Detroit GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Manual – PDF DOWNLOAD

Description

Detroit GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Manual – PDF DOWNLOAD

DESCRIPTION:

Detroit GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Manual – PDF DOWNLOAD

General Cleaning and Gasket Preparation Guidelines
Cleanliness is very important for any engine repair and particularly important for any repair that exposes the
engine lubrication system or fuel system to possible debris contamination. These systems contain parts with very
small clearances and material that can be easily damaged by debris. Failures can occur if foreign material is
allowed to enter oil or fuel galleries during repair. These failures can range from a minor nuisance to complete
engine replacement from damaged crankshaft bearings. The following guidelines should be used when making
repairs to any Detroit engine.
1.6.1 Disassembly
Careful disassembly is an important starting point for a clean repair. Spot cleaning the area prior to repair is
recommended to remove any residual fluid and loose debris. Steam cleaning is only necessary if called out in the
appropriate repair procedure in the Workshop Manual. Electrical contact cleaner may be used to wash away dirt
and debris. This is a good alternative to steam cleaning and compressed air.
Rust, paint and dirt can enter the lubrication or fuel system during removal of a component. A good practice is to
loosen a joint to break the paint and rust loose, and then clean the area again before final removal of any lines,
fittings or parts. This will minimize the potential for debris contamination.
1.6.2 Protection from Debris
Many performed repairs can expose the engine to harmful debris such as dirt, rust and paint. For example, the
clean side oil port to the main oil gallery is exposed when the oil coolant module is removed from the cylinder
block. Debris from disassembly, cleaning, or general shop debris can enter this port during repair and cause
severe engine damage.
Any opening in the engine that can introduce debris into the lubrication or fuel systems during repair must be
covered. This includes all oil returns to the oil sump. There are many options for providing this protection. Caps
and plugs should be used when available. Many new parts are shipped with protective covers. It would be wise to
save these covers for future use. When caps and plugs are not available, alternate methods can be used such as
clean shop towels and tape. Whatever method is used must also be clean. Using a dirty plug, for example, can
introduce as much debris as leaving the port open during repairs.
Do not use compressed air to clean passages after they have become contaminated. Compressed air will typically
push any debris farther into the cavity and make removal difficult, if not impossible.

TABLE OF CONTENTS:

Detroit GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Manual – PDF DOWNLOAD

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)_……………………………………………. 1
General Information……………………………………………………………….. 1
1.1  California Proposition 65 Warning and Engine Idle Notice………………………. 1
1.2  Cleaning and Preparation…………………………………………………… 2
General Steam Clean………………………………………………………… 2
1.3  Engine Storage……………………………………………………………. 3
Temporary Storage (30 Days or Less)………………………………………….. 3
Extended Storage (More than 30 Days)…………………………………………. 3
Procedure for Restoring an Engine to Service that Has Been in Extended Storage……. 5
1.4  Engine Model and Serial Number Designation…………………………………… 7
1.5  Engine Views……………………………………………………………… 8
DD5 Engine Components……………………………………………………….. 8
1.6  General Cleaning and Gasket Preparation Guidelines……………………………. 10
Disassembly………………………………………………………………… 10
Protection from Debris………………………………………………………. 10
Gasket Removal and Surface Preparation………………………………………… 10
Cleaning with Solvent……………………………………………………….. 10
Steam Cleaning……………………………………………………………… 11
Rust Prevention…………………………………………………………….. 11
Tool Cleaning………………………………………………………………. 11
1.7  General Engine Information…………………………………………………. 12
The Four-Cycle Principle for Diesel Engines …………………………………. 12
Intake Stroke ……………………………………………………………. 12
Compression Stroke ……………………………………………………….. 12
Power Stroke …………………………………………………………….. 12
Exhaust Stroke …………………………………………………………… 13
DD5 General Description …………………………………………………… 13
1.8  Maintenance Intervals……………………………………………………… 14
DD5 Short Haul…………………………………………………………….. 14
