manual

Engine Diagnostic Manual

Electronic Control Systems Diagnostics Forms

Service Bulletins

ENGINE SERVICE MANUAL 3

Safety InformationThis manual provides general and specificmaintenance procedures essential for reliable engineoperation and your safety. Since many variations inprocedures, tools, and service parts are involved,advice for all possible safety conditions and hazardscannot be stated.

Read safety instructions before doing any service andtest procedures for the engine or vehicle. See relatedapplication manuals for more information.

Obey Safety Instructions, Warnings, Cautions, andNotes in this manual. Not following warnings,cautions, and notes can lead to injury, death ordamage to the engine or vehicle.

Safety Terminology

Three terms are used to stress your safety and safeoperation of the engine: Warning, Caution, and Note

Warning: A warning describes actions necessary toprevent or eliminate conditions, hazards, and unsafepractices that can cause personal injury or death.

Caution: A caution describes actions necessaryto prevent or eliminate conditions that can causedamage to the engine or vehicle.

Note: A note describes actions necessary for correct,efficient engine operation.

Safety Instructions

Work Area

Keep work area clean, dry, and organized.

Keep tools and parts off the floor.

Make sure the work area is ventilated and well lit.

Make sure a First Aid Kit is available.

Safety Equipment

Use correct lifting devices.

Use safety blocks and stands.

Protective Measures

Wear protective safety glasses and shoes.

Wear correct hearing protection.

Wear cotton work clothing.

Wear sleeved heat protective gloves.

Do not wear rings, watches or other jewelry.

Restrain long hair.

Vehicle

Shift transmission to park or neutral, set parkingbrake, and block wheels before doing diagnosticor service procedures.

Clear the area before starting the engine.

Engine

The engine should be operated or serviced onlyby qualified individuals.

Provide necessary ventilation when operatingengine in a closed area.

Keep combustible material away from engineexhaust system and exhaust manifolds.

Install all shields, guards, and access coversbefore operating engine.

Do not run engine with unprotected air inlets orexhaust openings. If unavoidable for servicereasons, put protective screens over all openingsbefore servicing engine.

Shut engine off and relieve all pressure in thesystem before removing panels, housing covers,and caps.

If an engine is not safe to operate, tag the engineand ignition key.

Fire Prevention

Make sure charged fire extinguishers are in thework area.

NOTE: Check the classification of each fireextinguisher to ensure that the following firetypes can be extinguished.

1. Type A Wood, paper, textiles, and rubbish

2. Type B Flammable liquids

3. Type C Electrical equipment

Batteries

Always disconnect the main negative batterycable first.

Always connect the main negative battery cablelast.

Avoid leaning over batteries.

4 ENGINE SERVICE MANUAL

Protect your eyes.

Do not expose batteries to flames or sparks.

Do not smoke in workplace.

Compressed Air

Use an OSHA approved blow gun rated at 207kPa (30 psi).

Limit air pressure to 207 kPa (30 psi).

Wear safety glasses or goggles.

Wear hearing protection.

Use shielding to protect others in the work area.

Do not direct compressed air at body or clothing.

Tools

Make sure all tools are in good condition.

Make sure all standard electrical tools aregrounded.

Check for frayed or damaged power cords beforeusing power tools.

Fluids Under Pressure

Use extreme caution when working on systemsunder pressure.

Follow approved procedures only.

Fuel

Do not over fill the fuel tank. Over fill creates a firehazard.

Do not smoke in the work area.

Do not refuel the tank when the engine is running.

Removal of Tools, Parts, and Equipment

Reinstall all safety guards, shields, and coversafter servicing the engine.

Make sure all tools, parts, and service equipmentare removed from the engine and vehicle after allwork is done.

ENGINE IDENTIFICATION 5

Table of Contents

Engine Identification.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Engine Emission Label. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Engine Accessory Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7Engine Description.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Standard Features.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10Chassis Mounted Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Engine Component Locator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

6 ENGINE IDENTIFICATION


Engine IdentificationEngine Serial Number

Figure 1 Engine Serial Number

The engine serial number is in two locations:

Stamped on the right side of the crankcase, justabove the oil filter header

On the engine emission label on the valve cover

Engine Serial Number Examples

N9 and N10 : 570HM2UXXXXXXX

Engine Serial Number Codes

570 Engine displacementH Diesel, turbocharged, Charge Air Cooler (CAC)and electronically controlledM2 Motor truckU denotes built plant; U for Melrose Park, Y forHuntsville7 digit suffix start with 354XXXX

Engine Emission Label

Figure 2 U.S. Environmental Protection Agency(EPA) Exhaust Emission Label (Example)

The U.S. Environmental Protection Agency (EPA)exhaust emission label is attached on top of the valvecover. The EPA label typically includes the following:

Model year

Engine family, model, and displacement

Advertised brake horsepower and torque rating

Emission family and control systems

Valve lash specifications

Engine serial number

EPA, EURO, and reserved fields for specificapplications

Engine Accessory Labels

The following engine accessories may havemanufacturer's labels or identification plates:

Air compressor

Air conditioning compressor


Alternator

Cooling fan clutch

Power steering pump

Starter motor

Engine Description

N9 and N10 Diesel EnginesEngine configuration 4 stroke, inline six cylinder diesel

N9 and N10 displacement 9.3 L (570 in3)

Bore (sleeve diameter) 116.6 mm (4.59 in)

Stroke

N9 and N10 146 mm (5.75 in)

Compression ratio

N9 and N10 16.5 : 1

Aspiration Dual turbocharged and charge air cooled

Advertised brake horsepower @ rpm See EPA exhaust emission label.

Peak torque @ rpm See EPA exhaust emission label.

Engine rotation (facing flywheel) Counterclockwise

Combustion system Direct injection turbocharged

Fuel system Electro-hydraulic injection

Total engine weight (oil and accessories)

N9 and N10 845 kg (1864 lbs)

Cooling system capacity (engine only) 12.8 L (13.5 qts US)

Lube system capacity (including filter) 28 L (30 qts US)

Lube system capacity (overhaul only, with filter) 32 L (34 qts US)

Firing order 1-5-3-6-2-4


Standard Features

N9 and N10 diesel engines are designed for increaseddurability, reliability, and ease of maintenance.

The cylinder head has four valves per cylinder withcentrally located fuel injectors directing fuel overthe pistons. This configuration provides improvedperformance and reduces emissions.

The camshaft is supported by four insert bushingspressed into the crankcase. The camshaft gear isdriven from the front of the engine. A thrust flangeis located between the camshaft and the drive gear.The overhead valve train includes mechanical rollerlifters, push rods, rocker arms, and dual valves thatopen using a valve bridge.

N9 and N10 engines use one-piece steel pistons. Allpistons have zero pin offset and centered combustionbowls; therefore, pistons can be installed safelywithout orientation: there is NO front-of-engine arrowor CAMSIDE marking on the piston crown to indicatea necessary piston direction.

The one piece crankcase uses replaceable wetcylinder sleeves that are sealed by a single creviceseal ring. Some applications include a crankcaseladder which is designed to support heavier loadsand reduce engine noise.

The crankshaft has seven main bearings with foreand aft thrust controlled at the rear bearing. Onefractured cap connecting rod is attached at eachcrankshaft journal. A piston pin moves freely insidethe connecting rod and piston. Piston pin retainingrings secure the piston pin in the piston. The rear oilseal carrier is part of the flywheel housing.

A lube oil pump is mounted on the front cover and isdriven by the crankshaft. Pressurized oil is suppliedto engine components and the high-pressure injectionsystem. All N9 and N10 engines use an engine oilcooler and spin-on engine oil filter.

