EGES390

SERVICE MANUAL
ENGINE SERVICE MANUAL
EGES-390
2007
EGES-390
Read all safety instructions in the "Safety Information" section of this manual before doing any procedures.
Follow all warnings, cautions, and notes.
© 2007 International Truck and Engine Corporation
ENGINE SERVICE MANUAL I
Table of Contents
Foreword. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Service Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Safety Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Engine Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Mounting Engine on Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51
Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57
Dual Stage Turbocharger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103
Manifolds and Exhaust Gas Recirculation (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125
High-pressure Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161
Oil Cooler and Filter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189
Oil Pan and Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207
Front Cover, Vibration Damper, Oil Pump, and Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219
Cylinder Head and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241
Rear Cover and Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283
Power Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307
Crankcase, Crankshaft, and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329
In-Chassis Service - Rocker Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .377
Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385
Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397
Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407
EGES-390
II ENGINE SERVICE MANUAL
EGES-390
ENGINE SERVICE MANUAL 1
Foreword subscribers. If a technical publication is ordered, the

latest revision will be supplied.
International Truck and Engine Corporation is
committed to continuous research and development NOTE: To order technical service literature, contact
to improve products and introduce technological your International dealer.
advances. Procedures, specifications, and parts
defined in published technical service literature may Technical Service Literature
be altered.
1171897R1 International® MaxxForce™
This Service Manual provides a general sequence 5 Engine Operation and
of procedures for out-of-chassis engine overhaul Maintenance Manual
(removal, inspection, and installation). For in-chassis EGES-390 International® MaxxForce™ 5
service of parts and assemblies, the sequence may Service Manual
vary.
EGES-395 International® MaxxForce™ 5
NOTE: Photo illustrations identify specific parts or Diagnostic Manual
assemblies that support text and procedures; other
areas in a photo illustration may not be exact. EGED-410 International® MaxxForce™
5 Electronic Control Systems
See vehicle manuals and Technical Service Diagnostic Form
Information (TSI) bulletins for additional information.
Technical Service Literature is revised periodically
and mailed automatically to “Revision Service”
EGES-390
2 ENGINE SERVICE MANUAL
Service Diagnosis • Knowledge of the principles of operation for

engine application and engine systems
Service diagnosis is an investigative procedure that
must be followed to find and correct an engine • Knowledge to understand and do procedures in
application problem or an engine problem. diagnostic and service publications
If the problem is engine application, see specific Technical Service Literature required for Effective
vehicle manuals for further diagnostic information. Diagnosis
If the problem is the engine, see specific Engine • Engine Service Manual
Diagnostic Manual for further diagnostic information.
• Engine Diagnostic Manual
Prerequisites for Effective Diagnosis
• Diagnostics Forms
• Availability of gauges and diagnostic test
• Electronic Control Systems Diagnostics Forms
equipment
• Service Bulletins
• Availability of current information for engine
application and engine systems
EGES-390
ENGINE SERVICE MANUAL 3
Safety Information Protective measures
This manual provides general and specific service • Wear protective safety glasses and shoes.
procedures essential for reliable engine operation and • Wear correct hearing protection.
your safety. Since many variations in procedures,
tools, and service parts are involved, advice for all • Wear cotton work clothing.
possible safety conditions and hazards cannot be • Wear sleeved heat protective gloves.
stated.
• Do not wear rings, watches or other jewelry.
Read safety instructions before doing any service and
test procedures for the engine or vehicle. See related • Restrain long hair.
application manuals for more information. Fire prevention
Disregard for Safety Instructions, Warnings, Cautions, • Make sure charged fire extinguishers are in the
and Notes in this manual can lead to injury, death or work area.
damage to the engine or vehicle.
NOTE: Check the classification of each fire
SAFETY TERMINOLOGY extinguisher to ensure that the following fire types
can be extinguished.
Three terms are used to stress your safety and safe
operation of the engine: Warning, Caution, and Note 1. Type A — Wood, paper, textiles, and rubbish
Warning: A warning describes actions necessary to 2. Type B — Flammable liquids

prevent or eliminate conditions, hazards, and unsafe 3. Type C — Electrical equipment
practices that can cause personal injury or death.
Batteries
Caution: A caution describes actions necessary
to prevent or eliminate conditions that can cause Batteries produce highly flammable gas during and
damage to the engine or vehicle. after charging.
Note: A note describes actions necessary for correct, • Always disconnect the main negative battery
efficient engine operation. cable first.
• Always connect the main negative battery cable
SAFETY INSTRUCTIONS last.
Vehicle • Avoid leaning over batteries.
Make sure the vehicle is in neutral, the parking brake • Protect your eyes.
is set, and the wheels are blocked before doing
any work or diagnostic procedures on the engine or • Do not expose batteries to open flames or sparks.
vehicle. • Do not smoke in workplace.
Work area Compressed air
• Keep work area clean, dry, and organized. • Use an OSHA approved blow gun rated at 207
• Keep tools and parts off the floor. kPa (30 psi).
• Make sure the work area is ventilated and well lit. • Limit shop air pressure to 207 kPa (30 psi).
• Make sure a first aid kit is available. • Wear safety glasses or goggles.
Safety equipment • Wear hearing protection.
• Use correct lifting devices. • Use shielding to protect others in the work area.
• Use safety blocks and stands. • Do not direct compressed air at body or clothing.
EGES-390
4 ENGINE SERVICE MANUAL
Tools Fuel
• Make sure all tools are in good condition. • Do not over fill the fuel tank. Over fill creates a fire
hazard.
• Make sure all standard electrical tools are
grounded. • Do not smoke in the work area.
• Check for frayed power cords before using power • Do not refuel the tank when the engine is running.
tools.
Removal of tools, parts, and equipment
Fluids under pressure
• Reinstall all safety guards, shields, and covers
• Use extreme caution when working on systems after servicing the engine.
under pressure.
• Make sure all tools, parts, and service equipment
• Follow approved procedures only. are removed from the engine and vehicle after all
work is done.
EGES-390
ENGINE SYSTEMS 5
Table of Contents
Engine Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Serial Number. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Emission Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Engine Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Engine Description, Specifications, and Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Engine Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Optional Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Engine Systems Interaction Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Air Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Air, Exhaust, and Crankcase Gas Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Exhaust Gas Recirculation (EGR) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Dual Stage Turbocharger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Aftertreatment (AFT) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
Fuel Supply System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Fuel Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
Horizontal Fuel Conditioning Module (HFCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24
Secondary Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25
Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

High-pressure Oil Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28
Injection Control Pressure (ICP) System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
ICP System Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30
Fuel Injector Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31
Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Oil Flow Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34
Oil Cooler and Filter Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Front Cover Coolant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Crankcase and Cylinder Head Coolant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Oil Cooler and EGR Cooler Coolant Flow. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38
Thermostat Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Electronic Control System Operation and Function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Reference Voltage (VREF). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Signal Conditioner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Microprocessor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Intake Air Heater (IAH) Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
Glow Plug Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42
EGES-390
6 ENGINE SYSTEMS
Fuel Pump Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Boost Control Solenoid (BCS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Intake Throttle Valve (ITV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43
Sensors and Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Thermistor Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44
Variable Capacitance Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45
Micro Strain Gauge (MSG) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .46
Magnetic Pickup Sensors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47
Switches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48
Glow Plug System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50
EGES-390
ENGINE SYSTEMS 7
Engine Identification
Engine Serial Number
Figure 2 Example of U.S. Environmental

Protection Agency (EPA) emission label (50 state)
The EPA exhaust emission label is on top of the

crankcase breather, on the left valve cover. The label
includes the following:
• Advertised brake horsepower ratings
• Engine model code
• Service applications
• Emission family and control systems
Figure 1 Engine serial number
• Year the engine was certified to meet EPA
emission standards
The engine serial number is stamped on the
crankcase pad, on the rear left side below the
cylinder head. Engine Accessories
The following engine accessories may have
Engine Serial Number Example manufacturers’ labels or identification plates:
4.6HM2YXXXXXXX • Air conditioning compressor
4.6 – International® MaxxForce™ 5 • Alternator
H – Diesel, turbocharged, air intercooled and
electronically controlled • Cooling fan clutch
M2 – Motor truck or U2 power unit and OEM (Sold to • Dual turbocharger assembly
original equipment manufacturer)
Y – United States, Huntsville • Power steering pump
7 digit suffix – Sequence number • Starter motor
Labels or identification plates include information
Emission Labels and specifications helpful to vehicle operators and
technicians.
An Environmental Protection Agency (EPA) Engine
Emission Label is issued for the International®
MaxxForce™ 5 diesel engine.
EGES-390
8 ENGINE SYSTEMS
Component Locations
Figure 3 Top
1. Engine Oil Pressure (EOP) 7. Injection Control Pressure (ICP) 12. Turbocharger low-pressure
switch sensor turbine
2. Engine Oil Temperature (EOT) 8. Turbocharger high-pressure 13. Injector connection (6)
sensor compressor 14. Oil filter housing assembly
3. Intake Throttle Valve (ITV) 9. Turbocharger oil supply tube 15. Secondary fuel filter assembly
assembly assembly
4. Exhaust Gas Recirculation 10. High-pressure oil pump
(EGR) valve assembly
5. Boost Control Solenoid (BCS) 11. Injection Pressure Regulator
6. Turbocharger pneumatic (IPR) valve
actuator
EGES-390
ENGINE SYSTEMS 9
Figure 4 Front
1. Fuel filter to right cylinder head 6. Inlet Air Heater (IAH) element 11. 8-groove idler pulley
tube 7. Diagnostic port (oil cooler) 12. Water pump / fan drive pulley
2. Heater feed tube assembly 8. Intake Air Temperature (IAT) 13. Smooth idler pulley
3. Lifting eye sensor 14. Power steering pulley
4. Flat idler pulley 9. Thermostat assembly 15. Vibration damper
5. Manifold Absolute Pressure 10. Engine Coolant Temperature 16. Belt tensioner assembly
(MAP) sensor (ECT) sensor
EGES-390
10 ENGINE SYSTEMS
Figure 5 Right
1. Sensor wiring harnesses to 5. Exhaust Gas Recirculation 9. Crankshaft Position (CKP)
chassis mounted ECM, IAH and (EGR) valve sensor
glow plug relays 6. Boost Control Solenoid (BCS) 10. Crankcase coolant drain plug
2. Dual turbocharger assembly 7. Glow plug harness assembly (right)
3. Oil fill cap (right) 11. Coolant heater
4. Injection Control Pressure (ICP) 8. Exhaust manifold (right)
sensor
EGES-390
ENGINE SYSTEMS 11
Figure 6 Left
1. Intake Throttle Valve (ITV) 6. Crankcase coolant drain plug 12. Heater return port
assembly (left) 13. Glow plug harness assembly
2. Intake Air Temperature (IAT) 7. Fuel return to HFCM (left)
sensor 8. Fuel supply to filter tube 14. Exhaust Back Pressure (EBP)
3. Exhaust emission label 9. Power steering pump sensor
4. Crankcase breather assembly 10. Camshaft Position (CMP) sensor
5. Exhaust manifold (left) 11. Coolant inlet
EGES-390
12 ENGINE SYSTEMS
Figure 7 Rear
1. Lifting eye 4. Exhaust Gas Recirculation 6. Rear cover
2. Exhaust tube assembly (EGR) cooler 7. Flywheel assembly
3. Turbocharger/exhaust outlet 5. Injector connector (6)
EGES-390
ENGINE SYSTEMS 13
Engine Description, Specifications, and Features
Table 1 International® MaxxForce™ 5 Description and Specifications

Engine configuration 4 stroke V6 diesel, 4 valves/cylinder
Displacement 4.5 liters (275 in3)
Bore (sleeve diameter) 95 mm (3.74 in.)
Stroke 105 mm (4.134 in.)
Compression ratio 18.0:1
Aspiration Dual turbocharged and Charge Air Cooled (CAC)
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 International® electro-hydraulic generation 2 injection
Cooling system capacity (engine only) 11 liters (12 quarts US)
Lube system capacity (including filter) 13 liters (14 quarts US)
Lube system capacity (overhaul only, with 14 liters (15 quarts US)
filter)
Firing order 1-2-5-6-3-4
Engine Features
Table 2 International® MaxxForce™ 5 Standard and Optional Features

Standard Features Optional Features
Four valves per cylinder Coolant heater wiring harness
Primary balancer shaft assembly Chassis Mounted Features
Dual timing sensors Horizontal Fuel Conditioning Module (HFCM)
Two-piece crankcase Diamond Logic® Engine Control
One-piece aluminum alloy pistons Inlet air heater relay
Fracture cap joint connecting rods Glow plug relay
International® electro-hydraulic generation 2
Charge Air Cooler (CAC)
injection system
Dual turbocharger assembly
Secondary fuel filter
EGES-390
14 ENGINE SYSTEMS
Engine Description Fuel System

The Horizontal Fuel Conditioning Module (HFCM)
Cylinder Heads
includes an electric fuel pump, primary fuel filter,
Each cylinder head has four valves per cylinder for Diesel Thermo Recirculation Module (DTRM),
improved air flow. The overhead valve train includes fuel heater, water drain plug, and a Water In Fuel
hydraulic roller tappets, push rods, rocker arms, and (WIF) sensor. An amber Water In Fuel lamp is
valve bridges to operate the four valves. Each fuel illuminated when a predetermined quantity of water
injector is centrally located between the four valves, has accumulated.
directly over the piston combustion bowl, for improved
• The HFCM is mounted on the inside of the frame
performance and reduced emissions.
rail (operator’s side) for Cab Forward (CityStar™)
vehicles
Crankcase Assembly
• The HFCM is mounted near the transmission and
The crankcase assembly consists of an upper
frame rail (passenger side) for stripped chassis
crankcase and a lower crankcase. The upper
vehicles.
crankcase assembly includes the cylinders, main
bearing saddles, and cast or machined coolant A secondary fuel filter assembly (engine mounted)
passages. The lower crankcase, a structural plate includes outlets for the fuel lines to each cylinder head
that mates to the upper crankcase, has machined fuel rail, a fuel pressure regulator, an Engine Fuel
main bearing caps for improved load retention and Pressure (EFP) switch, and an air bleed orifice to
alignment. discharge air if the vehicle runs out of fuel.
Aluminum alloy pistons are mated to fractured cap The International® electrohydraulic generation 2
joint connecting rods. Piston pins, secured with injection system includes a high-pressure oil pump,
retaining rings, are free floating for lateral movement cast iron oil rail assemblies, and fuel injectors.
in the connecting rod and piston.
An Electronic Control Module (ECM) processes
The crankshaft is supported by four main bearings signals from the Crankshaft Position (CKP), Camshaft
with fore and aft thrust controlled at the upper half Position (CMP), exhaust aftertreatment, and other
of the number 3 main bearing. Two connecting rods, sensors. The ECM sends voltage pulses to opening
attached to each crankshaft rod journal, are offset to and closing coils of each injector to control injection
minimize vibration. timing, quantity, and duration.
The camshaft is supported by four bushings pressed
Lubrication System
into the crankcase. The camshaft is crankshaft driven
and thrust is controlled by a plate mounted behind the The engine lubrication system is pressure regulated,
number four cam journal. full flow cooled, and full flow filtered. A crankshaft
driven gerotor lube oil pump delivers oil through an
A closed crankcase breather system separates
oil filter element and oil cooler to engine components
crankcase vapors and oil. Vapors are vented through
and an oil reservoir for the high-pressure fuel system.
a hose to the air inlet duct, while oil drains back to the
An oil pressure regulator, in the front cover, maintains
crankcase.
the desired system pressure.
EGES-390
ENGINE SYSTEMS 15
Air Management System and starting. An Intake Air Heater (IAH) element,
mounted in the intake manifold under the inlet air
A dual stage turbocharger provides boost pressure
elbow, is controlled by an inlet air heater relay
for a variety of engine speeds and load conditions.
(chassis mounted). Six glow plugs are controlled by
An electronic Boost Control Solenoid (BCS) and a
a glow plug relay (chassis mounted).
pneumatic actuator control the turbocharger.
An Aftertreatment System processes engine exhaust
A Charge Air Cooler (CAC), an air-to-air heat
to meet EPA emissions requirements.
exchanger, cools and increases the density of the
air charge from the turbocharger. The cooled dense • An oxidation catalyst burns oxygen and
air flows to the intake manifold. An intake throttle hydrocarbons in the exhaust stream.
valve restricts air flow to help heat exhaust gas during
• A Diesel Particulate Filter (DPF) captures and
aftertreatment regeneration.
burns particulates in the exhaust stream.
An Exhaust Gas Recirculation (EGR) system includes
an EGR cooler and EGR valve. Some exhaust from
the exhaust tube assembly flows through the EGR Optional Features
cooler into a passage in the intake manifold and to
Although a 1250 watt coolant heater is standard
the EGR valve. When the EGR valve opens, cooled
equipment, an optional 120 volt cable is available
exhaust gases enter the intake manifold.
for operation. The coolant heater raises coolant
The Inlet Air Heater relay and glow plug relay work temperature around the cylinders to improve cold
together to improve cold weather engine performance engine starts.
EGES-390
16 ENGINE SYSTEMS
Engine Systems Interaction Diagram
Figure 8 Engine systems interactions
The primary engine systems are air management and • The lube oil system provides lubrication and heat
fuel management which share some subsystems or transfer for engine components.
have a subsystem that contributes to their operation.
• The Injection Control Pressure (ICP) system uses
• The electronic control system controls the air engine oil to actuate the fuel injectors.
management system and fuel management
• The fuel supply system pressurizes fuel to the fuel
system.
injectors.
• The Coolant System provides heat transfer for
crankcase and cylinder sleeves, cylinder head,
EGR gases, and lubrication oil.
EGES-390
ENGINE SYSTEMS 17
Air Management System
Figure 9 Air management system components and flow

1. Air flow 12. Exhaust in from left cylinders 23. Exhaust Back Pressure (EBP)
2. Crankcase gas flow 13. Intake Air Heater (IAH) sensor
3. Compressed air and crankcase 14. Manifold Absolute Pressure 24. Left exhaust manifold
gas flow (MAP) sensor 25. Left cylinder head
4. Exhaust gas flow 15. Right cylinder head 26. Manifold Air Temperature (MAT)
5. Air filter 16. Right exhaust manifold sensor
6. Intake Air Temperature (IAT) 17. Exhaust out from right cylinders 27. Intake throttle assembly
sensor 18. Exhaust out from left cylinders 28. Diesel Oxidation Catalyst (DOC)
7. Charge Air Cooler (CAC) 19. Exhaust Gas Recirculation 29. Diesel Particulate Filter (DPF)
8. Dual turbocharger (EGR) cooler 30. Left valve cover
9. Exhaust flow (bypass closed) 20. EGR valve 31. Crankcase breather
10. Exhaust flow (bypass open) 21. Intake manifold
11. Exhaust in from right cylinders 22. Exhaust tube assembly
EGES-390
18 ENGINE SYSTEMS
Air, Exhaust, and Crankcase Gas Flow The inlet air heater relay controls the operation of
the inlet air heating element depending on ambient
Ambient air is initially drawn through the air filter
temperature and atmospheric pressure.
assembly past the IAT sensor and into the air inlet
duct. Air flow continues in the intake manifold, past the
intake valves and into the cylinders. After combustion,
A crankcase breather and hose are used to draw
hot exhaust gases are forced through the exhaust
crankcase gasses from the engine.
manifolds and into the exhaust piping.
Air continues to flow through the low-pressure
Most of the hot exhaust gas flows into the
turbocharger compressor (larger turbo), where it is
turbocharger high-pressure turbine (smaller turbo),
compressed and discharged to the high-pressure
spinning the high-pressure turbine wheel. Exhaust
turbocharger compressor (smaller turbo). The
continues to flow onto the low pressure turbine (larger
high-pressure compressor compresses discharge
turbo), spinning the low-pressure turbine wheel before
air to a higher pressure and temperature before it
exiting the turbocharger to the exhaust system.
enters the CAC.
A portion of the hot exhaust gas is routed through
As the compressed air (hot) flows through the
the EGR cooler and EGR valve where it is metered
CAC, ambient air flows across the CAC and heat is
into the intake manifold to blend with filtered incoming
exchanged to the atmosphere. This heat exchange
air. This helps reduce combustion temperatures and
allows cooled (denser) air to enter the engine with
Oxides of Nitrogen (NOX).
enough pressure to give the correct air to fuel ratio.
Exhaust flows through the exhaust piping,
During cold weather startups, an inlet air heater
aftertreatment, and out the exhaust pipe.
warms the incoming air. The Electronic Control
Module (ECM) controls the inlet air heater relay.
EGES-390
ENGINE SYSTEMS 19
Exhaust Gas Recirculation (EGR) System

The EGR system reduces Nitrogen Oxide (NOX)
emissions. NOX gas forms when nitrogen and oxygen
react during high combustion temperatures. Mixing
exhaust with inlet air reduces combustion temperature
and NOX gas formation.
Some exhaust from the exhaust tube assembly
flows through the EGR cooler, intake manifold EGR
passage, and to the EGR valve. The Electronic
Control Module (ECM) commands the EGR valve to
open, when needed, allowing cooled exhaust gases
to enter the intake manifold to mix with intake air.
Figure 11 EGR valve
The EGR valve assembly consists of three major

components; a dual poppet valve, a DC motor, and
an Integrated Circuit (IC). The IC has three Hall effect
position sensors to monitor valve movement. The
Figure 10 EGR closed loop operation EGR valve uses a DC motor to control the position
of the valve assembly. The valve assembly has two
valve heads on a common shaft.
The ECM commands EGR valve position based The EGR valve is installed in the front of the intake
on engine speed, Exhaust Back Pressure (EBP), manifold.
Manifold Air Temperature (MAP), and Manifold
Air Pressure (MAT) sensor input. The EGR valve
provides feedback to the ECM on current valve
position.
EGES-390
20 ENGINE SYSTEMS
Dual Stage Turbocharger Assembly
Figure 12 Dual stage turbocharger

1. Crossover tube 6. Oil supply tube 11. High-pressure turbine
2. High-pressure compressor 7. Low-pressure compressor 12. High-pressure compressor
3. Exhaust inlet 8. Air inlet discharge
4. Exhaust outlet 9. Pneumatic actuator
5. Low-pressure turbine 10. Low-pressure compressor outlet
The dual stage turbocharger responds to engine During light loads, all exhaust flows through the
loads. During heavy loads, an increased flow of high-pressure turbine and low-pressure turbine.
exhaust gasses turn the turbine wheels faster. When boost pressure reaches a predetermined value,
Turbine wheel speed controls compressor boost the pneumatic actuator opens the bypass valve,
pressure. As engine rpm and load decrease, less fuel allowing some exhaust to bypass the high-pressure
and air enter the cylinders. Exhaust temperature and turbine and flow directly to the low-pressure turbine;
pressure decrease; lower exhaust energy decreases maximum boost pressure is limited. The dual stages
turbine and compressor speed which lowers the of the turbocharger contribute to lower exhaust
pressure and temperature of compressed air. emissions.
EGES-390
ENGINE SYSTEMS 21
Aftertreatment (AFT) System • Provides heat for exhaust system warm-up

The AFT System processes engine exhaust to meet • Aids in system temperature management for the
emissions requirements. The aftertreatment system DPF
consists of the Diesel Oxidation Catalyst (DOC),
• Oxidizes NO into NO2 for passive DPF
Diesel Particulate Filter (DPF), three Exhaust Gas
regeneration
Temperature (EGT) sensors, and a Exhaust Gas
Differential Pressure (EGDP) sensor. The Electronic
Diesel Particulate Filter (DPF)
Control Module (ECM) monitors aftertreatment and
engine sensors to control AFT regeneration cycles. The DPF does the following:
During a regeneration cycle the exhaust is heated to
• Captures and temporarily stores carbon-based
clear soot accumulation.
particulates in a filter
AFT Control System • Allows for oxidation (regeneration) of stored
particulates once loading gets to a particular level
The control system performs the following functions:
(pressure drop)
• Monitors exhaust gases, the aftertreatment
• Stores noncombustible ash
system, and controls engine operating
parameters for emission processing and failure
Sensors
recognition
Sensors produce an electronic signal based on
• Cancels regeneration in the event of catalyst or
temperature and pressure and are used by the
sensor failure
ECM to monitor aftertreatment function and control
• Monitors the level of soot accumulation in the regeneration.
Diesel Particulate Filter (DPF) and adapts engine
operating characteristics to compensate for AFT Conditions and Responses
increased back pressure
The operator is alerted audibly or with instrument
• Controls engine operating parameters to make panel indicators of AFT system status. Automatic or
regeneration automatic. manual regeneration is required when levels of soot
exceed acceptable limits. For additional information
• Maintains vehicle and engine performance during
see the applicable vehicle Operator’s Manual and the
regeneration
vehicle visor placard.
Diesel Oxidation Catalyst (DOC)
The DOC does the following:
• Oxidizes hydrocarbons and carbon monoxide
(CO)
EGES-390
22 ENGINE SYSTEMS
Fuel Supply System
Figure 13 Fuel supply system

1. Drilled passage to fuel injectors 5. Horizontal Fuel Conditioning 8. Banjo bolt with check valve (2)
(2) Module (HFCM) (chassis 9. Fuel line (supply left cylinder
2. Secondary fuel filter assembly mounted) head)
3. Banjo bolt (fuel supply) 6. Fuel line (supply from HFCM) 10. Fuel line (supply right cylinder
4. Fuel injector (6) 7. Fuel line (return to HFCM) head)
EGES-390
ENGINE SYSTEMS 23
Figure 14 Fuel supply system flow
Fuel Flow Fuel flows through each fuel line and a banjo bolt
connecting the fuel line to the cylinder head. Fuel
The fuel pump in the HFCM draws fuel through a fuel
flows through drilled passages in each cylinder head
line from the fuel tank. The HFCM heats, filters, and
to the fuel injectors. When the fuel injectors are
pressurizes the fuel. Conditioned fuel flows from the
activated, fuel flows into three inlets in each injector.
HFCM through the supply line to the secondary fuel
Fuel does not return to the fuel supply system from
filter assembly.
the injectors or cylinder heads; this is a deadhead
The secondary fuel filter assembly conditions, fuel system.
maintains system pressure, and deaerates fuel.
EGES-390
24 ENGINE SYSTEMS
Horizontal Fuel Conditioning Module (HFCM) The HFCM fuel pump draws fuel from the fuel tank,
across an electric fuel heater and through a 10
micron fuel filter. The electric fuel heater is activated
when the incoming fuel temperature is below 10
°C (50 °F) and is deactivated when incoming fuel
temperature reaches 27 °C (80 °F). A 10 micron fuel
filter/water separator separates particles and water
from the incoming fuel before reaching the pump. The
conditioned fuel is then pumped to the secondary fuel
filter assembly. The outlet fuel pressure is controlled
by a pressure relief valve located within the fuel
pump. When the water separated from the incoming
fuel accumulates in the water sump a Water In Fuel
(WIF) sensor sends a signal to the Electronic Control
Module (ECM) and illuminates the amber WATER IN
FUEL lamp.
During cold temperature operation, the Diesel Thermo
Figure 15 HFCM Recirculation Module (DTRM), located in the HFCM,
redirects the warm fuel returned from the secondary
1. Cover plate assembly
fuel filter assembly back into the unfiltered side of the
2. Fuel return to tank
HFCM filter. When the incoming fuel temperature is
3. Electric fuel pump
below 30 °C (85° F), a portion of the return fuel will be
4. Fuel supply to HFCM
redirected into the HFCM to increase the supply fuel
5. Water In Fuel (WIF) sensor connector
temperature. When the incoming fuel temperature
6. Water drain plug
reaches 38 °C (100 °F) the DTRM will divert all the
7. Fuel heater connector
return fuel back to the tank.
8. Fuel supply to engine
9. Primary filter cap
10. Fuel return from secondary filter
Figure 16 HFCM - fuel flow
EGES-390
ENGINE SYSTEMS 25
Secondary Fuel Filter Assembly
Figure 17 Secondary fuel filter assembly - fuel flow
Conditioned fuel flows through a fuel return tube to the A banjo bolt, with check valve, connects each fuel line
two fuel supply ports to the cylinder heads and the fuel to each cylinder head. The check valve prevents fuel
test port. return to the secondary fuel filter and keeps the drilled
passages full. Fuel flows through drilled passages to
An orifice is drilled through the side of the secondary
the fuel injectors in each cylinder head. When the fuel
fuel filter housing, to the return fuel passage on the
injectors are activated, fuel flows into three inlets in
side of the secondary fuel filter. Air trapped in the
each injector. Fuel does not return to the fuel supply
housing is returned through the return fuel passage.
system from the injectors; this is a deadhead fuel
During idle and low engine loads most of the fuel system.
is cycled between the fuel filter housing and HFCM.
A four micron filter element in the fuel filter separates
When engine load increases, engine fuel consumption
particles in the fuel.
increases; fuel flows through the filter with little or no
cycling.
EGES-390
26 ENGINE SYSTEMS
Figure 18 Fuel lines connected to the secondary

fuel filter assembly
1. Fuel return to fuel pump
2. Fuel supply from fuel pump
Figure 19 Secondary fuel filter assembly
3. Engine Fuel Pressure (EFP) switch
4. Conditioned fuel to left cylinder head 1. Orifice
5. Conditioned fuel to right cylinder head 2. Return fuel passage
3. Poppet valve (fuel pressure regulator)
The fuel pressure regulator is a spring loaded poppet

valve used to regulate and relieve excessive fuel
pressure. Fuel passing through the pressure regulator
returns to the HFCM.
EGES-390
ENGINE SYSTEMS 27
Fuel Management System
Figure 20 Fuel management system components and sub-systems
The fuel system uses high-pressure oil to increase The ECM distributes current to the injectors and
fuel pressure inside the injectors for high-pressure fuel controls engine fueling by sending voltage pulses to
injection. the OPEN and CLOSE coils of the injectors. The ECM
has a dual output DC to DC converter which supplies
The ECM uses sensor input signals to determine
current for generating injection pulses. The DC to DC
timing and quantity of fuel for the injectors. The ECM
converter boosts ECM input working voltage to a high
uses CMP and CKP input signals to calculate engine
level voltage (max 50 V) and a low level voltage (max
speed and valve train position.
24 V). The two voltages are used to achieve the peak
and hold injector current waveform.
EGES-390
28 ENGINE SYSTEMS
High-pressure Oil Flow
Figure 21 High-pressure oil flow and components

