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SUBJECT DATE

Engine Replacement Procedures September 2015

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0081 DD Platform

Removal of theComplete Powertrain

Assembly Three new procedures detailing how to remove a completepowertrain from a Freightliner Cascadia, how to prepare a

replacement long block engine for installation, and installation of acomplete powertrain into a Freightliner Cascadia.

Replacement Long BlockEngine Preparation

Installation of theComplete Powertrain

Assembly

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2 Removal of the Complete Powertrain Assembly

When possible, this is the preferred method for removing an engine for service outside of the chassis. Examples couldinclude crankshaft replacement or a long block engine replacement. The engine, cooling package and transmission will beremoved as an assembly.

NOTE: The instructions listed below are powertrain removal instructions based on a Freightliner Cascadia 113 or125 model truck with an EPA07, EPA10 or GHG14 DD engine. These instructions will vary some depending onthe chassis configuration.

NOTE: There are several instructional videos posted in DDCSN under Support, Multimedia, DD Platform andPowertrain Removal and Installation that may assist with this repair. The videos are also posted on theAftermarket Resource Center (ARC) website in Access Freightliner.

Special tools required:

Engine Lifting Bar W470589006200

Remove as follows:

WARNING: PERSONAL INJURY

To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removingany component.

WARNING: PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a levelsurface, parking brake is set, and the wheels are blocked.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION: ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magneticswitch studs are at battery voltage.

2. Disconnect the batteries. Refer to the Original Equipment Manufacturer (OEM) procedure.3. Remove the front bumper.4. Remove the hood.5. Remove both side fairings, if equipped, and inner fenders/splash shields.

NOTICE: The engine coolant can be reused if it is not contaminated and has been properly maintained.

6. Drain the engine cooling system. Refer to section "Cooling System Drain Procedure".7. Drain the radiator into a suitable drain pan.8. Remove the rain tray. Refer to the OEM procedure.9. On Freightliner Cascadia 113 models, remove the windshield wiper linkage.

10. Remove air cleaner assembly and inlet to the turbocharger. Install a protective cover over the turbocharger inlet.11. Remove the air cleaner brackets from the rocker cover.12. Disconnect the cab heater hoses from the water manifold.13. Disconnect the Diesel Exhaust Fluid (DEF) coolant lines from the water manifold.14. Evacuate the air conditioning (A/C) system, if equipped. Refer to the OEM procedure.15. Disconnect the A/C lines at the junction block.

2 Removal of the Complete Powertrain Assembly

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16. Remove the Aftertreatment System (ATS) inlet pipe and exhaust bellows pipe from the engine and ATS. Refer tosection "Removal of the GHG14 1-BOX From the Vehicle".

17. Disconnect the engine cooling fan clutch air line at the fan solenoid, if equipped.18. Disconnect the air compressor governor line and discharge line at the air compressor.19. Remove the air compressor inlet pipe from the engine.20. Disconnect the engine fuel supply and return lines at the fuel filter module.

Refer to section "Description and Operation of the Fuel Filter Module and Related Parts - Three-Filter System".Refer to section "Description and Operation of the Fuel Filter Module and Related Parts Two-Filter System".

NOTICE: The power steering fluid can be reused if it is not contaminated and has been properly maintained.

21. Remove the power steering fluid reservoir and reservoir bracket from the frame rail. Place a suitable drain pan under power steering fluid reservoir. Remove power steering fill line from the reservoir and drain the fluid. Move reservoir out of the way and support as

necessary.22. Remove power steering pressure line from steering gear box.23. Disconnect the chassis powertrain interface harness from the bulkhead connections. The Powertrain Distribution

Module (PDM) and harness will be removed with the powertrain. The steering shaft may need to be repositioned toallow clearance for removal of the PDM and harness. Refer to the OEM procedures.

24. Disconnect the driveline from the transmission. Remove the front carrier bearing bolts. Remove driveline to transmission output bolts. Position driveline out of the way and support as necessary.

25. Disconnect power, ground, and starter solenoid connections from the starter.26. Remove battery cable brackets from flywheel housing and transmission. Position cables out of the way and support as

necessary.27. Disconnect the shifter assembly from the transmission, if equipped with a manual transmission.28. Disconnect the shifter cable from the transmission, if equipped.

NOTE: Do not disconnect electrical connections from the transmission if they are part of the chassis powertraininterface harness, as this will be removed with the assembly.

29. Disconnect any chassis air lines or electrical connections from the transmission, if equipped.30. Remove the fuel junction bracket from the top of transmission and support as necessary. Do not disconnect the fuel

lines from the junction fittings.31. Disconnect DEF coolant lines from the DEF pump and remove any attachments to the chassis. The DEF coolant lines

will be removed with the powertrain.32. Remove chassis underslung crossmember (under flywheel housing).33. Drain the engine lubricating oil into a suitable drain pan. Reinstall the oil drain plug.

WARNING: PERSONAL INJURY

In order to avoid personal injury from a falling vehicle, never use any engine lifter brackets to raiseor lower any part of the vehicle. Engine lifter brackets are not designed to bear the weight of thevehicle. Always use approved lifting devices to raise and lower the vehicle.

NOTE: All of the remaining oil left in the oil galleries (approximately one gallon) will drain from the cylinder blockwhen the oil suction manifold is removed. Leave the oil pan in place underneath the engine to catch this oil.

NOTE: It may be necessary to raise and support the front of the vehicle to obtain clearance for removal of the oilpan.

34. Lower the oil pan to remove the oil suction manifold, oil lines and oil pump.35. Remove the oil pan. Refer to section "Removal of the Oil Pan".36. Remove chassis front closing crossmember (in front of the cooling package).

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37. Remove or disconnect any additional brackets and mounting hardware for air lines, fuel lines, electrical harnesses,electrical cables or hoses that attach to the powertrain and will interfere with complete powertrain removal.

38. Secure all lines, harnesses, hoses and cables in preparation for powertrain removal.

WARNING: FALLING ENGINE

To avoid injury from a falling engine, ensure an appropriately rated lifting device with a spreaderbar and sling is used to lift the engine. Moving the engine without an appropriately rated liftingdevice could result in the engine falling, which could cause serious personal injury and componentdamage. The sling and spreader bar should be adjusted so the lifting hooks are vertical to preventbending the lifter brackets. To ensure proper weight distribution, all provided lifter brackets must beused.

39. Connect engine lifting bar tool (W470589006200) to the engine using all three engine lifting brackets (two at the rearand one at the front).

40. Attach an appropriately rated lifting device (overhead crane or hoist) to W470589006200. See illustration belowshowing a DD13 engine in a Freightliner Cascadia 113 model truck. The Cascadia 125 will be similar. Attachmentpoint for the lifting hook may vary based on the weight distribution of the complete powertrain and desired angle ofremoval.

41. Remove the bolts securing the front engine mount to the frame.42. Remove the bolts securing the rear engine mounts to the frame mounts.

NOTICE: Use great care when lifting the powertrain assembly and removing it from the chassis to avoiddamaging any components. Adequate clearance to the heater lines, A/C lines, front wall and floor of the truck cabmust be maintained. An assistant is recommended for the following steps.

43. Place a transmission jack securely under the transmission and raise the rear of the powertrain assembly approximately 3inches off of the rear frame mounts.

44. Raise the powertrain assembly in the front while maintaining clearance to the cab.45. It may be necessary to alternate between the previous two steps before the powertrain is ready for removal.

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NOTICE: Ensure proper clearance between powertrain assembly and truck cab and chassis before removal.

46. Carefully remove the powertrain assembly from the chassis. See illustrations belo