The coolant supply housing serves as the mountingbracket for the refrigerant compressor. Mountingcapabilities for a dual refrigerant compressor areavailable as an option. The pad mounting design ofthe alternator and refrigerant compressor bracketsprovide easy removal and improved durability.

The electric low-pressure fuel supply pump drawsfuel from the fuel tank through the fuel filter assembly.The assembly includes a strainer, filter, drain valve,Water in Fuel (WIF) sensor, and Fuel Delivery

Pressure (FDP) sensor. If equipped, an optionalfuel heater element is installed in the fuel filterassembly. Conditioned fuel is pumped through theintake manifold and cylinder head to the fuel injectors.

The WIF sensor detects water in the fuel system.When water reaches the level of the sensor located inthe fuel filter assembly, the instrument panel's amberFUEL FILTER lamp will illuminate. The collectedwater must be removed immediately. Water is drainedby opening the drain valve on the fuel filter assembly.

The fuel injection system is electro-hydraulic. Thesystem includes an under-valve-cover high-pressureoil manifold, fuel injectors, and a high-pressure oilpump. The injectors are installed in the cylinder head,under the high-pressure oil manifold.

N9 and N10 engines use dual turbochargers with anair-to-air High Pressure Charge Air Cooler (HPCAC)after the second stage. An interstage cooler is usedafter the first stage for applications with 245 hp andabove.

The Inlet Air Heater (IAH) system warms the incomingair to aid cold engine starting and to reduce whitesmoke and engine noise. The IAH system will initiallyilluminate the WAIT TO START lamp located on theinstrument panel. When the lamp turns off, the enginecan be started.

The Exhaust Gas Recirculation (EGR) systemcirculates cooled exhaust into the intake air streamin the intake manifold. This cools the combustionprocess and reduces the formation of NOX engineemissions.

A closed crankcase breather system uses an enginemounted oil separator to return oil to the crankcaseand vent crankcase pressure into the intake system.

The Down Stream Injection (DSI) system aidesin controlling emissions by injecting fuel into theexhaust stream. The fuel causes an exothermicreaction which increases the temperature of theexhaust gas. This increase in temperature allowsfor more efficient conversion of soot into ash withinthe Diesel Particulate Filter (DPF). Along with DSI,the Diesel Oxidation Catalyst (DOC) aids in creatingthe required exothermic reaction. DSI consists ofthe Doser Control Unit (DCU), Downstream Injection(DSI) assembly, hydrocarbon injector assembly, fuellines, and coolant lines. The Electronic ControlModule (ECM) communicates with the DCU to controlthe timing and quantity of fuel sprayed from the


hydrocarbon injector assembly. The ECM signals theexhaust brake valve assembly to control the positionof the exhaust back pressure valve to increaseor decrease the exhaust gas back pressure andtemperature to allow the DOC and DPF to functionefficiently.

The exhaust back pressure valve acts asan aftertreatment device to manage exhausttemperature. The resulting rise in back pressure,increases exhaust temperature.

Optional Features

Optional features include the following:

Air compressor

Hydraulic pump

Engine brake

Exhaust brake

An air compressor is available for applications thatrequire air brakes or air suspension.

A hydraulic power steering pump can be used with orwithout the air compressor.

Engine brake and exhaust brake systems areavailable for applications that could benefit fromadded speed reduction capability.

Optional Cold Climate Features

Optional cold climate features include the following:

Oil pan heater

Coolant heater

Fuel heater

All three heaters use an electric element to warmengine fluids in cold weather.

The oil pan heater warms engine oil to ensureoptimum oil flow.

The coolant heater warms engine coolant surroundingthe cylinders. Warmed engine coolant aids in coldengine start-up and performance.

The fuel heater is installed in the fuel filter assemblyand warms the supply fuel. Warmed supply fuelprevents waxing, and improves performance and fueleconomy during cold weather start-up.

Chassis Mounted Features

A Charge Air Cooler (CAC) is an air-to-air heatexchanger, which increases the density of the aircharge.

The Aftertreatment System, part of the larger exhaustsystem, processes engine exhaust to meet tailpipeemission requirements.

Conforming to 2010 Federal Emissions Standardsset by the Environmental Protection Agency(EPA), the N9 and N10 engine utilizes anSelective Catalyst Reduction (SCR) ExhaustAftertreatment (AFT) system to reduce the tailpipeemissions of Particulate Matter (PM) and NitrogenOxide (NOx). The exhaust Aftertreatment systemis comprised of engine and chassis mountedcomponents.

The chassis mounted components include theAftertreatment Control Module (ACM), DieselOxidation Catalyst (DOC), Diesel ParticulateFilter (DPF), DPF/DOC Temperature sensors, aDPF Differential Pressure /DPF Outlet Pressure(DPFDP/DPFOP) sensor, SCR Canister, SCRTemperature sensors, Ammonia (NH3) sensor,Diesel Exhaust Fluid (DEF) Supply System, DEFDoser Valve (DEFDV), and Nitrogen Oxide Outlet(NOXOUT) sensor.


Engine Component Locator

Figure 3 Component Location Top


Figure 4 Component Location Front


Figure 5 Component Location Intake Side


Figure 6 Component Location Exhaust Side


Figure 7 Component Location Rear

Engine Component Locations

Component LocationAir and EGR mixer duct C-39, D-6

Air Compressor Assembly I-35, G-25

Alternator Bracket K-11

Automatic Belt Tensioner F-20

Cylinder Head Assembly C-68

Coolant Return Hose (Air Compressor) G-37

Coolant Supply Hose (Air Compressor) G-34

Coolant Supply Housing (refrigerant compressormount)

C-57

Coolant Supply Tube Assembly ( EGR cooler) F-55


Engine Component Locations (cont.)

Coolant Return Tube Assembly (EGR cooler) G-56

Coolant Return Tube (Oil Cooler) J-55

Crankcase Oil Separator Assembly With Turbine I-55

Crankcase Oil Separator (CCOS) Intake Tube H-55

Crankcase Oil Separator Outlet Tube H-54

Deaeration Hose Elbow A-22

Downstream Injection (DSI) Assembly C-41

Downstream Injection Feed Tube Assembly D-41

Dual Stage Turbocharger Assembly E-53

Engine Control Module (ECM) F-40

EGR Crossover Duct E-68

Electric Fuel Pump D-35

Electric Fuel Pump Intake D-35

Exhaust Back Pressure Valve F-48, L-4

Exhaust Back Pressure Control (EBPC) ValveAssembly

C-50, I-4

Exhaust Back Pressure Control (EBPC) Valve ToActuator Hose

D-70

EGR Cooler Assembly F-51

Exhaust Gas Recirculation (EGR) Valve C-8, C-37

Exhaust Pipe Assembly F-71

Fuel Filter Cap C-37

Fuel Filter Assembly With Heater E-35

Fan Drive Pulley F-23

Front Cover H-22

Front Engine Mounting Bracket K-25

Fuel Filter Cap D-9

Flywheel I-68

Flywheel Housing Assembly K-66

High Pressure Turbochager Outlet C-20, L-9

Hydrocarbon Doser Assembly K-4, E-49

High Pressure Oil Pump E-35

Intake Air Heater Ignitor Relay (IAHIR) E-5, C-40

Interstage Cooler (if applicable) B-23, G-9

Interstage Cooler Inlet Elbow F-11


Engine Component Locations (cont.)