1. Injection Control Pressure (ICP) 5. Branch tube assembly 10. Crankcase
sensor 6. Fuel injector (6) 11. Injection Pressure Regulator
2. High-pressure oil rail assembly 7. High-pressure oil inlet (injector) (IPR) valve
3. Case-to-head tube plug (2) 8. Oil exhaust ports 12. High-pressure pump assembly
4. Case-to-head tube assembly 9. Fuel inlet (4)
EGES-390
ENGINE SYSTEMS 29
Figure 22 High-pressure oil flow schematic
The lubrication system constantly refills the oil high-pressure oil rail. High pressure oil from the
reservoir located in the top of the crankcase below high-pressure oil rails enter the fuel injector oil inlet
the oil cooler. The reservoir provides oil for the ports in the top of each fuel injector.
high-pressure oil pump.
High-pressure oil is used by the fuel injectors to
A gear-driven, high-pressure oil pump is mounted on pressurize, inject, and atomize fuel in the cylinders.
the top rear of the crankcase under the turbocharger. Injection begins when the OPEN coil for each fuel
The high-pressure oil pump draws oil through a screen injector is energized. The CLOSE coils are energized
from the oil reservoir. to end injection. Injector exhaust oil exits through two
outlet ports in the top of each injector and drains back
High-pressure oil flows from the high-pressure
to the oil pan.
oil pump to the branch tube assembly, to both
case-to-head tube assemblies and then to each
EGES-390
30 ENGINE SYSTEMS
Injection Control Pressure (ICP) System ICP System Control
Figure 24 ICP system

Figure 23 ICP closed loop system
The IPR solenoid receives pulse width modulated

The ICP system is a closed loop system that uses ICP signals from the ECM to control IPR valve on and off
sensor voltage to provide feedback to the Electronic time. The pulse is modulated to control ICP pressure
Control Module (ECM). The ECM commands IPR in a range from 4.5 MPa (650 psi) up to 27 MPa
valve duty cycle to open or close to maintain ICP (3,920 psi). Maximum pressure relief occurs at about
pressure by dumping excess high-pressure oil back 31 MPa (4,500 psi).
to the crankcase sump.
The IPR valve is mounted in the body of the
As demand for ICP increases, the ECM increases the
pulse - width modulation to the IPR solenoid. When
ICP demand decreases, the ECM decreases the duty
cycle to the solenoid, allowing more oil to flow from the
drain orifice.
If the ICP signal is out of range the ECM will set one
or more Diagnostic Trouble Code (DTC). The ECM will
ignore ICP signals that are out of range and the IPR
valve will operate from programmed default values.
This is called an Open Loop operation.
EGES-390
ENGINE SYSTEMS 31
Fuel Injector Assembly
Figure 25 Fuel injector assembly

1. Lower O-ring 3. Upper O-ring 5. Harness connector
2. Fuel inlet screens (3) 4. Clamp alignment slot
Fuel Injector Features Intensifier Piston and Plunger

Two 48 volt, 20 amp coils control a spool valve When the spool valve opens, high-pressure oil enters
that directs oil flow in and out of the injector. The the injector and pushes down the intensifier piston and
injector coils are turned on for approximately 800 µs plunger. The intensifier piston is 7.1 times greater
(microseconds). Each injector has a single four pin in area than the plunger so, injection pressure is 7.1
connector that couples to the engine sensor wiring times greater than injection control pressure.
harness through the rocker arm carrier.
Plunger and Barrel
Injector Coils and Spool Valve
Fuel pressure builds at the base of the plunger in the
An OPEN coil and a CLOSE coil on the injector move barrel. When the intensifier piston pushes the plunger
the spool valve from side to side using magnetic force. down, the plunger increases fuel pressure in the barrel
The spool has two positions: 7.1 times greater than injection control pressure. The
plunger has a hardened coating to resist scuffing.
• When the spool valve is open, oil flows into the
injector from the high-pressure oil manifold.
Injector Needle
• When the spool valve is closed, oil exits from the
The injector needle opens inward when fuel pressure
top of the fuel injector and drains back to the oil
overcomes the Valve Opening Pressure (VOP) of 20
pan.
MPa (2,900 psi). Fuel is atomized at high-pressure
through the nozzle tip.
EGES-390
32 ENGINE SYSTEMS
Fuel Injector Operation Low-pressure fuel fills the three ports and enters
through the fuel inlet screens on its way to the
Injector operation has three stages:
chamber beneath the plunger. The needle control
• Fill spring holds the needle onto its seat to prevent fuel
from entering the combustion chamber.
• Injection
• End of injection Injection
1. A pulse-width controlled current energizes the
OPEN coil. Magnetic force moves the spool
valve open. High-pressure oil flows past the
spool valve and onto the top of the intensifier
piston. Oil pressure overcomes the force of
the intensifier piston spring and the intensifier
starts to move down. An increase in fuel
pressure under the plunger seats the fuel inlet
check ball, and fuel pressure starts to build on
the needle.
2. The pulse-width controlled current to the
OPEN coil is shut off, but the spool valve
remains open. High-pressure oil from
high-pressure oil manifold continues to
flow past the spool valve. The intensifier
piston and plunger continue to move and
fuel pressure increases in the barrel. When
fuel pressure rises above Valve Opening
Pressure (VOP), the needle lifts off its seat
and injection begins.
End of Injection
1. When the ECM determines the correct
injector on-time has been reached (the
correct amount of fuel has been delivered),
the ECM sends a pulse-width controlled
current to the CLOSE coil of the injector.
The current energizes the CLOSE coil
and magnetic force closes the spool valve.
High-pressure oil is stopped against the spool
valve.
2. The pulse-width controlled current to close
the coil is shut off, but the spool valve remains
Figure 26 Fuel injector cross section closed. Oil above the intensifier piston flows
past the spool valve through the exhaust
ports. The intensifier piston and plunger
Fill return to their initial positions. Fuel pressure
During Fill, both coils are de-energized and the decreases until the needle control spring
spool valve is closed. High-pressure oil from the forces the needle back onto its seat.
high-pressure oil manifold is stopped at the spool
valve.
EGES-390
ENGINE SYSTEMS 33
Engine Lubrication System
Figure 27 Lubrication system

1. Dual stage turbocharger 8. Crankshaft main bearing (4) 15. Front cover
assembly 9. Piston cooling tube (6) 16. Primary balancer shaft bushing
2. Turbocharger oil supply line 10. Upper oil pan (2) (inside camshaft)
3. Oil filter assembly 11. Oil pickup tube 17. Camshaft bushing (4)
4. Oil cooler assembly 12. Oil pan 18. Rocker arm assembly (12)
5. Push rod (12) 13. Rotor assembly (gerotor oil
6. Hydraulic roller follower (12) pump)
7. Oil galleries 14. Oil pressure regulator
EGES-390
34 ENGINE SYSTEMS
Oil Flow Diagram
Figure 28 Lubrication system schematic
A gerotor oil pump draws oil from the oil pan through gear of the gerotor pump. Discharge oil flows through
an oil pickup tube bolted to the upper oil pan. Oil a passage in the front cover through the regulator
flows through passages in the upper oil pan, in the valve to the gerotor pump suction.
lower crankcase, and in the front cover to the oil pump.
The Electronic Control Module (ECM) monitors
The oil pump includes the front cover assembly, rotor
Engine Oil Pressure (EOP) switch and Engine Oil
assembly (inner and outer gears), and the gerotor
Temperature (EOT) sensor signals.
housing cover. The crankshaft drives the inner rotor
EGES-390
ENGINE SYSTEMS 35
Oil Cooler and Filter Assemblies
Figure 29 Oil cooler cover and oil filter base

1. Unfiltered oil flow from pump 6. Oil cooler bypass valve 11. Oil pressure sensor port
2. Oil cooler outlet (oil) 7. Filtered oil to crankcase galleries 12. Oil filter drain to sump
3. Filtered oil to reservoir 8. Unfiltered oil inlet 13. Coolant outlet
4. Oil pressure test port fitting 9. Oil temperature sensor port 14. Oil cooler inlet (oil)
5. Coolant inlet 10. Turbocharger oil supply port 15. Oil drain to sump
Pressurized oil from the oil pump flows through a restricted, a bypass valve in the oil filter return line
passage in the front cover, through a passage in the opens, oil bypasses the oil filter element, and flows to
upper crankcase, to the oil cooler cover. Passages the oil filter base.
in the oil cooler cover direct lube oil and coolant. Oil
Both bypass valves ensure full flow of oil to the engine,
flows through plates in the oil cooler from the back to
if the filter or cooler is restricted.
the front, cools, and flows back to the oil cooler cover.
The oil filter base directs filtered oil to the turbocharger
If the oil cooler is restricted, a bypass valve in the oil
oil supply tube, EOP switch, EOT sensor, diagnostic
filter base opens, oil bypasses the oil cooler, and flows
port, and to the oil cooler cover. Lubricating oil from
to the oil filter base.
the turbocharger drains back to the oil pan through the
Oil flows through the oil filter base to the oil filter high-pressure oil pump cover.
element outside to inside, up the outside of the filter
When the oil filter is removed, oil flows from a drain
stand pipe and down the inside of the stand pipe, and
valve in the oil filter base back to the oil pan.
back to the oil filter base. If the oil filter element is
EGES-390
36 ENGINE SYSTEMS
Figure 30 Oil reservoir in crankcase

1. Oil feed to high-pressure oil 3. Oil feed to left side of main lube 5. Oil feed to right side of main lube
pump oil gallery oil gallery
2. Oil filter drain to pan 4. Oil feed to oil cooler cover 6. Coolant feed to oil cooler
The oil cooler cover and oil cooler base direct filtered • One passage supplies filtered oil to the right
oil in three ways: side for the main lube oil gallery, push rods and
rocker arms, piston cooling tubes, camshaft
• One passage supplies oil to the reservoir in the
bushings, crankshaft main bearings, connecting
crankcase for the high-pressure oil pump and
rod bearings, primary balancer shaft bushings,
ICP system. A screen in the oil reservoir catches
and lifters.
debris before oil goes to the high-pressure oil
pump.
• One passage supplies filtered oil to the left side
for the main lube oil gallery, push rod and rocker
arms, piston cooling tubes, and lifters.
EGES-390
ENGINE SYSTEMS 37
Cooling System
Figure 31 Cooling system components and flow

1. Intake manifold 5. Crankcase 8. Coolant inlet (from radiator)
2. EGR cooler assembly 6. Thermostat assembly (coolant 9. Front cover assembly
3. Oil cooler outlet to radiator) 10. Water pump assembly
4. Cylinder head (2) 7. Coolant return (from heater) 11. Coolant supply (to heater)
The cooling system circulates coolant to keep the centrifugal water pump (hub and impeller) is mounted
engine within a designated temperature range. A in the pump housing of the front cover.
EGES-390
38 ENGINE SYSTEMS
Front Cover Coolant Flow flows through the front of both sides of the crankcase,
evenly distributing coolant around the cylinders, and
The water pump draws coolant from the radiator
exits the crankcase flowing up to the cylinder heads.
through the front cover coolant inlet. Coolant flows
from the water pump through three passages in the Coolant flows from the rear of the cylinder heads to
front cover. Two passages (left and right) direct the front, exits down a passage in the crankcase, and
coolant into the crankcase coolant jackets (front to returns to the front cover.
rear) to cool the cylinder walls and the cylinder heads.
For increased performance in cold weather, an
The third passage directs coolant through a passage
optional power cord can be connected to the coolant
in the crankcase to the oil cooler cover.
heater installed in the crankcase.
NOTE: If an oil cooler seal is damaged, weep holes in
the oil filter base allow coolant to seep from the cooler
cover.
Oil Cooler and EGR Cooler Coolant Flow
Coolant returns through three front cover passages.
Returned coolant is directed to the thermostat by The front cover directs coolant to passages in the
the front cover. If the engine has reached operating crankcase. Coolant flows from the crankcase to the
temperature and the thermostat is open, coolant front of the oil cooler cover. The oil cooler and the oil
flows to the radiator to be cooled. If the thermostat is filter base direct coolant to the front of the oil cooler.
closed, coolant is returned to the water pump through Coolant flows through the oil cooler from the front to
a bypass passage in the front cover. rear and exits through the EGR cooler supply tube.
Coolant flows from the rear of the EGR cooler to the
front returning to the front cover though a passage in
the intake manifold.
Crankcase and Cylinder Head Coolant Flow
A deaeration port is on top of the intake manifold.
Coolant flows through passages in the front cover to
the left and right sides of the crankcase. Coolant
EGES-390
ENGINE SYSTEMS 39
Thermostat Operation
The thermostat has two outlets. One directs coolant
to the radiator when the engine is at operating
temperature. The other directs coolant to the water
pump until the engine reaches operating temperature.
The thermostat begins to open at 89 °C (192 °F) and
is fully open at 104 °C (219 °F).
Figure 33 Coolant flow - thermostat open
As coolant temperature reaches opening temperature

the thermostat starts to open allowing some coolant
to flow to the radiator. When coolant temperature
reaches operating temperature, the lower seat blocks
the water pump port directing full coolant flow to the
radiator.
Figure 32 Coolant flow - thermostat closed
When engine coolant is below operating temperature

the thermostat is closed, blocking flow to the radiator.
Coolant is forced through a bypass port back to the
water pump.
EGES-390
40 ENGINE SYSTEMS
Electronic Control System
Figure 34 Electronic Control System components
Table 3 The Electronic Control System includes the following:

Electronic Control Module (ECM) Engine Oil Temperature (EOT) sensor
Manifold Air Temperature (MAT) sensor Engine Coolant Temperature (ECT) sensor
Intake Air Temperature (IAT) sensor Injection Pressure Regulator (IPR) valve
Crankshaft Position (CKP) sensor Injection Control Pressure (ICP) sensor
Camshaft Position (CMP) sensor Accelerator Pedal Position Sensor and Idle Validation
Switch (APS/IVS)
Manifold Absolute Pressure (MAP) sensor Exhaust Gas Recirculation (EGR) valve
Boost Control Solenoid (BCS) Intake Throttle Valve (ITV) assembly
Exhaust Back Pressure (EBP) sensor Exhaust Gas Temperature (EGT) sensors
Engine Oil Pressure (EOP) sensor
EGES-390
ENGINE SYSTEMS 41
Electronic Control System Operation and Continuous calculations in the ECM occur at
Function two different levels or speeds: Foreground and
Background.
The Electronic Control Module (ECM) monitors sensor
input signals and controls engine performance with • Foreground calculations are faster than
actuators and relays to ensure maximum performance background calculations and are critical for
while adhering to emissions standards. The ECM also engine operation. Engine speed control is an
has an internal barometric air pressure sensor which example.
measures atmospheric pressure to compensate for
• Background calculations are variables that
changes in elevation.
change at slower rates. Engine temperature
The ECM has four primary functions: is an example.
• Provides Reference Voltage (VREF) Diagnostic strategies are also programmed into the
ECM. Some strategies monitor inputs continuously
• Conditions input signals
and command the necessary outputs for correct
• Processes and stores control strategies performance of the engine. If inputs or conditions are
not within expected values, the microprocessor sets
• Controls actuators
a Diagnostic Trouble Code (DTC).
The ECM microprocessor includes Read Only
Reference Voltage (VREF) Memory (ROM) and Random Access Memory (RAM).
The ECM supplies a 5 volt VREF signal to input ROM stores permanent information for calibration
sensors in the electronic control system. By tables and operating strategies. Permanently stored
comparing the 5 volt VREF signal sent to the sensors information cannot be changed or lost by turning
with their respective returned signals, the ECM the ignition switch OFF or when ECM power is
determines pressures, positions, and other variables. interrupted. ROM includes the following:
The ECM supplies two independent circuits for VREF: • Vehicle configuration, modes of operation, and
options
• VREF A supplies 5 volts to engine sensors
• Engine Family Rating Code (EFRC)
• VREF B supplies 5 volts to vehicle sensors
• Engine warning and protection modes
RAM stores temporary information for current engine
Signal Conditioner
conditions. Temporary information in RAM is lost
A signal conditioner in the ECM converts analog when the ignition switch is turned to OFF or when
signals to digital signals, squares up sine wave ECM power is interrupted. RAM information includes
signals, or amplifies low intensity signals. the following:
• Engine temperature
Microprocessor • Engine rpm
The ECM microprocessor stores operating • Accelerator pedal position
instructions (control strategies) and value tables
(calibration parameters). The ECM compares stored
instructions and values with conditioned input values
to determine the correct operating strategy for all
engine operations.
EGES-390
42 ENGINE SYSTEMS
Actuators Intake Air Heater (IAH) Relay

The ECM controls engine operation with the following:
• Intake Air Heater (IAH) relay
• Glow plug relay
• Fuel pump relay
• Injection Pressure Regulator (IPR) valve
• Boost Control Solenoid (BCS)
• Exhaust Gas Recirculation (EGR) valve
• Intake Throttle Valve (ITV) assembly
Actuators are controlled in the following ways: Figure 35 IAH and glow plug relays
• Switched on or off 1. Glow plug relay
• Pulse Width Modulation (PWM) 2. IAH relay
3. ECM bracket
• Controller Area Network (CAN) digital signals
• Duty cycle (percent time on/off)
The IAH heats incoming air to aid cold starting and
The ECM controls actuators by applying a low level engine performance.
signal (low side driver) or a high level signal (high side
driver). When switched on, both drivers complete a The ECM controls the IAH relay by switching on a
ground or power circuit to an actuator. voltage source. The relay delivers VREF to the Intake
Air Heater for up to 30 seconds KOEO, depending
on Engine Oil Temperature and altitude. Ground is
supplied through pin–1 of the 16–pin connector to
battery ground at all times. After the engine starts the
IAH can stay on up to 30 minutes in cold conditions.
Glow Plug Relay

The glow plug system heats the engine cylinders to aid
cold engine starting and to reduce exhaust emissions
during warm-up.
The ECM controls the glow plug relay by switching
on a voltage source. The relay delivers VREF to
the glow plugs for up to 120 seconds, depending
on engine coolant temperature and atmospheric
pressure. Ground is supplied through pin–1 of the
16–pin connector to battery ground at all times.
EGES-390
ENGINE SYSTEMS 43
Fuel Pump Relay Exhaust Gas Recirculation (EGR) Valve

The fuel pump is installed inside the Horizontal Fuel The EGR valve controls the flow of cooled exhaust
Conditioning Module (HFCM). Power to the fuel pump gases into the intake air stream to reduce NOx
is supplied through the fuel pump relay. emissions by reducing combustion temperatures.
The ECM controls the fuel pump relay by switching on The EGR valve changes valve position in response to
a voltage source. private Controller Area Network (CAN) digital signals
from the ECM.
Injection Pressure Regulator (IPR) Valve

Intake Throttle Valve (ITV) Assembly
The IPR valve releases excess high-pressure oil to
regulate Injection Control Pressure (ICP). The ITV assembly restricts inlet air flow to control
air/fuel ratio and increase exhaust temperature during
The ECM controls the IPR valve with Pulse Width
aftertreatment regeneration. The ITV also restricts air
Modulation (PWM) signals in response to ICP sensor
flow for engine shutdowns due to Engine Warning and
input.
Protection System (EWPS) or Idle Shutdown Timer
(IST) features, where the engine is shut-off without
turning the key-off.
Boost Control Solenoid (BCS)
The ECM controls the ITV with Pulse Width
The BSC assembly is a two position valve that controls
Modulation (PWM) signals through H-bridge circuitry.
intake manifold boost pressure to the turbocharger
The ITV contains an integral position sensor which
pneumatic actuator. The pneumatic actuator controls
monitors valve position and sends a position signal to
the turbocharger bypass valve and turbocharger boost
the ECM.
pressure.
The ECM controls the BCS by setting its duty cycle to
100% or 0%.
EGES-390
44 ENGINE SYSTEMS
Sensors and Switches Engine Coolant Temperature (ECT) Sensor

Thermistor Sensors The ECM monitors the ECT signal and uses this
information for the instrument panel temperature
gauge, coolant compensation, Engine Warning
Protection System (EWPS), and glow plug operation.
The ECM will use ECT sensor input as a backup, if
EOT sensor values are out of range. The ECT sensor
is installed in the left side of the front cover assembly.
Manifold Air Temperature (MAT) Sensor

The ECM monitors the MAT signal for EGR operation.
The MAT sensor is installed in the left side of the intake
manifold.
Intake Air Temperature (IAT) Sensor

The ECM monitors the IAT signal to control fuel timing
Figure 36 Thermistor and rate during cold starts. The IAT sensor is mounted
in the turbocharger air intake, between the inlet of the
turbocharger and the air filter.
Thermistor sensors:
Exhaust Gas Temperature (EGT) Sensors
• Engine Oil Temperature (EOT)
Three EGT sensors are used in the aftertreatment
• Engine Coolant Temperature (ECT)
system.
• Manifold Air Temperature (MAT)
The EGT1 sensor provides a signal to the ECM
• Intake Air Temperature (IAT) indicating Diesel Oxidation Catalyst (DOC) inlet
temperature. The EGT1 sensor is the first
• Exhaust Gas Temperature (EGT)
temperature sensor installed past the turbocharger
Thermistor sensors change electrical resistance with and just before the DOC.
changes in temperature. Resistance in the thermistor
The EGT2 sensor provides a feedback signal to
decreases as temperature increases, and increases
the ECM indicating Diesel Particulate Filter (DPF)
as temperature decreases. Thermistors work with a
inlet temperature. The EGT2 sensor is the second
resistor that limits current in the ECM to form a voltage
temperature sensor installed past the turbocharger
signal matched with a temperature value.
and just after the DOC.
The top half of the voltage divider is the current limiting
The EGT3 sensor provides a feedback signal to the
resistor inside the ECM. Thermistor sensors have two
ECM indicating DPF outlet temperature. The EGT3
electrical connectors, signal return and ground. The
sensor is the third temperature sensor installed past
output of a thermistor sensor is a nonlinear analog
the turbocharger and just after the DPF.
signal.
During catalyst regeneration, the ECM monitors all
Engine Oil Temperature (EOT) Sensor three EGT sensors and adjusts the Intake Throttle
Valve (ITV) and Exhaust Gas Recirculation (EGR)
The ECM monitors the EOT signal to control fuel
valve as needed.
quantity and inlet air heater operation. The EOT
signal allows the ECM to compensate for differences
in oil viscosity as oil temperature changes. The EOT
sensor is installed in the oil filter base.
EGES-390
ENGINE SYSTEMS 45
Variable Capacitance Sensors
Figure 37 Variable capacitance sensor
Variable capacitance sensors: Exhaust Gas Differential Pressure (EGDP) Sensor

• Exhaust Gas Differential Pressure (EGDP) sensor The EGDP sensor provides a signal to the ECM
indicating the pressure difference between the inlet
• Exhaust Back Pressure (EBP) sensor
and outlet of the Diesel Particulate Filter (DPF).
• Manifold Air Pressure (MAP) sensor During catalyst regeneration, the ECM monitors
this sensor, three Exhaust Gas Temperature (EGT)
Variable capacitance sensors measure pressure.
sensors, the EGR System, and the Intake Throttle
When pressure is applied to the sensor a ceramic
Valve (ITV).
material is forced closer to a thin metal disk which
changes the capacitance of the sensor. The EGDP sensor is a differential pressure sensor
with two tap-offs installed past the turbocharger. A
Variable capacitance sensors are connected to the
tap-off is located before and after the DPF.
ECM by three wires:
• VREF Exhaust Back Pressure (EBP) Sensor
• Signal The ECM monitors exhaust back pressure to control
turbocharger, EGR, and intake throttle systems. The
• Signal ground
EBP sensor is installed in a tube connected to the left
The sensor receives the VREF and returns an analog exhaust manifold.
signal voltage to the ECM. The ECM compares the
voltage with pre-programmed values to determine Manifold Air Pressure (MAP) Sensor
pressure.
The ECM monitors the MAP signal to determine intake
The operational range of a variable capacitance manifold pressure (boost). This information is used to
sensor is linked to the thickness of the ceramic disk. control the turbocharger boost. The MAP sensor is
The thicker the ceramic disk the more pressure the installed in the intake manifold, left of the MAT sensor.
sensor can measure.
EGES-390
46 ENGINE SYSTEMS
Micro Strain Gauge (MSG) Sensor Potentiometer
Figure 38 MSG sensor
Micro strain gauge sensor:

• Injection Control Pressure (ICP)
A Micro Strain Gauge (MSG) sensor measures
pressure. Pressure exerts force on a pressure Figure 39 Potentiometer
vessel that stretches and compresses to change
resistance of strain gauges bonded to the surface
of the pressure vessel. Internal sensor electronics Potentiometer:
convert the changes in resistance to a ratiometric
voltage output. • APS
The Micro Strain Gauge (MSG) sensor is connected A potentiometer is a variable voltage divider that
to the ECM by three wires: senses the position of a mechanical component.
A reference voltage is applied to one end of the
• VREF potentiometer. Mechanical rotary or linear motion
• Signal moves the wiper along the resistance material,
changing voltage at each point along the resistive
• Signal ground material. Voltage is proportional to the amount of
The sensor is powered by VREF received from the mechanical movement.
ECM and is grounded through the ECM to a common
sensor ground. Accelerator Position Sensor (APS)
The APS provides the ECM with a feedback signal
Injection Control Pressure (ICP) Sensor (linear analog voltage) that indicates the operator’s
The ICP sensor measures injection control pressure. demand for power. The APS is mounted in the
The ECM monitors the ICP signal for closed loop accelerator pedal.
control of the Injection Pressure Regulator (IPR)
valve. The ICP sensor is installed through the right
side valve cover in the oil high-pressure oil rail.
EGES-390
ENGINE SYSTEMS 47
Magnetic Pickup Sensors
Figure 40 Magnetic pickup
Magnetic pickup sensors: crankshaft turns the CKP sensor detects a 60 tooth
timing disk on the crankshaft. Teeth 59 and 60 are
• Crankshaft Position (CKP)
missing. By comparing the CKP signal with the CMP
• Camshaft Position (CMP) signal, the ECM calculates engine rpm and timing
requirements. The CKP is installed in the front right
Magnetic pickup sensors generate an alternating
side of the lower crankcase.
frequency that indicates speed. Magnetic pickups
have a two wire connection for signal and ground.
This sensor has a permanent magnetic core
Camshaft Position (CMP) Sensor
surrounded by a wire coil. The signal frequency
is generated by the rotation of gear teeth that disturb The CMP sensor provides the ECM with a signal that
the magnetic field. indicates camshaft position. As the cam rotates, the
sensor identifies the position of the cam by locating a
Crankshaft Position (CKP) Sensor peg on the cam. The CMP is installed in the front left
side of the lower crankcase.
The CKP sensor provides the ECM with a signal
that indicates crankshaft speed and position. As the
EGES-390
48 ENGINE SYSTEMS
Switches Idle Validation Switch (IVS)

The IVS is a redundant switch that provides the ECM
with a signal that verifies when the APS is in the idle
position.
Water In Fuel (WIF) Switch

A WIF switch detects water in the fuel filter of the
HFCM. When enough water accumulates in the filter
housing, the WIF switch sends a signal to the ECM.
The ECM sets a Diagnostic Trouble Code (DTC) and
illuminates the amber water in fuel lamp (fuel pump
next to a fuel tank) on the right side of the instrument
panel. The WIF switch is installed in the HFCM.
Engine Oil Pressure (EOP) Switch

Figure 41 Switch The ECM monitors the EOP signal for reference only.
The ECM uses the EOP signal to control EWPS
warning and lights the red Stop Engine Lamp for
Switches: low oil pressure. The EOP switch closes a circuit to
• Driveline Disengagement Switch (DDS) ground when the engine oil pressure reaches 34 to
(transmission select) 48 kPa (5 to 7 psi). The EOP switch is installed in the
oil filter base assembly.
• Idle Validation Switch (IVS)
• Water In Fuel (WIF) Engine Coolant Level (ECL) Switch
• Engine Oil Pressure (EOP) The ECL is part of the Engine Warning Protection
System (EWPS). The ECL switch is used in plastic
• Engine Coolant Level (ECL) deaeration tanks. When a magnetic switch is OPEN,
• Engine Fuel Pressure (EFP) switch the tank is full.
Switches indicate position or condition. They operate If engine coolant is low, the red Stop Engine Lamp on
OPEN or closed, allowing or preventing the flow of the instrument panel is illuminated.
current. A switch can be a voltage input switch or a
grounding switch. A voltage input switch supplies the Engine Fuel Pressure (EFP) switch
ECM with a voltage when it is closed. A grounding The ECM monitors the EFP to detect low fuel supply
switch grounds the circuit when closed, causing a pressure. If fuel supply pressure drops below 30 psi,
zero voltage signal. Grounding switches are usually due to a fuel filter restriction or other problem, the ECM
installed in series with a current limiting resistor. reduces ICP pressure to 14 MPa. The EFP is installed
in the secondary fuel filter housing.
Driveline Disengagement Switch (DDS)
The Transmission Control Module (TCM) monitors the
transmission shifter position. A signal from the TCM
functions as the DDS signal to the ECM. A manual
transmission application will have a clutch switch for
the DDS signal.
EGES-390
ENGINE SYSTEMS 49
Glow Plug System
Figure 42 Glow plug system
The glow plug system warms the engine cylinders to START lamp ON time and the activation of the glow
aid cold engine starting and reduce exhaust emissions plug relay. The ECM controls the WAIT TO START
during warm-up. lamp and the glow plug relay separately. The glow
plugs are self-limiting and do not require cycling
The ECM energizes the glow plugs, by energizing
on and off. The glow plug relay will cycle on and off
the glow plug relay, while monitoring engine coolant
repeatedly if system voltage is greater than 14.0 volts.
temperature and atmospheric pressure. Glow plug
activation time is increased, if the engine is cold and The engine is ready to start when the WAIT TO
barometric pressure is low (high altitude). START lamp is turned off by the ECM. The glow plugs
can remain on up to 120 seconds while the engine is
The ECM monitors battery voltage and uses
running to reduce exhaust emissions during engine
information from its internal barometric pressure
warm-up.
sensor and the ECT sensor to determine WAIT TO
EGES-390
50 ENGINE SYSTEMS
Inlet Air Heater System
Figure 43 Inlet air heater system
The inlet air heater system warms the incoming air to time, based on EOT, IAT, and BAP. The inlet air heater
aid cold engine starting and reduce exhaust emissions can remain on while the engine is running to reduce
during warm-up. exhaust emissions and white smoke during engine
warm-up.
The ECM energizes the inlet air heater, by energizing
the inlet air heater relay, while monitoring programmed If the EOT is above 70 °C (158 °F), the inlet air heater
conditions for engine oil temperature, inlet air will not reactivate when restarting the engine unless
temperature, and atmospheric pressure. the IAT is 15 °C (59 °F) or colder.
The ECM controls the WAIT TO START lamp and inlet Once the engine starts to crank, the IAH is turned off.
air heater relays separately. Depending on factory calibration, once the engine
starts the IAH can be reactivated for a calibrated
The engine is ready to start when the WAIT TO START
amount of time.
lamp is turned off by the ECM. The ECM will turn
the inlet air heater on for a predetermined amount of
EGES-390
MOUNTING ENGINE ON ENGINE STAND 51
Table of Contents
Engine Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Clean Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Drain Engine Oil and Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .53
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .54
Mounting Engine on Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56
EGES-390
52 MOUNTING ENGINE ON ENGINE STAND
EGES-390
Engine Preparation Drain Engine Oil and Coolant