DD5 Long Haul……………………………………………………………… 14
DD5 Severe Service…………………………………………………………. 15
1.9  Safety Precautions………………………………………………………… 17
Exhaust (Start/Run Engine) …………………………………………………. 17
Stands ………………………………………………………………….. 17
Glasses …………………………………………………………………. 17
Welding …………………………………………………………………. 17
Work Place ………………………………………………………………. 18
Clothing…………………………………………………………………. 18
Power Tools………………………………………………………………. 19
Air………………………………………………………………………. 19
Fluids and Pressure……………………………………………………….. 19
Fuel……………………………………………………………………… 19
Batteries………………………………………………………………… 20
Fire…………………………………………………………………….. 20
Cleaning Agent……………………………………………………………. 21
Working on a Running Engine………………………………………………… 21
Turbocharger Compressor Inlet Shield………………………………………… 21
Fluoroelastomer (VITON®) Caution…………………………………………….. 22
2……………………………………………………………………………………. 23
Aftertreatment System……………………………………………………………… 23
2.1  Aftertreatment System Overview……………………………………………… 23
Aftertreatment Variances……………………………………………………. 23
Description and Operation of the Diesel Oxidation Catalyst……………………… 23
Description and Operation of the Diesel Particulate Filter……………………… 24
Description and Operation of the Selective Catalytic Reduction (SCR) Catalyst…….. 25
Description and Operation of the Diesel Exhaust Fluid Flow……………………… 26
Description and Operation of the Diesel Exhaust Fluid Heating…………………… 27
1-BOX™ Aftertreatment Exhaust Flow…………………………………………… 28
Aftertreatment Regeneration Strategy…………………………………………. 29
Parked Regeneration………………………………………………………… 29
Performing a Parked Regeneration…………………………………………….. 31
Aftertreatment Diesel Exhaust Fluid Gauge/Lamps……………………………….. 33
Instrument Panel Lamps……………………………………………………… 34
2.2  1-BOX™ Aftertreatment Contol Module…………………………………………. 35
Description and Operation of the 1-BOX™ Aftertreatment Contol Module…………….. 35
Removal of the 1-BOX™ Aftertreatment Control Module……………………………. 35
Inspection of the 1-BOX™ Aftertreatment Control Module…………………………. 37
Installation of the 1-BOX™ Aftertreatment Control Module……………………….. 37
2.3  1-BOX™ Aftertreatment Harness………………………………………………. 40
Removal of the 1-BOX™ Aftertreatment Harness………………………………….. 40
Inspection of the 1-BOX™ Aftertreatment Harness……………………………….. 43
Installation of the 1-BOX™ Aftertreatment Harness……………………………… 43
2.4  1-BOX™ Aftertreatment Sensors………………………………………………. 48
Aftertreatment Device Sensor Locations……………………………………….. 48
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor………………….. 48
Inspection of the Diesel Oxidation Catalyst Inlet Pressure Sensor……………….. 49
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor……………… 49
Removal of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube……………… 50
Inspection of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube…………… 51
Installation of the Diesel Oxidation Catalyst Inlet Pressure Sensor Tube…………. 51
Removal of the Diesel Particulate Filter Outlet Pressure Sensor Tube…………….. 51
Inspection of the Diesel Particulate Filter Outlet Pressure Sensor Tube………….. 52
Installation of the Diesel Particulate Filter Outlet Pressure Sensor Tube………… 52
Removal of the Diesel Oxidation Catalyst Inlet Temperature Sensor……………….. 53
Inspection of the Diesel Oxidation Catalyst Inlet Temperature Sensor…………….. 53
Installation of the Diesel Oxidation Catalyst Inlet Temperature Sensor…………… 53
Removal of the Diesel Oxidation Catalyst Outlet Temperature Sensor………………. 54
Inspection of the Diesel Oxidation Catalyst Outlet Temperature Sensor……………. 55
Installation of the Diesel Oxidation Catalyst Outlet Temperature Sensor………….. 55
Removal of the Diesel Particulate Filter Outlet Temperature Sensor………………. 56
Inspection of the Diesel Particulate Filter Outlet Temperature Sensor……………. 56
Installation of the Diesel Particulate Filter Outlet Temperature Sensor………….. 56
Removal of the Selective Catalytic Reduction Inlet NOx Sensor…………………… 57
Inspection of the Selective Catalytic Reduction Inlet NOx Sensor………………… 58
Installation of the Selective Catalytic Reduction Inlet NOx Sensor………………. 58
Removal of the Selective Catalytic Reduction Outlet NOx Sensor………………….. 59
Inspection of the Selective Catalytic Reduction Outlet NOx Sensor……………….. 60
Installation of the Selective Catalytic Reduction Outlet NOx Sensor……………… 60
Removal of the Selective Catalyst Reduction Outlet Temperature Sensor……………. 62
Inspection of the Selective Catalyst Reduction Outlet Temperature Sensor…………. 62
Installation of the Selective Catalyst Reduction Outlet Temperature Sensor……….. 62