Interstage Cooler Inlet Duct I-11

Injection Unit Inlet Tube Assembly D-42, E-4

Intake Manifold E-40

Lifting Eye C-42, B-55

Low Pressure Turbocharger K-6, C-53

M16 Plug Assembly (Coolant Drain Under Oil CoolerModule)

I-52

NOx In Sensor Module E-54

NOx In Sensor Probe E-50

Oil Cooler Module H-52

Oil Drain Hose (Air Compressor) J-35

Oil Filler Tube E-65

Oil Filter Assembly I-50

Oil Pan L-40

Oil Supply Hose (Air Compressor) H-34

Power Steering Pump Assembly I-37

Rear Engine Mounting Bracket G-64, G-71

Turbo Air Inlet Duct E-19

Turbocharger Heat Shield C-51

Turbo Oil Supply Tube Assembly E-52

Valve Cover R-68

Vibration Damper Assembly J-23

Water Drain Valve Assembly E-37

Water Inlet Elbow J-20

Water Outlet Tube Assembly B-20

Water Pump Pulley I-20

MOUNTING ENGINE ON ENGINE STAND 19

Table of Contents

Engine Preparation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Clean Engine .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Drain Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Drain Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Removing Engine from Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve . . . . .21Turbo Air Inlet Duct Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21NOxIN Concentration Sensor and Module assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Hydrocarbon Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Throttle Coupling Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21Exhaust Brake Valve Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22ISC Inlet Duct Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22ISC Cooler Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Turbo Oil Supply Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Turbo Wastegate Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Dual Stage Turbo Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Drain High Fin Density EGR Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22High Fin Density EGR Cooler Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Oil Filter Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Oil Cooler Removal Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Mounting Engine Stand Bracket and Engine.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22Mounting Engine Stand Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

20 MOUNTING ENGINE ON ENGINE STAND


Engine Preparation

GOVERNMENT REGULATION: Enginefluids (oil, fuel, and coolant) may be a hazardto human health and the environment.Handle all fluids and other contaminatedmaterials (e.g. filters, rags) in accordancewith applicable regulations. Recycleor dispose of engine fluids, filters, andother contaminated materials according toapplicable regulations.

WARNING: To prevent personal injury ordeath, read all safety instructions in the SafetyInformation section of this manual.

WARNING: To prevent personal injury ordeath, shift transmission to park or neutral, setparking brake, and block wheels before doingdiagnostic or service procedures.

WARNING: To prevent personal injury ordeath, do not let engine fluids stay on your skin.Clean skin and nails using hand cleaner and washwith soap and water. Wash or discard clothingand rags contaminated with engine fluids.

WARNING: To prevent personal injury ordeath, wear safety glasses with side shields.

WARNING: To prevent personal injuryor death, remove ground cable from negativeterminal of main battery before disconnectingor connecting electrical components. Alwaysconnect ground cable last.

Clean Engine

1. Disconnect the negative battery cable.

2. Cap all engine openings to prevent water anddegreasing agents from entering engine.

3. Cover exposed electrical connectors and the ECMusing plastic and duct tape.

4. Use an appropriate detergent mixed in the correctratio and apply to engine using a hot pressurewasher or similar cleaning equipment.

Drain Coolant

5. Drain Coolant Procedure (page 220)

Drain Oil

6. Drain Oil Procedure (page 239)

Removing Engine from Vehicle

7. Remove Engine

Boost Control Harness Assembly andTurbocharger 2 Wastegate Control (TC2WC) Valve

8. Boost Control Harness Assembly and Turbo-charger 2 Wastegate Control (TC2WC) ValveProcedure (page 32)

Turbo Air Inlet Duct Assembly

9. Turbo Air Inlet Duct Procedure (page 90)

NOxIN Concentration Sensor and Moduleassembly

10. NOxIN Concentration Sensor Module Procedure(page 51)

Hydrocarbon Injector Assembly

11. Hydrocarbon Injector Procedure (page 65)

Throttle Coupling Assembly

12. Throttle Coupling Procedure (page 86)


Exhaust Brake Valve Assembly

13. Exhaust Brake Valve Procedure (page 87)

ISC Inlet Duct Assembly

14. ISC Inlet Duct Procedure (page 81)

ISC Cooler Assembly

15. ISC Cooler Procedure (page 84)

Turbo Oil Supply Assembly

16. Turbo Oil Supply Procedure (page 86)

Turbo Wastegate Assembly

17. Turbo Wastegate Procedure (page 90)

Dual Stage Turbo Assembly

18. Dual Stage Turbo Procedure (page 90)

Drain High Fin Density EGR Cooler

19. Drain High Fin Density EGR Cooler Procedure(page 126)

High Fin Density EGR Cooler Assembly

20. HIgh Fin Density EGR Cooler (page 127)

Oil Filter Removal

21. Oil Filter Removal Procedure (page 222)

Oil Cooler Removal Assembly

22. Oil Cooler Removal Procedure (page 222)

Mounting Engine Stand Bracketand EngineMounting Engine Stand Bracket

WARNING: To prevent personal injury ordeath, use metric Class 10.9 or SAE grade 8bolts when mounting the Engine Stand Bracketto the engine and Engine Stand. See instructionsincluded with Engine Stand and Engine StandBracket.

WARNING: To prevent personal injury ordeath, use a chain hoist rated for the weight of theengine, follow manufacturer's, installation andsafety instructions, and attach safety latch liftinghooks to lifting eyes on the engine.

Figure 8 Engine Stand Bracket and EngineStand

1. Engine Stand2. Square plate (top)3. Class 10.9 M16 bolt (8)4. Engine Stand Bracket5. Class 10.9 M8 bolt (9)6. Square plate (bottom)

1. Install bottom square plate on the Engine Standusing two Class 10.9 M16 bolts and tighten tostandard torque (page 491).

2. Match Engine Stand Bracket holes with bolt holesin the exhaust side of the crankcase and install 11appropriately sized Class 10.9 M8 bolts.

3. Tighten all 11 bolts to standard torque (page 491).

4. Raise or lower the engine to the approximateheight of the Engine Stand.


5. Install two Class 10.9 M16 bolts through thebottom square plate and Engine Stand Bracket.Install two Class 10.9 M16 nuts and washers onbolts and finger tighten.

6. Install the top square plate on the Engine Standusing two Class 10.9 M16 bolts and tighten tostandard torque (page 491).

7. Raise or lower the engine as needed to match theengine plate to the Engine Stand.

8. Install two Class 10.9 M16 bolts and washerssecuring the top plate to the engine stand. Tighteneight M16 bolts to standard torque (page 491).

9. Slowly release tension from engine hoist.

10. Remove hoist safety chain hooks from enginelifting eyes.

NOTE: When installing components back ontoengine, be sure to use new gaskets, seals, andO-rings.

NOTE: After engine rebuild, remove engine fromstand and do previous procedures in reverseorder.