NOTE: See vehicle service publications for engine
removal.
WARNING: To prevent personal injury or

death, read all safety instructions in the “Safety
Information” section of this manual.

death, wear safety glasses with side shields.
Limit compressed air pressure to 207 kPa (30 psi).

death, do not let engine fluids stay on your skin.
Clean skin and nails using hand cleaner, and wash
with soap and water. Wash or discard clothing
and rags contaminated with engine fluids. Figure 44 Oil filter cap removal
1. Remove oil filter cap from filter housing to allow oil

GOVERNMENT REGULATION: Engine to drain back into the oil pan. This must be done
fluids (oil, fuel, and coolant) may be a threat before removing the oil drain plug.
to the environment. Recycle or dispose
of engine fluids and filters according to
applicable regulations. Never put engine
fluids in the trash, on the ground, in sewers
or bodies of water.
NOTE: Refer to engine stand and engine stand

bracket manufacturer’s instructions for specific
directions on their safe use.
Clean Engine
1. Cap all engine openings to prevent water and Figure 45 Oil drain plug removal
degreasing agents from entering engine.
2. Cover exposed electrical connectors and the ECM
using plastic and duct tape. 2. Remove the oil pan drain plug and drain oil into a
suitable container.
3. Use an appropriate detergent mixed in the correct
ratio and apply to engine using a hot pressure
washer or similar cleaning equipment.
EGES-390
4. Remove four M10 x 20 bolts and the right side

engine mount.
5. Remove the right side coolant drain plug and drain
coolant into a suitable container.
6. Install new O-rings on the coolant and oil drain
plugs.
7. After oil and coolant have drained, install drain
plugs in the crankcase and oil pan. Tighten oil and
coolant drain plugs to special torque (page 56).
Removal
Figure 46 Coolant drain plug – left side 1. Remove the electrical cable and wires from the
1. Exhaust manifold starter motor.
2. Coolant drain plug
2. Remove bolts holding the starter motor to the rear
cover and remove the starter.
3. Remove the left side coolant drain plug and drain 3. Rotate the belt tensioner clock wise to relieve
coolant into a suitable container. tension and remove the serpentine drive belt.
4. Remove bolts holding the Freon® compressor to
the engine and remove the compressor.
Figure 47 Right side engine mount and coolant

drain plug
1. Right engine mount
2. M10 x 20 bolt (4)
3. Starter wiring
4. Coolant drain plug
EGES-390
Mounting Engine on Engine Stand
Figure 48 Engine Stand and Engine Stand Bracket

1. Engine Stand 2. Class 10.9 M10 bolt (4) 3. Engine Stand Bracket
3. Tighten four M10 bolts to standard torque (page

WARNING: To prevent personal injury or 400).
death, use a minimum three ton rated chain hoist,
equipped with safety hooks to lift the engine from 4. Raise or lower the engine to the approximate
factory installed lifting eyes. height of the Engine Stand (page 56).
5. Mount engine and Engine Stand Bracket on the
WARNING: To prevent personal injury or Engine Stand using four Class 10.9 M16 bolts.
death, use metric Class 10.9 or SAE grade 8 bolts 6. Tighten M16 engine stand bolts to standard torque
when mounting the Engine Mounting Bracket to (page 400).
the engine and Engine Stand. See instructions
included with Engine Stand and Engine Mounting 7. Slowly release tension from engine hoist.
Bracket. 8. Remove hoist safety chain hooks from engine
1. Lift engine from factory installed lifting eyes using lifting eyes.
a minimum three ton rated chain hoist equipped
with safety hooks.
2. Match Engine Stand Bracket (page 56) holes with
bolt holes in the right side of the crankcase and
install four Class 10.9 M10 bolts.
EGES-390
Special Torque
Oil pan drain plug 44 N·m (32 lbf·ft)
Crankcase coolant drain plug 20 N·m (15 lbf·ft)
Special Service Tools

Engine Stand Bracket ZTSE4507
Engine Stand OTC1750A
EGES-390
ENGINE ELECTRICAL 57
Table of Contents
Electronic Component Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Electronic Components – Top. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59
Electronic Components – Front. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60
Electronic Components – Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61
Electronic Components – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
Description of Engine Sensors, Valves, and Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Camshaft Position (CMP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Crankshaft Position (CKP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63
Exhaust Back Pressure (EBP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Boost Control Solenoid (BCS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Engine Coolant Temperature (ECT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .64
Engine Oil Temperature (EOT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Engine Oil Pressure (EOP) Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Manifold Absolute Pressure (MAP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .65
Intake Air Temperature (IAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Manifold Absolute Temperature (MAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Engine Fuel Pressure (EFP) switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .66
Injection Control Pressure (ICP) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Intake Throttle Valve (ITV) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .67
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Glow Plug. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Intake Air Heater (IAH) Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69
Injection Pressure Regulator (IPR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .70
Glow Plug Wiring Harness – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72
Injector Harness Connectors – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73
Manifold Air Temperature (MAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Intake Air Heater (IAH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74
Intake Throttle Valve (ITV) Assembly Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .75
Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Switch. . . . . . . . . . . . . . . . . . . .75
Boost Control Solenoid (BCS) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76
Exhaust Gas Recirculation (EGR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Injector Harness Connectors – Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .77
Glow Plug Wiring Harness – Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .79
EGES-390
58 ENGINE ELECTRICAL
Engine Sensor Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .82
Glow Plug and Intake Air Heater (IAH) Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .83
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84

Engine Sensor Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Sensors and Actuators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Glow Plug Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
ECM Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .84
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Glow Plug and Intake Air Heater (IAH) Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .85
Electronic Control Module (ECM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86
Glow Plug Wiring Harness – Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .87
Injector Harness Connectors – Right. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89
Exhaust Gas Recirculation (EGR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .90
Boost Control Solenoid (BCS) Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .91
Engine Oil Temperature (EOT) Sensor and Engine Oil Pressure (EOP) Switch. . . . . . . . . . . . . . . . . . . .91
Intake Throttle Valve (ITV) Assembly Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Intake Air Heater (IAH). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .92
Manifold Air Temperature (MAT) Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93
Injector Harness Connectors – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94
Glow Plug Wiring Harness – Left. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95
Injection Pressure Regulator (IPR) Valve Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97
Alternator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98
Engine Sensor Wiring Harnesses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101
EGES-390
Electronic Component Locations

Electronic Components – Top
Figure 49 Sensor and switch locations – top (typical)

1. Engine Oil Pressure (EOP) 4. Exhaust Gas Recirculation 7. Injection Pressure Regulator
switch (EGR) valve (IPR) valve
2. Engine Oil Temperature (EOT) 5. Boost Control Solenoid (BCS)
sensor assembly
3. Intake Throttle Valve (ITV) 6. Injection Control Pressure (ICP)
assembly sensor
EGES-390
Electronic Components – Front
Figure 50 Sensor locations – front (typical)

1. Manifold Absolute Pressure 4. Intake Throttle Valve (ITV) 7. Engine Coolant Temperature
(MAP) sensor Assembly (ECT) sensor
2. Boost Control Solenoid (BCS) 5. Intake Air Temperature (IAT) 8. Intake Air Heater (IAH) element
assembly sensor
3. Manifold Air Temperature (MAT) 6. Exhaust Back Pressure (EBP)
sensor sensor
EGES-390
Electronic Components – Right
Figure 51 Sensor locations – right (typical)

1. Exhaust Gas Recirculation 3. Injection Control Pressure (ICP) 5. Crankshaft Position (CKP)
(EGR) valve sensor sensor
2. Boost Control Solenoid (BCS) 4. Glow plug harness (right)
assembly
EGES-390
Electronic Components – Left
Figure 52 Sensor locations – left (typical)

1. Intake Throttle Valve (ITV) 2. Intake Air Temperature (IAT) 4. Glow plug harness (left)
Assembly sensor 5. Exhaust Back Pressure (EBP)
3. Camshaft Position (CMP) sensor sensor
EGES-390
Description of Engine Sensors, Crankshaft Position (CKP) Sensor

Valves, and Actuators
NOTE: For information on diagnostics and
troubleshooting, refer to the following publications:
• EGES-395, International® MaxxForce™ 5
Diagnostic Manual
• EGED-410, International® MaxxForce™ 5
Electronic Control Systems Diagnostic Form
Camshaft Position (CMP) Sensor
Figure 54 CKP sensor
The CKP sensor, a magnetic pickup sensor, indicates

crankshaft speed and position.
Figure 53 CMP sensor The CKP sensor sends a pulsed signal to the ECM
as the crankshaft turns. The CKP sensor reacts to a
60 tooth timing disk rotating on the crankshaft. For
The CMP sensor, a magnetic pickup sensor, indicates crankshaft position reference, teeth 59 and 60 are
camshaft speed and position. missing. By comparing the CKP signal with the CMP
signal, the ECM calculates engine rpm and timing
The CMP sensor sends a pulsed signal to the ECM
requirements.
when a single peg on the camshaft rotates past
the CMP sensor once during each revolution of the The CKP is installed in the right front side of the
camshaft. The ECM calculates camshaft speed and crankcase.
position from CMP signal frequency.
The CMP sensor is installed in the left front of the NOTE: There will be no RPM readings without both
crankcase. CMP and CKP signals.
EGES-390
Exhaust Back Pressure (EBP) Sensor The BSC assembly is a two position valve that controls
intake manifold boost pressure to the turbocharger
pneumatic actuator.
The ECM sends signals to the BCS assembly
to control the turbocharger pneumatic actuator
which controls the turbocharger bypass valve and
turbocharger boost.
The BCS is mounted on the air inlet elbow.
Engine Coolant Temperature (ECT) Sensor
Figure 55 EBP sensor
The EBP sensor, a variable capacitance sensor,

measures exhaust back pressure before the
turbochargers.
The EBP sensor provides feedback to the ECM for
closed loop control of the turbocharger Boost Control
Solenoid (BCS), EGR rate calculations, and Intake Figure 57 ECT sensor
Throttle Valve (ITV) control.
The EBP sensor is installed in a tube connected to the
left exhaust manifold. The ECT sensor, a thermistor sensor, detects engine
coolant temperature.
The ECT signal is monitored by the ECM for operation
Boost Control Solenoid (BCS) of the instrument panel temperature gauge, coolant
temperature compensation, optional Engine Warning
Protection System (EWPS), glow plugs, and the wait
to start lamp. The ECM will use ECT sensor input as
a backup, if EOT sensor values are out of range.
The ECT sensor is installed in the left side of the front
cover, above the water pump.
Figure 56 BCS assembly
EGES-390
Engine Oil Temperature (EOT) Sensor The EOP switch, a ceramic diaphragm switch, detects
engine oil pressure.
The EOP signal is monitored by the ECM for operation
of the low oil pressure warning lamp and optional
EWPS. The EOP switch completes a circuit to ground
when engine oil pressure is 31 kPa to 52 kPa (4.5 psi
to 7.5 psi) or greater.
The EOP sensor is installed in the oil filter base
assembly.
Figure 58 EOT sensor Manifold Absolute Pressure (MAP) Sensor
The EOT sensor, a thermistor sensor, detects engine

oil temperature.
The EOT signal is monitored by the ECM for inlet
air heater operation and engine fueling calculations.
The EOT signal allows the ECM to compensate
for differences in oil viscosity, due to temperature
changes.
The EOT sensor is installed in the oil filter base.
Engine Oil Pressure (EOP) Switch Figure 60 MAP sensor
The MAP sensor, a variable capacitance sensor,

measures intake manifold boost pressure.
The MAP signal is monitored by the ECM for BCS,
EGR valve, and engine fueling calculations.
The MAP sensor is installed in the right front top of the
intake manifold next to the air inlet elbow.
Figure 59 EOP switch
EGES-390
Intake Air Temperature (IAT) Sensor The MAT sensor, a thermistor sensor, detects intake
manifold air temperature.
The MAT signal is monitored by the ECM for EGR
operation.
The MAT sensor is installed in the left side of the intake
manifold toward the front of the engine.
Engine Fuel Pressure (EFP) switch
Figure 61 IAT sensor
The IAT sensor, a thermistor sensor, detects intake air

temperature.
The IAT signal is monitored by the ECM for fuel rate
and timing during cold starts.
The IAT sensor is installed in the turbocharger air
intake duct.
Manifold Absolute Temperature (MAT) Sensor Figure 63 EFP switch
The EFP, a ceramic diaphragm switch, detects fuel

supply pressure.
The EFP signal is monitored by the ECM for engine
protection in case a fuel filter restriction or other
problem results in low fuel supply pressure. The ECM
reduces ICP pressure to 14 MPa if the fuel supply
pressure drops below 30 psi.
The EFP is installed in the secondary fuel filter
Figure 62 MAT sensor housing.
EGES-390
Injection Control Pressure (ICP) Sensor The IPR valve is controlled by a ground circuit in the
ECM in response to ICP sensor input. Voltage is
supplied through the ignition switch. The IPR valve
includes a high-pressure relief valve which releases
excessive injection control pressure.
The IPR valve is installed in the left rear side of the
Intake Throttle Valve (ITV) Assembly
Figure 64 ICP sensor
The ICP sensor, a micro-strain gauge sensor,

measures injection control pressure.
The ICP signal is monitored by the ECM for closed
loop control of the IPR valve and engine fueling
calculations.
The ICP sensor is installed through the right side valve
cover in the right high-pressure oil rail.

Figure 66 Intake throttle assembly
The ITV assembly, a variable position actuator,

restricts inlet air flow to control air/fuel ratio and
increase exhaust temperature during aftertreatment
regeneration. The ITV also restricts air flow for
engine shutdowns due to Engine Warning and
Protection System (EWPS) or Idle Shutdown Timer
(IST) features, where the engine is shut-off without
Figure 65 IPR valve turning the key-off.
The ITV assembly changes valve position in response
to Pulse Width Modulated (PWM) signals from the
The IPR valve, a variable position Pulse Width
ECM.
Modulated (PWM) valve, regulates injection control
pressure. The ITV assembly is mounted on the air intake elbow.
EGES-390
Exhaust Gas Recirculation (EGR) Valve Glow plugs are compact electric heating devices that
heat the cylinders to aid cold engine starting and
reduce exhaust emissions during warm-up. There
are three glow plugs installed in each cylinder head,
one for each cylinder.
Intake Air Heater (IAH) Element
Figure 67 EGR valve
The EGR valve, a variable position electromechanical Figure 69 IAH element

valve, recirculates cooled exhaust gases into the
intake air stream to reduce NOx emissions by
reducing combustion temperatures. The IAH element is a ceramic coiled heating element
used to warm incoming air to aid cold engine starting
The EGR valve changes valve position in response to and reduce exhaust emissions during warm-up.
private Controller Area Network (CAN) digital signals
from the ECM. The ECM energizes the IAH relay, while monitoring
programmed conditions for Engine Oil Temperature
The EGR valve has three major components: a (EOT), Inlet Air Temperature (IAT), and barometric
dual poppet valve assembly, a DC motor, and an pressure.
Integrated Circuit (IC). The IC has three Hall effect
position sensors that monitor valve movement. The IAH element is installed in the front bottom center
of the intake manifold.
The EGR valve is installed in the front of the intake
manifold behind the air inlet elbow.
Glow Plug
Figure 68 Glow plug
EGES-390
Removal
WARNING: To prevent personal injury or Alternator

death, shift transmission to park or neutral, set
parking brake, and block wheels before doing
diagnostic or service procedures.

death, disconnect the main battery negative
terminal before disconnecting or connecting
electrical components.
CAUTION: To prevent engine damage, do not tug on
wiring harnesses; if resistance is felt, find the problem
and free connectors or clips.
Figure 70 Alternator and sensor harness
connections
death, do not let engine fluids stay on your skin. 1. Alternator control harness connector
Clean skin and nails using hand cleaner, and wash 2. Alternator power connector
and rags contaminated with engine fluids.
1. Disconnect battery ground cable.
2. Rotate belt tensioner clock wise to release belt
tension and remove drive belt from alternator
GOVERNMENT REGULATION: Engine pulley.
fluids (oil, fuel, and coolant) may be a threat
3. Push in the control connector tab and pull the
alternator control harness connector off the
alternator.
fluids in the trash, on the ground, in sewers 4. Pull back the rubber boot and remove the nut and
or bodies of water. alternator power connector from the alternator.
5. Remove three M10 x 80 bolts holding the
alternator to the intake manifold and remove
alternator.
EGES-390
Intake Air Temperature (IAT) Sensor Injection Pressure Regulator (IPR) Valve
Connector
1. Cut zip tie and remove IPR harness connector
heat shield.
Figure 71 IAT sensor and harness connector

1. IAT sensor
2. Locking tab (locked position)
3. Release tab
Figure 72 IPR valve and harness connector
(connector heat shield removed)
1. Pull out the harness connector locking tab. 1. IPR valve
2. IPR harness connector
2. Push in the release tab and pull the 2-pin sensor
harness connector off the IAT sensor, installed in
the turbocharger air inlet duct.
2. Release the IPR valve harness connector wire
3. Remove the IAT sensor and discard O-ring. retainer or tabs and pull 2-pin connector off the
IPR valve.
3. See “High-pressure Oil System” for IPR valve
removal.
EGES-390
Exhaust Back Pressure (EBP) Sensor Camshaft Position (CMP) Sensor
Figure 73 EBP assembly Figure 74 CMP sensor and harness connector
1. EBP sensor harness connector 1. CMP sensor harness connector

2. EBP sensor 2. M6 x 14 bolt
3. Zip tie
1. Push in the connector release tab and pull the

1. Cut zip tie holding sensor harness to EBP sensor. 2-pin sensor harness connector off the CMP
sensor, installed in the left front side of the
2. Pull the EBP sensor harness connector tab out crankcase.
and pull 3-pin connector off the EBP sensor.
2. Remove the M6 x 14 sensor retaining bolt.
3. Remove EBP sensor from tube assembly.
3. Pull the CMP sensor out of the crankcase and
discard O-ring.
EGES-390
Glow Plug Wiring Harness – Left
Figure 76 Glow Plug Connector Installer /

Remover
Figure 75 Left glow plug harness 1. Glow plug
2. Glow plug harness connector
1. Connector locking tab
3. Glow Plug Connector Remover / Installer
2. Left glow plug harness
3. Glow plug harness connector release tab
4. Remove each glow plug connector using the Glow

Plug Connector Installer / Remover (page 101)
1. Slide glow plug harness connector locking tab to
tool.
the side to unlock connector.
5. Remove and discard O-rings from glow plug
2. Push in the release tab and pull the 3-pin glow
harness connectors.
plug harness connector off the sensor harness
connector. 6. See “Cylinder Head” for glow plug removal.
3. Disconnect the glow plug harness from the
connection point on the front of the left valve
cover under the sensor harness.
EGES-390
Injector Harness Connectors – Left Engine Fuel Pressure (EFP) switch
Figure 77 Left injector harness connectors Figure 78 EFP switch
1. Zip tie 1. EFP switch

2. Injector harness connector 2. Release tab
3. Snap ring

1. Cut three zip ties holding the sensor harness to
death, do not smoke and keep fuel away from
the left valve cover.
flames and sparks.
NOTE: Do not pull snap rings out of injector harness
1. Place a suitable container under the secondary
connectors.
fuel filter housing to catch draining fuel.
2. Push each snap ring into its harness connector
2. Push in the connector release tab and pull the
and lift up to remove each of the three left side
1-pin sensor harness connector off the EFP
injector connectors.
switch, installed in the secondary fuel filter
housing.
3. Remove the EFP switch and discard O-ring.
EGES-390
Manifold Air Temperature (MAT) Sensor 1. Pull out the harness connector locking tab.
harness connector off the ECT sensor, installed in
the top left of the front cover.
3. Remove the ECT sensor and discard O-ring.
Intake Air Heater (IAH)
Figure 79 MAT sensor and harness connector

2. MAT sensor
3. Release tab
1. Pull up the harness connector locking tab.

harness connector off the MAT sensor, installed in
the left front of the intake manifold. Figure 81 IAH element and harness connection
3. Remove the MAT sensor and discard O-ring. 1. IAH element
2. Rubber boot
3. M5 nut
Engine Coolant Temperature (ECT) Sensor
1. Pull back rubber boot covering intake heater nut,

on the bottom front of the intake manifold.
2. Loosen and remove intake heater M5 nut and
cable.
3. Remove IAH element from the intake manifold.
Figure 80 ECT sensor and harness connector

2. ECT sensor
3. Release tab
EGES-390
Intake Throttle Valve (ITV) Assembly Connector Engine Oil Temperature (EOT) Sensor and Engine
Oil Pressure (EOP) Switch
Figure 82 ITV assembly and harness connector

2. Release tab
3. ITV assembly
Figure 83 EOT sensor and EOP switch
1. Pull out the harness connector locking tab. 1. EOP switch harness connector
2. EOT sensor harness connector
2. Push in the release tab and pull the sensor
3. EOT locking tab (locked position)
harness connector off the ITV assembly.
4. EOP release tab
3. See “Manifolds and Exhaust Gas Recirculation”
for ITV removal.
1. Pull up the EOT harness connector locking tab.
2. Push in the EOT connector release tab and pull
the 2-pin harness connector off the EOT sensor,
installed in the oil filter base assembly.
3. Push in the EOP connector release tab and pull
the 1-pin harness connector off the EOP switch.
4. Remove the EOP switch and the EOT sensor.
5. Remove and discard O-rings.
EGES-390
Boost Control Solenoid (BCS) Assembly Manifold Absolute Pressure (MAP) Sensor
Figure 84 BCS, harness connector, and tube

assembly Figure 85 MAP sensor and harness connector
1. BCS tube assembly 1. MAP sensor

2. BCS assembly 2. Connector release tab
3. M6 x 30 bolt
1. Pull the connector release tab up and pull the

1. Push in the BCS connector release tab and 3-pin sensor harness connector off of the MAP
pull the 2-pin harness connector off the BCS sensor, installed in the right front of the intake
assembly, installed on the air inlet elbow. manifold.
2. Pull the BCS tube assembly off the BCS 2. Remove MAP sensor and discard O-ring.
assembly, air inlet elbow, turbocharger phonemic
actuator, and air inlet duct.
3. Remove the M6 x 30 bolt securing the BCS
assembly to the air inlet elbow and remove the
BCS.
EGES-390
Exhaust Gas Recirculation (EGR) Valve Injector Harness Connectors – Right

Connector
Figure 87 Right injector harness connectors

1. Injector harness connector
Figure 86 EGR valve and harness connector 2. Snap ring
1. Connector release tab 3. Zip tie
2. EGR valve
1. Cut three zip ties holding the sensor harness to

1. Push down the EGR valve connector release tab the right valve cover.
and pull the connector off the EGR valve, mounted NOTE: Do not pull snap rings out of injector harness
in the front of the intake manifold. connectors.
2. See “Manifolds and Exhaust Gas Recirculation 2. Push each snap ring into its harness connector
(EGR)” for EGR valve removal. and lifting up to remove each of the three right side
injector connectors.
EGES-390
Crankshaft Position (CKP) Sensor Injection Control Pressure (ICP) Sensor
Figure 88 CKP sensor and harness connector

Figure 89 ICP sensor and harness connector
1. M6 x 14 bolt
2. CKP sensor 1. Connector release tab
3. Connector release tab 2. ICP sensor
1. Push down the connector release tab and pull 1. Pull the connector release tab up and pull the
the 2-pin harness connector off the CKP sensor, 3-pin sensor harness connector off the ICP
mounted in the right side of the crankcase. sensor, installed in the right high-pressure oil
manifold.
2. Remove the M6 x 14 sensor retaining bolt.
2. Remove ICP sensor and discard O-ring.
3. Pull the CKP sensor out of the crankcase and
discard O-ring.
EGES-390
Glow Plug Wiring Harness – Right
Figure 90 Right glow plug harness Figure 91 Glow Plug Connector Installer /
Remover
2. Connector release tab 1. Glow plug
3. Right glow plug harness 2. Glow plug harness connector
3. Glow Plug Connector Remover / Installer
1. Slide the connector locking tab to the side to

unlock connector. 4. Remove each glow plug connector using the Glow
2. Push in the release tab and pull the 3-pin glow
tool.
plug harness connector off the sensor harness
connector. 5. Remove and discard O-rings from glow plug
harness connectors.
3. Disconnect the glow plug harness from the
connection point on the right front lifting eye. 6. See “Cylinder Head” for glow plug removal.
EGES-390
Engine Sensor Wiring Harnesses

NOTE: Refer to Removal procedures for location
photos of individual components.
1. Disconnect the main negative (-) battery cable.
2. Disconnect the alternator (page 69) harness
connectors.
3. Disconnect the IAT sensor (page 70) harness
connector.
4. Remove the turbocharger intake air duct.
5. Disconnect the IPR valve (page 150), EBP sensor
(page 71), and CMP sensor harness connectors.
Figure 93 Sensor wiring harness connection

points – intake manifold
1. M6 nut on stud in right front of intake manifold
2. M6 nut on air intake elbow stud
10. Remove the M6 nut holding the sensor wiring

harness to the air intake elbow stud.
11. Disconnect the EOT sensor and EOP switch
(page 75) harness connectors.
12. Disconnect the BCS assembly (page 76), MAP
sensor, and EGR valve (page 77) harness
connectors.
13. Remove the M6 nut holding the sensor wiring
harness to the top right front of the intake
manifold.
Figure 92 CMP sensor wiring harness 14. Cut zip ties and remove sensor wiring harness
connection point – left cylinder head from right side injector connectors (page 77).
15. Disconnect wiring harness connections from the
starter.
6. Disconnect the CMP sensor wiring harness from
connection point on the left front cylinder head. 16. Disconnect the CKP sensor (page 78) and ICP
sensor harness connectors.
7. Remove left side glow plug harness (page 72).
17. Cut zip ties and disconnect sensor wiring harness
8. Cut zip ties and remove sensor wiring harness connection point on the front of the right cylinder
from left side injector connectors (page 73). head.
9. Disconnect the EFP switch (page 73), MAT 18. Remove the right glow plug harness (page 79).
sensor (page 74), ECT sensor, IAH element, and
ITV assembly (page 75) harness connectors.
EGES-390
Figure 94 Sensor wiring harness connection points – right valve cover

1. M6 x 16 bolt 2. Stud bolts
19. Remove M6 x 16 bolt from right valve cover and 21. Pull out and disconnect the sensor harness
remove the sensor wiring harness bracket from connectors from the ECM.
valve cover stud bolts.
22. Disconnect the IAH relay and the glow plug relay
20. Press two ECM sensor harness connector lever (page 83) harness connectors.
release tabs and carefully pull open the connector
lever.
EGES-390
Electronic Control Module (ECM)

1. Disconnect ground (-) cable from battery.
Figure 95 ECM and ECM mounting bracket

1. ECM mounting bracket (chassis 3. Vibration isolator grommet (8) 6. M8 stud bolt
mounted) 4. Vibration isolator bushing (4)
2. ECM 5. M8 x 45 bolt (3)
2. Disconnect engine sensor harness and chassis 3. Remove three M8 x 45 bolts, one M8 stud bolt and
harness connectors from the ECM. Press remove the ECM.
connector release tabs, rotate connector lever,
4. Remove the vibration isolator bushings and
and pull each connector out of the ECM.
grommets.
EGES-390
Glow Plug and Intake Air Heater (IAH) Relays

1. Disconnect ground (-) cable from battery.
Figure 96 Glow plug relay and IAH relay

1. ECM mounting bracket 3. Intake Air Heater (IAH) relay
2. Glow plug relay 4. M6 nut (4)
2. Disconnect engine sensor harness from the glow 3. Remove four M6 nuts and remove the glow plug
plug relay and the IAH relay. relay and the IAH relay.
EGES-390
Cleaning and Inspection Sensors and Actuators

NOTE: See EGES-395 Diagnostic Manual for further 1. Check all connector pins on sensors and
inspection and repair of engine electrical components actuators. If any are bent or corroded, replace
and systems. that sensor or actuator.
Engine Sensor Wiring Harness 2. Remove any scale or carbon build up.
1. Carefully inspect wiring harness for bent, missing 3. Check for sensor or actuator body cracks or other
or broken retaining clips, worn or cut conduit, indications of leakage.
frayed insulation, or heat damage to wires.
4. If any sensor orifices or actuators are plugged,
Repair or replace as necessary.
replace sensor or actuator as necessary.
2. Check engine wiring harness connectors,
connector covers, seals, and cover shields for
damage, cracks, cuts, or worn areas. Replace as Glow Plug Harness
required.
1. Inspect left and right glow plug wiring harness
3. Inspect each sensor and actuator connector for assemblies for defective or twisted O-rings and
the following, replace as required: pin recesses that are corroded.
• Chaffing 2. Wipe down glow plug harness assemblies with a
shop towel. Do not use solvents. Inspect the glow
• Cracked connector body.
plug harness for missing or damaged O-rings,
• Bent, missing, or broken socket pins. replace as necessary.
• Corroded connectors (green or gray) and
white deposits on metal terminals.
ECM Assembly
• Terminals incorrectly latched in connector
1. Inspect rubber seal on harness connector and in
body or “pushed back” relative to other
ECM assembly pin recesses.
terminals in same connector.
2. Check for bent pins in ECM assembly
• Damaged or missing O-rings or seals.
connections.
NOTE: Make sure each connector has its
ribbed seal in place. In some cases, upon
disassembly, a ribbed seal may pull off of its
connector and remain in the mating socket
of a sensor or actuator. A connector that is
assembled without the appropriate ribbed seal
can become contaminated with moisture and
corrode terminals, resulting in a poor electrical
connection.
EGES-390
Installation
Glow Plug and Intake Air Heater (IAH) Relays
Figure 97 Glow plug relay and IAH relay