Removal of the Soot Sensor………………………………………………….. 63
Inspection of the Soot Sensor……………………………………………….. 64
Installation of the Soot Sensor……………………………………………… 64
2.5  1-BOX™ DOC and SCR Assembly………………………………………………… 66
Description and Operation of the 1-BOX™ DOC and SCR Assembly……………………. 66
Removal of the 1-BOX™ DOC and SCR Assembly……………………………………. 66
Inspection of the 1-BOX™ DOC and SCR assembly…………………………………. 70
Installation of the 1-BOX™ DOC and SCR Assembly……………………………….. 73
Replacement of the 1-BOX™ DOC and SCR Assembly………………………………… 77
2.6  Diesel Exhaust Fluid Dosing System………………………………………….. 80
Description and Operation of the Diesel Exhaust Fluid Dosing System……………… 80
Removal of the Diesel Exhaust Fluid Dosing Unit……………………………….. 80
Inspection of the Diesel Exhaust Fluid Dosing Unit…………………………….. 83
Installation of the Diesel Exhaust Fluid Dosing Unit…………………………… 84
Removal of the Diesel Exhaust Fluid Dosing Unit Inlet Screen……………………. 86
Inspection of the Diesel Exhaust Fluid Dosing Unit Inlet Screen…………………. 88
Installation of the Diesel Exhaust Fluid Dosing Unit Inlet Screen……………….. 88
2.7  Diesel Exhaust Fluid Lines…………………………………………………. 91
Removal of the Diesel Exhaust Fluid Lines…………………………………….. 91
Inspection of the Diesel Exhaust Fluid Lines………………………………….. 94
Installation of the Diesel Exhaust Fluid Lines………………………………… 94
2.8  Diesel Exhaust Fluid Pump Module and Components………………………………. 97
Description and Operation of the Airless Dosing System Diesel Exhaust Fluid Pump….. 97
Removal of the Diesel Exhaust Fluid Pump Module……………………………….. 97
Inspection of the Diesel Exhaust Fluid Pump Module…………………………….. 99
Installation of the Diesel Exhaust Fluid Pump Module…………………………… 99
Flushing of the Diesel Exhaust Fluid System……………………………………102
Removal of the Diesel Exhaust Fluid Pump Pressure Relief Valve…………………..103
Inspection of the Diesel Exhaust Fluid Pump Pressure Relief Valve………………..104
Installation of the Diesel Exhaust Fluid Pump Pressure Relief Valve………………104
Removal of the Diesel Exhaust Fluid Pump Module Inlet Screen…………………….107
Inspection of the Diesel Exhaust Fluid Pump Module Inlet Screen………………….108
Installation of the Diesel Exhaust Fluid Pump Module Inlet Screen………………..108
Removal of the Diesel Exhaust Fluid Pump Module Coolant Line Connector Fitting…….110
Inspection of the Diesel Exhaust Fluid Pump Module Coolant Connector Fitting………112
Installation of the Diesel Exhaust Fluid Pump Module Coolant Connector Fitting…….112
Removal of the Diesel Exhaust Fluid Pump Module Filter………………………….114
Inspection of the Diesel Exhaust Fluid Pump Module Filter……………………….116
Installation of the Diesel Exhaust Fluid Pump Module Filter……………………..116
2.9  Diesel Exhaust Fluid Tank…………………………………………………..119
Description and Operation of the Diesel Exhaust Fluid Tank………………………119
Removal of the Six-Gallon Diesel Exhaust Fluid Tank…………………………….119
Inspection of the Six-Gallon Diesel Exhaust Fluid Tank………………………….121
Installation of the Six-Gallon Diesel Exhaust Fluid Tank………………………..121
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank………………………122
Inspection of the 13- and 23-Gallon Diesel Exhaust Fluid Tank……………………123
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank………………….123
2.10  Diesel Exhaust Fluid Tank Header Unit……………………………………….126
Description and Operation of the Diesel Exhaust Fluid Tank Header Unit……………126
Removal of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit……………126
Inspection of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit…………128
Installation of the 13- and 23-Gallon Diesel Exhaust Fluid Tank Header Unit……….128
Removal of the Six-Gallon Diesel Exhaust Fluid Tank Header Unit………………….130
Inspection of the Six-Gallon Diesel Exhaust Fluid Tank Header Unit……………….131
Installation of the Six-Gallon Diesel Exhaust Fluid Tank Header Unit……………..131
2.11  Diesel Particulate Filter………………………………………………….134
Description and Operation of the Diesel Particulate Filter………………………134
Removal of the Diesel Particulate Filter………………………………………134
Inspection of the Diesel Particulate Filter……………………………………137
Installation of the Diesel Particulate Filter………………………………….142
2.12  Diesel Particulate Filter Ash Accumulator……………………………………145
Resetting the Diesel Particulate Filter Ash Accumulators………………………..145
2.13  Hydrocarbon Doser Block Feed Line…………………………………………..151
Removal of the Hydrocarbon Doser Block Feed Line……………………………….151
Installation of the Hydrocarbon Doser Block Feed Line…………………………..151