ENGINE ELECTRICAL 25

Table of Contents

Illustrations.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Electronic Components Top.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27Electronic Components Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28Electronic Components Exhaust Side. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29Electronic Components Intake Side.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30Electronic Components Rear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve. . . . .32Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33Exhaust Back Pressure (EBP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Engine Control Module (ECM) and Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35CCOS Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35NOxIN Concentration Sensor and Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Electric Fuel Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36Exhaust Gas Recirculation (EGR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Exhaust Gas Temperature (EGT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37Fuel Heater (250 watt). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Intake Air Heater (IAH) Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38Injection Control Pressure (ICP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Engine Throttle Valve (ETV) Assembly Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Injection Pressure Regulator (IPR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40Downstream Injection (DSI) Assembly Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Water In Fuel (WIF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41Engine Harness Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42Valve Cover Gasket Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45Inspect Wiring Harness, Connectors, and Electrical Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Engine Harness Assembly and Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46Boost Control Harness Assembly and Turbocharger 2 Wastegate Control (TC2WC) Valve. . . . .49Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Exhaust Back Pressure (EBP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49Electronic Control Module (ECM) and Mounting Bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50Engine Coolant Temperature 1 (ECT1) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50CCOS Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51NOxIN Concentration Sensor and Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

26 ENGINE ELECTRICAL

Fuel Delivery Pressure (FDP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Exhaust Gas Recirculation (EGR) Control Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51Electric Fuel Pump Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Exhaust Gas Temperature (EGT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52Engine Oil Pressure (EOP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Fuel Heater (250 watt) Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53Intake Air Heater (IAH) Relay Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Injector Control Pressure (ICP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54Engine Throttle Valve (ETV) Assembly Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Injection Pressure Regulator (IPR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Intake Manifold Temperature (IMT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55Intake Manifold Pressure (IMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Downstream Injection (DSI) Assembly Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Water In Fuel (WIF) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56Valve Cover Gasket Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57


IllustrationsElectronic Components Top

Figure 9 Electronic Components Top

1. Injection Control Pressure (ICP)sensor (under valve cover)

2. Exhaust Gas Recirculation(EGR) valve assembly

3. Engine Throttle Valve (ETV)assembly

4. Electric fuel pump

5. Engine Coolant Temperature 1(ECT1) sensor


Electronic Components Front

Figure 10 Electronic Components Front

1. Exhaust Gas Recirculation(EGR) valve assembly

2. Fuel heater3. Camshaft Position (CMP) sensor


Electronic Components Exhaust Side

Figure 11 Electronic Components Exhaust Side

1. Exhaust brake valve2. Exhaust Gas Temperature

(EGT) sensor (behind turbo airinlet duct)

3. Turbocharger 2 WastegateControl (TC2WC) valve

4. Exhaust Back Pressure (EBP)sensor

5. Engine Coolant Temperature 1(ECT1) sensor

6. NOxIn Concentration SensorModule

7. CCOS Sensor8. NOxIn Concentration Sensor


Electronic Components Intake Side

Figure 12 Electronic Components Intake Side

1. Water In Fuel (WIF) sensor2. Intake Manifold Pressure (IMP)

sensor3. Intake Manifold Temperature

(IMT) sensor4. Intake Air Heater (IAH) relay

assembly5. 16-pin truck interconnect6. Downstream Injection (DSI)

assembly

7. Engine Control Module (ECM)8. Engine Oil Pressure (EOP)

sensor9. Injection Pressure Regulator

(IPR) valve10. Fuel Delivery Pressure (FDP)

Sensor11. Engine Oil Temperature (EOT)

sensor12. 250 Watt fuel heater (optional)

13. Electric fuel pump


Electronic Components Rear

Figure 13 Electronic Components Rear

1. Crankshaft Position (CKP)sensor


Removal


WARNING: To prevent personal injury ordeath, disconnect the main battery negativeterminal before disconnecting or connectingelectrical components.



CAUTION: To prevent engine damage, do not tug onwiring harnesses; if resistance is felt, find the problemand free connectors or clips.


Figure 14 Boost Control Harness Assembly andTC2WC Valve

1. Turbocharger wastegate actuatorconnectorvacuum line

2. Connector wire clip lock3. Turbocharger 2 Wastegate Control (TC2WC) valve

2-pin connector4. M5 x 16 socket head bolt (2)5. Insulatorhigh temperature plastic (2)6. Exhaust Gas Temperature (EGT) connector7. Interstage Cooler (ISC) inlet duct8. Exhaust Gas Temperature (EGT) sensor9. Turbocharger air inlet duct connectorvacuum line

1. Push connector wire clip lock on Turbocharger2 Wastegate Control (TC2WC) valve 2-pinconnector and disconnect connector fromTC2WC valve.

2. Disconnect boost control harness assembly(vacuum lines) from TC2WC valve, turbochargerair inlet duct, and turbocharger wastegateactuator connector. Discard boost controlharness assembly.

3. Disconnect boost to solenoid tube assembly(vacuum lines) from TC2WC valve and throttlecoupling. Discard boost control harnessassembly.

4. Remove two M5 x 16 socket head bolts and theTC2WC valve from ISC inlet duct. Remove anddiscard two insulators (high temperature plastic).


Crankshaft Position (CKP) Sensor

Figure 15 CKP Sensor

1. M6 x 16 sensor retaining bolt2. CKP 2-pin connector

1. Disconnect CKP 2-pin connector from CKPsensor installed in the top left of the flywheelhousing.

2. Remove M6 x 16 sensor retaining bolt.

3. Pull up and remove CKP sensor.

4. Discard sensor O-rings.

Camshaft Position (CMP) Sensor

Figure 16 CMP Sensor

1. M8 x 20 bolt2. Engine harness bracket3. CMP sensor4. CMP sensor 2-pin connector5. M6 x 16 sensor retaining bolt

1. Disconnect CMP sensor 2-pin connector fromCMP sensor installed in the front cover.

2. Remove M6 x 16 sensor retaining bolt.

3. Pull out and remove CMP sensor.

4. Discard sensor O-ring.

5. If required, remove M8 x 20 bolt securing sensorbracket to front cover.


Exhaust Back Pressure (EBP) Sensor

Figure 17 EBP Sensor

1. Disconnect 3-pin engine harness connector fromthe EBP sensor, installed in a tubemounted on thecoolant supply housing (refrigerant compressorbracket).

2. Remove EBP sensor.

Engine Control Module (ECM) and MountingBracket

1. Disconnect ground (-) cable from battery.

Figure 18 ECM Assembly

1. Isolator grommet (4)2. Vibration isolator bushing (4)3. Ground connection4. Connector lock lever5. M8 x 45 bolts (4)

2. Pull ground connection from terminal on ECM.

3. Squeeze orange latch on ECM harness connectorand swing connector lock lever toward center ofECM.

4. Disconnect engine harness assembly and chassisharness connectors from ECM.

5. Remove four M8 x 45 bolts holding ECM tomounting bracket.

6. Remove ECM assembly with vibration isolatorbushings and isolator grommets.


Figure 19 ECM Bracket Mounting Bolts (M8 x 20)

7. Remove four M8 x 20 bolts holding ECM bracketto crankcase and remove bracket assembly.

Engine Coolant Temperature 1 (ECT1) Sensor

Figure 20 ECT1 Sensor and CCOS Sensor

1. ECT1 Sensor2. CCOS Sensor

ECT1 Sensor

1. Place a coolant drain pan under the engine.

2. Pull lock tab up to unlock connector.

3. Press the release tab and disconnect 2-pinengine harness connector from the ECT1 sensor,installed in the coolant supply housing (refrigerantcompressor bracket).

4. Remove ECT1 sensor.


6. Recycle or dispose of coolant according toapplicable regulations.

CCOS Sensor

1. Pull CCOS sensor connector lock tab up to unlockconnector and remove connector from sensor.

2. Remove CCOS Sensor retainer M5 bolt fromCCOS sensor bracket.

3. Remove CCOS Sensor from CCOS housing.


NOxIN Concentration Sensor and Module

Figure 21 NOxIn Concentration Sensor andModule

1. Harness clipping (4)2. M6 nut (2)3. NOxIn Concentration Module4. Tie straps (3)5. NOxIn Concentration Sensor

1. Remove two NOxIn Concentration SensorModule M6 nuts from NOxIn ConcentrationSensor bracket.

2. Cut three NOxIn Concentration sensor harness tiestraps.

3. Undo NOxIn Concentration sensor harness fromfour routing and clipping points.

4. Remove NOxIN Sensor and Module from exhaustbrake under rail housing.

Electric Fuel Pump Connector

See Brushless Electric Fuel Pump Assembly (page166) for removal procedure.