1. ECM mounting bracket 3. Intake Air Heater (IAH) relay
2. Glow plug relay 4. M6 nut (4)
1. Install the glow plug relay and the IAH relay on the 3. Connect the engine sensor harness to the glow
ECM mounting bracket and install four M6 nuts plug relay and the IAH relay.
finger tight.
2. Tighten M6 nuts to standard torque (page 400).
EGES-390
Electronic Control Module (ECM)
Figure 98 ECM and ECM mounting bracket

1. ECM mounting bracket (chassis 3. Vibration isolator grommet (8) 6. M8 stud bolt
mounted) 4. Vibration isolator bushing (4)
2. ECM 5. M8 x 45 bolt (3)
1. Install eight vibration isolator grommets and four 3. Tighten three M8 x 45 bolts and one M8 stud bolt
bushings on the ECM. to standard torque (page 400).
2. Install the ECM on the ECM mounting bracket and 4. Install the sensor harness connector into the ECM
finger tighten three M8 x 45 bolts and one M8 stud and close the connector lever until it locks in place.
bolt.
EGES-390
Glow Plug Wiring Harness – Right

1. See “Cylinder Head” for glow plug installation.
Figure 100 Right glow plug harness

2. Connector release tab
3. Right glow plug harness

Remover 4. Connect the 3-pin glow plug harness connector to
the sensor harness connector.
1. Glow plug
2. Glow plug harness connector 5. Slide the connector locking tab in, to lock the
3. Glow Plug Connector Remover / Installer connector.
6. Attach the glow plug harness to connection point
on the right front lifting eye.
2. Install a new O-ring on each of the right glow
plug harness connectors and lubricate with clean
engine oil.
3. Install each glow plug connector using the Glow
tool.
EGES-390
Injection Control Pressure (ICP) Sensor Crankshaft Position (CKP) Sensor
Figure 102 CKP sensor and harness connector

Figure 101 ICP sensor and harness connector
1. M6 x 14 bolt
1. Connector release tab 2. CKP sensor
2. ICP sensor 3. Connector release tab
1. Install a new O-ring on the ICP sensor and 1. Install a new O-ring on the CKP sensor and
lubricate with clean engine oil. lubricate with clean engine oil.
2. Install the ICP sensor into the right high-pressure 2. Install the CKP sensor in the right side of the
oil manifold and tighten to special torque (page crankcase.
101).
3. Install the M6 x 14 sensor retaining bolt and
3. Connect the 3-pin sensor harness connector to tighten to standard torque (page 400).
the ICP sensor.
4. Connect the 2-pin sensor harness connector to
the CKP sensor.
EGES-390
Injector Harness Connectors – Right
Figure 104 Right injector harness connectors

1. Harness connector
Figure 103 Injector and sensor harness 2. Snap ring
connections 3. Zip tie
1. Sensor harness connector

2. Injector connector 2. Install three zip ties to hold the sensor harness to
the right valve cover.
1. Connect sensor harness connectors to three right

side injector connectors, installed in the right
rocker arm carrier. A “click” can be heard when
connectors are seated.
EGES-390
Exhaust Gas Recirculation (EGR) Valve Manifold Absolute Pressure (MAP) Sensor
Connector
Figure 105 EGR valve and harness connector

Figure 106 MAP sensor and harness connector
2. EGR valve 1. MAP sensor
1. See “Manifolds and Exhaust Gas Recirculation

(EGR)” for EGR valve installation. 1. Install a new O-ring on the MAP sensor.
2. Connect the sensor harness connector to the 2. Install the MAP sensor into the right front of the
EGR valve, installed in the front of the intake intake manifold and tighten to special torque
manifold. (page 101).
the MAP sensor.
EGES-390
Boost Control Solenoid (BCS) Assembly Engine Oil Temperature (EOT) Sensor and Engine
Oil Pressure (EOP) Switch
Figure 107 BCS, harness connector, and tube

assembly
1. BCS tube assembly
Figure 108 EOT sensor and EOP switch
2. BCS assembly 1. EOP switch harness connector
3. M6 x 30 bolt 2. EOT sensor harness connector
3. EOT locking tab (locked position)
4. EOP release tab
1. Install the BCS assembly and M6 x 30 bolt on the
air inlet elbow.
2. Tighten M6 x 30 bolt to standard torque (page 1. Install a new O-ring on the EOT sensor and EOP
400). switch.
3. Install the BCS tube assembly on the BCS 2. Lubricate O-rings with clean engine oil.
assembly, air inlet elbow, turbocharger phonemic 3. Install the EOT sensor and EOP switch into the oil
actuator, and air inlet duct. filter base assembly and tighten each to its special
4. Connect the 2-pin sensor harness connector to torque (page 101).
the BCS assembly. 4. Connect the 2-pin sensor harness connector to
the EOT sensor and connect the 1-pin connector
to the EOP switch.
5. Push in the EOT harness connector locking tab.
EGES-390
Intake Throttle Valve (ITV) Assembly Connector Intake Air Heater (IAH)
Figure 109 ITV assembly and harness connector

Figure 110 IAH element and harness connection
2. Release tab
3. ITV assembly 1. IAH element
2. Rubber boot
3. M5 nut
1. See “Manifolds and Exhaust Gas Recirculation”
for ITV assembly installation.
1. Install the IAH element into the intake manifold
2. Connect the sensor harness connector to the ITV
and tighten to special torque (page 101).
assembly.
2. Install the intake heater M5 nut and cable.
3. Push in the harness connector locking tab.
3. Tighten M5 nut to special torque.
4. Install rubber boot covering intake heater nut.
EGES-390
Engine Coolant Temperature (ECT) Sensor 1. Install a new O-ring on the MAT sensor.
2. Install the MAT sensor into the left front of the
intake manifold and tighten to special torque
(page 101).
the MAT sensor.
Engine Fuel Pressure (EFP) switch
Figure 111 ECT sensor and harness connector

2. ECT sensor
3. Release tab
1. Install a new O-ring on the ECT sensor.

2. Install the ECT sensor into the top left of the front
cover and tighten to special torque (page 101).
the ECT sensor.
Manifold Air Temperature (MAT) Sensor Figure 113 EFP switch

1. EFP switch
2. Release tab

flames and sparks.
1. Install a new O-ring on the EFP.
2. Install the EFP into the secondary fuel filter
housing and tighten to special torque (page 101).
the EFP.
Figure 112 MAT sensor and harness connector
2. MAT sensor
3. Release tab
EGES-390
Injector Harness Connectors – Left
Figure 114 Injector and sensor harness

connections
1. Sensor harness connector Figure 115 Left injector harness connectors
2. Injector connector 1. Zip tie
2. Injector harness connector
3. Snap ring
1. Connect sensor harness connectors to three
left side injector connectors, installed in the left
rocker arm carrier. A “click” can be heard when 2. Install three zip ties to hold the sensor harness to
connectors are seated. the left valve cover.
EGES-390
Glow Plug Wiring Harness – Left

1. See “Cylinder Head” for glow plug installation.
Figure 117 Left glow plug harness

2. Left glow plug harness
3. Glow plug harness connector release tab
Remover
1. Glow plug
2. Glow plug harness connector 4. Connect the 3-pin glow plug harness connector to
3. Glow Plug Connector Remover / Installer the sensor harness connector.
5. Slide the connector locking tab in, to lock the
connector.
2. Install a new O-ring on each of the three left glow
plug harness connectors and lubricate with clean 6. Attach the glow plug harness to connection point
engine oil. on the front of the left valve cover under the sensor
harness.
3. Install each glow plug connector using the Glow
tool.
EGES-390
Camshaft Position (CMP) Sensor Exhaust Back Pressure (EBP) Sensor
Figure 118 CMP sensor and harness connector Figure 119 EBP assembly
1. CMP sensor harness connector 1. EBP sensor harness connector
2. M6 x 14 bolt 2. EBP sensor
3. Zip tie
1. Install a new O-ring on the CMP sensor and

lubricate with clean engine oil.
1. Install the EBP sensor into the tube assembly
2. Install the CMP sensor in the left front side of the attached to the left exhaust manifold and tighten
crankcase. to special torque (page 101).
3. Install the M6 x 14 sensor retaining bolt and 2. Connect the 3-pin sensor harness connector to
tighten to standard torque (page 400). the EBP sensor.
4. Connect the 2-pin sensor harness connector to 3. Attach a zip tie to hold the sensor harness to the
the CMP sensor. EBP sensor.
EGES-390

Connector
1. See “High-pressure Oil System” for IPR valve
installation.
Figure 120 IPR valve and harness connector (connector heat shield removed)
1. IPR valve 2. IPR harness connector
2. Install 2-pin IPR valve harness connector into the 3. Install IPR harness connector heat shield and
IPR valve. secure heat shield with a zip tie.
EGES-390
Intake Air Temperature (IAT) Sensor Alternator
Figure 121 IAT sensor and harness connector

Figure 122 Alternator and sensor harness
1. IAT sensor connections
3. Release tab 1. Alternator control harness connector
2. Alternator power connector
1. Install a new O-ring on the IAT sensor.

1. Install three M10 x 80 bolts holding the alternator
2. Install the IAT sensor into the turbocharger air to the intake manifold.
intake duct and tighten to special torque (page
101). 2. Tighten three M10 x 80 bolts to special torque
(page 101).
the IAT sensor. 3. Install the alternator power connector nut and
tighten to special torque.
4. Install the rubber boot over the power connector
nut.
5. Install the alternator control harness connector.
EGES-390
Engine Sensor Wiring Harnesses 8. Connect wiring harness connections to the starter.
NOTE: Refer to Installation procedures for location 9. Install sensor wiring harness to the right side
photos of individual components. injector connectors (page 89) and install new zip
ties.
1. Connect the IAH relay and the glow plug relay
(page 85) harness connectors.
2. Install the sensor harness connectors into the
ECM (page 86) and close the connector lever
until it locks in place.
Figure 124 Sensor wiring harness connection

points – intake manifold
Figure 123 Sensor wiring harness connection 1. M6 nut on stud in right front of intake manifold
points – right valve cover 2. M6 nut on air intake elbow stud
1. M6 x 16 bolt
2. Stud bolt (2) 10. Install M6 nut holding the sensor wiring harness to
the top right front of the intake manifold. Tighten
M6 nut to standard torque (page 400).
3. Install the sensor wiring harness bracket on the
right valve cover stud bolts. 11. Connect the EGR valve (page 90), MAP sensor,
BCS assembly (page 91), EOT sensor, and EOP
4. Install M6 x 16 bolt on the right valve cover and switch harness connectors.
tighten to standard torque (page 400).
12. Install the M6 nut holding the sensor wiring
5. Install the right glow plug harness (page 87). harness to the air intake elbow stud. Tighten M6
6. Connect the sensor wiring harness to connection nut to standard torque (page 400).
point on the front of the right cylinder head and 13. Connect the ITV assembly (page 92), IAH
install zip ties. element, ECT sensor (page 93), MAT sensor,
7. Connect the ICP sensor (page 88) and CKP and EFP switch harness connectors.
sensor harness connector.
EGES-390
14. Install sensor wiring harness on the left side

injector connectors (page 94) and install new zip
ties.
15. Install left side glow plug harness (page 95).
Figure 125 CMP sensor wiring harness connection point – left cylinder head
16. Connect the CMP sensor wiring harness to 19. Connect the IAT sensor (page 98) harness
connection point on the left front cylinder head. connector.
17. Connect the CMP sensor (page 96) , EBP sensor, 20. Connect the alternator (page 98) harness
and IPR valve (page 97) harness connectors. connectors.
18. Install the turbocharger air intake duct.
EGES-390
Specifications
Glow plugs 10.9 V to 11.1 V

Intake Air Heater (IAH) 60 Amps
Camshaft Position (CMP) sensor operating speed 30 rpm to 3000 rpm
Crankshaft Position (CKP) sensor operating actuator speed 15 rpm to 2000 rpm
Special Torque
Alternator M10 x 80 mounting bolts 48 N·m (35 lbf·ft)

Alternator power connector nut 8 N·m (71 lbf·in)
Engine Coolant Temperature (ECT) sensor 17.5 N·m (154 lbf·in)
Engine Oil Pressure (EOP) sensor 14 N·m (124 lbf·in)
Engine Oil Temperature (EOT) sensor 17.5 N·m (154 lbf·in)
Exhaust Back Pressure (EBP) sensor 20 N·m (178 lbf·in)
Engine Fuel Pressure (EFP) switch 14 N·m (124 lbf·in)
Injection Control Pressure (ICP) sensor 17 N·m (150 lbf·in)
Intake Air Heater (IAH) element 61 N·m (45 lbf·ft)
Intake Air Heater (IAH) element M5 cable nut 4 N·m (35 lbf·in)
Intake Air Temperature (IAT) sensor 14 N·m (124 lbf·in)
Manifold Absolute Pressure (MAP) sensor 11.5 N·m (101 lbf·in)
Manifold Air Temperature (MAT) sensor 14 N·m (124 lbf·in)
Glow Plug Connector Installer / Remover ZTSE4670
EGES-390
EGES-390
DUAL STAGE TURBOCHARGER ASSEMBLY 103
Table of Contents
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109
Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .110
Exhaust Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .111
Dual Turbocharger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112
Disassembly of Dual Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .113
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115

Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Related Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Disassembly Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Visual and Mechanical Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .115
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Assembly of Dual Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118
Dual Turbocharger. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .120
Exhaust Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .121
Turbocharger and Exhaust Tube Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .122
Oil Supply Line. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Air Inlet Duct. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .123
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .124
EGES-390
104 DUAL STAGE TURBOCHARGER ASSEMBLY
EGES-390
Illustrations
Figure 126 Dual stage turbocharger flow and

components
1. Inlet air flow
2. Compressed air flow
3. Exhaust flow
4. Low-pressure compressor
5. Pneumatic actuator
6. High-pressure turbine
7. High-pressure turbocharger air outlet
8. High-pressure compressor
9. Turbocharger bypass valve
10. Exhaust flow with bypass valve open
11. Normal exhaust flow with bypass valve closed
12. Low-pressure turbine
EGES-390
Figure 127 Dual stage turbocharger assembly
EGES-390
1. Crossover tube 15. O-ring 26. Crankcase breather hose

2. V-band clamp 16. Low-pressure turbocharger oil assembly
3. High-pressure compressor drain tube 27. M6 x 16 bolt
4. M12 bonded seal type B washer 17. Turbocharger oil drain O-ring 28. Turbocharger worm gear clamp
5. M12 Bango bolt 18. M8 x 25 bolt (2) 29. M6 x 30 bolt
6. Turbocharger oil supply tube 19. High-pressure turbocharger oil 30. Boost Control Solenoid (BCS)
assembly drain upper adaptor assembly
7. M6 x 16 bolt 20. M6 x 25 bolt (2) 31. BCS tube harness assembly
8. Turbo SPL seal 21. High-pressure turbocharger oil
9. M6 x 20 bolt drain lower housing
10. O-ring seal 22. O-ring
11. Low-pressure turbine 23. High-pressure turbocharger oil
12. M8 x 55 bolt (3) drain tube
13. M10 x 25 high-temp locking stud 24. High-pressure turbocharger oil
(3) drain housing tube
14. Turbocharger spacer 25. Air inlet duct assembly
EGES-390
Figure 128 Exhaust tube assembly

1. Exhaust tube assembly 4. M8 x 50 exhaust flange bolt (4) 7. M8 x 27 high temp bolt (3)
2. Turbocharger inlet gasket 5. M8 nut (4)
3. M10 x 30 high temp bolt (4) 6. Exhaust gasket
EGES-390
Removal Air Inlet Duct



death, allow engine to cool before working with
components.

death, disconnect ground (-) cable from battery Figure 129 Air inlet duct assembly
before doing service or diagnostic procedures.
1. Worm gear clamp
2. Crankcase breather hose
3. M6 x 16 bolt
death, inspect turbocharger with engine off,
4. Boost Control Solenoid (BCS) tubing
and turbocharger not spinning. Turbocharger
components may be extremely hot. Turbocharger
wheels are very sharp and spin at high speeds.
1. Remove the BCS tubing from the air inlet duct and
pneumatic actuator.
2. Remove the M6 x 16 bolt holding the air inlet duct
to the intake manifold.
3. Remove the air inlet duct crankcase breather
hose from the crankcase breather on the left
valve cover.
Clean skin and nails using hand cleaner, and wash 4. Loosen the worm gear clamp and remove the air
with soap and water. Wash or discard clothing inlet duct.
NOTE: See Boost Control Solenoid (BCS) Assembly
(page 76) for BCS removal.
GOVERNMENT REGULATION: Engine
or bodies of water.
EGES-390
Oil Supply Line
Figure 130 Turbocharger oil supply line

1. M12 Bango bolt and seal 2. M6 x 16 bolt
washers 3. M6 x 20 bolt
1. Remove M12 banjo bolt and seal washers from 4. Pull up and remove the oil supply line.
the high-pressure turbocharger. Discard seal
5. Remove and discard two oil supply line O-rings.
washers.
6. Cap oil ports to prevent foreign material from
2. Remove M6 x 16 bolt from the low-pressure
entering.
turbocharger.
3. Remove M6 x 20 bolt from the oil filter housing.
EGES-390
Exhaust Tubing

1. Exhaust tube assembly 3. Turbocharger inlet gasket 5. M8 x 27 bolts (3)
2. M10 x 30 high temp bolts (4) 4. M8 x 50 bolts and M8 nuts (2) 6. M8 x 50 bolts and M8 nuts (2)
1. Remove two M8 x 50 bolts and nuts securing 5. Remove and discard the turbocharger inlet gasket
the exhaust tube assembly to the left exhaust and EGR cooler exhaust gasket.
manifold.
6. Remove turbocharger exhaust tube assembly.
2. Remove two M8 x 50 bolts and nuts securing
7. Use protective caps to cover all openings. See
the exhaust tube assembly to the right exhaust
Cap Kit (all) Special Service Tools (page 124). If
manifold.
plastic caps are not available, cover openings with
3. Remove the three M8 x 27 bolts securing the tape.
exhaust tube assembly to the EGR cooler.
4. Remove four M10 x 30 bolts securing the exhaust
tube assembly to the turbocharger.
EGES-390
Dual Turbocharger Assembly
Figure 133 Turbocharger spacer, O-ring, and

drain housing
1. Turbocharger spacer
2. Low-pressure turbocharger oil drain tube O-ring
3. M6 x 25 bolt (2)
Figure 132 Turbocharger mounting bolts 4. High-pressure turbocharger oil drain lower housing
assembly
1. M8 x 55 bolt (3)
3. Remove the turbocharger spacer and

low-pressure turbocharger oil drain tube
1. Remove three M8 x 55 turbocharger mounting
O-ring from the high-pressure oil pump cover.
bolts.
Discard O-ring.
2. Lift up and remove turbocharger assembly from
4. Remove two M6 x 25 bolts and remove the
engine.
high-pressure turbocharger oil drain lower
housing assembly.
EGES-390
Disassembly of Dual Turbocharger
Figure 135 Turbocharger assembly crossover

Figure 134 Dual turbocharger assembly (bottom tube
view)
1. Crossover tube
1. M8 x 25 bolt (2) 2. V-band clamp
2. Low-pressure turbocharger oil drain tube
3. M8 x 25 bolt (2)
4. High-pressure turbocharger oil drain tube 4. Loosen the crossover tube V-band clamp.
5. High-pressure turbocharger oil drain upper adaptor
5. Pull out and remove the crossover tube.

low-pressure turbocharger oil drain tube. Discard
tube O-ring.
2. Remove the high-pressure turbocharger oil drain
tube.
high-pressure turbocharger oil drain upper
adaptor. Discard O-ring.
Figure 136 Crossover tube O-ring seal
6. Remove and discard the crossover tube O-ring

seal.
EGES-390
Figure 138 Crossover tube seal removal
10. Install a Slide Hammer on the Turbo Crossover

Figure 137 Crossover tube seal Tube Seal Remover / Installer.
1. Vise 11. Pull the crossover tube seal out and discard.
2. Turbo Crossover Tube Seal Remover / Installer
3. Crossover tube seal
7. Place Turbo Crossover Tube Seal Remover /

Installer (page 124) holding fixture into vise and
clamp securely.
8. Place crossover tube into holding fixture and
clamp securely.
9. Install the Turbo Crossover Tube Seal Remover /
Installer into the crossover tube seal.
Figure 139 Turbine housing alignment marks
12. Using a permanent marker, place alignment

marks over both high and low-pressure
turbochargers and the turbine mating V-band
clamp.
13. Remove the turbine mating V-band clamp.
NOTE: The Pneumatic actuator is not serviceable.
EGES-390
Cleaning and Inspection • Engine over fueling can cause excessive

temperatures which can cause aluminum
components to melt.
NOTE: Do not use caustic solutions to clean
turbocharger or related components.
Turbocharger
Clean turbocharger assembly and bracket with a
suitable solvent and nylon brush. Dry with filtered
compressed air.
Related Components
1. Rinse the inside of the oil supply tube with parts
cleaning solvent. Remove all solvent from inside
tube.
Figure 140 Turbocharger wheel rotation
2. Clean turbocharger mounting bracket, exhaust inspection
piping, and oil drain tubing with parts cleaning
solvent.
1. Each turbocharger shaft must spin freely when
turned by hand. Inspect turbine and compressor
Disassembly Inspection housing for evidence of wheel rubbing, blade
If the turbocharger does not meet the following erosion, bending, or breakage. Replace
requirements, it must be replaced: turbocharger assembly if any of these conditions
are found.
2. Perform same steps on adjacent turbocharger.
Visual and Mechanical Inspection
3. Inspect oil supply line for kinks, clogs, restrictions.
NOTE: Replace turbocharger if any impeller or turbine
blades are bent. Do not attempt to straighten blades. 4. Inspect oil drain tubes for clogs, restrictions, and
other defects.
Compressor impeller and turbine wheel deposits can
be caused by the following:
• High air inlet restriction allows oil to transfer
from the turbocharger center housing, resulting
in oil deposits. Excessive oil consumption can
result in turbine wheel carbon deposits. Replace
turbocharger if turbine wheel deposits can not be
cleaned off.
EGES-390
Figure 141 Checking axial end play
5. With turbocharger in a stable position, place tip d. If measurement exceeds Specifications

of a dial indicator with magnetic base (page 124) (page 124), turbocharger assembly must
onto end of shaft (turbine side). be replaced.
a. Push shaft in either direction and hold in 6. Perform the previous steps on adjacent
position. turbocharger.
b. Zero dial indicator face and needle.
c. Pull shaft in opposite direction and record
measured distance on dial face.
EGES-390
Figure 142 Left – boost control test setup, Right – actuator rod
1. Boost control diaphragm 2. Shop air pressure regulator
7. Proceed with the following steps to inspect the c. Slowly regulate shop air to approximately 103
boost control actuator: kPa (15 psi) and observe the actuator arm. It
should begin to move at this pressure.
a. Remove tubing from boost control diaphragm.
d. If the actuator rod does not begin to move at
b. Connect shop air and pressure regulator to
103 kPa (15 psi) or if diaphragm is leaking,
the boost control diaphragm.
replace the dual turbocharger assembly.
CAUTION: To prevent engine damage, do not
exceed 207 kPa (30 psi) to the boost control
diaphragm.
EGES-390
Installation 2. Secure Turbo Crossover Tube Seal Remover /

Installer (page 124) holding fixture into a bench
NOTE: Apply a light coat of clean engine oil on bolt
vise.
threads and under bolt head when installing used nuts
and bolts. 3. Install crossover tube into holding fixture and
tighten clamps.
Assembly of Dual Turbocharger
4. Position seal onto crossover tube and drive seal
into crossover tube until seal is seated, using
Turbo Crossover Tube Seal Remover / Installer.
Figure 143 Turbine housing alignment marks
1. Install the high-pressure turbine housing on the Figure 145 Small crossover seal
low-pressure turbine housing and loosely install
the V-band clamp. Align turbine housing marks.
Do not tighten V-band clamp at this time. 5. Install a new O-ring seal onto short end of
crossover tube.
Figure 144 Crossover tube seal installation
EGES-390
Figure 147 Turbocharger oil drain tubes

Figure 146 Turbocharger crossover tube
1. M8 x 25 bolt (2)
1. Crossover tube 2. Low-pressure turbocharger oil drain tube
2. V-band clamp 3. M8 x 25 bolt (2)
4. High-pressure turbocharger oil drain tube
5. High-pressure turbocharger oil drain upper adaptor
6. Install the V-band clamp onto the crossover tube.
7. Install crossover tube onto turbocharger
CAUTION: To prevent engine damage, do not pinch
assembly. A slight twisting motion may be
O-rings when installing turbocharger oil drain tubes.
necessary to start the long end of tube.
8. Install a new O-ring on the low-pressure
turbocharger oil drain tube and high-pressure
oil drain upper adaptor. Lubricate O-rings with
clean engine oil.
9. Install the low-pressure oil drain tube and finger
tighten two M8 x 25 bolts.
10. Install the high-pressure oil drain upper adaptor
and finger tighten two M8 x 25 bolts.
11. Tighten four M8 x 25 bolts to standard torque
(page 400).
EGES-390
Dual Turbocharger
Figure 148 Turbocharger spacer, O-ring, and

drain housing
Figure 149 Turbocharger mounting bolts
1. M8 x 55 bolt (3)
2. Low-pressure turbocharger oil drain tube O-ring
3. M6 x 25 bolt (2)
4. High-pressure turbocharger oil drain lower housing
assembly
5. Carefully install the dual turbocharger assembly
on the engine. Align the high-pressure oil drain
tube into oil drain housing.
1. Install a new low-pressure oil drain tube O-ring
and lubricate with clean engine oil. 6. Install three M8 x 55 bolts and finger tighten.
2. Install the high-pressure oil drain lower housing
and tighten two M6 x 25 bolts to standard torque
(page 400).
3. Install high-pressure turbocharger oil drain tube
(Figure 147) on the high-pressure oil drain lower
housing assembly.
4. Install the turbocharger spacer on the
high-pressure oil pump cover.
EGES-390
Exhaust Tubing

1. Exhaust tube assembly 3. Turbocharger inlet gasket 5. M8 x 27 bolts (3)
2. M10 x 30 high temp bolts (4) 4. M8 x 50 bolts and M8 nuts (2) 6. M8 x 50 bolts and M8 nuts (2)
1. Apply anti-seize to four M10 x 30 and three M8 x 5. Install a new exhaust gasket between the EGR
27 bolts. cooler and the exhaust tubing. Install three M8 x
27 bolts finger tight.
2. Apply a light coat of clean engine oil to four M8 x
50 bolts and M8 nuts. 6. Install two M8 x 50 bolts and nuts securing
the exhaust tube assembly to the right exhaust
3. Install the exhaust tube assembly on the engine
manifold and finger tighten bolts
and install a new turbocharger inlet gasket
between the turbocharger assembly and the 7. Install two M8 x 50 bolts and nuts securing
exhaust tube assembly. the exhaust tube assembly to the left exhaust
manifold and finger tighten bolts
4. Install four M10 x 30 high temp bolts securing the
exhaust tube assembly to the turbocharger and
finger tighten bolts.
EGES-390
Turbocharger and Exhaust Tube Torque

Sequence

1. M8 x 55 bolt (3) 3. M8 x 27 bolt (3) 5. V-band clamp (crossover tube)
2. M8 x 50 bolts and M8 nuts (4) 4. M10 x 30 high temp bolts (4) 6. Turbine V-band clamp
1. Tighten three M8 x 55 turbocharger mounting 3. Tighten three M8 x 27 bolts securing the exhaust
bolts to standard torque (page 400). tube assembly to the EGR cooler to standard
torque.
2. Tighten two M8 x 50 bolts and nuts securing the
exhaust tube assembly to each exhaust manifold 4. Tighten four M10 x 30 high temp bolts securing
in the following order: the exhaust tube assembly to the turbocharger to
standard torque.
A. Tighten M8 x 50 bolts and nuts to 10.3
N·m (91 lbf·in). 5. Tighten the crossover tube V-band clamp to
special torque (page 124).
B. Tighten M8 x 50 bolts and nuts to 20.6
N·m (183 lbf·in). 6. Verify alignment marks are together, then tighten
the turbine V-band clamp to special torque.
C. Tighten M8 x 50 bolts and nuts to 31 N·m
(23 lbf·ft).
EGES-390
Oil Supply Line Air Inlet Duct
Figure 153 Air inlet duct assembly

Figure 152 Turbocharger oil supply line 1. Worm gear clamp
1. M12 Bango bolt and seal washers 2. Crankcase breather hose
2. M6 x 16 bolt 3. M6 x 16 bolt
3. M6 x 20 bolt 4. Boost Control Solenoid (BCS) tubing
1. Lubricate oil inlet hole of each turbocharger 1. Install air inlet duct onto the turbocharger.
assembly with clean engine oil, spinning 2. Install the crankcase breather hose to the
compressor wheel several times to allow oil crankcase breather on the left valve cover.
to reach bearings. Refill oil inlet hole prior to
installing oil supply line. 3. Install the M6 x 16 bolt and tighten to the standard
torque (page 400).
2. Install two new O-ring seals on the oil supply line.
4. Tighten worm gear clamp to special torque (page
3. Uncap oil ports and install turbocharger oil 124).
supply line into oil filter housing and low-pressure
turbocharger. 5. Install BCS tubing.
4. Install M6 x 20 and M6 x 16 bolts and tighten to

standard torque (page 400). NOTE: See Boost Control Solenoid (BCS) Assembly
(page 91) for BCS installation.
5. Install M12 banjo bolt and two new seal washers
into the high-pressure turbocharger.
6. Tighten M12 banjo bolt to special torque (page
124).
EGES-390
Specifications
Maximum turbine shaft axial end play (LP turbocharger) 0.091 mm (0.0036 in)
Maximum turbine shaft radial shaft movement (clearance) (LP turbocharger) 0.5 mm (0.02 in)
Maximum turbine shaft axial end play (HP turbocharger) 0.091 mm (0.0036 in)
Maximum turbine shaft radial shaft movement (clearance) (HP turbocharger) 0.5 mm (0.02 in)
Special Torque
Air inlet duct worm gear clamp 5 N·m (48 lbf·in)

Bango bolt, M12 24 N·m (18 lbf·ft)
Boost Control Solenoid mounting bolt, M6 x 30 9 N·m (79 lbf·in)
See Turbocharger and
Exhaust tubing to exhaust manifold, M8 x 50 Exhaust Tube Torque
Sequence (page 122).
Low-pressure turbine exhaust outlet studs 22 N·m (16 lbf·ft)
V-band clamp (crossover tube) 7 N·m (62 lbf·in)
V-band clamp (turbine mating) 10 N·m (88 lbf·in)
Cap Kit (all) ZTSE4610

Dial indicator with magnetic base Obtain locally
Intake Guard ZTSE4293
Turbo Crossover Tube Seal Remover / Installer ZTSE4676
Slide Hammer ZTSE4398A
EGES-390
MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR) 125
Table of Contents
Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Intake Throttle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .129
Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .130
Exhaust Gas Recirculation (EGR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .131
Intake Manifold and EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .132
Exhaust Gas Recirculation (EGR) Cooler. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .133
Cleaning, Inspection and Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

Exhaust Manifold Warpage Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134
Intake Manifold. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .135
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Intake Manifold and EGR Cooler Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .136
Intake Throttle Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .139
Exhaust Manifolds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .140
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142
EGES-390
126 MANIFOLDS AND EXHAUST GAS RECIRCULATION (EGR)
EGES-390
Exploded Views
Figure 154 Intake manifold and EGR components

1. M6 x 25 bolt 11. Manifold Air Pressure sensor 20. EGR cooler
2. Intake throttle assembly 12. O-ring 21. Coolant hose assembly with
3. Intake throttle gasket 13. M6 x 55 x 20 stud bolt (2) clamps
4. Intake elbow assembly 14. M6 x 80 bolt (10) 22. EGR cooler to manifold gasket
5. M6 x 25 bolt (5) 15. M6 x 25 EGR cooler mounting 23. O-ring seal
6. M6 x 25 stud bolt bolt 24. M6 x 80 stud bolt (2)
7. M8 x 35 bolt (2) 16. EGR cooler insulator 25. O-ring
8. EGR valve seal 17. Intake manifold 26. MAT sensor
9. O-ring seal 18. Intake manifold gasket (2) 27. Intake elbow seal
10. EGR valve assembly 19. Exhaust gasket
EGES-390
Figure 155 Exhaust manifolds and Exhaust Back Pressure (EBP) sensor
1. Right exhaust manifold 4. Left exhaust manifold 6. Exhaust Back Pressure (EBP)
2. M8 nut (4) 5. Exhaust manifold gasket (2) sensor assembly
3. M8 x 50 exhaust flange bolt (4) 7. M8 x 40 bolt (12)
EGES-390
Removal Intake Throttle Assembly

1. Disconnect sensor harness connector from the
WARNING: To prevent personal injury or intake throttle assembly.



components.
WARNING: To prevent personal injury or Figure 156 Intake throttle assembly

1. Intake elbow
2. M6 x 25 bolt (3)
electrical components.
3. Intake throttle assembly

death, do not let engine fluids stay on your skin. 2. Remove three M6 x 25 bolts securing the intake
Clean skin and nails using hand cleaner, and wash throttle assembly to the intake elbow and remove
with soap and water. Wash or discard clothing throttle assembly.
3. Remove and discard intake throttle gasket.

or bodies of water.
EGES-390
Exhaust Manifolds
1. Remove turbocharger exhaust tube assembly.
See “Dual Stage Turbocharger Assembly”.
2. Disconnect Exhaust Back Pressure (EBP) sensor
connector.
Figure 158 Right exhaust manifold

1. Exhaust manifold gasket
2. M8 x 40 bolt (6)
6. Remove six M8 x 40 bolts securing the right

exhaust manifold to the right cylinder head.
Discard six M8 x 40 bolts and exhaust manifold
gasket.
Figure 157 Left exhaust manifold and Exhaust
Back Pressure (EBP) tube
1. M6 nut
2. M8 x 40 bolt (6)
3. EBP tube nut
4. Exhaust manifold gasket
3. Remove M6 nut from left valve cover stud bolt.