2.14  Hydrocarbon Fuel Doser Block……………………………………………….154
Description and Operation of the Hydrocarbon Fuel Doser Block……………………154
Removal of the Hydrocarbon Fuel Doser Block……………………………………154
Inspection of the Hydrocarbon Fuel Doser Block…………………………………158
Installation of the Hydrocarbon Fuel Doser Block……………………………….158
2.15  Hydrocarbon Fuel Doser Injector Valve……………………………………….162
Description and Operation of the Hydrocarbon Fuel Doser Injector Valve……………162
Removal of the Hydrocarbon Fuel Doser Injector Value……………………………162
Installation of the Hydrocarbon Fuel Doser Injector Valve……………………….165
2.16  Hydrocarbon Fuel Doser Housing……………………………………………..168
Removal of the Hydrocarbon Fuel Doser Housing………………………………….168
Inspection of the Hydrocarbon Fuel Doser Housing……………………………….168
Installation of the Hydrocarbon Fuel Doser Housing……………………………..169
3…………………………………………………………………………………….171
Air Compressor…………………………………………………………………….171
3.1  Air Compressor Coolant Lines………………………………………………..171
Description and Operation of the Air Compressor Coolant Return Line………………171
Removal of the Air Compressor Coolant Return Line………………………………171
Inspection of the Air Compressor Coolant Return Line……………………………172
Installation of the Air Compressor Coolant Return Line………………………….172
Description and Operation of the Air Compressor Coolant Supply Line………………173
Removal of the Air Compressor Coolant Supply Line………………………………174
Inspection of the Air Compressor Coolant Supply Line……………………………175
Installation of the Air Compressor Coolant Supply Line………………………….176
3.2  Air Compressor Drive Gear…………………………………………………..177
Removal of the Air Compressor Drive Gear………………………………………177
Installation of the Air Compressor Drive Gear………………………………….179
3.3  Air Compressor Resonator……………………………………………………181
Description and Operation of the Air Compressor Resonator……………………….181
Removal of the Air Compressor Resonator……………………………………….181
Installation of the Air Compressor Resonator…………………………………..182
4…………………………………………………………………………………….184
Air System and Turbocharger…………………………………………………………184
4.1  Air Intake Manifold………………………………………………………..184
Description and Operation of the Air Intake Manifold……………………………184
Removal of the Air Intake Manifold……………………………………………184
Inspection of the Air Intake Manifold…………………………………………186
Installation of the Air Intake Manifold……………………………………….186
4.2  Cold Boost Pipe……………………………………………………………189
Description and Operation of the Cold Boost Pipe……………………………….189
Removal of the Cold Boost Pipe……………………………………………….189
Inspection of the Cold Boost Pipe…………………………………………….191
Installation of the Cold Boost Pipe…………………………………………..191
4.3  Cold Boost Pipe Resonator…………………………………………………..194
Description and Operation of the Cold Boost Pipe Resonator………………………194
Removal of the Cold Boost Pipe Resonator………………………………………194
Inspection of the Cold Boost Pipe Resonator……………………………………195
Installation of the Cold Boost Pipe Resonator………………………………….196
4.4  Turbocharger Inlet Elbow……………………………………………………198
Description and Operation of the Turbocharger Inlet Elbow……………………….198
Removal of the Turbocharger Inlet Elbow……………………………………….198
Inspection of the Turbocharger Inlet Elbow…………………………………….199
Installation of the Turbocharger Inlet Elbow…………………………………..199
4.5  Turbocharger Outlet Pipe……………………………………………………201
Removal of the Turbocharger Outlet Pipe……………………………………….201
Installation of the Turbocharger Outlet Pipe…………………………………..202
4.6  Turbocharger Outlet Pipe Heat Shield…………………………………………206
Removal of the Turbocharger Outlet Pipe Heat Shield…………………………….206
Installation of the Turbocharger Outlet Pipe Heat Shield………………………..206
4.7  Turbocharger Wastegate Actuator……………………………………………..208
Description and Operation of the Turbocharger Wastegate Actuator…………………208
Removal of the Turbocharger Wastegate Actuator…………………………………209
Inspection of the Turbocharger Wastegate Actuator………………………………213
Installation of the Turbocharger Wastegate Actuator…………………………….213
4.8  Turbocharger Wastegate Actuator – Coolant Lines……………………………….215
Description and Operation of the Turbocharger Wastegate Actuator Coolant Lines…….215
Removal of the Turbocharger Wastegate Actuator Coolant Return Line……………….215
Installation of the Turbocharger Wastegate Actuator Coolant Return Line…………..216
Removal of the Turbocharger Wastegate Actuator Coolant Supply Line……………….217
Installation of the Turbocharger Wastegate Actuator Coolant Supply Line…………..218
5…………………………………………………………………………………….220
Cooling System…………………………………………………………………….220