Figure 22 Electric Fuel Pump Connector

1. Pull lock tab out to unlock connector.

2. Press the release tab and disconnect 2-pin engineharness connector from the electric fuel pump.

Fuel Delivery Pressure (FDP) Sensor

Figure 23 FDP Sensor (Typical)

1. Disconnect 3-pin engine harness connector fromthe FDP sensor.

2. Remove FDP sensor from fuel filter assembly.



Exhaust Gas Recirculation (EGR) ValveConnector

Figure 24 EGR Valve Connector

1. Disconnect engine harness connector from EGRvalve, installed in the air and EGR mixer duct.

2. See EGR Valve Assembly (page 130).

Exhaust Gas Temperature (EGT) Sensor

Figure 25 EGT Sensor Connector

1. Press the release tab to disconnect EGT sensorfrom wiring connector.

2. Remove EGT sensor from front section of exhaustmanifold.

Engine Oil Pressure (EOP) Sensor

Figure 26 EOP Sensor

1. Disconnect engine sensor harness retaining clipfrom EOP sensor.

2. Disconnect 3-pin engine harness connector fromthe EOP sensor, installed in the intake side of thecrankcase.

3. Remove EOP sensor.

4. Discard EOP sensor O-ring.

Engine Oil Temperature (EOT) Sensor

Figure 27 EOT Sensor (Typical)


1. Pull lock tab out to unlock connector.

2. Press the release tab and disconnect the 2-pinengine harness connector from the EOT sensor,installed in the rear of the front cover assembly onthe intake side of the engine.

3. Remove EOT sensor.

4. Discard EOT sensor O-ring.

Fuel Heater (250 watt)

Figure 28 Fuel Heater (250 Watt) (Typical)

1. Disconnect engine harness connector from fuelheater.

2. See WIF sensor, FDP Sensor, and Fuel Heater(page 165).

Intake Air Heater (IAH) Relay Assembly

Figure 29 IAH Relay Assembly

1. 5/16 18 nut2. M6 x 25 bolt (2)3. IAH harness connector4. M6 serrated nut (2)5. IAH relay buss bar6. Battery power supply buss bar

1. Disconnect IAH harness connector.

2. Remove 5/16 18 nut that secures the batterypower supply buss bar to the battery powerjunction block.

3. Remove M6 serrated nut that secures the batterypower supply buss bar to the IAH relay, thenremove the battery power supply buss bar.

4. Remove two M6 serrated nuts securing IAH relaybuss bar to the single grid heater assembly andIAH relay.

5. Remove two M6 x 25 bolts that secure the IAHrelay.

6. Remove IAH relay assembly.


Injection Control Pressure (ICP) Sensor

1. Remove interstage cooler (if equipped) and valvecover. See Interstage Inlet Duct Assembly (page81) and Valve Cover (page 305).

Figure 30 ICP Sensor

1. ICP sensor connector2. Valve cover gasket harness connector3. ICP sensor

2. Disconnect 3-pin valve cover gasket harnessconnector from the ICP sensor, installed in thehigh-pressure oil manifold rear of cylinder 5 fuelinjector.

3. Remove ICP sensor.


Engine Throttle Valve (ETV) Assembly Connector

Figure 31 ETV Assembly Connector

1. Pull out locking tab.

2. Push release tab and disconnect engine harnessconnector from ETV assembly, installed on theintake side of the engine.

3. See Engine Throttle Valve (ETV) Assembly (page130).

Injection Pressure Regulator (IPR) ValveConnector

Figure 32 IPR Valve

1. Wire lock clip2. IPR valve connector


1. Swing wire lock clip downwards to unlock.

2. Pull connector to disconnect from IPR valve,installed in the rear of the high-pressure oil pumpon the intake side of the engine.

3. For IPR valve removal, see High-pressure OilPump Assembly and Injection Pressure Regulator(IPR) Valve Assembly (page 182).

Intake Manifold Pressure (IMP) Sensor

Figure 33 IMP Sensor

1. Push release tab and disconnect 3-pin engineharness connector from IMP sensor.

2. Remove IMP sensor.

3. Discard IMP sensor O-rings.

Intake Manifold Temperature (IMT) Sensor

Figure 34 IMT Sensor

1. Pull up IMT sensor locking tab.

2. Push release tab and disconnect 2-pin engineharness connector from IMT sensor.

3. Remove IMT sensor.

4. Discard IMT sensor O-rings.


Downstream Injection (DSI) AssemblyConnectors

Figure 35 DSI Assembly

1. Upstream pressure/temperature sensor connector2. Tie strap3. Dosing Valve (DV) connector4. Downstream pressure sensor5. Yellow connector lock6. Shutoff Valve (SV)

1. Pull out the yellow connector lock and thendisconnect engine harness connectors for theUpstream pressure / temperature sensor, DV,downstream pressure sensor and SV.

2. Remove engine harness from DSI assembly.

3. For DSI assembly removal, see Down StreamInjection (DSI) Assembly (page 63).

Water In Fuel (WIF) Sensor

Figure 36 WIF Sensor

1. Disconnect engine harness connector from theWIF sensor.

2. Remove WIF sensor.



Engine Harness Assembly

1. Disconnect the battery ground (-) cable.

Figure 37 Engine Wiring Harness Connection Points Intake Side

1. Tie strap (3)2. Exhaust brake valve assembly

connector

3. Valve cover gasket connector (4)4. M10 nut (2)5. 16-pin interconnect

6. M8 nut (2)7. Electro Magnetic Interference

(EMI) ground connection

2. Squeeze orange latch on ECM harness connectorand lift lever to unlock connectors.

3. Disconnect engine harness assembly and chassisharness connectors from ECM and disconnectEMI ground connection.

4. Disconnect engine harness assembly connectorsfrom sensors and actuators on intake side ofengine.

5. Remove two M10 nuts.

6. Cut three tie straps.

7. Remove Engine Harness Assembly from fourvalve cover gasket connectors.

8. Remove M6 x 16 bolt securing the 16-pininterconnect.

9. Remove two M8 nuts.


Figure 38 Engine Wiring Harness ConnectionPoints Front Top View (M8 x 12 Bolt)

10. Remove M8 x 12 bolt.

Figure 39 Engine Wiring Harness ConnectionPoints Exhaust Side


11. Cut tie straps on fir zip harness retainers.

12. Disconnect connectors from ECT1 sensor, EGTsensor, CCOS Sensor, and TC2WC valve.

13. Remove engine wiring harness from coolantsupply housing.

14. Cut 3 CCOS Sensor harness tie straps.

15. Remove Engine Harness assembly from theengine.


Valve Cover Gasket Assembly

1. Remove interstage cooler and valve cover. SeeInterstage Cooler (ISC) (page 84) and ValveCover (page 305).

Figure 40 Valve Cover Gasket Assembly Connectors

1. Injector 1 harness connector2. ECBP sensor connector3. Injector 2 harness connector4. Injector 3 harness connector

5. ECB valve connector6. Injector 4 harness connector7. Injector 5 harness connector8. Injector 6 harness connector

9. ICP sensor connector10. Valve cover gasket connector (4)

2. Disconnect four valve cover gasket connectors,ICP sensor connector, and six injector harnessconnectors.

3. Disconnect ECBP sensor connector and ECBvalve connector.

4. Starting at one side, lightly pry up and open eachof the six wire channel retainers while gentlypulling up to remove valve cover gasket harnessfrom engine.


InspectInspect Wiring Harness, Connectors, andElectrical Components

1. Inspect each wiring harness for corrosion (green,gray, or white deposits), female connector sleevesthat are spread open, and terminal pins that arepushed back relative to the other terminals inthe same connector. Clean, repair, or replaceconnectors and terminals if necessary.