4. Remove EBP tubing nut from the left exhaust
manifold and remove EBP tube assembly.
5. Remove six M8 x 40 bolts securing the left
exhaust manifold to the left cylinder head. Discard
six M8 x 40 bolts and exhaust manifold gasket.
EGES-390
Exhaust Gas Recirculation (EGR) Valve

1. Disconnect EGR valve sensor harness connector.
Figure 159 EGR valve

1. EGR valve
2. M8 x 35 bolt (2) Figure 160 EGR valve removal
1. EGR Valve Puller
2. EGR Valve
2. Remove two M8 x 35 bolts.
CAUTION: To prevent engine damage, when
removing or installing the EGR valve, vacuum or 3. Turn the EGR valve.
remove loose carbon deposits and debris from inside 4. Position the EGR Valve Puller (page 142) support
the intake manifold. legs over the EGR bolt holes in the intake
manifold.
5. Install arm pins under the EGR valve bolt holes
and attach other end to puller beam.
6. Turn puller shaft counter-clockwise to remove
EGR valve.
7. Remove and discard EGR valve seal and two
O-rings seals.
8. Vacuum out any debris from inside the intake
manifold.
EGES-390
Intake Manifold and EGR Cooler Assembly

1. Remove the turbocharger air intake duct, oil
supply line, exhaust tube assembly, and dual
turbocharger assembly. See “Dual Stage
Turbocharger Assembly”.
2. Remove the secondary fuel filter assembly. See
“Fuel Systems”.
3. Remove the oil filter housing assembly. See “Oil
Cooler and Filter Housing”.
Figure 161 Intake manifold and intake elbow

1. M6 x 80 bolt (10) 3. Hose clamp (2) 5. M6 x 25 bolt (5)
2. M6 x 80 x 10 stud bolt (2) 4. M6 x 25 x 25 stud bolt
EGES-390

CAUTION: To prevent engine damage, blow out or
vacuum any dirt and debris from around and under
the intake manifold. This minimizes the chances
something could fall in the cylinder head intake ports.
4. If required, remove M6 x 25 x 25 stud bolt, five M6
x 25 bolts, intake elbow and gasket.
5. Vacuum or blow out dirt and debris from around
the intake manifold.
6. Remove two M6 x 80 x 10 stud bolts and ten M6
x 80 bolts.
7. Loosen two EGR coolant hose clamps. Figure 162 Front cover O-ring seal
NOTE: The EGR cooler should remain attached to the
intake manifold.
12. Remove and discard the front cover O-ring seal.
8. Lift intake manifold and EGR cooler assembly up
and off engine.
Exhaust Gas Recirculation (EGR) Cooler
9. Carefully remove dirt and debris from around
mating surfaces of intake ports, making sure
debris does not fall into intake ports.
10. Use a borescope to inspect the inside of intake
ports. Remove objects and debris from intake
ports. Use a magnet to remove metal objects or
fragments.
11. Install Magnetic Covers for Cylinder Head Intake
Ports (page 142).
Figure 163 EGR cooler retaining bolts

1. M6 x 55 x 20 stud bolt (2)
2. M6 x 25 EGR cooler mounting bolt and EGR cooler
insulator
1. Remove M6 x 25 EGR cooler mounting bolt and

two M6 x 55 x 20 stud bolts securing the EGR
cooler to the intake manifold.
2. Remove EGR cooler from the intake manifold and
discard O-ring seal, cooler to manifold gasket, and
EGR cooler insulator.
EGES-390
Cleaning, Inspection and Test Exhaust Gas Recirculation (EGR) Cooler

Exhaust Manifold Warpage Test
1. Clean machined surfaces of exhaust manifolds
and mating surfaces of cylinder heads.
2. Install exhaust manifolds onto cylinder heads
without gasket.
3. Tighten bolts using Exhaust manifold torque
sequence (page 140).
Figure 165 EGR Cooler Pressure Test Plates

1. Air pressure regulator assembly
2. EGR Cooler Pressure Test Plates
1. Install EGR Cooler Pressure Plates (page 142) to

each end of the EGR cooler assembly.
2. Attach an air pressure regulator to the EGR
cooler. Connect to air supply and adjust air
pressure to approximately 172 to 207 kPa (25 to
30 psi).
3. Submerge EGR cooler in water. Inspect for air
Figure 164 Exhaust manifold warpage bubbles coming from coolant passages. Replace
measurement EGR cooler if leaking.
4. Check each exhaust manifold port by trying to

pass a 0.003 inch Feeler gauge (page 142)
between the exhaust manifold and cylinder head.
If the feeler gauge passes through the gap,
replace that manifold.
5. Remove exhaust manifolds.
Exhaust Gas Recirculation (EGR) Valve

1. Clean gasket mating surfaces of EGR valve
assembly and remove carbon deposits.
2. Check EGR valve assembly pintle shaft and
carriage for misalignment.
NOTE: For EGR valve electrical inspections see
EGES-395 Engine Diagnostics Manual.
EGES-390
Intake Manifold
The Intake manifold may be cleaned with steam or a
suitable non-caustic solvent.
Clean the EGR O-ring contact areas in the intake
manifold with Injector Sleeve Brush (page 142).
Make sure carbon above and below O-ring contact
areas is free enough to be vacuumed from the intake
manifold.
1. Clean machined surfaces of intake manifold and
mating surfaces of cylinder heads.
2. Install intake manifold onto cylinder heads without
gasket.
3. Tighten bolts to special torque (page 142) using
intake manifold torque sequence (Figure 171) .
4. Check each intake manifold port by trying to pass
a 0.003 inch feeler gauge (page 142) between
the intake manifold and the cylinder head. If the
feeler gauge passes through the gap, replace the
manifold. Remove intake manifold from engine.
Figure 166 Intake manifold pressure test

1. Intake Manifold Pressure Test 2. Intake Manifold Pressure Test 3. Intake Manifold Pressure Test
Plug Plates Cap
4. Air pressure regulator
5. Install Intake Manifold Pressure Test Plates (page 8. Pressurize intake manifold to 172 to 206 kPa
142). (25 to 30 psi) using regulated filtered air supply.
Submerge the intake manifold assembly in water.
6. Install Intake Manifold Pressure Test Plug (page
Inspect for leaks in the intake plenum, EGR and
142) in EGR valve opening.
coolant passages. Replace intake manifold if
7. Install Intake Manifold Pressure Test Cap (page necessary.
142) onto air intake throttle.
9. Inspect intake manifold gasket seal beads for
CAUTION: To prevent engine damage, do not defects. Replace if necessary.
pressurize intake manifold over 206 kPa (30 psi).
EGES-390
Installation 3. Install M6 x 25 EGR cooler mounting bolt and

finger tighten.
NOTE: Apply a light coat of clean engine oil on bolt
threads and under bolt head when installing used nuts 4. Tighten M6 x 25 EGR cooler mounting bolt and
and bolts. two M6 x 55 x 20 stud bolts to special torque (page
142).
Exhaust Gas Recirculation (EGR) Cooler
Intake Manifold and EGR Cooler Assembly
Figure 168 Front cover O-ring seal
1. Install a new front cover O-ring seal between the

intake manifold and front cover assembly.
Figure 167 EGR cooler retaining bolts and

gasket
1. Intake manifold
2. M6 x 55 x 20 stud bolt (2)
3. M6 x 25 EGR cooler mounting bolt
4. O-ring seal
5. EGR cooler
6. EGR cooler to manifold gasket
Figure 169 Intake manifold gasket with

1. Install a new O-ring seal and EGR cooler centering tab
insulators on the EGR cooler.
2. Install a new EGR cooler to manifold gasket and 2. Install a new gasket on each side of the intake
install two M6 x 55 x 20 stud bolts through the manifold and run a few bolts through to hold
intake manifold and into the EGR cooler. Finger gasket in place. Make sure centering tabs are
tighten bolts. facing up towards the manifold, while positioned
inboard toward engine valley.
EGES-390
3. Remove Magnetic Covers from cylinder head

intake ports.
4. Before installing the intake manifold, use a
borescope to make sure intake ports are free
of objects and debris. Use a magnet to remove
metal objects or fragments.
5. Install intake manifold and EGR cooler assembly
onto cylinder heads.
Figure 170 Intake manifold bolts

1. M6 x 80 bolt (10) 3. Hose clamp (2) 5. M6 x 25 bolt (5)
2. M6 x 80 x 10 stud bolt (2) 4. M6 x 25 x 25 stud bolt
6. Install ten M6 x 80 bolts and two M6 x 80 x 10 stud 7. Install intake elbow, new elbow seal, M6 x 25 x
bolts finger tight. 25 stud bolt, and five M6 x 25 bolts. Tighten bolts
and stud bolt to standard torque (page 400).
EGES-390
Figure 171 Intake manifold bolt torque sequence
8. Tighten twelve intake manifold bolts to special

torque (page 142) and in the proper sequence
shown above.
EGES-390
Exhaust Gas Recirculation (EGR) Valve Intake Throttle Assembly
Figure 173 Intake throttle assembly

1. Intake elbow
2. M6 x 25 bolt (3)
3. Intake throttle assembly
1. Install a new intake throttle gasket on the intake

Figure 172 EGR valve and seals throttle assembly.
1. M8 x 35 bolt (2) 2. Install three M6 x 25 bolts securing the intake
2. EGR valve throttle assembly to the intake elbow.
3. O-ring seal
4. EGR valve seal 3. Tighten M6 x 25 bolts to standard torque (page
400).
CAUTION: To prevent engine damage, completely

seat the EGR valve in the intake manifold before
installing bolts.
1. Install EGR valve seal onto the EGR valve.
2. Install two smaller O-rings seals onto the EGR
valve.
3. Install the EGR valve into the intake manifold.
Seat EGR valve into the intake manifold using
only hand pressure.
4. Install two M8 x 35 bolts and tighten, alternating
between both bolts to standard torque (page 400).
EGES-390
Exhaust Manifolds 3. Install the right exhaust manifold and install one
new M8 x 40 bolt starting with the center top
bolt hole. The hole diameter is smaller, allowing
alignment of remaining bolts.
4. Install remaining new M8 x 40 bolts through the
exhaust manifold and gasket.
Figure 175 Exhaust manifold torque sequence –

right
Figure 174 Right exhaust manifold

1. Exhaust manifold gasket 5. Tighten right exhaust manifold bolts to 19 N·m (14
2. M8 x 40 bolt (6) lbf·ft) using the above torque sequence.
6. Tighten right exhaust manifold bolts to 38 N·m (28
lbf·ft) using the above torque sequence.
1. Apply anti-seize to six new M8 x 40 bolts.
2. Install a new exhaust manifold gasket on the right
exhaust manifold.
EGES-390
9. Install the left exhaust manifold and install one

new M8 x 40 bolt starting with the center top bolt
hole.
10. Install remaining new M8 x 40 bolts through the
exhaust manifold and gasket.
Figure 177 Exhaust manifold torque sequence

– left
Figure 176 Left exhaust manifold and Exhaust 11. Tighten left exhaust manifold bolts to 19 N·m (14
Back Pressure (EBP) tube lbf·ft) using the above torque sequence.
1. M6 nut 12. Tighten left exhaust manifold bolts to 38 N·m (28

2. M8 x 40 bolt (6) lbf·ft) using the above torque sequence.
3. EBP tube nut 13. Install EBP tube assembly on left valve cover stud
4. Exhaust manifold gasket bolt and left exhaust manifold and finger tighten
EBP tube nut.
7. Apply anti-seize to six new M8 x 40 bolts. 14. Install M6 nut on valve cover stud bolt and tighten
to standard torque (page 400).
8. Install a new exhaust manifold gasket onto the left
exhaust manifold. 15. Tighten EBP tube nut.
EGES-390
Specifications
Exhaust Manifolds
Maximum allowable warpage 0.08 mm (0.003 in)
Intake Manifold
Special Torque
Coolant deaeration fitting 10 N·m (90 lbf·in)

EGR cooler mounting bolt assembly, M6 x 25 11 N·m (97 lbf·in)
EGR cooler to manifold stud bolts, M6 x 55 x 20 11 N·m (97 lbf·in)
1
Exhaust manifold bolts, M8 x 40 See Exhaust Manifolds
(page 140) torque
sequence
Intake manifold bolts, M6 bolts and stud bolts 11 N·m (97 lbf·in) See
intake manifold bolt torque
sequence (page 136)
1
Apply anti-seize compound to bolt threads before assembly
Anti-seize compound Obtain locally

EGR Cooler Pressure Test Plates ZTSE4707
EGR Valve Puller ZTSE4669
Feeler gauge Obtain locally
Injector Sleeve Brush Set ZTSE4304
Intake Manifold Pressure Test Plates ZTSE4527
Intake Manifold Pressure Test Plug ZTSE4888
Intake Manifold Pressure Test Cap ZTSE4682
Magnetic Covers for Cylinder Head Intake Ports ZTSE4559
EGES-390
HIGH-PRESSURE OIL SYSTEM 143
Table of Contents
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
High-pressure Oil System Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145
High-pressure Oil Flow Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
High-pressure Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147
Case-to-head Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .149
Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .150
High-pressure Oil Pump Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .151
High-pressure Oil Pump and Branch Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .152

High-pressure Oil Pump (Perform if Oil Pump was Removed). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Branch Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
High-pressure Oil Pump and Branch Tube Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .154
Injection Pressure Regulator (IPR) Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157
High-pressure Oil Rail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Case-to-Head Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .158
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .159
EGES-390
144 HIGH-PRESSURE OIL SYSTEM
EGES-390
Illustrations
High-pressure Oil System Components
Figure 178 High-pressure oil system

1. Branch tube adaptor 13. D-ring seal (13.3 mm I.D.) 25. D-ring seal (8.22 mm I.D.)
2. M6 x 30 bolt (2) 14. Case-to-head tube plug 26. High-pressure oil pump
3. M8 x 45 bolt (3) assembly (with check valve) assembly
4. Hydraulic pump cover gasket 15. Rail port plug 27. O-ring seal, #207
5. M6 x 25 bolt (8) 16. D-ring seal (13.3 mm I.D.) 28. O-ring seal, #16
6. Hydraulic pump cover 17. D-ring seal (11.7 mm I.D.) 29. Branch tube assembly, brazed
7. High-pressure pump plug, M12 18. High-pressure oil rail (2) 30. M6 x 40 bolt (2)
8. O-ring seal 19. D-ring seal 31. M6 x 40 bolt (14)
9. Injection Pressure Regulator 20. Rail end plug (4) 32. Injection Control Pressure (ICP)
(IPR) valve 21. O-ring seal sensor assembly
10. Pump O-ring 22. Single ball tube 33. O-ring seal
11. D-ring seal (8.22 mm I.D.) 23. Internal hex ferrule 34. Prime port plug, M8
12. D-ring seal (11.7 mm I.D.) 24. Case-to-head tube
EGES-390
High-pressure Oil Flow Schematic
Figure 179 High-pressure oil flow
EGES-390
Removal
death, read all safety instructions in the "Safety
Information" section of this manual.


death, disconnect the main battery negative Figure 180 High-pressure oil rail (left)
terminal before disconnecting or connecting 1. High-pressure oil rail (left)
electrical components. 2. Rail port plug
3. Case-to-head tube plug
WARNING: To prevent personal injury or 4. M6 x 40 bolt (7)
CAUTION: To prevent engine damage, replace
case-to-head tubes and rail port plugs if removed.
WARNING: To prevent personal injury or D-ring seals are not replaceable. Inspect each D-ring
death, do not let engine fluids stay on your skin. carefully for cuts, abrasions, and twisting. Never use
Clean skin and nails using hand cleaner, and wash a tube with any of these problems.
and rags contaminated with engine fluids. NOTE: It is not necessary to remove the rail port plug
when removing the oil rail assemblies. Only remove
the rail port plug if it is leaking.
2. Remove case-to-head tube plug assemblies with
GOVERNMENT REGULATION: Engine a 10 mm hex bit socket or wrench. Discard
fluids (oil, fuel, and coolant) may be a threat case-to-head tube because seals are not
to the environment. Recycle or dispose serviceable.
applicable regulations. Never put engine NOTE: On occasion, the case-to-head tube (lower)
fluids in the trash, on the ground, in sewers will come out along with the case-to-head plug. If this
or bodies of water. occurs, discard entire case-to-head tube assembly.
Refer to case-to-head tube assembly (Figure 182).
NOTE: If removing only the high-pressure oil pump, it 3. Loosen and remove seven M6 x 40 bolts securing
is not necessary to remove the branch tube assembly, the oil rail assembly to the rocker arm carrier.
rear cover, or cylinder heads.
High-pressure Oil Rail

1. Remove valve covers. See “Cylinder Head and
Valve Train”.
EGES-390
4. Lift oil rail assembly straight away from injectors

and case-to-head tube assembly. Allow oil to
drain back to the sump or other suitable container.
CAUTION: To prevent engine damage, do not remove
the 1¼ x 20 UNF oil rail end plugs or single ball tubes.
Service parts are not available to support these
components.
Figure 181 Non-serviceable oil rail components

1. Single ball tube (3) 2. Oil rail end plug (2)
EGES-390
Case-to-head Tubes
Figure 182 Case-to-head tube assembly

1. Assembled case-to-head tube
2. Case-to-head tube (lower)
3. Case-to-head tube plug

case-to-head tubes and rail port plugs if removed.
D-ring seals are not replaceable. Inspect each D-ring
carefully for cuts, abrasions, and twisting. Never use
a tube with any of these problems.
NOTE: The procedure for removing the case-to-head
tube assembly is the same for both sides of the
engine.
1. If the case-to-head tube came out with the
case-to-head plug before high-pressure rail
removal, the following step will be unnecessary.
Figure 183 Case-to-head Tube Removal Tool
1. Case-to-head tube (lower)
2. Case-To-Head Tube Removal Tool
2. Push the Case-to-head Tube Removal Tool

(page 159) into the case-to-head tube and tighten
T-handle until a positive lock is felt. Pull out tube
and discard.
EGES-390

1. Cut zip tie and remove IPR harness connector
heat shield.
Figure 185 IPR Removal / Installation Tool
3. Remove IPR valve from the high-pressure oil

pump with IPR Removal / Installation Tool (page
159).
Figure 184 IPR valve and harness connector 4. Remove and discard IPR valve O-rings.
1. IPR valve
2. IPR harness connector with wire retainer
2. Release the IPR valve harness connector wire

retainer or tabs and pull 2-pin connector off the
IPR valve.
EGES-390
High-pressure Oil Pump Cover

1. Remove the dual turbocharger assembly. See
“Dual Turbocharger Assembly”.
2. Remove the intake manifold and EGR cooler
assembly. See “Manifolds and Exhaust Gas
Recirculation (EGR)”.
Figure 187 High-pressure oil pump cover

sealant separation
CAUTION: To prevent engine damage, cut Liquid

Gasket (RTV) before lifting up high-pressure cover.
The rear cover gasket could be pulled up and out,
requiring removal of the rear cover to replace gasket.
4. Use a thin gasket scraper to separate the
sealant bond between crankcase, rear cover,
Figure 186 High-pressure oil pump cover
and high-pressure oil pump cover.
1. M6 x 25 bolt (8)
5. After cutting sealant, lift the high-pressure oil
pump cover straight up to clear pump gear.
3. Remove eight M6 x 25 bolts from the 6. Remove and discard the high-pressure pump
high-pressure oil pump cover. cover gasket seal.
EGES-390
High-pressure Oil Pump and Branch Tube

Assembly
Figure 189 Branch tube adapter

1. Jam nut
2. Seal ring
3. O-ring
5. Loosen branch tube adapter jam nut and remove

branch tube adapter from the high-pressure oil
pump. Discard O-ring
Figure 188 High-pressure oil pump and branch 6. Remove the rear cover. See “Rear Cover and
tube Flywheel”.
1. Branch tube adaptor

2. M6 x 30 bolt (2)
3. M8 x 45 bolt (3)
4. High-pressure oil pump
5. O-ring seal (pump inlet)
6. O-ring seal (branch tube)
7. Branch tube assembly
8. M6 x 40 bolt (2)
CAUTION: To prevent engine damage, do not drop

bolts into engine. Bolts are not captured within the
branch tube or high-pressure oil pump.
1. Remove two M6 x 30 bolts securing the branch
Figure 190 Branch tube bolt removal
tube adapter to the branch tube.
2. Remove three M8 x 45 bolts securing the
high-pressure oil pump to the crankcase. 7. Remove M6 x 40 bolt from each side of the
branch tube assembly and remove branch tube
3. Remove the high-pressure oil pump assembly.
assembly.
4. Remove and discard the high-pressure oil pump
inlet and branch tube adapter O-rings. Cap off oil
holes.
EGES-390
Cleaning and Inspection 3. Clean and inspect the branch tube adapter
sealing surfaces for dirt, raised metal or other
High-pressure Oil Pump Cover
indications of seating seal failure. Correct any
1. Clean any old sealant residue from pump cover, defects as required.
crankcase, and rear cover mating surfaces.
4. Clean and inspect the high-pressure oil pump
2. Inspect the high-pressure oil pump cover, inlet O-ring groove for dirt, raised metal or other
crankcase, and rear cover sealing surfaces indication of seal failure. Correct any defects as
for dirt, raised metal, cracking or other indications required.
of seal failure. Correct as required.
3. Clean and inspect the IPR valve.
Branch Tube
a. Inspect the O-ring sealing surfaces for dirt,
1. Clean and inspect the branch tube assembly
raised metal or other indications of seal
end blocks for debris, galling or other damage
failure. Correct as required.
indicating evidence of misalignment. Replace the
b. Inspect electrical connectors. branch tube assembly as required.
c. Inspect valve openings for dirt or debris, 2. Inspect branch tube adapter bores, the outside of
investigate causes and correct as required. the adapter connection and the inside of the pump
connection for debris, galling or other damage
indicating misalignment or defects. Replace
High-pressure Oil Pump (Perform if Oil Pump was adapter as required.
Removed)
3. Clean and inspect the brazed joints for cracks or
NOTE: The high-pressure oil pump and gear are not other indications of joint failure. Replace branch
serviceable independently. The pump and gear must tube assembly as required.
be replaced as an assembly.
4. Clean and inspect the branch tube adapter
1. Clean and inspect the pump-to-cover O-ring (if high-pressure oil pump assembly was not
sealing surface for dirt, raised metal or other removed) O-ring groove for dirt, raised metal
indications of seal failure. Correct any defects as or other indications of seal failure. Correct any
required. defects as required.
2. Clean and inspect the branch tube adapter O-ring
groove for dirt, raised metal or other indications of
seal failure. Correct any defects as required.
EGES-390
Installation CAUTION: To prevent engine damage, do not drop

bolts into crankcase. Bolts are not captured within the
High-pressure Oil Pump and Branch Tube
branch tube or oil pump.
Assembly
1. Install branch tube assembly into crankcase.
2. Install two M6 x 40 branch tube mounting bolts
through the right and left sides of the branch tube
assembly and finger tighten.
Figure 192 Branch tube adapter

1. Jam nut
Figure 191 High-pressure oil pump and branch 2. Seal ring
tube 3. O-ring

2. M6 x 30 bolt (2) 3. Rotate jam nut to the base of the branch tube
3. M8 x 45 bolt (3) adaptor.
4. High-pressure oil pump
5. O-ring seal (pump inlet) 4. Install a new branch tube adaptor O-ring and
6. O-ring seal (branch tube) lubricate with clean engine oil.
7. Branch tube assembly 5. Thread the branch tube adapter into the
8. M6 x 40 bolt (2) high-pressure oil pump. Do not tighten jam
nut at this time. Oil outlet hole must face down.
EGES-390
7. Lubricate and install a new O-ring into the

branch tube assembly O-ring recess and into
the high-pressure oil pump inlet recess.
Figure 193 Branch Tube Adaptor Installation

Depth Gauge
Figure 195 High-pressure oil pump and branch

CAUTION: To prevent engine damage, branch tube
tube adaptor
adaptor must be installed at the correct depth to
prevent high-pressure oil leaks. 1. High-pressure oil pump
6. Check branch tube adaptor installed depth by
3. M6 x 30 bolt (2)
placing Branch Tube Adaptor Installation Depth
4. M8 x 45 Torx bolt (3)
Gauge (page 159) on the high-pressure oil
pump and aligning gauge holes with branch tube
adaptor holes. Install branch tube adaptor at
8. Install the high-pressure oil pump and branch tube
depth that best aligns gauge and adaptor holes.
adapter assembly. Branch tube adaptor oil outlet
hole must face down.
9. Install three M8 x 45 bolts securing the
high-pressure oil pump to the crankcase and
finger tighten.
10. Align the branch tube adaptor and branch tube
holes and install two M6 x 30 bolts into the branch
tube finger tight.
11. Tighten three M8 x 45 bolts securing the
high-pressure oil pump to the crankcase to
standard torque (page 400).
Figure 194 High-pressure oil pump inlet and

branch tube adapter O-rings
1. Branch tube adapter O-ring seal recess
2. Branch tube adapter O-ring seal
3. High-pressure oil pump inlet O-ring seal, #207
EGES-390
Figure 196 Branch tube assembly mounting bolt

installation (right) Figure 197 Branch tube adaptor and
Anti-rotation Handle
1. Anti-rotation Handle
12. Tighten two M6 x 40 bolts securing the branch 2. Branch tube adaptor jam nut
tube assembly to the crankcase to standard 3. M6 x 30 bolt (2)
torque (page 400).
CAUTION: To prevent engine damage, use only

Anti-rotation Handle to provide counter-torque for
branch tube adaptor while tightening jam nut. Other
tools will damage branch tube threads and cause
high-pressure oil leaks.
13. Remove the left M6 x 30 bolt and insert the
Anti-rotation Handle (page 159) into the branch
tube assembly.
14. Provide proper counter-torque on Anti-rotation
Handle while tightening branch tube adaptor jam
nut with a 15/16 inch, 12-point (flare nut) crowfoot
to special torque (page 159).
15. Remove Anti-rotation Handle and install left M6 x
30 bolt in the branch tube adaptor. Tighten two
M6 x 30 bolts to standard torque (page 400).
EGES-390
High-pressure Oil Pump Cover Injection Pressure Regulator (IPR) Valve

1. Install new O-rings on the IPR valve.
2. Install IPR valve into the high-pressure oil pump
with IPR Removal / Installation Tool (page 159).
3. Tighten IPR valve to special torque (page 159).
Figure 198 High-pressure oil pump seals