6.1  Cooling System Drain Procedure………………………………………………220
Cooling System Drain Procedure……………………………………………….220
6.2  Cooling System Fill Procedure……………………………………………….222
Cooling System Fill Procedure………………………………………………..222
6.3  Cooling System Flushing Procedure……………………………………………223
Inspecting and Flushing the Cooling System…………………………………….223
6.4  Coolant Inlet Elbow………………………………………………………..225
Removal of the Coolant Inlet Elbow……………………………………………225
Installation of the Coolant Inlet Elbow……………………………………….225
6.5  Coolant Thermostat…………………………………………………………226
Description and Operation of the Coolant Thermostat…………………………….226
Removal of the Coolant Thermostat…………………………………………….226
Inspection of the Coolant Thermostat………………………………………….227
Installation of the Coolant Thermostat………………………………………..228
6.6  Coolant Requirements……………………………………………………….229
Coolant Requirements………………………………………………………..229
6.7  Water Pump………………………………………………………………..230
Description and Operation of the Water Pump……………………………………230
Removal of the Water Pump……………………………………………………230
Inspection of the Water Pump…………………………………………………231
Installation of the Water Pump……………………………………………….231
6…………………………………………………………………………………….232
Engine Mechanical………………………………………………………………….232
7.1  Cylinder Block…………………………………………………………….232
Description and Operation of the Cylinder Block………………………………..232
Inspection of the Cylinder Bores……………………………………………..239
Cylinder Block Oil Gallery Plug Replacement……………………………………240
Piston Cooling Nozzle Replacement…………………………………………….242
7.2  Cylinder Head and Valves……………………………………………………248
Description and Operation of the Cylinder Head…………………………………248
Removal of the Cylinder Head Assembly…………………………………………248
Cleaning and Inspection of the Cylinder Head…………………………………..254
Installation of the Cylinder Head Assembly…………………………………….256
Cylinder Head Replacement……………………………………………………264
Valve Stem Oil Seal Replacement………………………………………………265
Removal of the Intake and Exhaust Valves………………………………………277
Inspection of the Intake and Exhaust Valves……………………………………284
Installation of the Intake and Exhaust Valves………………………………….285
7.3  Engine Replacement Procedures……………………………………………….291
Removal of the Complete Powertrain Assembly……………………………………291
Replacement Engine Preparation……………………………………………….296
Installation of the Complete Powertrain Assembly……………………………….297
7.4  Engine Brakes……………………………………………………………..303
Description and Operation of Engine Braking……………………………………303
Removal of the Hydraulic Brake Units………………………………………….304
Inspection of the Hydraulic Brake Units……………………………………….306
Installation of the Hydraulic Brake Units……………………………………..306
Removal of the Engine Brake Solenoid………………………………………….307
Inspection of the Engine Brake Solenoid……………………………………….309
Installation of the Engine Brake Solenoid……………………………………..309
7.5  Flywheel and Ring Gear……………………………………………………..312
Description and Operation of the Flywheel and Ring Gear…………………………312
Removal of the Flywheel……………………………………………………..312
Inspection of the Flywheel…………………………………………………..314
Installation of the Flywheel…………………………………………………314
Removal of the Ring Gear…………………………………………………….317
Installation of the Ring Gear………………………………………………..317
7.6  Flywheel Housing and Rear Crankshaft Oil Seal…………………………………319
Description and Operation of the Flywheel Housing and Rear Crankshaft Oil Seal…….319
Removal of the Flywheel Housing………………………………………………319
Inspection of the Flywheel Housing……………………………………………322
Installation of the Flywheel Housing………………………………………….323
Removal of the Rear Crankshaft Oil Seal……………………………………….326
Installation of the Rear Crankshaft Oil Seal…………………………………..327
7.7  Front Engine Cover and Front Crankshaft Oil Seal………………………………334
Description and Operation of the Front Engine Cover and Front Crankshaft Oil Seal….334
Removal of the Front Engine Cover…………………………………………….334
Inspection of the Front Engine Cover………………………………………….336
Installation of the Front Engine Cover………………………………………..337
Removal of the Front Crankshaft Oil Seal………………………………………340
Installation of the Front Crankshaft Oil Seal………………………………….342
7.8  Front Engine Mount/Radiator Support………………………………………….349
Description and Operation of the Front Engine Mount/Radiator Support……………..349
Removal of the Front Engine Mount/Radiator Support……………………………..349
Inspection of the Front Engine Mount/Radiator Support…………………………..351
Installation of the Front Engine Mount/Radiator Support…………………………352
7.9  Gear Train………………………………………………………………..354
Description and Operation of the Gear Train……………………………………354