2. Inspect wire harness near sensors and actuatorsfor damage due to sharp bends; see diagnosticmanual for continuous monitor testing.

3. Inspect each wiring harness for wear and heatdamage to wiring and connectors. Repair orreplace if necessary.

4. Replace any broken harness connection pointsand zip ties.

5. Check for damage caused by zip ties that are tootight.

6. Inspect connector pins on all electricalcomponents. If any pins are bent or pushed in,repair or replace component.

7. Inspect female connector terminals for spreading.

8. Inspect electrical sensors, actuators, and valvesfor cracks and damage. Replace damagedcomponents if necessary.

9. Inspect pressure sensors for soot, sludge, debris,or other contamination. Clean or replace asneeded.

NOTE: See EGES-455 Engine Diagnostic Manualfor further inspection and repair of engineelectrical components and systems.


InstallationEngine Harness Assembly and Camshaft Position(CMP) Sensor

Figure 41 Sensor Wiring Harness Connection Points Intake Side

1. Tie strap (3)2. Exhaust brake valve assembly

connector

3. Valve cover gasket connector (4)4. M10 nut (2)5. 16-pin interconnect

6. M8 nut (2)7. Electro Magnetic Interference

(EMI) ground connection

1. Position engine harness on intake side of engineand under fuel filter assembly.

2. Install M8 and M10 nuts. Tighten to special torque.

3. Install three new tie straps on fir zip harnessretainers.

4. Connect exhaust brake valve assembly connectornear top of valve cover.

5. Connect EMI ground connection.

6. Connect four valve cover gasket connectors.

7. Install 16-pin interconnect and tightenM6 x 16 boltto standard torque (page 491).

8. Position engine harness over top of valve cover.


Figure 42 Sensor Wiring Harness ConnectionPoints Front Top View (M8 x 12 Bolt)

9. Install M8 x 12 bolt to secure wiring harness tovalve cover. Tighten to special torque .

Figure 43 CMP Sensor Connection with DualBelt Pulley Bracket Installed

1. Camshaft Position (CMP) sensor2. CMP sensor harness connector3. Flexible conduit

Figure 44 CMP Sensor Connection without DualBelt Pulley Bracket

1. M8 x 20 bolt2. Engine harness bracket3. CMP sensor4. CMP sensor connector5. M6 x 16 sensor retaining bolt

NOTE: Perform step 10 only if flexible conduit hasnot been installed.

10. Install flexible conduit, under CMP sensorconnector, on new engine harness.

11. Slide engine harness bracket behind fan pulley.Install M8 x 20 engine harness bracket bolt andtighten to standard torque (page 491).

12. Connect CMP sensor connector to CMP sensor.

If engine has dual belt pulley kit installed, referto (Figure 43).

If engine has single pulley installed, refer to(Figure 44).


Figure 45 EGR Sensor Connector Cap andCable Lock Strap

1. Connector cap2. Cable lock strap

13. For engine harnesses with an Exhaust GasRecirculation (EGR) pressure sensor connectordo the following:

Press connector cap (Figure 45) onto theEGR pressure sensor harness connector. Aclick should be heard when connector cap isinstalled correctly.

Insert cable lock strap (Figure 45) throughhole in connector cap and around engineharness under Exhaust Gas Temperature(EGT) sensor connector to secure the cap.

Figure 46 Engine Harness Connection Points Exhaust Side


14. Weave engine harness around casting featureson coolant supply housing.

15. Secure engine harness to fir zip harness retainerswith new tie straps.

16. Insert fir zip connector into interstage cooler inletpipe.

17. Route CCOS sensor harness and secure with 3new tie straps.



Figure 47 Boost Control Harness Assembly andTC2WC Valve

1. Turbocharger wastegate actuatorconnectorvacuum line

2. Connector wire clip lock3. Turbocharger 2 Wastegate Control (TC2WC) valve

2-pin connector4. M5 x 16 socket head bolt (2)5. Insulatorhigh temperature plastic (2)6. Exhaust Gas Temperature (EGT) connector7. Interstage Cooler (ISC) inlet duct8. Exhaust Gas Temperature (EGT) sensor9. Turbocharger air inlet duct connectorvacuum line

1. Install TC2WC valve on ISC inlet duct with two M5x 16 socket head bolts and two new insulators.Make sure insulators are placed on bolts betweenTC2WC valve and ISC inlet duct. Tighten bolts tostandard torque (page 491).

2. Install a new boost control harness assembly(vacuum lines) to turbocharger wastegateactuator connector, turbocharger air inlet ductconnector, TC2WC valve, and throttle coupling.Crimp clamps at throttle coupling and TC2WCvalve.

3. Connect TC2WC 2-pin connector to TC2WCvalve and push in connector wire clip lock.

Crankshaft Position (CKP) Sensor

Figure 48 CKP Sensor

1. M6 x 16 sensor retaining bolt2. CKP 2-pin connector

1. Lubricate new O-rings with clean engine oil andinstall on CKP sensor.

2. Install CKP sensor into the flywheel housing.

3. Install M6 x 16 retaining bolt and tighten tostandard torque (page 491).

4. Connect engine harness connector to CKPsensor.

Exhaust Back Pressure (EBP) Sensor

Figure 49 EBP Sensor


1. Install EBP sensor into tube mounted on thecoolant supply housing (refrigerant compressorbracket).

2. Tighten EBP sensor to special torque .

3. Connect engine harness connector to EBPsensor.

Electronic Control Module (ECM) and MountingBracket

Figure 50 ECM Bracket Bolts

1. Install four M8 x 20 bolts securing the ECMbracket to the crankcase and tighten bolts tostandard torque (page 491).

Figure 51 ECM Assembly

1. Isolator grommet (4)2. Vibration isolator bushing (4)3. Electro Magnetic Interference (EMI) ground

connection4. Connector lock lever5. M8 x 45 bolts (4)

2. Install ECM assembly with vibration isolatorbushings and isolator grommets.

3. Install four M8 x 45 bolts securing the ECM to themounting bracket and tighten to special torque .

4. Push ECM harness and chassis connectors firmlyinto ECM and rotate connector lock lever until itlocks in place.

5. Connect EMI ground connection to terminal onECM.

Engine Coolant Temperature 1 (ECT1) Sensor

Figure 52 ECT1 Sensor and CCOS Sensor


ECT1 Sensor

1. Install a new O-ring on ECT1 sensor.

2. Install ECT1 sensor into the coolant supplyhousing (refrigerant compressor bracket) andtighten to special torque .


3. Connect engine harness connector to ECT1sensor.

4. Push lock tab down to lock connector.

CCOS Sensor

1. Install CCOS sensor onto CCOS mountingsupport.

2. Install M5 CCOS sensor bolt onto CCOS sensorhousing and tighten.

3. Connect engine harness connector to CCOSsensor pushing connector until the lock tab issecured.

NOxIN Concentration Sensor and Module

Figure 53 NOxIn Concentration Sensor andModule

1. Harness clipping (4)2. M6 nut (2)3. NOxIn Concentration Module4. Tie straps (3)5. NOxIn Concentration Sensor

1. Install NOxIn Concentration sensor into exhaustbrake under rail housing.

2. Torque NOxIn Concentration sensor to 50 Nm(37lbft).

3. Route NOxIn Concentration module harnessthrough four routing and clipping points.

4. Install three new tie straps onto NOxInConcentration module harness.

5. Install NOxIn Concentration module onto NOxInConcentration module support.

6. Install two NOxIn Concentration module M6 nutsonto NOxIn Concentration module support andtorque nuts to 10 Nm (7 lbft).