1. Hydraulic pump cover gasket
2. Pump O-ring
3. Liquid Gasket (RTV) application location (2)
Figure 199 IPR valve and harness connector
1. Install a new pump O-ring in the high-pressure
1. IPR valve
oil pump-to-cover recess. Lubricate O-ring with
2. IPR harness connector
clean engine oil.
2. Apply Liquid Gasket (RTV) (page 159) to two
locations where rear cover, high-pressure pump 4. Install engine sensor harness on IPR valve.
cover, and crankcase join.
5. Install IPR valve heat shield and secure with a zip
3. Install a new hydraulic pump cover gasket in the tie.
recess of the high-pressure oil pump cover.
CAUTION: To prevent engine damage, the
high-pressure oil pump cover must be firmly seated
onto the high-pressure oil pump O-ring by hand to
prevent cracking the pump cover.
4. Apply even pressure to seat the high-pressure oil
pump cover on the high-pressure pump O-ring.
5. Install eight M6 x 25 mounting bolts and tighten to
EGES-390
High-pressure Oil Rail Case-to-Head Tubes
Figure 200 Align oil rail assembly to injector oil Figure 202 Case-to-head tube assembly
inlets installation
1. Using both hands, align the oil rail assembly with CAUTION: To prevent engine damage, replace
the oil inlets of each fuel injector. Push down case-to-head tubes and rail port plugs if removed.
evenly until oil rail assembly is firmly seated. D-ring seals are not replaceable. Inspect each D-ring
carefully for cuts, abrasions, and twisting. Never use
2. Install oil rail assembly M6 x 40 bolts finger tight. a tube with any of these problems.
1. Lubricate the D-rings on the case-to-head tube
assembly with clean engine oil and install through
oil rail and into the branch tube.
NOTE: Oil rail must be completely torqued before
installing case-to-head tube.
2. Tighten case-to-head tube assembly to special
torque (page 159).
Figure 201 Oil rail torque sequence
3. Tighten M6 x 40 bolts to standard torque (page

400) in the above sequence.
EGES-390
Specifications
0 to 30 MPa (0 to 4,350
Injection Control Pressure (ICP) sensor operating pressure range
psi)
Injection Pressure Regulator (IPR) valve relief pressure 31 MPa (4,500 psi)
IPR valve maximum pressure 38 MPa (5,500 psi)
Special Torque
Branch tube adaptor jam nut 72 N·m (53 lbf·ft)

Case-to-head tube and rail port plug 82 N·m (60 lbf·ft)
Injection Pressure Regulator (IPR) 50 N·m (37 lbf·ft)
Prime port plug, M8 8 N·m (71 lbf·in)
High-pressure pump plug, M12 35 N·m (26 lbf·ft)
Anti-rotation Handle (branch tube adaptor) ZTSE4876-1

Branch Tube Adaptor Installation Depth Gauge ZTSE4876-2
Case-to-head Tube Removal Tool ZTSE4694
IPR Removal / Installation Tool ZTSE4666
Liquid Gasket (RTV, 6 oz. tube) 1830858C1
15/16 inch, 12-point (flare nut) crowfoot Obtain locally
EGES-390
EGES-390
FUEL SYSTEM 161
Table of Contents
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .163
Periodic Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Primary Fuel Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .168
Secondary Fuel Filter Element. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Fuel System Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .170
Secondary Fuel Filter Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .171
Horizontal Fuel Conditioning Module (HFCM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .172
Fuel Injector Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .173
Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175
Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .178
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Fuel Injector Assemblies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .180
Fuel System Tubing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .186
EGES-390
162 FUEL SYSTEM
EGES-390
FUEL SYSTEM 163
Illustrations
Figure 203 Fuel system flow and components
EGES-390
164 FUEL SYSTEM
Figure 204 Fuel System Components (engine)

1. Fuel injector assembly (6) 17. Copper washer (2) 31. Saddle clamp
2. Upper fuel seal 18. O-ring seal, size #012 32. M10 x 16 bolt
3. Lower fuel seal 19. Fuel outlet fitting, M16 33. Dual tube clamp
4. Injector nozzle gasket 20. O-ring seal 34. Copper washers (4)
5. Viton seal (2) 21. Screw, M6 x 25 (3) 35. M12 Banjo bolt with check valve
6. Fuel plug, M12 (2) 22. O-ring seal (2)
7. Fuel filter cap 23. Engine Fuel Pressure (EFP) 36. Fuel supply line, left cylinder
8. Secondary fuel filter element switch head
9. O-ring, size #146 24. O-ring seal (2) 37. Fuel filter to right cylinder head
10. Fuel return tube (stand pipe) 25. M12 fuel outlet fitting (2) tube
11. Screw, 8/32 x 3/8 in (2) 26. O-ring seal, size #011 (2) 38. M6 x 16 bolt
12. O-ring, size #112 27. Hollow screw 39. Oil filter housing assembly
13. Secondary fuel filter housing 28. Fuel return to HFCM tube
14. Fuel pressure regulator 29. Fuel supply to secondary filter
15. Pressure regulator cover seal tube
16. O-ring seal, size #115 30. M6 x 16 bolt
EGES-390
FUEL SYSTEM 165
Figure 205 Horizontal Fuel Conditioning Module (HFCM) (chassis mounted)

1. Fuel supply port to engine 5. Electric fuel pump connection 8. Mounting grommet (3)
2. Fuel return port from engine 6. Water In Fuel (WIF) electrical 9. Fuel heater electrical connection
3. Fuel return port to tank connection 10. Primary filter element cap
4. Fuel supply port to HFCM 7. Water drain plug
EGES-390
166 FUEL SYSTEM
Figure 206 HFCM

1. Primary filter element cap 7. Water In Fuel (WIF) sensor 12. O-ring seal
2. Cap O-ring seal 8. Thermo recirculating valve 13. Water drain plug
3. Primary fuel filter element assembly 14. M5 x 23 screw (4)
4. Primary fuel filter housing 9. Cover plate gasket 15. Mounting grommet (3)
5. Electric fuel pump 10. Fuel heater 16. M8 x 40 bolt with shoulder (3)
6. Self-tapping screw, #10 (3) 11. Cover plate
EGES-390
FUEL SYSTEM 167
Periodic Service
WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin.
death, read all safety instructions in the "Safety Clean skin and nails using hand cleaner, and wash
Information" section of this manual. with soap and water. Wash or discard clothing
death, shift transmission to park or neutral, set WARNING: To prevent personal injury or
parking brake, and block wheels before doing death, do not smoke and keep fuel away from
diagnostic or service procedures. flames and sparks.

death, do not turn ignition "KEY ON" during any
GOVERNMENT REGULATION: Dispose
phase of fuel system disassembly. Turning on
of fuel according to applicable regulations in
the ignition key could pump fuel to disconnected
a correct container clearly marked DIESEL
tubing, resulting in fire.
FUEL.

electrical components. GOVERNMENT REGULATION: Engine
or bodies of water.
EGES-390
168 FUEL SYSTEM
Primary Fuel Filter Element
Figure 207 Primary fuel filter (chassis mounted)

1. Primary fuel filter element cap 3. Primary fuel filter element 4. Horizontal Fuel Conditioning
2. Cap O-ring seal Module (HFCM)
6. Clean out debris from inside the HFCM.

death, do not smoke and keep fuel away from 7. Install a new primary fuel filter element in the
flames and sparks. HFCM.
1. Collect fuel in a correct container clearly marked 8. Lubricate fuel filter cap threads and new O-ring
DIESEL FUEL. Loosen water drain plug and drain with clean diesel fuel.
HFCM. 9. Tighten primary fuel filter cap to special torque
2. Remove primary fuel filter element cap from (page 186).
HFCM. 10. Install a new O-ring on the water drain plug. Install
3. Remove and discard cap O-ring seal. and tighten drain plug.
4. Pull fuel filter out of HFCM and dispose of filter 11. When all fuel system components are installed
element properly. and tight, turn key on and check for fuel leaks. If
fuel is leaking turn off engine and repair leaks.
5. Clean seal areas and install a new cap O-ring seal
on fuel filter cap.
EGES-390
FUEL SYSTEM 169
Secondary Fuel Filter Element

1. Oil filter housing assembly 2. Secondary fuel filter cap
5. Clean out debris from inside the secondary fuel

WARNING: To prevent personal injury or filter housing.
flames and sparks. 6. Install a new fuel filter element in the secondary
fuel filter housing. Rotate filter element slightly
NOTE: Engine will not run without the secondary until filter engages the return tube assembly
fuel filter element installed properly. When installed and can be moved up and down against spring
properly the secondary fuel filter element pushes pressure.
down the fuel return tube, allowing fuel to flow into
the filter housing. 7. Lubricate fuel filter cap threads and new O-ring
with clean diesel fuel.
1. Remove fuel filter cap from the secondary fuel
filter housing. 8. Tighten secondary fuel filter cap to special torque
(page 186).
2. Remove and discard fuel filter cap O-ring.
9. When all fuel system components are installed
3. Pull fuel filter up and out of fuel filter housing and and tight, turn key on and check for fuel leaks. If
dispose of filter element properly. fuel is leaking turn off engine and repair leaks.
4. Clean seal areas and install a new O-ring on fuel
filter cap.
EGES-390
170 FUEL SYSTEM
Removal
Fuel System Tubing
1. Remove the air inlet duct. See “Dual
Turbocharger Assembly”.
Figure 209 Fuel system tubing and connections

1. M6 x 16 bolt (2) 4. Fuel filter to left cylinder head 7. M10 x 16 bolt
2. Fuel filter to right cylinder head tube 8. M12 banjo bolt with check valve
tube 5. Fuel supply to filter tube (2)
3. Secondary fuel filter housing 6. Fuel return to tank tube
3. Remove the Engine Fuel Pressure (EFP) switch,

WARNING: To prevent personal injury or installed in the bottom of secondary fuel filter
death, do not smoke and keep fuel away from housing.
flames and sparks.
4. Remove secondary fuel filter cap to allow air into
2. Place a suitable container under the secondary filter housing so fuel will drain.
fuel filter housing to catch draining fuel.
5. After fuel has drained, install EFP switch into filter
housing and tighten to special torque (page 186).
EGES-390
FUEL SYSTEM 171
6. Remove M6 x 16 bolt securing the fuel return and Secondary Fuel Filter Assembly
fuel supply tubes to the oil pan.
1. Remove three M6 x 25 screws and remove the
7. Remove M10 x 16 bolt securing the fuel return and secondary fuel filter assembly from the oil filter
fuel supply tubes to the left cylinder head. assembly.
8. Remove M6 x 16 bolt securing the right fuel supply
tube to the intake manifold.
9. Remove each M12 banjo bolt securing right 2
and left fuel supply tubes to each cylinder head.
3
Discard copper washers.
4
5
1 6
7
8
J11060
Figure 210 Secondary fuel filter tubes and Figure 211 Fuel pressure regulator poppet
housing assembly
1. Fuel return to HFCM tube 1. Oil filter assembly
2. Fuel supply to filter tube 2. Secondary fuel filter housing
3. Engine Fuel Pressure (EFP) switch 3. M6 x 25 screw (3)
4. Fuel filter to left cylinder head tube 4. Pressure regulator cover gasket
5. Fuel filter to right cylinder head tube 5. Viton O-ring, size #115
6. Poppet gasket seal
7. Brass poppet
10. Remove hollow screw from fuel supply to filter 8. Pressure regulator valve spring
tube and discard copper washers.
11. Disconnect fuel return to HFCM tube from fuel
filter housing. Discard fitting O-ring. 2. Removing the secondary fuel filter assembly
exposes the fuel pressure regulator poppet
12. Disconnect fuel filter to left and right cylinder components. Remove these parts for later
head tubes from fuel filter housing. Discard fitting inspection.
O-rings.
13. Remove fuel tubes from engine.
14. Cap all open ports on the secondary fuel filter
housing using the Cap Kit (all) (page 187).
EGES-390
172 FUEL SYSTEM
Horizontal Fuel Conditioning Module (HFCM)
Figure 212 HFCM (chassis mounted)

1. Fuel supply port to engine 5. Electric fuel pump connection 8. Mounting grommet (3)
2. Fuel return port from engine 6. Water In Fuel (WIF) electrical 9. Fuel heater electrical connection
3. Fuel return port to tank connection 10. Primary filter element cap
4. Fuel supply port to HFCM 7. Water drain plug
For CityStar™ applications, the HFCM is mounted on 3. Disconnect fuel pump, fuel heater, and Water In
the driver’s side vehicle frame rail. Fuel (WIF) electrical connectors.
For stripped chassis applications, the HFCM is 4. Press in retaining clips to release fuel hoses from
mounted on a bracket attached to the transmission HFCM housing.
housing on the passenger side.
5. Disconnect fuel hoses and discard fuel hose
1. Place a container under the HFCM to drain fuel retaining clips
and any accumulated water.
6. Remove three M8 mounting nuts and remove
2. Rotate water drain plug to release fuel pressure HFCM from chassis.
and drain HFCM.
EGES-390
FUEL SYSTEM 173
Fuel Injector Assemblies

1. Remove valve covers. See “Cylinder Head and
Valve Train”.
2. Remove high-pressure oil manifolds. See
“High-pressure Oil System”.
Figure 213 Releasing the injector connector from rocker arm carrier
1. Injector Connector Remover tool 2. Injector Connector Remover tool 3. Injector Connector Remover tool
with handle (cylinders 1, 2, 6) without handle (cylinders 3, 5) without handle (cylinder 4)
NOTE: Injector connector removal procedures are NOTE: On some connectors remove the tool handle,
based on the engine being out-of-chassis. fit the remover portion onto connector and use a
screwdriver or other tool to push down and release
NOTE: There is no need to drain fuel rail when
connector.
removing an injector.
5. Push down on the injector connector to release it
3. Disconnect injector harness from the injector
from the rocker arm carrier.
connector.
4. Release injector connectors using Injector
Connector Remover (page 187).
EGES-390
174 FUEL SYSTEM
7. Remove fuel injector from cylinder head bore by

lifting injector and hold down clamp assembly up
and out.
CAUTION: To prevent engine damage, do not clean
injectors with parts solvent or other chemicals.
8. Remove and discard injector upper and lower
O-rings and nozzle gasket with a non-metalic
hand tool.
NOTE: If nozzle gasket is missing from any injector
removed, look for gasket at the bottom of its injector
bore. Remove and discard all nozzle gaskets.
CAUTION: To prevent engine damage, when injectors
are removed from the engine, place injectors in a
Figure 214 Fuel injector hold down clamp closeable container, cover with clean engine oil, and
removal close container.
1. Fuel injector assembly 9. Remove each fuel injector assembly, place in a
2. Fuel injector hold down clamp closeable container, cover with clean engine oil,
and close container.
NOTE: Fuel injectors are self extracting and come out

of injector bores as injector hold down clamp bolt is
loosened.
6. Loosen each fuel injector hold down clamp bolt
using a T45 Torx bit socket (page 187).
Figure 216 Injector Sleeve Brush

Figure 215 Fuel injector removal from cylinder
head
10. If removing or replacing any of the injectors and
1. Fuel injector assembly not the sleeves, clean injector sleeve with Injector
2. Fuel injector hold down clamp assembly Sleeve Brush (page 187).
EGES-390
FUEL SYSTEM 175
Disassembly

1. Fuel filter cap 5. Screw, 8/32 x 3/8 in (2) 9. M12 left and right cylinder head
2. O-ring seal 6. Viton O-ring, size #112 fuel tube assembly fitting (2)
3. Fuel filter element 7. Secondary fuel filter housing 10. Engine Fuel Pressure (EFP)
4. Fuel return tube assembly 8. M16 fuel return fitting switch
1. Loosen fuel filter cap and discard O-ring seal. 4. Remove two 8/32 x 3/8 screws and remove the
fuel return tube assembly. Discard O-ring.
2. Before removing fuel filter element, depress filter
to verify spring loaded fuel return tube moves 5. Remove M16 and M12 fittings and discard
freely. O-rings.
3. Pull up secondary fuel filter element and discard. 6. Unplug EFP switch harness connector and
remove EFP. Discard switch O-ring.
EGES-390
176 FUEL SYSTEM
Figure 218 HFCM

1. Primary filter element cap 7. WIF sensor 12. O-ring seal
1. Remove the water drain plug assembly and 5. Remove fuel heater from the cover plate.
discard O-ring.
6. Remove the thermo recirculating valve assembly
2. Remove the primary filter cap and discard O-ring from the primary fuel filter housing.
seal.
7. Remove three (#10 self-tapping) fuel pump
3. Remove primary fuel filter element and dispose of screws and remove fuel pump. Discard O-rings.
properly.
4. Remove four M5 x 23 cover plate screws and
remove cover plate. Discard cover plate gasket.
EGES-390
FUEL SYSTEM 177
Cleaning and Inspection 3. Check the fuel return tube assembly (Figure 217)
for broken or cracked pieces.
WARNING: To prevent personal injury or 4. Clean out any accumulated sediment in the
death, wear safety glasses with side shields. bottom of the secondary fuel filter housing and
Limit compressed air pressure to 207 kPa (30 psi). HFCM housing.
1. Inspect fuel lines for kinks, chaffing or other signs 5. Wash all fuel filter components in a suitable
of damage. Replace fuel lines if necessary. solvent and dry with filtered compressed air.
NOTE: See EGES-395 Diagnostic Manual for further
inspection and repair of fuel system components.
2
3
4
5
1 6
7
8
J11060
Figure 219 Fuel pressure regulator poppet

assembly
1. Oil filter assembly
2. Secondary fuel filter housing
3. M6 x 25 screw (3)
4. Pressure regulator cover gasket
5. Viton O-ring, size #115
6. Poppet gasket seal
7. Brass poppet
8. Pressure regulator valve spring
2. Check poppet valve and spring for signs of

misalignment. Inspect poppet gasket seal for
signs of uneven seating with the fuel filter housing.
EGES-390
178 FUEL SYSTEM
Assembly
Figure 220 HFCM

1. Primary filter element cap 7. WIF sensor 12. O-ring seal
1. Install the thermo recirculating valve assembly 7. Install three (#10 self-tapping) screws and tighten
into the primary fuel filter housing. to special torque.
2. Install the fuel heater into the cover plate. 8. Install primary filter element into HFCM.
3. Install cover plate gasket onto cover plate. 9. Install a new O-ring on the primary filter cap and
lubricate O-ring with clean diesel fuel.
4. Install cover plate onto filter housing and install
four M5 x 23 screws. Tighten screws to special 10. Install filter cap onto HFCM and tighten to special
torque (page 186). torque.
5. Install new O-rings onto the fuel pump and 11. Install a new O-ring on water drain plug. Install
lubricate with clean diesel fuel. and tighten plug.
6. Install fuel pump assembly into fuel filter housing.
EGES-390
FUEL SYSTEM 179
Secondary Fuel Filter Assembly NOTE: The engine will not run without the secondary
fuel filter element. When installed properly the
secondary fuel filter element pushes down the fuel
return tube which opens a valve, allowing fuel to flow
into the filter housing.
1. Install a new O-ring gasket into the base of the
fuel filter housing.
2. Install return tube assembly over O-ring and
secure with two 8/32 x 3/8 in. screws. Tighten
screws to special torque (page 186).
3. Install fuel filter element over return tube. Rotate
element slightly until filter engages teeth and can
be moved up and down against spring pressure.
4. Apply a coating of clean diesel fuel to a new O-ring
and install onto fuel filter cap. Thread fuel filter cap
onto filter housing and tighten to special torque.
5. Install new O-rings onto M12 and M16 fittings
and install in fuel filter housing. Tighten fittings to
special torque.

1. Fuel filter cap
2. O-ring seal
3. Fuel filter element
4. Fuel return tube assembly
5. Screw, 8/32 x 3/8 in (2)
6. Viton O-ring, size #112
7. Secondary fuel filter housing
8. M16 fuel return fitting
9. M12 left and right cylinder head fuel tube assembly
fitting (2)
EGES-390
180 FUEL SYSTEM
Installation
Fuel Injector Assemblies
Figure 223 Fuel injector copper nozzle gasket

installation
1. Injector (nozzle end)
2. Gasket (copper)
Figure 222 Fuel injector 3. Deep socket
1. O-ring, lower (white Teflon® coating) (smaller
diameter)
2. Fuel inlet screens (3)
NOTE: The copper gasket may be installed in either
3. O-ring, upper (black Teflon® coating) (larger
direction.
diameter) 4. Install a new copper gasket on the tip of the fuel
4. Clamp alignment slot injector nozzle. Push gasket on with a deep
5. O-ring, harness connector (dark blue) socket.

external O-rings and copper nozzle gasket each time
the fuel injector is removed.
1. Install a new Teflon® coated (white) O-ring
(smaller diameter) in the lower recess just below
the fuel screens.
2. Install a new Teflon® coated (black) O-ring (larger
diameter) in the recess just above the fuel inlet
screens.
3. Lubricate upper and lower O-rings with clean
engine oil.
Figure 224 Injector hold down clamp assembly

1. Clamp alignment index
2. M8 x 45 bolt
3. Retainer
EGES-390
FUEL SYSTEM 181
5. Align slot in injector assembly with the injector

hold down clamp alignment index.
Figure 226 Top D-ring lubrication
Figure 225 Fuel injector installation 9. Lubricate the D-ring in the top of the injector oil
1. Fuel injector inlet with clean engine oil.
2. Fuel injector hold down clamp assembly
CAUTION: To prevent engine damage, do not use air

tools to install fuel injectors. Use caution not to scratch
fuel injector surfaces.
6. Install fuel injector and injector hold down clamp
assembly into injector bore as one unit.
7. Install fuel injector hold down clamp assembly
using a T45 Torx bit socket (page 187) . Do not
use power tools to install injectors.
8. Tighten fuel injector hold down clamp bolt to
special torque (page 186). Figure 227 Injector harness connector
installation
10. Lubricate injector harness connector O-ring with

clean engine oil and install connector into rocker
arm carrier by pushing connector straight in until it
snaps into place. Identification marks should face
up.
CAUTION: To prevent engine damage, be sure
injector wiring is clear of moving parts.
EGES-390
182 FUEL SYSTEM
Figure 228 HFCM (chassis mounted)

1. Fuel supply port to engine 5. Electric fuel pump connection 9. Fuel heater electrical connection
2. Fuel return port from engine 6. WIF electrical connection 10. Primary filter element cap
3. Fuel return port to tank 7. Water drain plug
4. Fuel supply port to HFCM 8. Mounting grommet (3)
1. CityStar™ – Install HFCM to chassis rail. Thread 2. Install new retaining clips onto fuel hoses.
three M8 mounting nuts onto mounting M8 x 40
3. Install fuel hoses onto HFCM cover plate.
bolts and tighten to special torque (page 186).
4. Connect the WIF, fuel heater, and fuel pump
Stripped chassis – Install HFCM to transmission
electrical connectors.
housing mounting bracket. Thread three M8
mounting nuts onto M8 x 40 mounting bolts and 5. Close water drain plug.
tighten to special torque (page 186).
EGES-390
FUEL SYSTEM 183
2
3
4
5
1 6
7
8
J11060
Figure 229 Fuel pressure regulator poppet assembly

1. Oil filter assembly 4. Pressure regulator cover gasket 7. Brass poppet
2. Secondary fuel filter housing 5. Viton O-ring, size #115 8. Pressure regulator valve spring
3. Screw, M6 x 25 (3) 6. Poppet gasket seal
1. Install a new pressure regulator cover gasket and 3. Install three M6 x 25 screws through the fuel
new O-ring into the fuel filter housing. filter housing and into the oil filter assembly.
Thread screws in evenly, watching the alignment
2. Make sure brass poppet has a new gasket seal on
of gasket, O-ring and poppet spring.
it before placing assembly into fuel filter housing.
Brass poppet goes in first, spring is oriented 4. Tighten Three M6 x 25 screws to special torque
toward oil filter side. (page 186).
EGES-390
184 FUEL SYSTEM
Fuel System Tubing
Figure 230 Fuel system tubing and connections

1. M6 x 16 bolt (2) 4. Fuel filter to left cylinder head 7. M10 x 16 bolt
2. Fuel filter to right cylinder head tube 8. M12 banjo bolt with check valve
tube 5. Fuel supply to filter tube (2)
3. Secondary fuel filter housing 6. Fuel return to HFCM tube
NOTE: Install all fuel tube fittings and anchor clamps 3. Position “fuel filter to left cylinder head tube”, “fuel
finger tight before tightening any to final torque. supply to filter tube”, and “fuel return to HFCM
tube” on the engine.
1. Position the “fuel filter to right cylinder head tube”
on the engine. 4. Install a new copper washer on M12 banjo
bolt and install bolt through the “fuel filter to
2. Install a new copper washer on an M12 banjo
left cylinder head tube”. Install second copper
bolt and install bolt through the “fuel filter to right
washer on banjo bolt and install bolt into front of
cylinder head tube”. Install second copper washer
left cylinder head and finger tighten.
on banjo bolt and install bolt into front of right
cylinder head and finger tighten.
EGES-390
FUEL SYSTEM 185
8. Install M6 x 16 bolt to secure fuel return and

supply tubes to the oil pan and finger tighten.
9. Install M10 x 16 bolt to secure fuel return and
supply tubes to the left cylinder head and finger
tighten.
10. Install M6 x 16 bolt to secure “fuel filter to right
cylinder head tube” to the intake manifold” and
finger tighten.
Figure 231 Secondary fuel filter tubes and

housing
1. Fuel return to HFCM tube
2. Fuel supply to filter tube
Figure 232 Tightening wrench and backup
wrench
4. Fuel filter to left cylinder head tube
5. Fuel filter to right cylinder head tube
11. Using a backup wrench, tighten right and left

cylinder head fuel tubes and fuel return to tank
5. Connect left and right cylinder head fuel tubes to
tube to special torque (page 186).
the fuel filter assembly and finger tighten.
12. Tighten fuel supply to filter tube hollow screw to
6. Connect the “fuel return to HFCM tube” to the fuel
special torque.
filter assembly and finger tighten.
13. Tighten right and left fuel supply tube banjo bolts
7. Install a new copper washer on the “fuel supply to
to special torque.
filter tube” hollow screw and install screw through
tube. Install second copper washer on hollow 14. Tighten M10 x 16 and two M6 x 16 bolts to
screw and install screw into the fuel filter assembly standard torque (page 400).
and finger tighten.
EGES-390
186 FUEL SYSTEM
Specifications

Electric heater 150 W
Filter efficiency 10 micron
Rated flow capacity 98 L/hr (26 gph @ 60 psi)
Secondary Fuel Filter
400 kPa (58 psi @ 35
Maximum fuel pressure in secondary filter
gph)
Valve unseating pressure 310 ± 28 kPa (45 ± 4 psi)
Injection Pressure Regulator (IPR) valve
-40 °C to 220 °C (-40 °F
Operating temperature range
to 428 °F)
Maximum operating pressure 28 MPa (4,061 psi)
Special Torque
Banjo bolt, 12 mm (fuel supply tube to each cylinder head) 38 N·m (28 lbf·ft)
Fuel injector hold down clamp bolt 35 N·m (26 lbf·ft)
Fuel supply hollow screw, M14 35 N·m (26 lbf·ft)
Fuel pump mounting screws, self tapping #10 5 N·m (44 lbf·in)
Fuel return fitting, M16 46 N·m (34 lbf·ft)
Fuel return to HFCM tube fitting 25 N·m (19 lbf·ft)
Fuel return tube assembly mounting screws, 8/32 x 3/8 2-3 N·m (20-25 lbf·in)
HFCM cover plate screws, M5 x 23 5 N·m (44 lbf·in)
HFCM housing mounting nuts (M8) 15 N·m (132 lbf·in)
Left and right cylinder head supply tube fittings at filter, M12 25 N·m (18 lbf·ft)
Plug assembly, M12 (rear of cylinder head) 36 N·m (27 lbf·ft)
Primary fuel filter cap 25 N·m (18 lbf·ft)
Secondary Fuel filter cap 14 N·m (124 lbf·in)
Secondary fuel filter housing mounting screws, M6 x 25 10 N·m (88 lbf·in)
EGES-390
FUEL SYSTEM 187

T45 Torx bit socket Obtain locally
Fuel Injector Tip Cleaning Brush ZTSE4301
Injector Connector Remover ZTSE4650
Turbocharger Inlet Guard ZTSE4293
EGES-390
188 FUEL SYSTEM
EGES-390
OIL COOLER AND FILTER HOUSING 189
Table of Contents
Illustrations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Oil Cooler Cover and Oil Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .191
Oil Cooler Cover and Filter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .192
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Oil Filter Housing Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .194
Oil Cooler Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .195
Oil Filter Base Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .197
Cleaning, Inspection, and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199

Oil Cooler Cover and Oil Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Oil Cooler Pressure Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .199
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Oil Filter Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .200
Oil Cooler Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .202
Oil Filter Base and Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .203
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .206
EGES-390
190 OIL COOLER AND FILTER HOUSING
EGES-390
Illustrations
Oil Cooler Cover and Oil Filter Base
1 2 3 4 5 6 7 8
12
15 10
11
14 13
J13035
Figure 233 Oil cooler cover and oil filter base