Removal of the Gear Train……………………………………………………354
Inspection of the Gear Train…………………………………………………357
Installation of the Gear Train……………………………………………….358
Checking and Adjusting Gear Lash in Chassis……………………………………366
7.10  General Information and Specifications………………………………………369
Engine Mechanical Specifications……………………………………………..369
7.11  Lifting Brackets………………………………………………………….371
Description and Operation of the Front Engine Lifting Bracket……………………371
Removal of the Front Engine Lifting Bracket……………………………………371
Inspection of the Front Engine Lifting Bracket…………………………………372
Installation of the Front Engine Lifting Bracket……………………………….372
Description and Operation of the Left Rear Engine Lifting Bracket………………..373
Removal of the Left Rear Engine Lifting Bracket………………………………..374
Inspection of the Left Rear Engine Lifting Bracket……………………………..375
Installation of the Left Rear Engine Lifting Bracket……………………………375
Description and Operation of the Right Rear Engine Lifting Bracket……………….376
Removal of the Right Rear Engine Lifting Bracket……………………………….377
Inspection of the Right Rear Engine Lifting Bracket…………………………….378
Installation of the Right Rear Engine Lifting Bracket…………………………..378
7.12  Piston and Connecting Rod Assembly………………………………………….380
Description and Operation of the Piston and Connecting Rod………………………380
Removal of the Piston and Connecting Rod Assembly………………………………380
Disassembly of the Piston and Connecting Rod…………………………………..380
Cleaning of the Piston and Connecting Rod……………………………………..381
Inspection of the Piston, Piston Rings and Connecting Rod……………………….381
Assembly of the Piston and Connecting Rod……………………………………..381
Installation of the Piston and Connecting Rod Assembly………………………….381
7.13  Rocker Arm……………………………………………………………….382
Description and Operation of the Rocker Arm Assemblies………………………….382
Removal of the Intake Rocker Arm Shaft Assembly………………………………..382
Inspection of the Intake Rocker Arm Shaft Assembly……………………………..385
Installation of the Intake Rocker Arm Shaft Assembly……………………………385
Removal of the Exhaust Rocker Arm Shaft Assembly……………………………….388
Inspection of the Exhaust Rocker Arm Shaft Assembly…………………………….390
Installation of the Exhaust Rocker Arm Shaft Assembly…………………………..391
Setting the Valve and Engine Brake Lash……………………………………….393
7.14  Rocker Arm Housing and Camshafts……………………………………………396
Description and Operation of the Rocker Arm Housing and Camshafts………………..396
Removal of the Rocker Arm Housing and Camshafts………………………………..397
Inspection of the Rocker Arm Housing, Camshafts and Rocker Arm Assemblies…………402
Installation of the Rocker Arm Housing and Camshafts……………………………403
Camshaft Timing Verification…………………………………………………411
7.15  Rocker Cover……………………………………………………………..416
Description and Operation of the Rocker Cover………………………………….416
Removal of the Rocker Cover………………………………………………….416
Inspection of the Rocker Cover……………………………………………….418
Installation of the Rocker Cover……………………………………………..418
7.16  Timing Case………………………………………………………………422
Description and Operation of the Timing Case…………………………………..422
Removal of the Timing Case…………………………………………………..422
Inspection of the Timing Case………………………………………………..424
Installation of the Timing Case………………………………………………425
7.17  Variable Camshaft Phaser Solenoid…………………………………………..430
Description and Operation of the Variable Camshaft Phaser Solenoid……………….430
Removal of the Variable Camshaft Phaser Solenoid……………………………….430
Inspection of the Variable Camshaft Phaser Solenoid…………………………….432
Installation of the Variable Camshaft Phaser Solenoid…………………………..432
7.18  Vibration Damper………………………………………………………….435
Description and Operation of the Vibration Damper………………………………435
Removal of the Vibration Damper………………………………………………435
Inspection of the Vibration Damper……………………………………………436
Installation of the Vibration Damper………………………………………….437
7…………………………………………………………………………………….439
Engine Electrical………………………………………………………………….439
8.1  Engine Wiring Harness………………………………………………………439
Removal of the Engine Wiring Harness………………………………………….439
Installation of the Engine Wiring Harness……………………………………..448
8.2  Engine Sensors…………………………………………………………….460
DD5 Engine Sensors………………………………………………………….460
Description and Operation of the Camshaft Position Sensor……………………….460
Removal of the Camshaft Position Sensor……………………………………….460
Installation of the Camshaft Position Sensor…………………………………..462
Description and Operation of the Crankshaft Position Sensor……………………..462