Fuel Delivery Pressure (FDP) Sensor

Figure 54 FDP Sensor (Typical)

1. Install new O-ring on FDP sensor

2. Install FDP sensor and tighten to special torque .

3. Connect 3-pin engine harness connector to theFDP sensor.

Exhaust Gas Recirculation (EGR) Control ValveConnector

1. See EGR Valve Assembly (page 136) for EGRcontrol valve installation.


Figure 55 EGR Valve Connector

2. Connect engine harness connector to the EGRvalve.

NOTE: Perform steps 3 and 4 if an EGR pressuresensor is not installed in the EGR coolant supplytube.

Figure 56 EGR Pressure Sensor HarnessConnector

1. EGR pressure sensor harness connector2. Connector cap3. Cable lock strap

3. Press connector cap onto EGR pressure sensorharness connector. A click should be heard whenconnector cap is installed correctly.

4. Insert cable lock strap through hole in connectorcap, around engine harness, and under Exhaust

Gas Temperature (EGT) sensor connector tosecure cap.

Electric Fuel Pump Connector

Figure 57 Electric Fuel Pump Connector

1. Connect engine harness connector to electric fuelpump.

2. Push lock tab into lock connector.

Exhaust Gas Temperature (EGT) Sensor

Figure 58 EGT Sensor Connector

1. Install EGT sensor and tighten to special torque .


2. Connect engine harness connector to the EGTsensor.

Engine Oil Pressure (EOP) Sensor

Figure 59 EOP Sensor

1. Lubricate a new O-ring with clean engine oil andinstall on EOP sensor.

2. Install EOP sensor into the intake side of thecrankcase and tighten to special torque .

3. Connect engine harness connector to EOPsensor.

4. Connect engine sensor harness retaining clip toEOP sensor.

Engine Oil Temperature (EOT) Sensor

Figure 60 EOT Sensor

1. Lubricate a new O-ring with clean engine oil andinstall on EOT sensor.

2. Install EOT sensor into the back of the front coverand tighten to special torque .

3. Connect engine harness connector to the EOTsensor.

4. Push lock tab down to lock connector.

Fuel Heater (250 watt) Connector

1. See Water In Fuel (WIF) Sensor, Fuel DeliveryPressure (FDP) Sensor, and 250Watt Fuel Heater(page 165) for 250 Watt Fuel Heater installation.


Figure 61 Fuel Heater (250 Watt) (Typical)

2. Connect engine harness connector to 250 wattfuel heater.

Intake Air Heater (IAH) Relay Assembly

Figure 62 IAH Relay Assembly

1. 5/16 18 nut2. M6 x 25 bolt (2)3. IAH harness connector4. M6 serrated nut (2)5. IAH relay buss bar6. Battery power supply buss bar

1. Install two M6 x 25 bolts. Tighten bolts to standardtorque (page 491).

2. Install IAH relay buss bar on single grid heaterstud and secure with two M6 serrated nuts.Tighten nut to special torque .

3. Install the battery power supply buss bar on 5/16and M6 studs. Tighten 5/16 18 nut and M6serrated nut to special torque .

4. Connect IAH harness connector to IAH relayassembly.

Injector Control Pressure (ICP) Sensor

Figure 63 ICP Sensor

1. ICP sensor connector2. Valve cover gasket harness connector3. ICP sensor

1. Lubricate a new O-ring with clean engine oil andinstall on the ICP sensor.

2. Install ICP sensor into high-pressure oil manifold,to the rear of cylinder 5 fuel injector, and tightento special torque .

3. Connect valve cover gasket harness connector tothe ICP sensor connector.


Engine Throttle Valve (ETV) Assembly Connector

1. See Engine Throttle Valve (ETV) Assembly (page136) for ETV installation.

Figure 64 ETV Assembly Engine HarnessConnector

2. Connect engine harness connector to ETVassembly.

3. Push down locking tab to lock engine harnessconnector.

Injection Pressure Regulator (IPR) ValveConnector

1. See High-pressure Oil Pump Assembly andInjection Pressure Regulator (IPR) ValveAssembly (page 180) for IPR valve installation.

Figure 65 IPR Valve on High-Pressure Oil Pump(Typical)

1. Wire clip lock2. IPR valve connector

2. Connect IPR valve connector to IPR valve.

3. Connect engine harness wire clip lock.

4. Secure wire clip with a Zip tie.

Intake Manifold Temperature (IMT) Sensor

Figure 66 IMT Sensor

1. Install a new O-ring on the IMT sensor.

2. Install IMT sensor into the intake manifold andtighten to special torque .


3. Connect engine harness connectors to the IMTsensor.

4. Push down IMT sensor locking tab to lock engineharness connector.

Intake Manifold Pressure (IMP) Sensor

Figure 67 IMP Sensor

1. Install a new O-ring on the IMP sensor.

2. Install IMP sensor into the intake manifold andtighten to special torque .

3. Connect engine harness connectors to the IMPsensor.

Downstream Injection (DSI) AssemblyConnectors

1. Install DSI assembly. See Down Stream Injection(DSI) Assembly (page 70).

Figure 68 DSI Assembly

1. Upstream pressure/temperature sensor connector2. Tie strap3. Dosing Valve (DV) connector4. Downstream pressure sensor connector5. Shutoff Valve (SV) connector6. Shutoff Valve (SV)

2. Connect engine harness connectors to Upstreampressure / temperature sensor, DV, downstreampressure sensor, and SV.

3. Push in the yellow connector lock to secureconnector.

Water In Fuel (WIF) Sensor

Figure 69 WIF Sensor


1. Install new O-ring on WIF sensor.

2. Install WIF sensor and tighten to special torque .

3. Connect engine harness connector toWIF sensor.

Valve Cover Gasket Assembly

Figure 70 Valve Cover Gasket Assembly Connectors

1. Injector 1 harness connector2. ECBP sensor connector3. Injector 2 harness connector4. Injector 3 harness connector

5. ECB valve connector6. Injector 4 harness connector7. Injector 5 harness connector8. Injector 6 harness connector

9. ICP sensor connector10. Valve cover gasket connector (4)

1. Position valve cover gasket harness on cylinderhead and carefully push down each of the sixwire channel retainers to snap harness ontohigh-pressure oil manifold.

2. Connect four valve cover gasket connectors,ICP sensor connector, and six injector harnessconnectors.

3. If equipped, connect ECB valve and ECBP sensorconnectors.

DOWN STREAM INJECTION (DSI) & RELATED COMPONENTS 59

Table of Contents

Exploded Views.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Down Stream Injection (DSI) Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61Hydrocarbon Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Down Stream Injection (DSI) Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63Injection Unit Inlet Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64Hydrocarbon Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65

Cleaning and Inspection.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67Hydrocarbon Injector (HCI) / Aftertreatment Fuel Injector (AFI) Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . .67

Installation.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Hydrocarbon Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68Injection Unit Inlet Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69Down Stream Injection (DSI) Assembly.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70

60 DOWN STREAM INJECTION (DSI) & RELATED COMPONENTS


Exploded ViewsDown Stream Injection (DSI) Assembly

Figure 71 Down Stream Injection (DSI) Assembly

1. M8 nut (3)2. Down Stream Injection (DSI)

assembly3. Down Stream Injection (DSI)

support4. M10 nut (2)5. Rubber cushioned clamp (2)

6. M6 x 12 bolt (2)7. M6 x 14 bolt8. Tube clamp (2 pcs)9. Injection unit inlet tube assembly10. 90 degree M12 tube fitting elbow11. Down Stream Injection (DSI)

inlet tube assembly (hard tube)

12. Fitting assembly (2)13. O-ring seal (2)14. Down Stream Injection (DSI)

inlet tube assembly (flexibletube)



Figure 72 Hydrocarbon Injector Assembly

1. M8 x 45 bolt (2)2. Hydrocarbon injector assembly3. Hydrocarbon injector gasket

4. Injector coolant inlet tubeassembly

5. Injector coolant outlet tubeassembly

6. Tube fitting (90 degree elbow)7. M10 37 degree flare fitting


Removal




WARNING: To prevent personal injury ordeath, wear safety glasses with side shields.Limit compressed air pressure to 207 kPa (30 psi).