1. Unfiltered oil flow from pump 7. Filtered oil to crankcase galleries 12. Oil filter drain to sump
2. Oil cooler outlet (oil) and other components 13. Coolant outlet
3. Filtered oil to reservoir 8. Unfiltered oil inlet 14. Oil cooler inlet (oil)
4. Oil pressure test port fitting 9. Oil temperature sensor port 15. Oil drain to sump
5. Coolant inlet 10. Dual turbocharger oil supply port
6. Oil cooler bypass valve 11. Oil pressure sensor port
EGES-390
Oil Cooler Cover and Filter Housing
Figure 234 Oil cooler cover and filter housing assembly
EGES-390
1. Thread forming screw, M6 x 25 13. Dust cap 26. Fuel filter housing (see Fuel
(3) 14. Diagnostic port System section)
2. Viton O-ring, size #241 15. Bolt, M8 x 30 (10) 27. Oil filter base
3. Return tube gasket 16. Coolant inlet gasket 28. Viton O-ring, size #113
4. Bolt, M8 x 45 (Torx®) 17. O-ring 29. O-ring retaining washer
5. Screw, M8 x 23 (6) 18. EGR coolant supply elbow 30. Oil filter adapter
6. Viton O-ring, size #112 19. M6 screw 31. Viton O-ring, size #212 (2)
7. Screw, M5 x 18 (2) 20. Oil filter cap 32. O-ring retaining washer (2)
8. Oil filter base assembly 21. Oil filter cap seal 33. Oil filter assembly gasket
9. Oil filter base gasket 22. Oil filter element 34. Oil filter housing
10. Oil cooler cover assembly 23. Latching return tube 35. Screw, M6 x 25 (6)
11. High-pressure pump inlet 24. Viton O-ring, size #122 36. M8 x 75 bolt (3)
strainer 25. M8 x 55 x 16 stud bolt (2) 37. Oil drain valve assembly
12. O-ring, size #906
EGES-390
Removal


death, allow engine to cool before removing
components.
Figure 235 Oil filter housing and base
WARNING: To prevent personal injury or 1. Oil filter cap
death, wear safety glasses with side shields. 2. Oil filter housing
Limit compressed air pressure to 207 kPa (30 psi). 3. M8 x 50 x 16 stud bolt (2)
4. M6 x 25 screw (6)
WARNING: To prevent personal injury or 5. Oil filter base
death, do not let engine fluids stay on your skin. 6. M8 x 55 bolt
and rags contaminated with engine fluids. 3. Loosen oil filter cap and allow oil to drain through
filter housing.
4. Remove the oil filter cap and oil filter. Discard
O-ring gasket on cap.
fluids (oil, fuel, and coolant) may be a threat CAUTION: To prevent engine damage, do not remove
to the environment. Recycle or dispose latching return tube unless oil filter housing and oil
of engine fluids and filters according to filter base have been separated.
applicable regulations. Never put engine 5. Remove M8 x 55 bolt securing the oil filter housing
fluids in the trash, on the ground, in sewers assembly to the oil filter adapter.
or bodies of water.
6. Remove the two M8 x 50 x 16 stud bolts securing
the oil filter housing to the intake manifold.
7. Pull up and remove oil filter housing assembly
Oil Filter Housing Assembly from engine. Discard O-rings.
1. Remove the air intake duct and turbocharger 8. Remove six M6 x 25 screws securing the oil filter
oil supply tube assembly. See “Dual Stage housing to the oil filter base. Remove and discard
Turbocharger Assembly”. oil filter assembly gasket.
2. Remove the secondary fuel filter assembly. See
“Fuel Systems”.
EGES-390
J13039
Figure 236 Latching return tube assembly

1. Latching return tube
Figure 237 Oil cooler assembly
2. Viton O-ring seal, size #122
3. Oil filter housing 1. Oil cooler assembly with oil filter base
2. M8 x 30 bolt (10)
9. Remove the oil filter latching return

tube by pushing down and rotating tube CAUTION: To prevent engine damage, always
counter-clockwise 120°, then lift tube straight up. replace the oil cooler cover assembly after a
Remove O-ring seal and discard. catastrophic engine failure. Debris cannot be
removed from the oil cooler.
2. Remove ten M8 x 30 oil cooler cover assembly
Oil Cooler Cover mounting bolts.
1. Remove the intake manifold. See “Manifolds and
Exhaust Gas Recirculation (EGR)”.
Figure 238 Oil cooler module removal
3. Remove oil cooler assembly from crankcase.
EGES-390
Figure 239 High-pressure oil pump inlet strainer Figure 241 Oil cooler cover gasket removal
4. Remove pump inlet strainer from oil reservoir and 7. Remove oil cooler cover gasket and discard.
clean or discard.
5. Remove remaining oil from reservoir.
Figure 240 Oil reservoir magnetic cover

installation
6. Install oil reservoir Magnetic Covers (page 206).
EGES-390
Oil Filter Base Disassembly
Figure 242 Oil filter adapter O-ring removal Figure 243 Oil filter adapter removal
1. Remove and discard all three oil filter base 3. Remove the oil filter adapter and discard three
assembly O-rings on top. O-ring seals.
2. Remove the three M8 x 75 bolts securing the oil
filter adapter.
EGES-390
Figure 244 Oil bypass / filter inlet guide valve Figure 245 Oil filter base removal
assembly
1. Coolant inlet gasket
1. Oil cooler bypass valve washer seal 2. Oil filter base gasket
2. Oil filter inlet washer seal
5. Remove oil filter base assembly from oil cooler

NOTE: Remove oil bypass assembly only if you cover assembly. Remove and discard oil and
suspect problems. coolant gaskets.
4. Remove two M5 x 18 screws and remove the oil
bypass / filter inlet guide valve.
NOTE: Do not remove the oil filter base until oil cooler
pressure test has been performed.
EGES-390
Cleaning, Inspection, and Testing NOTE: If oil cooler is leaking, replace the oil cooler
assembly. There are no serviceable parts for this unit.
WARNING: To prevent personal injury or NOTE: The oil filter base must be installed on the oil
death, wear safety glasses with side shields. cooler cover assembly before pressure testing.
1. Fabricate an air adapter with the following items:
Oil Cooler Cover and Oil Filter Base
• Rubber hose
1. Drain and flush oil cooler cover, oil filter base, and
• Reducer bushing (hose to fitting)
housing to remove any internal residue.
• Shop air fitting (male)
2. Dry all components thoroughly with filtered
compressed air. • Two clamps
2. Fasten Oil Cooler Pressure Test Plate (page 206)
to oil cooler assembly.
Oil Cooler Pressure Test
3. Install air pressure regulator to EGR cooler
coolant outlet port (air adapter).
4. Apply 207 kPa (30 psi) of air pressure.
5. Spray a soapy water solution around oil cooler
and oil filter base.
submerge the oil cooler in water. Submerging can
allow water into oil passages.
6. If leaking, bubbles will be present. Replace
leaking component or seal.
7. Remove soapy water residue and blow off with
filtered compressed air.
Figure 246 Oil cooler air pressure leakage test

1. Air pressure regulator
2. Air adapter (make locally)
3. Test plate
EGES-390
Installation 2
1
Oil Filter Base
1
Figure 247 Oil filter base assembly gaskets

1. Coolant inlet gasket
2. Oil filter base gasket J11057
Figure 248 Oil filter base and oil cooler cover

1. Install new oil filter base gasket and coolant inlet
gasket onto oil filter base assembly. 1. Screw, M8 X 23 (5)
2. Bolt, M8 X 45 (Torx®)
3. Oil filter base assembly
4. Screw, M6 X 25 (6)
5. Oil cooler cover assembly
2. Install oil filter base onto oil cooler cover

assembly.
3. Install all oil filter base assembly bolts and screws.
Tighten to special torque (page 206).
4. Do oil cooler pressure test.
EGES-390
Figure 249 Oil bypass / filter inlet guide valve Figure 251 Oil filter base O-rings
assembly
1. O-ring, size #241
1. Oil cooler bypass valve washer seal 2. Return tube gasket
2. Oil filter inlet washer seal 3. O-ring, size #112
5. If removed, install a new oil bypass / filter inlet 7. Install two oil adapter O-rings and return tube
guide valve and two screws. gasket.
Figure 250 Oil bypass / filter inlet guide screws Figure 252 Oil adapter assembly bolts
6. Tighten the oil bypass / filter inlet guide screws 8. Install oil adapter assembly onto oil filter base
(M5 x 18) to special torque (page 206). assembly. Tighten three Torx® socket screws (M8
x 75) to standard torque (page 400).
EGES-390
Figure 253 Oil filter adapter O-rings Figure 255 Oil cooler cover gasket
1. O-ring, size #212 (position below retainer washer)
2. O-ring retainer washer (position above O-ring)
3. Install a new reservoir cover gasket on the oil
3. O-ring retainer washer (position above O-ring)
cooler cover.
4. O-ring, size #113 (position below retainer washer)
9. Install a new set of O-rings onto the oil filter

adapter.
Oil Cooler Cover

1. Remove Magnetic Covers from oil reservoir.
Figure 256 Oil cooler cover assembly

installation
4. Install oil cooler assembly onto crankcase.
Figure 254 Pump inlet strainer
2. Install a new or clean pump inlet strainer in the oil

reservoir.
EGES-390
Figure 257 Oil cooler cover assembly bolts

J13039
Figure 258 Latching return tube

5. Install ten M8 x 30 oil cooler cover assembly
mounting bolts and tighten to standard torque 1. Latching return tube
(page 400). 2. Latching return tube gasket
3. Oil filter housing
6. Lubricate three O-ring seals on top of the oil filter
adapter with clean engine oil.
2. Lubricate a new latching return tube gasket with
clean engine oil and install onto latching return
Oil Filter Base and Housing
tube.
1. Install intake manifold. See “Manifolds and
3. Install latching return tube by pushing down and
Exhaust Gas Recirculation (EGR)”.
twisting tube 120° clockwise until latched.
EGES-390
6 1
J13040
Figure 259 Oil filter base and housing

1. Screw, (M6 x 25) 4. Oil filter housing 7. Oil filter element
2. Oil filter base 5. Oil drain valve assembly 8. Oil filter cap seal
3. Oil filter housing gasket 6. Latching return tube assembly 9. Oil filter cap
4. Install a new oil filter housing gasket between the 5. Install six M6 x 25 oil filter housing mounting
housing and base. screws and tighten to special torque (page 206).
EGES-390
Figure 260 Oil filter housing assembly

1. Oil filter cap 3. M8 x 50 x 16 stud bolt (2) 5. Oil filter base
2. Oil filter housing 4. M6 x 25 screw (6) 6. M8 x 55 bolt
6. Install oil filter housing assembly onto oil filter 9. Install oil filter and cap as a combined unit.
adapter and intake manifold. Tighten cap to special torque (page 206).
7. Install M8 x 55 bolt and two M8 x 50 x 16 stud CAUTION: To prevent engine damage, add the
bolts. Tighten bolts to standard torque (page 400). correct viscosity oil to the engine before starting. See
Engine Operation and Maintenance Manual.
8. Install a new O-ring on the oil filter cap and
lubricate with clean engine oil.
EGES-390
Specifications
Oil Cooler
Type Full-flow: oil, coolant
Location Engine valley (forward)
Oil Filter
Type Cartridge, full flow - disposable
Filter bypass location Oil filter return tube assembly
Special Torque
Oil filter base assembly screws (M6 x 25) 10 N·m (85 lbf·in)
Oil filter base assembly bolt (M8 x 45) 11 N·m (97 lbf·in)
Oil filter base assembly screws (M8 x 23) 23 N·m (17 lbf·ft)
Oil bypass / filter inlet guide valve screws (M5 x 18) 7 N·m (62 lbf·in)
Oil filter housing mounting screws (M6 x 25) 15 N·m (132 lbf·in)
Diagnostic port 16 N·m (144 lbf·in)
EGR coolant supply elbow, M6 screw 9.7 N·m (85 lbf·in)
Oil filter cap 25 N·m (18 lbf·ft)
Magnetic Covers ZTSE4557

Oil Cooler Pressure Test Plate ZTSE4525
EGES-390
OIL PAN AND OIL PICKUP TUBE 207
Table of Contents
Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .209
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Lower Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .212
Upper Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .213

Lower Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Upper Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .214
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Upper Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .215
Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
Lower Oil Pan. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .216
EGES-390
208 OIL PAN AND OIL PICKUP TUBE
EGES-390
Exploded Views
Figure 261 Lube oil pan and related components (CityStar™)

1. Upper oil pan gasket 5. Oil pickup tube O-ring 9. Drain plug gasket
2. Upper oil pan assembly 6. Bolt, M6 x 20 (2) 10. Drain plug
3. Dowel pin (2) 7. Oil pickup tube assembly 11. Lower oil pan
4. Upper oil pan bolts (Figure 268) 8. Lower oil pan bolts (Figure 263) 12. Lower oil pan gasket
EGES-390
Figure 262 Lube oil pan and related components (stripped chassis)
1. Oil level gauge and tube 5. Bolts (Figure 269) 11. Oil pickup tube assembly
assembly (gauge blade removed 6. Lower oil pan gasket 12. Bolt - patch type, M6 x 25 (3)
for clarity) 7. Bolts (Figure 265) 13. Lower oil pan
2. Upper oil pan gasket 8. Drain plug gasket 14. Oil level gauge tube seal
3. Dowel pin (4) 9. Drain plug 15. Bolt, M6 x 20
4. Upper oil pan assembly 10. Oil pickup tube O-ring
EGES-390
Removal 1

1


death, allow engine to cool before removing
components.
2 J06051
death, do not let engine fluids stay on your skin. Figure 263 Lower oil pan bolt locations
Clean skin and nails using hand cleaner, and wash (CityStar™)
and rags contaminated with engine fluids. 1. M6 x 35 bolt (5)
2. M6 x 16 bolt (15)

or bodies of water.
Lower Oil Pan

1. Remove safety guards, shields, and covers.
Figure 264 Lower oil pan mounting bolts
EGES-390
Figure 265 Lower oil pan bolt locations (stripped

chassis)
1. M6 x 25 bolt (4) Figure 266 Lower oil pan removal (typical)
2. M6 x 35 bolt (14)
3. Remove the lower oil pan.
2. CityStar™ - Remove five lower oil pan mounting

bolts (M6 x 35) and 15 lower oil pan mounting Oil Pickup Tube
bolts (M6 x 16).
Stripped chassis - Remove four lower oil pan
mounting bolts (M6 x 25) and 14 lower oil pan
mounting bolts (M6 x 35).
Figure 267 Oil pickup tube removal (typical)
1. CityStar™ - Remove two oil pickup tube mounting

bolts (M6 x 20) and oil pickup tube.
Stripped chassis - Remove three oil pickup tube
mounting bolts (M6 x 25 - patch type) and oil
pickup tube.
2. Remove and discard the oil pickup tube O-ring.
EGES-390
Upper Oil Pan Stripped chassis - Remove eight upper oil pan
2. Remove upper oil pan.
Figure 268 Upper oil pan mounting bolts

(CityStar™)
Figure 270 Lower oil pan gasket (lower face)

(typical)
Figure 271 Upper oil pan gasket (upper face)

(typical)
Figure 269 Upper oil pan mounting bolts 3. Remove and discard gasket from each face of
(stripped chassis) upper oil pan.
1. CityStar™ - Remove seven upper oil pan

EGES-390
Cleaning and Inspection Oil Pickup Tube

1. Clean tube in a suitable solvent.
2. Dry with filtered compressed air.
Limit compressed air pressure to 207 kPa (30 psi). 3. Inspect the oil pickup tube assembly for cracking.
Replace if necessary.
Lower Oil Pan
1. Inspect bottom of oil pan for metallic debris or
other evidence of engine damage. Investigate Upper Oil Pan
any abnormalities as required.
1. Clean oil pan in a suitable solvent.
2. Clean oil pan with a suitable solvent.
3. Inspect for signs of warping or cracking. Replace
4. Look for warping, dents, and cracking. Replace if necessary.
the oil pan if necessary.
EGES-390
Installation
Upper Oil Pan

Figure 272 Upper oil pan gasket installation (CityStar™)
(upper face) (typical)
Figure 273 Upper oil pan gasket installation

(lower face) (typical)
1. Install a new gasket for each face on the upper oil

pan gasket.

(stripped chassis)
2. CityStar™ – Install upper oil pan and seven

Stripped chassis — Install upper oil pan and eight
Tighten bolts to the standard torque (page 400).
EGES-390
Oil Pickup Tube Lower Oil Pan
Figure 276 Oil pickup tube O-ring (typical)
1. Lubricate a new O-ring with clean engine oil and

install onto oil pickup tube.
Figure 277 Lower oil pan installation (typical)
2. CityStar™ - Install oil pickup tube and two
mounting bolts (M6 x 25). Tighten bolts to
1. Place lower oil pan onto upper oil pan mating
Stripped chassis - Do the following: surface.
• Clean threads of three mounting bolts (M6 x
25 - patch type) with suitable solvent.
• Apply Loctite® #242 (obtain locally) to
threads.
• Install oil pickup tube and three mounting
bolts.
• Tighten bolts to standard torque (page 400).
EGES-390
2 J06051
Figure 278 Lower oil pan bolt locations Figure 279 Lower oil pan bolt locations (stripped
(CityStar™) chassis)
1. Five bolts (M6 x 35) 1. Four bolts (M6 x 25)
2. 15 bolts (M6 x 16) 2. 14 bolts (M6 x 35)
2. CityStar™ – Install five lower oil pan mounting

bolts (M6 x 35) and 15 lower oil pan mounting
bolts (M6 x 16).
Stripped chassis — Install four lower oil pan
mounting bolts (M6 x 25) and 14 lower oil pan
Tighten all bolts to standard torque (page 400)
3. Remove tools, parts and equipment.
a. Reinstall all safety guards, shields, and
covers after servicing engine.
b. Make sure all tools, covers, loose parts and
service equipment are removed from engine
area after all work is done.
EGES-390
EGES-390
FRONT COVER, VIBRATION DAMPER, OIL PUMP, AND COOLING 219
SYSTEM
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .221
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .222
Vibration Damper. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .223
Front Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .224
Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .225
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .226
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .229
Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .230
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Front Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .232
Thermostat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .233
Water Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .234
Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .235
Front Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .236
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .238
EGES-390
220 FRONT COVER, VIBRATION DAMPER, OIL PUMP, AND COOLING
SYSTEM
EGES-390
SYSTEM
Exploded View
Figure 280 Front cover components

1. Heater feed tube assembly 16. Spacer 30. Bolt, M6 x 25 (5)
2. Nut, M10 17. Smooth idler pulley assembly 31. Bolt, M12 x 59 (4)
3. Bolt, M6 x 14 18. Spacer 32. Vibration damper
4. O-ring seal 19. Ball bearing assembly 33. Reinforcement ring
5. Front cover O-ring seal 20. Retaining ring 34. Bolt, M8 x 16 (4)
6. Stud bolt, M8 x 30 x 19 (2) 21. Dust cover 35. Water pump / fan drive pulley
7. Thermostat assembly 22. Bolt, M10 x 45 36. Water pump assembly
8. Front cover assembly 23. Gerotor cover seal 37. Bolt, M8 x 30 (4)
9. Front cover gasket 24. Gerotor oil pump assembly 38. O-ring, size #242
10. 8-groove idler pulley 25. Front crankshaft oil seal 39. Bolt, M8 x 35 (17)
11. O-ring, size #904 26. Gerotor cover assembly 40. Smooth idler pulley assembly
12. Ball bearing assembly 27. Oil pressure regulating valve 41. Bolt, M8 x 115
13. Retaining ring 28. Spring 42. Bolt, M8 x 72
14. Bolt, M10 x 50 29. End pressure regulator plug with 43. Belt tensioner assembly
15. Dust cover O-ring
EGES-390
SYSTEM
Removal
WARNING: To prevent personal injury or death, disconnect the main battery negative
death, read all safety instructions in the "Safety terminal before disconnecting or connecting
Information" section of this manual. electrical components.
WARNING: To prevent personal injury or WARNING: To prevent personal injury or

death, shift transmission to park or neutral, set death, do not let engine fluids stay on your skin.
parking brake, and block wheels before doing Clean skin and nails using hand cleaner, and wash
diagnostic or service procedures. with soap and water. Wash or discard clothing
death, make sure engine has cooled before
removing components.
WARNING: To prevent personal injury or to the environment. Recycle or dispose
death, do not open pressurized Freon® lines. of engine fluids and filters according to
WARNING: To prevent personal injury or fluids in the trash, on the ground, in sewers
death, wear safety glasses with side shields. or bodies of water.
EGES-390
SYSTEM
Vibration Damper
1. Before removing vibration damper, measure
damper runout as follows:
Figure 282 Vibration damper mounting bolts

1. Bolt, M12 x 59 (4)
2. Vibration damper
Figure 281 Check vibration damper runout

1. Dial indicator with magnetic base WARNING: To prevent personal injury or
2. Paint removed, four points (90° apart) death, support the vibration damper during
mounting bolt removal. The damper can easily
slide off the end of the crankshaft.
a. Remove paint from face of vibration damper
2. Remove and discard the four bolts (M12 x 59)
at four points approximately 90° apart.
that secure vibration damper to crankshaft. The
b. Attach a dial indicator with magnetic base vibration damper retaining bolts are not reusable.
(page 239) to front of crankcase. Position
3. Remove vibration damper from crankshaft.
indicator tip onto an unpainted surface.
c. Pry crankshaft forward and zero the dial
immerse damper in petroleum based solvents.
indicator. This becomes the baseline.
Damage to rubber damping element may result.
NOTE: Pry only in one direction to eliminate
possible error induced by crankshaft end play.
d. Turn crankshaft 90°. Pry crankshaft forward
and record reading.
e. Repeat at each unpainted surface. If run
out exceeds specification (page 238), replace
vibration damper.
EGES-390
SYSTEM
Front Oil Seal and Wear Sleeve

NOTE: International® MaxxForce™ 5 is not equipped
with a wear sleeve during factory production. Wear
sleeves are available with an oil seal service kit.
NOTE: If removing only the seal, do steps 1 through
3. Otherwise, remove seal and wear sleeve by doing
steps 1 through 4.

1. Drill two holes 180° apart in the front oil seal.
Figure 284 Front Wear Sleeve Remover
Figure 285 Front wear sleeve removed

Figure 283 Front seal removal 1. Front wear sleeve
2. Thread a slide hammer with an appropriately a. Install the tool’s two half shell ridges behind
sized screw in one of the two holes. the front wear sleeve.
3. Slide hammer until one side of the seal begins to b. Place the threaded shaft and pulling flange
pull out the gerotor cover. Move the slide hammer inside the two shells while holding the shells
to the other hole and repeat until the front oil seal together.
is removed completely. c. Place the shell collar over the two shells.
NOTE: The following steps are only necessary if the d. Thread the shaft up to the crankshaft, and
engine is equipped with a front wear sleeve. Wear apply tension to the two half shells. Remove
sleeves are only available in oil seal service kits. the wear sleeve.
4. Install the Front Wear Sleeve Remover. See
Special Service Tools (page 239). Do the
following steps:
EGES-390
SYSTEM
Gerotor Oil Pump
Figure 288 Gerotor orientation marking
Figure 286 Gerotor oil pump cover mounting

bolts 3. Using a permanent marker, mark the forward
side of each gerotor for proper reassembly and
1. Gerotor oil pump cover mounting bolts (5)
orientation.
2. Gerotor oil pump cover
use paint to identify internal components or their
1. Remove five gerotor oil pump cover mounting orientation. Use permanent markers only.
bolts (M6 x 25).
4. Remove gerotor gear set from housing.
2. Carefully remove cover to expose gerotor.
Figure 287 Gerotor oil pump

1. Gerotor cover
2. O-ring
3. Dowel (2)
4. Gerotor assembly
EGES-390
SYSTEM
Water Pump 2. Remove four M8 x 30 bolts securing water pump

assembly to front cover.
NOTE: If removing the front cover, the water pump
and thermostat do not need to be removed, however 3. Remove and discard water pump O-ring.
the water pump / fan drive pulley must be removed for
access to some front cover bolts.
Thermostat
Figure 289 Water pump / fan drive pulley

removal
Figure 291 Thermostat assembly
1. Stud bolt, M8 x 30 x 19 (2)
NOTE: If not using pneumatic tools, use a holding
2. Coolant outlet side of front cover (left side)
device to lock the fan drive pulley when removing
bolts.
1. Remove four bolts (M8 x 12) securing the pulley 1. Remove two stud bolts (M8 x 30 x 19) that secure
to the water pump and remove pulley. thermostat assembly to left side of front cover.
2. Remove thermostat assembly from front cover.
Remove and discard O-ring.
Figure 290 Water pump assembly

1. M8 x 30 bolt (4)
EGES-390
SYSTEM
Front Cover
Figure 293 Front cover retaining bolts
Figure 292 Heater feed tube assembly 1. Bolt, M8 x 35 (17)
1. Nut, M10
2. Bolt, M6 x 14 CAUTION: To prevent engine damage, cut sealant
where crankcase and lower crankcase meet, when
removing the front cover gasket. Failure to adequately
1. Remove bolt (M6 x 14) securing heater feed tube cut sealant before removing front cover and front
to front cover. Loosen nut (M10) at lifting eye cover gasket, can cause gasket between upper
bracket and slide heater feed tube from front crankcase and lower crankcase to pull out. Engine
cover. Remove and discard O-ring seal. removal and disassembly will be required to replace
the crankcase gasket.
2. Remove 17 M8 x 35 bolts from the front cover.
EGES-390
SYSTEM
3. Two conditions can occur when removing the b. Condition 2: Front cover gasket and lower
front cover. Use the appropriate procedure listed crankcase gasket are stuck together.
below.
a. Condition 1: Front cover and front cover
gasket are stuck together.
Figure 295 Cutting sealant between front

cover gasket and upper / lower crankcase joint
(condition 2)
Figure 294 Cutting sealant between front cover
and front cover gasket (condition 1)
Use a thin blade scraper to cut sealant where
crankcase, lower crankcase and front cover
gasket meet. Cut the front cover gasket loose
Use a thin blade scraper to cut sealant
and discard.
between the front cover and front cover
gasket. Remove front cover and follow
Condition 2 instructions.
EGES-390
SYSTEM
Cleaning, Inspection, and Testing 1. Manually open thermostat enough to insert a

nylon ribbon under the valve seat. Suspend the
thermostat in a container so the thermostat does
not touch the bottom of the container.
Front Cover
1. Wash components thoroughly in a suitable
cleaning solvent.
3. Inspect front cover for cracks.
4. Replace front cover if cracked.
Water Pump
Inspect water pump for leaks, cracks, bearing failure,
and problems with the shaft seal. Replace as
necessary.
Vibration Damper
CAUTION: To prevent engine damage, do not Figure 296 Test thermostat operation
immerse damper in petroleum based solvents.
1. Suspension line
Damage to rubber damping element may result.
2. Ribbon
1. Clean vibration damper with soap, water, and a 3. Thermometer
soft parts brush. Dry with filtered compressed air. 4. Thermostat
5. Heat source
2. Inspect vibration damper rubber compound for
cracking, bulging or separation. See rubber
bulging maximum (page 238) specification.
2. Heat 50/50 ethylene glycol and water filled
Replace as necessary.
container to the approximate normal operating
temperature of the thermostat.
Thermostat 3. Observe thermometer and record temperature
thermostat drops from nylon ribbon. This is
WARNING: To prevent personal injury or the point where normal operating temperature
death, wear heat resistant gloves and appropriate begins.
eye protection during thermostat operation check.
4. Continue to heat ethylene glycol and water
CAUTION: To prevent engine damage, when to the full-open temperature (page 238) of
servicing thermostat, make sure the thermostat the thermostat and observe thermometer and
opens fully at the specified temperature to avoid movement of thermostat sleeve.
engine overheating.
5. Remove thermostat from container with
NOTE: Only genuine International® thermostats suspension line and let cool.
ensure proper coolant flow and positive sealing for
6. Inspect seat area for pitting and foreign deposits.
proper engine cooling.
Replace thermostat if it is damaged or does not
Check thermostat operation as follows: operate correctly.
EGES-390
SYSTEM
Gerotor Oil Pump

Wash all parts thoroughly in a suitable solvent. Dry
with filtered compressed air.
1. Lay front cover assembly on workbench.
2. Inspect gerotors and housing for nicks, burrs or
scoring.
3. Replace any damaged components.
NOTE: The inner and outer gerotors are a
matched set and cannot be replaced individually.
• When installing new gerotors, correct
orientation is not required.
• When installing old gerotors, correct
orientation is required. Figure 298 Check oil pump end clearance
4. Place inner and outer gerotors in oil pump 1. Feeler gauge
housing. 2. Straightedge
3. Inner gerotor
4. Outer gerotor
6. Check oil pump end clearance as follows:

a. With the gerotors in place in the front cover,
place straightedge across housing.
b. Insert feeler gauge under straightedge at
inner and outer gerotors. Compare end
clearance with Specifications (page 238).
c. If measurements are not within specifications,
replace both gerotors (as a set).
Figure 297 Inspect gerotors for wear

1. Feeler gauge
2. Front cover assembly
3. Outer gerotor
5. Use a feeler gauge to inspect for wear by checking

the radial clearance (page 238) between outer
gerotor and oil pump housing.
EGES-390
SYSTEM
7. Use a 12 mm internal hex wrench to remove oil

pressure regulator.
Figure 299 Oil pressure regulator components

1. End cap and O-ring 2. Oil pressure bypass spring 3. Piston poppet
8. Inspect oil pressure regulator piston poppet to experience any significant dimensional wear.
(steel) for binding and sticking due to debris Refer to Specifications (page 238). Replace as
or severe piston poppet scoring. Check for a necessary.
broken oil pressure bypass spring. The spring
10. Install a new O-ring on the end cap.
should normally be the only potential cause of
any malfunction in this assembly. Replace as 11. Install regulator components and tighten end cap
necessary. to special torque (page 238).
9. Check regulator bore (aluminum) for severe
piston poppet scoring. It should not be expected
EGES-390
SYSTEM
Installation 2. Apply Liquid Gasket (RTV) (page 239) to joining

surfaces of crankcase and lower crankcase.
Front Cover
3. Install a new front cover gasket on the crankcase.
Figure 300 Front cover crankcase dowels

Figure 302 Front cover and gasket
1. If removed, install front cover crankcase dowels.