Removal of the Crankshaft Position Sensor……………………………………..463
Installation of the Crankshaft Position Sensor…………………………………464
Description and Operation of the Engine Coolant Outlet Temperature Sensor…………465
Removal of Engine Coolant Outlet Temperature Sensor…………………………….466
Installation of Engine Coolant Outlet Temperature Sensor………………………..467
Description and Operation of the Engine Oil Pressure Switch……………………..468
Removal of the Engine Oil Pressure Switch……………………………………..469
Installation of the Engine Oil Pressure Switch…………………………………470
Description and Operation of the Engine Oil Temperature Sensor…………………..471
Removal of the Engine Oil Temperature Sensor…………………………………..472
Installation of the Engine Oil Temperature Sensor………………………………473
Description and Operation of the Fuel Rail Pressure Sensor………………………474
Removal of the Fuel Rail Pressure Sensor………………………………………475
Installation of the Fuel Rail Pressure Sensor………………………………….476
Description and Operation of the Intake Manifold Air Temperature Sensor…………..477
Removal of the Intake Manifold Air Temperature Sensor…………………………..478
Installation of the Intake Manifold Air Temperature Sensor………………………479
Description and Operation of the Intake Pressure/Temperature Sensor………………480
Removal of the Intake Pressure/Temperature Sensor………………………………481
Installation of the Intake Pressure/Temperature Sensor………………………….482
Description and Operation of the Low Pressure Fuel Sensor……………………….483
Removal of the Low Pressure Fuel Sensor……………………………………….484
Installation of the Low Pressure Fuel Sensor…………………………………..485
Description and Operation of the Oxygen Sensor…………………………………486
Removal of the Oxygen Sensor…………………………………………………487
Installation of the Oxygen Sensor…………………………………………….488
Description and Operation of the Supply Fuel Temperature Sensor………………….489
Removal of the Supply Fuel Temperature Sensor………………………………….490
Installation of the Supply Fuel Temperature Sensor……………………………..491
8.3  Motor Control Module (MCM)………………………………………………….493
Description and Operation of the Motor Control Module (MCM)……………………..493
Removal of the Motor Control Module (MCM)……………………………………..493
Inspection of the Motor Control Module (MCM)…………………………………..496
Installation of the Motor Control Module (MCM)…………………………………496
8…………………………………………………………………………………….500
Exhaust and Exhaust Gas Recirculation………………………………………………..500
9.1  Exhaust Gas Recirculation Cooler Bracket……………………………………..500
Removal of the Exhaust Gas Recirculation Cooler Bracket…………………………500
Installation of the Exhaust Gas Recirculation Cooler Bracket…………………….501
9.2  Exhaust Gas Recirculation Crossover Pipe……………………………………..503
Removal of the Exhaust Gas Recirculation Crossover Pipe…………………………503
Installation of the Exhaust Gas Recirculation Crossover Pipe…………………….503
9.3  Exhaust Gas Recirculation Crossover Pipe Elbow………………………………..505
Removal of the Exhaust Gas Recirculation Crossover Pipe Elbow……………………505
Installation of the Exhaust Gas Recirculation Crossover Pipe Elbow……………….505
9.4  Exhaust Gas Recirculation Delivery Elbow……………………………………..507
Description and Operation of the Exhaust Gas Recirculation Delivery Elbow…………507
Removal of the Exhaust Gas Recirculation Delivery Elbow…………………………508
Inspection of the Exhaust Gas Recirculation Delivery Elbow………………………509
Installation of the Exhaust Gas Recirculation Delivery Elbow…………………….509
9.5  Exhaust Gas Recirculation Hot Pipe…………………………………………..511
Removal of the DD5 Exhaust Gas Recirculation Hot Pipe…………………………..511
Installation of the DD5 Exhaust Gas Recirculation Hot Pipe………………………511
9.6  Exhaust Gas Recirculation Hot Pipe Heat Shield………………………………..514
Removal of the Exhaust Gas Recirculation Hot Pipe Heat Shield……………………514
Installation of the Exhaust Gas Recirculation Hot Pipe Heat Shield……………….514
9.7  Exhaust Gas Recirculation Mixer Housing………………………………………516
Description and Operation of the Exhaust Gas Recirculation Mixer Housing………….516
Removal of the Exhaust Gas Recirculation Mixer Housing………………………….516
Installation of the Exhaust Gas Recirculation Mixer Housing……………………..517
9.8  Exhaust Gas Recirculation Valve……………………………………………..519
Description and Operation of the Exhaust Gas Recirculation Valve…………………519
Removal of the Exhaust Gas Recirculation Valve…………………………………519
Inspection of the Exhaust Gas Recirculation Valve………………………………521
Installation of the Exhaust Gas Recirculation Valve…………………………….521
9.9  Front Exhaust Manifold……………………………………………………..523
Description and Operation of the Front Exhaust Manifold…………………………523