WARNING: To prevent personal injury ordeath, do not let engine fluids stay on your skin.Clean skin and nails using hand cleaner and washwith soap and water. Wash or discard clothingand rags contaminated with engine fluids.

Down Stream Injection (DSI) Assembly

1. Disconnect engine harness connectors fromDown Stream Injection (DSI) assembly electricalconnectors.

Figure 73 Down Stream Injection (DSI)Assembly (hard tube)

1. Down Stream Injection (DSI) assembly2. M8 nut (3)3. Fitting assembly (2)4. Injection unit inlet tube assembly5. 90 degree M12 tube fitting elbow6. Down Stream Injection (DSI) inlet tube assembly


Figure 74 Down Stream Injection (DSI)Assembly (flexible tube)

1. Down Stream Injection (DSI) assembly2. M8 nut (3)3. Fitting assembly (2)4. Injection unit inlet tube assembly5. 90 degree M12 tube fitting elbow6. Down Stream Injection (DSI) inlet tube assembly

WARNING: To prevent personal injury ordeath, do not smoke and keep fuel away fromflames and sparks.

2. Using line wrenches, disconnect Down StreamInjection (DSI) inlet tube assembly and injectionunit inlet tube assembly from fitting assemblies onDown Stream Injection (DSI) assembly.

3. Remove DSI inlet tube assembly from 90 degreeM12 tube fitting elbow.

4. Remove and save three M8 nuts from DSIassembly.

5. Remove DSI assembly from DSI assemblysupport.

6. If required, remove fitting assemblies from DSIassembly and discard O-rings.

7. If required, remove 90 degree M12 tube fittingelbow from intake manifold.

Figure 75 Down Stream Injection (DSI) Support

1. Down Stream Injection (DSI) support2. M10 nut (2)

8. Remove two M10 nuts from studs in cylinderhead.

9. Remove Down Stream Injection (DSI) supportfrom cylinder head.

Injection Unit Inlet Tube Assembly



Figure 76 Injection Unit Inlet Tube Assembly atHydrocarbon Injector

1. M6 x 12 bolts (2)2. Injection unit inlet tube assembly3. Injection unit inlet tube flare nut4. Hydrocarbon injector

1. Use a backup wrench to prevent movement ofhydrocarbon injector and disconnect injection unitinlet tube flare nut.

2. Remove two M6 x 12 bolts securing injection unitinlet tube assembly to crossover tube support oncylinder head.

3. Remove injection unit inlet tube assembly.

NOTE: The injection unit inlet tube assemblyhas precise specifications; only use properreplacement parts. Do not fabricate any fuel linesfor Down Stream Injection (DSI) system.


Figure 77 Hydrocarbon Injector Assembly

1. M8 x 45 bolt (2)2. Hydrocarbon injector assembly3. Tube fitting (90 degree elbow)4. Injector coolant inlet tube assembly5. Injector coolant outlet tube assembly6. 37 degree flare nut (2)7. M10 37 degree flare fitting


1. Use a backup wrench to prevent movement ofM10 37 degree flare fitting while removing 37degree flare nut. Remove injector coolant outlettube 37 degree flare nut from fitting.

2. Loosen and remove injector coolant inlet tube 37degree flare nut from 90 degree elbow tube fitting.


Figure 78 Hydrocarbon Injector Coolant Tubes

1. Injector coolant inlet tube assembly2. High fin density EGR cooler3. Injector coolant outlet tube assembly

3. Remove and discard Injector coolant inlet tubeassembly from high fin density EGR cooler.

4. Remove and discard Injector coolant outlet tubeassembly from high fin density EGR cooler.

5. RemoveM10 37 degree flare fitting and 90 degreeelbow tube fitting from hydrocarbon injector, ifrequired.

6. Remove and discard twoM8 x 45 bolts that securehydrocarbon injector assembly.

NOTE: Do not reuse M8 x 45 bolts. These bolts arespecial high temperature fasteners. Install newbolts.

7. Remove hydrocarbon injector assembly.

Figure 79 Hydrocarbon Injector Gasket

1. HCI / AFI assembly2. Injector nozzle tip3. Hydrocarbon injector gasket4. Raised sealing lip

8. Remove and discard hydrocarbon injector gasket.


Cleaning and InspectionHydrocarbon Injector (HCI) / Aftertreatment FuelInjector (AFI) Cleaning

Figure 80 Hydrocarbon / Aftertreatment FuelInjector Assembly


CAUTION: To prevent component damage,cleaning of the HCI / AFI assembly using cleaneror solvents is NOT recommended. Do not blastthe injector with compressed air. Do not pull orotherwise manipulate the injector nozzle tip.

1. Inspect HCI / AFI assembly and injector nozzletip for cracks and other damage. If damage ispresent, replace HCI / AFI assembly.

2. Use Fuel Injector Tip Cleaning Brush ZTSE4301to clean any carbon buildup that may be presenton the injector nozzle tip.

Exhaust Back Pressure Valve Housing Cleaning

Figure 81 Exhaust Back Pressure Valve Housing

1. HCI / AFI port2. Exhaust back pressure valve housing

CAUTION: To prevent damage to theaftertreatment system or plugging of the PDOC /DOC / DPF, ensure no carbon debris remains inHCI / AFI port upon completion of steps 1 and 2.

3. Carefully remove carbon from the HCI / AFI porton the exhaust back pressure valve housing witha chisel or other appropriate tool. Remove debriswith a shop vac.


InstallationHydrocarbon Injector Assembly

NOTE: New hydrocarbon injector gasket may lookdifferent from gasket pictured below.

Figure 82 Hydrocarbon Injector Gasket


1. Install a new hydrocarbon injector gasket.

Figure 83 Hydrocarbon Injector Unit

1. M8 x 45 bolt (2)2. Hydrocarbon injector assembly3. Tube fitting (90 degree elbow)4. Injector coolant inlet tube assembly5. Injector coolant outlet tube assembly6. 37 degree flare nut (2)7. M10 37 degree flare fitting

2. Position hydrocarbon injector assembly somounting holes align with holes in gasket.

NOTE: Do not reuse M8 x 45 bolts. These bolts arespecial high temperature fasteners. Install newbolts.

3. Install two new M8 x 45 bolts. Tighten bolts totwo-step special torque .

4. If previously removed, install M10 37 degreeflare fitting and 90 degree elbow tube fitting intohydrocarbon injector assembly. Tighten M10 37degree flare fitting to special torque . Tighten 90degree elbow tube fitting finger tight. Back out 90degree elbow tube fitting to allow for installationof Injector coolant inlet tube assembly.

NOTE: Install injector coolant inlet tube assemblyfirst, then the injector coolant outlet tubeassembly. The injector coolant inlet tubeassembly attaches at the lower port (90 degreeelbow tube fitting) on the hydrocarbon injectorassembly. Ports are labeled in and out.


Figure 84 Hydrocarbon Injector Coolant Tubes

1. Injector coolant inlet tube assembly2. High fin density EGR cooler3. Injector coolant outlet tube assembly

5. With new injector coolant inlet tube assembly,connect injector coolant inlet tube assembly tohigh fin density EGR cooler and 90 deg

Documents

Engine Manual Navistar N9 and 10