Removal of the Front Exhaust Manifold…………………………………………523
Inspection of the Front Exhaust Manifold………………………………………524
Installation of the Front Exhaust Manifold…………………………………….524
9…………………………………………………………………………………….527
Fuel System……………………………………………………………………….527
10.1  Fuel System Overview………………………………………………………527
Fuel System Schematic……………………………………………………….527
Operation of the Fuel System…………………………………………………529
10.2  Fuel System Draining Procedure……………………………………………..531
Draining the Fuel System Prior to Repairs……………………………………..531
10.3  Fuel System Priming……………………………………………………….533
Priming the Fuel System……………………………………………………..533
10.4  Fuel Filters……………………………………………………………..534
Description and Operation of the Fuel Prefilter………………………………..534
Removal of the Fuel Prefilter………………………………………………..534
Installation of the Fuel Prefilter……………………………………………535
Description and Operation of the Fuel Final Filter……………………………..537
Removal of the Final Filter………………………………………………….538
Installation of the Final Filter……………………………………………..540
10.5  Fuel Filter Module………………………………………………………..542
Description and Operation of the Fuel Filter Module and Related Parts…………….542
Removal of the Fuel Filter Module…………………………………………….543
Installation of the Fuel Filter Module………………………………………..544
10.6  Fuel Injectors……………………………………………………………547
Description and Operation of the Fuel Injector…………………………………547
Removal of the Fuel Injector…………………………………………………547
Installation of the Fuel Injector…………………………………………….551
10.7  Fuel Injector Cup…………………………………………………………555
Description and Operation of the Fuel Injector Cup……………………………..555
Removal of the Fuel Injector Cup……………………………………………..555
Inspection of the Fuel Injector Cup…………………………………………..556
Installation of the Fuel Injector Cup…………………………………………558
10.8  Fuel Injector Wiring Harness……………………………………………….560
Description of the Fuel Injector Wiring Harness………………………………..560
Removal of the Fuel Injector Wiring Harness……………………………………560
Installation of the Fuel Injector Wiring Harness……………………………….561
10.9  Fuel Rail………………………………………………………………..563
Description and Operation of the Fuel Rail and Related Parts…………………….563
Removal of the Fuel Rail…………………………………………………….563
Installation of the Fuel Rail………………………………………………..564
10.10  Low Pressure Fuel Pump……………………………………………………569
Description and Operation of the Low Pressure Fuel Pump and Related Parts…………569
Removal of the Low Pressure Fuel Pump…………………………………………569
Inspection of the Low Pressure Fuel Pump………………………………………570
Installation of the Low Pressure Fuel Pump…………………………………….572
10.11  Low Pressure Fuel Pump Lines………………………………………………573
Description and Operation of Low Pressure Fuel Pump Lines……………………….573
Removal of the Low Pressure Fuel Pump Lines……………………………………573
Inspection of the Low Pressure Fuel Pump Lines…………………………………574
Installation of the Low Pressure Fuel Pump Lines……………………………….575
10.12  High Pressure Fuel Injector Lines………………………………………….577
Description and Operation of the High Pressure Fuel Injector Lines……………….577
Removal of the High Pressure Fuel Injector Lines……………………………….577
Installation of the High Pressure Fuel Injector Lines…………………………..580
10.13  High Pressure Fuel Pump…………………………………………………..583
Description and Operation of the High Pressure Fuel Pump and Related Parts………..583
Removal of the High Pressure Fuel Pump………………………………………..583
Installation of the High Pressure Fuel Pump……………………………………584
Removal of the High Pressure Fuel Pump Drive Gear………………………………586
Installation of the High Pressure Fuel Pump Drive Gear………………………….591
10.14  High Pressure Fuel Rail Feed Line………………………………………….594
Description and Operation of the High Pressure Fuel Rail Feed Line……………….594
Removal of the High Pressure Fuel Rail Feed Line……………………………….594
Installation of the High Pressure Fuel Rail Feed Line…………………………..596
10.15  Needle and Pressure Control Valve Return Line……………………………….598
Description and Operation of the Needle and Pressure Control Valve Return Line…….598
Removal of the Needle and Pressure Control Valve Return Line…………………….598
Installation of the Needle and Pressure Control Valve Return Line………………..600
10.16  Quantity Control Valve……………………………………………………602
Description and Operation of the Quantity Control Valve…………………………602
Removal of the Quantity Control Valve…………………………………………602
Inspection of the Quantity Control Valve and High Pressure Pump Housing…………..603
Installation of the Quantity Control Valve…………………………………….605

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