NOTE: Dowels may become lodged in front cover. 4. Align front cover with crankcase dowels.
Remove dowels and install in crankcase. If dowels
are bent, replace with new ones.
Figure 303 Front cover module retaining bolts

1. Bolt, M8 x 35 (17)
Figure 301 Locations for Liquid Gasket (RTV)
application
5. Install seventeen M8 x 35 bolts and finger tighten.
CAUTION: To prevent engine damage, install and 6. Tighten seventeen M8 x 35 bolts to special torque
torque gasket and cover within five minutes of (page 238).
applying Liquid Gasket (RTV).
EGES-390
SYSTEM
Thermostat
Figure 304 Heater feed tube O-ring
7. Lubricate a new heater feed tube O-ring with the

recommended coolant. Figure 306 Thermostat assembly
CAUTION: To prevent engine damage, do not 1. Thermostat assembly

lubricate heater feed tube O-ring with engine oil. Oil 2. Thermostat O-ring seal
produces swelling of O-ring, resulting in leakage.
1. Install a new O-ring seal onto thermostat

assembly.
2. Install thermostat assembly on front cover coolant
outlet. Secure with two mounting stud bolts (M8 x
30 x 19) and tighten to special torque (page 238).
Figure 305 Heater feed tube assembly

1. Nut, M10
2. Bolt, M6 x 14
8. Install heater feed tube into front cover while

aligning bracket slot with stud at lifting eye.
Install bolt (M6 x 14) into front cover and tighten
to standard torque (page 400). Tighten nut to
special torque (page 238).
EGES-390
SYSTEM
Water Pump
1. Install a new water pump O-ring onto the front
cover assembly.
Figure 308 Water pump / fan drive pulley

installation
1. Water pump / fan drive pulley mounting bolts
Figure 307 Water pump assembly installation

3. Install water pump / fan drive pulley with four bolts
1. M8 x 30 bolt (4)
(M8 x 12) and tighten to special torque (page 238).
2. Install water pump assembly on front cover over

the new O-ring and secure with four M8 x 30 bolts.
Tighten bolts to special torque (page 238).
EGES-390
SYSTEM
Gerotor Oil Pump
Figure 310 Gerotor oil pump housing

1. Gerotor oil pump cover retaining bolts, M6 x 25 (5)
Figure 309 Gerotor oil pump
2. O-ring
3. Dowel pins (2) 2. Align dowel pins and install oil pump cover on front
4. Gerotor assembly cover. Install five retaining bolts (M6 x 25) to oil
pump cover. Tighten bolts to special torque (page
238).
CAUTION: To prevent engine damage, when
installing used oil pump rotors, make sure oil pump
inner and outer rotors rotate in the same direction as
before removal. See marks added during removal for
proper rotor orientation.
1. Lubricate inner gear with lithium assembly grease
and install on crankshaft. Lubricate outer gear
with lithium assembly grease and mesh with inner
gear rotor in oil pump housing. Wipe off excess
assembly grease.
EGES-390
SYSTEM
Front Oil Seal and Wear Sleeve

NOTE: A wear sleeve is not installed during engine
production. The wear sleeve is required for rebuild
and is supplied with the front oil seal as a service part
only.
Figure 312 Front oil seal and wear sleeve

installation
1. Wear sleeve
2. Front oil seal
3. Front Oil Seal/Wear Sleeve Installer
2. Install the oil seal and wear sleeve into the oil
Figure 311 Loctite® Hydraulic Sealant
pump cover using Front Seal / Wear Sleeve
application to crankshaft
Installer (page 239).
3. Install the seal and sleeve until the tool bottoms
1. Remove oil from front of crankshaft with a suitable out (correct depth).
solvent and clean rag.
Place a 360° bead of Loctite® Hydraulic Sealant
(page 239) on the leading edge of the crankshaft
prior to wear sleeve installation.
EGES-390
SYSTEM
Vibration Damper
1. Align vibration damper with dowel pin located on
the front of the crankshaft.
Figure 313 Vibration damper mounting bolts

Figure 314 Vibration damper torque sequence
1. Mounting bolts, M12 x 59 (4)
2. Vibration damper
3. Tighten vibration damper bolts to special torque
(page 238) using the above sequence.
WARNING: To prevent personal injury or NOTE: Refer to Accessories Drive Belt Routing
death, always install four new vibration damper (Figure 540) for idler pulley and accessory location
bolts when installing the vibration damper. and identification.
2. Install four new bolts (M12 x 59) to secure 4. Remove tools, parts and equipment.
vibration damper onto crankshaft.
a. Install all safety guards, shields and covers
after servicing the engine.
b. Make sure all tools, loose parts and service
equipment are removed from the engine area
after all work is done.
EGES-390
SYSTEM
Specifications
Vibration Damper
Face runout (maximum) 0.635 mm (0.025 in)
Rubber bulging (maximum) 1.5 mm (0.060 in)
Lubricating Oil Pump and Pressure Regulator
Type Gerotor
Drive Crankshaft
Gerotor oil pump housing
Location
(front cover)
Oil Pressure:
• Engine oil pressure, low idle (min. @ 110 °C (230 °F) oil temp.) 69 kPa (10 psi)
• Engine oil pressure, high idle (min. @ 110 °C (230 °F) oil temp.) 276 kPa (40 psi)
483 to 621 kPa (70 to 90
• Oil pump discharge pressure (2,500 rpm)
psi)
0.025 to 0.095 mm (0.001
Oil pump end clearance (inner and outer rotor to housing)
to 0.004 in)
0.15 to 0.28 mm (0.006 to
Oil pump radial clearance (between outer rotor and housing)
0.011 in)
18.81 ± 0.02 mm (0.741 ±
Oil pressure regulator bore
0.001)
Thermostat
Balanced pressure, wax
Type
pellet
Full open temperature, >10 mm (0.394 in) stroke 104 °C (219 °F)
Special Torque
Water pump / fan drive pulley bolts, M8 x 12 36 N·m (26 lbf·ft)

Front cover bolts, M8 x 35 24 N·m (18 lbf·ft)
Nut (heater feed to lifting eye), M10 41 N·m (35 lbf·ft)
Oil pressure regulator end cap 27 N·m (240 lbf·in)
Gerotor oil pump cover bolts, M6 x 25 13 N·m (110 lbf·in)
Thermostat stud bolts, M8 x 30 x 19 22 N·m (200 lbf·in)
New bolts only: 68 N·m
Vibration damper mounting bolts, M12 x 59
(50 lbf·ft) + 90° rotation
Water pump mounting bolts, M8 x 30 23 N·m (17 lbf·ft)
EGES-390
SYSTEM

Fan Hub Wrench (2 inch) ZTSE43972
Fan Wrench (pulley bolts) ZTSE4587
Front Seal / Wear Sleeve Installer ZTSE4680
Front Wear Sleeve Remover ZTSE4517
Liquid Gasket (RTV) (6 oz. tube) 1830858C1
Loctite® Hydraulic Sealant Obtain locally
EGES-390
SYSTEM
EGES-390
CYLINDER HEAD AND VALVE TRAIN 241
Table of Contents
Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .243
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .246
Crankcase Breather Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Valve Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247
Rocker Arm Carrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .248
Valve Bridges and Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .249
Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .250
Hydraulic Cam Followers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .252
Cleaning, Inspection, and Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253

Cylinder Head and Valve Train Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Cylinder Head Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .253
Removing Valves from Cylinder Head. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257
Cylinder Head Inspection – Valves Removed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .258
Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
Valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .259
Valve Springs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .260
Valve Spring Retainer Keys. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .261
Fuel Injector Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .262
Fuel Injector Sleeve Bore and Gallery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .263
Fuel Injector Sleeve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .264
Glow Plug Sleeve Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .265
Glow Plug Sleeve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .266
Valve Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267
Rocker Arm and Fulcrum Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .268
Cleaning and Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Rocker Arm and Fulcrum Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .270
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Hydraulic Cam Follower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .272
Cylinder Heads. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .273
Valve Bridges and Push Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .275
Cylinder Head Bolt Torque Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .277
Glow Plugs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Valve Covers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .278
Crankcase Breather Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .279
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .280
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .281
EGES-390
242 CYLINDER HEAD AND VALVE TRAIN
EGES-390
Exploded Views
Figure 315 Cylinder head, rocker arm carrier, valve covers, and crankcase breather
1. Oil fill cap 5. Bolt, M6 x 43 (6) 10. Rocker arm carrier gasket (2)
2. ICP sensor seal 6. Valve cover bolt (18) 11. Cylinder head assembly (2)
3. Valve cover (right side) 7. Valve cover (left side)
4. Crankcase breather housing 8. Valve cover gasket (2)
assembly 9. Rocker arm carrier (2)
EGES-390
Figure 316 Cylinder head and valve train components

1. Hydraulic cam follower (12) 7. Valve spring retainer (24) 13. Core plug (10)
2. Cam follower guide (2) 8. Valve spring (24) 14. Exhaust valves (12)
3. Bolt, M8 x 70 (8) 9. Valve stem oil seal (24) 15. Intake valves (12)
4. Push rod (12) 10. Fuel injector sleeve (6) 16. Cylinder head (2)
5. Valve bridges (12) 11. Glow plug sleeve (6) 17. Bolt/washer (2)
6. Valve retainer keys (48) 12. Fuel rail port
EGES-390
Figure 317 Rocker arm carrier components

1. Head bolt, M14 x 193 (16) 7. Dowel sleeve (end fulcrums 11. Fulcrum plate (dual) (4)
2. Fulcrum bolt spacer (12) only) (4) 12. Dowel sleeve bushing (4)
3. Bolt, M8 X 45 (12) 8. Fulcrum plate (exhaust) (2) 13. Bolt, M8 X 50 (4)
4. Rocker arm clip (12) 9. Rocker arm (exhaust) (6) 14. Fulcrum plate (intake) (2)
5. Ball, ⅜ chrome (12) 10. Self tapping bolt stud, M10 x 30
6. Rocker arm (intake) (6) x M8 x 10 (CityStar™ only)
EGES-390
Removal
WARNING: To prevent personal injury or death, do not let engine fluids stay on your skin.
death, read all safety instructions in the “Safety Clean skin and nails using hand cleaner, and wash
Information” section of this manual. with soap and water. Wash or discard clothing
WARNING: To prevent personal injury or of engine fluids and filters according to
death, allow engine to cool before working with applicable regulations. Never put engine
components. fluids in the trash, on the ground, in sewers
or bodies of water.
death, disconnect ground (-) cable from battery

EGES-390
Crankcase Breather Housing 3. Remove crankcase breather from valve cover.

NOTE: Remove the crankcase breather only if 4. Remove four breather opening seals.
necessary. The left valve cover may be removed
NOTE: The breather and seals are supplied as a
without removing the crankcase breather housing.
service kit. Seals are not available separately.
1. Remove the crankcase breather hose from the
crankcase breather housing.
Valve Covers
Figure 320 Valve cover mounting bolts – right

Figure 318 Crankcase breather and left valve
cover 1. Valve cover stud bolt assembly (3)
2. Valve cover bolt assembly (6)
1. Crankcase breather hose connection
2. M6 x 43 breather bolt (6)
3. Left valve cover
1. Loosen six valve cover bolts and three valve cover
4. Crankcase breather
stud bolts securing right valve cover to the right
cylinder head.
6. Valve cover stud bolt assembly (2)
2. Remove the right valve cover.
3. Loosen seven valve cover bolts and two valve
2. Remove six M6 x 43 bolts securing crankcase
cover stud bolts securing left valve cover to the
breather to the left valve cover.
left cylinder head.
4. Remove the left valve cover.
Figure 319 Crankcase breather removal
EGES-390
Rocker Arm Carrier

1. Remove the right and left high-pressure oil rails.
See “High-pressure Oil System”.
2. Remove the fuel injectors. See “Fuel System”.
Figure 322 Rocker arm carrier removal
4. Lift rocker arm carrier assembly from cylinder

head and set aside for disassembly, cleaning,
Figure 321 Rocker arm carrier assembly inspection, and assembly.
1. Rocker arm carrier mounting bolts (2)

2. Cylinder head bolts (8)
3. Rocker arm carrier assembly
4. Hole for mounting stud
3. Remove two rocker arm carrier bolts (M8 x 50)

and eight cylinder head bolts (M14 x 193) using
a circular pattern to loosen. Begin with the outer
bolts and loosen bolts moving inward. Discard
cylinder head bolts.
EGES-390
Valve Bridges and Push Rods
Figure 323 Valve bridge identification (left Figure 324 Push rod removal
cylinder head)
3. Remove and identify all push rods so that they
CAUTION: To prevent engine damage, use may be returned to their original positions during
permanent marker to identify internal components installation.
and their orientation. Do not use paint or temporary
markers.
1. Identify each valve bridge with its respective
valve set so they can be installed in their original
locations.
Example: 2 - I
• Cylinder number 2 as counted from the front
of engine
• I = Intake, E = Exhaust
2. Remove valve bridge by lifting bridge straight up.
EGES-390
Cylinder Heads
Figure 326 Cylinder Head Lifting Bracket

Figure 325 Glow plug removal
1. Cylinder Head Lifting Bracket
2. Lifting bracket mounting bolts (4)
1. Remove six glow plugs.
2. Remove two inboard bolts (M8 x 50) along upper
edge of cylinder head. WARNING: To prevent personal injury or
death, mount cylinder head lifting bracket on the
center of the cylinder head. Make sure lifting
hook has a safety latch.
3. Install Cylinder Head Lifting Bracket (page 281)
on the cylinder head using four lifting bracket
mounting bolts. Locate bracket in center of head.
NOTE: The lifting bracket allows the cylinder head
to lift squarely from the crankcase.
4. Attach a lifting hoist hook or suitable lifting sling to
lifting bracket.
EGES-390
Figure 329 Cylinder head spring dowel pins
Figure 327 Cylinder head removal from

crankcase NOTE: Inspect cylinder head spring dowel pins. If pins
are loose, damaged or missing, replace with new.
5. Lift cylinder head from the crankcase. Be careful

not to damage cylinder head locating spring dowel
pins. Place cylinder head on suitable surface,
using caution not to scratch cylinder head surface.
Figure 328 Cylinder head gasket removal
6. Remove and discard the cylinder head gasket.
EGES-390
Hydraulic Cam Followers

NOTE: As a general rule, hydraulic cam followers
should not be serviced when they are functioning
satisfactorily and operate quietly.
NOTE: If it is necessary to remove the cam followers,
the rear cover, high-pressure oil pump cover, and
branch tube assembly must be removed. See “Rear
Cover” and “High-pressure Oil System”.
CAUTION: To prevent engine damage, keep cam
followers in the order they were removed. Install all
cam followers back in their original positions.
Figure 331 Cam followers and roller follower

guide removal
2. Remove cam followers and roller follower guide

by lifting the guide straight up. Some followers
may need to be removed individually using hand
tools.
Figure 330 Roller follower guide bolt / washer

removal
NOTE: Be careful when removing the mounting bolt /

washer assembly used to secure roller follower guide
to crankcase. These are small parts which can easily
fall into the crankcase during removal.
1. Remove one bolt and washer (M6 x 12) assembly
Figure 332 Cam follower removal from guide
from forward guide hole and lift out guide and
roller lifters.
NOTE: Identify location and orientation of each cam 3. Remove individual cam followers from roller
follower and guide during disassembly. follower guide.
EGES-390
Cleaning, Inspection, and Tests 5. Use a Head Bolt Bottoming Tap (page 281) to
clean each tapped hole in crankcase top deck.
Remove debris with filtered compressed air.
death, wear safety glasses with side shields. CAUTION: To prevent engine damage, install new
Limit air pressure to 207 kPa (30 psi). head bolts when installing the cylinder head.
Cylinder Head and Valve Train Components 6. Thoroughly clean each push rod using a suitable
solvent and dry with filtered compressed air.
Cleaning
1. With valves installed to protect seats, remove
deposits and gasket material from valve heads Cylinder Head Inspection
and gasket surface with a scraper and wire brush.
NOTE: Cylinder head condition must be evaluated by
Be careful not to damage cylinder head gasket
inspecting for thickness, warping, cracks, and valve
surface.
leakage.
2. Use a suitable solvent to remove dirt, grease, and
other deposits from parts removed.
3. Clean all bolt holes and be sure gasket surfaces,
oil returns, and coolant passages are clean.
After a thorough rinsing with hot water, blow out
passages with filtered compressed air.
4. Wash all bolts and hardware (except head bolts,
these must be replaced) with a suitable solvent
and dry thoroughly.
NOTE: Clean crankcase threads are essential. Dirt or
damaged threads may cause binding and false torque
readings.
Figure 334 Cylinder head thickness

measurement
1. To determine if cylinder head has been resurfaced

previously, use a 3-4 inch micrometer to measure
cylinder head deck thickness at four corner
locations. If overall cylinder head thickness
(deck-to-deck) specification is not met, replace
cylinder head. See Specifications (page 280).
Figure 333 Crankcase cylinder head bolt hole

cleaning
EGES-390
Figure 335 Inspection points for cylinder head

flatness check
NOTE: It is not necessary to remove the valves to do

Figure 337 Checking valve recession
the cylinder head flatness check.
1. Straightedge
2. Feeler gauge
3. Valve head
3. Before removing valves, check valve head

recession (relative to deck) as follows:
a. Place a straightedge across each valve.
b. Place a feeler gauge between straightedge
and valve head. Record valve recession
clearance.
c. If out of specification, replace valve. Perform
step 2 over again, and if specifications are
still not met, replace cylinder head. See
Specifications (page 280).
Figure 336 Cylinder head flatness measurement
1. Straightedge
2. Feeler gauge
2. Use a straightedge (page 281) and 0.051 mm

(0.002 in) feeler gauge to check cylinder head
gasket surface for flatness. Position straightedge
only in the direction of the double ended arrow
line shown above. Check cylinder head flatness
at each point 1 through 10. If the feeler gauge
passes through the gap between the cylinder
head and straight edge easily, replace that
cylinder head.
EGES-390
Figure 338 Spraying cleaner on cylinder head Figure 340 Spraying developer onto cylinder
head
4. Inspect for cracks in the cylinder head using the

Dye Penetrant Kit (page 281).
a. Spray cleaner on gasket surface of cylinder
head and wipe dry.
Figure 341 Cylinder head crack between intake

and exhaust valves
Figure 339 Spraying Dye Penetrant onto
cylinder head
d. Spray developer on gasket surface of cylinder
head and let dry for 5 to 15 minutes. Cracks
b. Spray dye penetrant onto gasket surface of will show up as purple lines against white
cylinder head. Allow dye to remain on surface developer.
from 1 to 30 minutes. e. Replace cylinder head if cracks are present.
c. Wipe dye off cylinder head surface.
NOTE: Dye will remain in any cracks during
this ’wipe off’ step.
EGES-390
5. Check for valve leakage using mineral spirits as

follows:
a. Position cylinder head on wooden blocks with
gasket surface facing down.
Figure 343 Inspecting for leaks

1. Inspection mirror
2. Reflection of valve
3. Flashlight
Figure 342 Squirting ports with mineral spirits

c. Wait five minutes. Use an inspection mirror to
inspect valve seat area for leakage of mineral
b. Squirt mineral spirits in intake and exhaust spirits.
ports.
NOTE: There should be no leakage. Valve
seat reconditioning is not required if the
cylinder head passes the mineral spirits test.
d. If leakage is observed, the valves require
reconditioning.
EGES-390
Removing Valves from Cylinder Head 2. Remove valve spring retainers.

NOTE: Valve removal is only required if replacing 3. Remove valve springs from cylinder head.
valves or reconditioning valve seats. Valve seat
reconditioning is not required if the cylinder head
passes the mineral spirits test, see Cleaning,
Inspections, and Tests.
Figure 346 Removing valves from cylinder head
4. Remove valves from cylinder head.

Figure 344 Removing the valve retainer keys
1. Valve retainer keys
2. Valve Spring Compressor
1. Use the Valve Spring Compressor to compress

valve springs. Remove valve retainer keys. A
small magnet is useful for this procedure. See
Special Service Tools (page 281).
Figure 347 Removing valve stem oil seal
5. Remove valve stem oil seals and discard. Valve

stem seals are not reusable. Pliers will be
necessary to get seal off end of the valve stem
guide.
Figure 345 Valve spring retainer
EGES-390
Cylinder Head Inspection – Valves Removed • Lower cylinder head deck

• Injector sleeve area
• Glow plug sleeve area
Limit air pressure to 207 kPa (30 psi). 2. With the valves removed from the cylinder head,
clean all valve guides using a nylon brush, soap
1. Pressure testing the cylinder head will reveal
and water. Blow out any residue with filtered
cracks in ports or sleeve leakage which cannot
compressed air.
be observed using dye penetrant. Pressure test
the cylinder head as follows: 3. Position an inspection light at the bottom of the
valve guide bores and examine the walls for
burning or cracking. Replace the cylinder head
as necessary.
Figure 348 Cylinder Head Test Plate

1. Pressure gauge and regulator
2. Mounting bolts (12 total)
3. Pressure test plate Figure 349 Measuring the small hole gauge
(valve guide ID)
a. Fasten the Cylinder Head Pressure Test Plate

tool, with rubber gasket attached, to gasket 4. Measure each valve guide by using a 0-1 inch
side of cylinder head. Secure plate using outside micrometer.
eight (M14) bolts and four (M8) bolts. See
a. Record each valve guide inner diameter so
valve-to-guide running clearance may be
b. Install pressure test regulator and gauge determined.
assembly to cylinder head test plate.
b. If valve guide inner diameter exceeds
c. Immerse cylinder head in water. Apply air specifications, replace cylinder head. See
pressure and adjust to 124 to 138 kPa (18 to Specifications (page 280).
20 psi) and inspect for leaks at the following
5. Clean valve seat area using suitable solvent, prior
places. If any leaks are observed replace the
to visual inspection.
cylinder head:
6. Inspect the exhaust valve seats for burned or
• Ports
cracked conditions. If any of these conditions
• Upper cylinder head deck exist, replace cylinder head.
EGES-390
Push Rods
1. Inspect each push rod for wear and deposits
which may restrict the flow of oil into the rocker
arm assemblies. Replace push rods as required.
Figure 351 Valve stem measurement points

1. Two measurements 90 degrees apart
2. Three valve stem diameter measurement locations
3. Measure each valve stem diameter for wear

using a 0-1 inch micrometer. Measure valves at
three locations 90° apart and record readings.
Figure 350 Checking for push rod straightness Replace valves not within minimum stem diameter
specification (page 280).
NOTE: The intake valve has a larger diameter head.
2. Check all push rods for straightness by rolling
them on a straight flat surface. If a push rod 4. Using the valve guide inside diameters
is not straight, replace as necessary. See measured earlier and the valve stem diameter
Specifications (page 280). measurements just recorded, determine valve
stem-to-guide running clearance. Replace valve
or cylinder head as required. See Specifications
Valves (page 280).
1. Remove carbon deposits from valve stems and

valve heads.
2. Inspect each valve, replacing any that show
excessive burn marks, warping, scuffing,
bending, or valve tip spalling.
EGES-390
Valve Springs
1. Clean all valve springs in a suitable solvent.
2. Inspect valve springs for rust, pitting, distortion,
and cracks. If any of these conditions exist,
replace the valve spring.
Figure 352 Measuring the valve face
5. Measure the valve face margin at four locations

(90° apart) using a dial caliper.
CAUTION: To prevent engine damage, the minimum
Figure 353 Check the squareness of each valve
valve face margin must be maintained across the
spring
entire valve face. An insufficient margin will not
provide proper heat dissipation and lead to valve
warping or breakage. Intake and exhaust valve
3. Inspect valve spring ends to verify they are
margins are different. Replace valve if the margin is
square. Square ends prevent lateral loads on
less than the specified minimum. See Specifications
valve stem. Replace springs as required.
(page 280).
NOTE: If valves and seats are in a serviceable
condition, they may be re-faced to the specified
angles. See Specifications (page 280).
EGES-390
Figure 355 Measuring valve spring length under

load
Figure 354 Check valve spring free length b. Apply the appropriate test loads to each
spring and determine whether test length is
achieved. See Specifications (page 280).
4. Measure valve spring tension using Valve Spring
Tester (page 281). Replace any springs as
required.
Valve Spring Retainer Keys
a. Measure valve spring free length. See
Specifications (page 280). 1. Clean all valve spring retainer keys with a suitable
cleaning solvent.
2. Inspect the inside and outside of the valve spring
retainer keys for wear. Replace any worn valve
spring keys as required.
EGES-390
Fuel Injector Sleeve Removal

NOTE: Fuel injector sleeve removal is only required
if leaks were found during pressure test or the inner
surface is nicked or scratched.
CAUTION: To prevent engine damage, (if replacing
fuel injector sleeves in chassis), coat bottom of the
injector sleeve with a dab of grease prior to cutting
threads. The grease will prevent small metal chips
from entering combustion chamber.
NOTE: The fuel injector sleeve is made of stainless
steel. Lubrication of the Injector Sleeve Remover
(thread tap) is required.
1. Lubricate Injector Sleeve Remover (thread tap)
(page 281) with clean engine oil.
Figure 357 Injector Sleeve Remover and slide
hammer
3. Install Injector Sleeve Remover (page 281) (slide

hammer adapter) into the cut threads of the fuel
injector sleeve and tighten.
4. Thread slide hammer into Injector Sleeve
Remover.
Figure 356 Cutting threads in fuel injector

sleeve
2. Thread Injector Sleeve Remover (thread tap)

into fuel injector sleeve. Cut threads at least ¾
inch deep to accommodate the Injector Sleeve
Remover.
Figure 358 Fuel injector sleeve removed

1. Fuel injector bore
2. Fuel injector sleeve
3. Injector Sleeve Remover
4. Slide hammer
5. Using the slide hammer, remove fuel injector

sleeve and discard.
EGES-390
Fuel Injector Sleeve Bore and Gallery 3. Clean the fuel gallery with the Fuel Gallery
Cleaning Brush. See Special Service Tools (page
281).

Limit air pressure to 207 kPa (30 psi).
Figure 359 Cleaning the injector bore
1. Use Injector Sleeve Brush to remove deposits and

hardened sealant from injector bore. See Special
Service Tools (page 281).
Figure 361 Blowing out fuel gallery
2. Remove fuel rail plug assembly (M12).
4. Using filtered compressed air, clean out all debris

from fuel gallery port.
5. Install the fuel rail plug assembly and tighten to
the special torque (page 281).
Figure 360 Cleaning the fuel gallery

1. Fuel Gallery Cleaning Brush
2. Fuel gallery port
EGES-390
Fuel Injector Sleeve Replacement 4. Carefully center the fuel injector sleeve in the
injector bore.
1. Verify injector bore is completely clean and dry.
2. Place fuel injector sleeve onto Injector Sleeve
Installer. See Special Service Tools (page 281).
Figure 362 Applying Loctite® #620 sealant to Figure 364 Installing fuel injector sleeve into
fuel injector sleeve bore
1. Wall (end)
2. Upper wall (top) 5. Drive Injector Sleeve Installer with new sleeve
into fuel injector bore until sleeve bottoms. If any
Loctite® #620 sealant gets into the inside of the
3. Apply Loctite® #620 sealant to fuel injector injector sleeve, it must be cleaned out before it
sleeve. See Special Service Tools (page 281). begins to harden.
6. Inspect the inside surface of the installed fuel
injector sleeve. If nicks and scratches are evident,
replace the fuel injector sleeve again. Make sure
the installation tool is not causing damage. Use a
different installation tool if necessary.
Figure 363 Installing fuel injector sleeve
EGES-390
Glow Plug Sleeve Removal

CAUTION: To prevent engine damage, (if replacing
glow plug sleeves in chassis), place a small dab of
grease into the bottom of the glow plug sleeve prior to
cutting threads. The grease will prevent small metal
chips from entering the combustion chamber.
NOTE: Glow plug sleeve removal is not required
unless the sleeve is leaking or the inner surface
is nicked or scratched. See Cleaning, Inspection
and Tests in this section to determine if sleeve
replacement is required.
NOTE: The glow plug sleeve is made of stainless
steel. Lubrication of the Glow Plug Sleeve Remover Figure 366 Installing the Glow Plug Sleeve
(thread tap) is required, otherwise excessive force will Remover
be necessary.
1. Lubricate Glow Plug Sleeve Remover (page 281)
(thread tap) with clean engine oil. 3. Thread Glow Plug Sleeve Remover (bolt and
sleeve adapter) into glow plug sleeve. See
4. Using a wrench, tighten the bolt in the remover
until the glow plug sleeve adapter is extracted.
5. Remove glow plug sleeve and discard.
Figure 365 Glow Plug Sleeve Remover (thread

tap) installation
2. Install Glow Plug Sleeve Remover (thread tap) to

cut threads in the glow plug sleeve. Cut threads
at least ½ inch deep to accommodate Glow Plug
Sleeve Remover (bolt and sleeve adapter).
Figure 367 Glow plug bore cleaning
6. Clean glow plug bore with Glow Plug Sleeve

Brush (page 281).
EGES-390
Glow Plug Sleeve Replacement

NOTE: Be certain that the glow plug recess was
cleaned out with the Glow Plug Sleeve Brush, rinsed
with a suitable cleaning solution, and blown out with
shop air.
Figure 370 Installing glow plug sleeve into place

Figure 368 Applying Loctite® #620 sealant to 1. Glow plug installation tool
sleeve locations 2. Glow plug sleeve
1. Wall (end)
2. Upper wall (top)
2. Install glow plug sleeve in cylinder head with the
Glow Plug Sleeve Installer. Continue to tap the
1. Apply Loctite® #620 sealant to the wall and upper installer until the sleeve bottoms. See Special
wall on the glow plug sleeve. See Special Service Service Tools (page 281).
Tools (page 281). 3. Clean glow plug sleeve after installation with a
nylon brush and solvent. Make sure Loctite®
sealant is cleaned out before it hardens.
4. Inspect the inside surface of the installed glow
plug sleeve. If nicks and scratches are evident,
replace the glow plug sleeve again. Make sure
the installation tool is not causing damage. Use a
different installation tool if necessary.
Figure 369 Glow plug sleeve installation

1. Glow Plug Sleeve Installer
2. Glow plug sleeve
EGES-390
Valve Installation 4. Place valve spring over valve stem seal.

5. Install valve spring retainer on top of spring.
Clean valve faces and seats with a suitable cleaning
solvent to remove all dirt or foreign material. Blow
dry all new and used components using filtered
compressed air.
NOTE: Guides must be clean! Use a valve guide
brush to clean guides.
1. Dry valve guides with filtered compressed air.
2. Lubricate inside diameter of new valve stem seal
and inside diameter of valve guide with clean
engine oil. Install stem seal over valve guide until
it stops.
NOTE: Valve seal will not seat completely over valve Figure 372 Valve retainer keys installation
guide by hand. Seals can be seated using a suitable
1. Valve retainer key
deep socket and rubber mallet to provide a positive
2. Valve spring compressor
contact with machined base.
3. Lubricate valve stem with clean engine oil and
insert valve into cylinder head. CAUTION: To prevent engine damage, make sure
when the valve spring compressor is released, the
inside bead of each valve retainer key locks into the
key groove of the valve stem.
6. Compress valve spring with Valve Spring
Compressor (page 281), install two valve stem
keys, and release spring compressor.
7. After valve replacement, measure valve
head recession (page 280) and compare to
specifications.
Figure 371 Valve seal, spring, and retainer

1. Valve seal
2. Valve spring
3. Valve retainer
EGES-390
Rocker Arm Carrier

Rocker Arm and Fulcrum Disassembly
Figure 374 Removing the end fulcrum plate and

fulcrum bolt spacer
1. End fulcrum plate
Figure 373 Removing the rocker arm fulcrum 2. Fulcrum bolt spacer
bolt
1. Remove six bolts (M8 x 45) and fulcrum bolt

spacer holding all the rocker arm fulcrums to the
rocker arm carrier. Remove fulcrums and rocker
arms as assemblies.
EGES-390
Figure 375 Compressing the rocker arm clip

Figure 376 Removing the rocker arm
1. Rocker arm
2. Rocker arm clip 1. Fulcrum plate
3. Fulcrum plate 2. Rocker arm ball
3. Rocker arm clip
4. Rocker arm
NOTE: Disassembly and assembly of dual and single
rocker arm fulcrum plates are similar.
3. Move the rocker off the ball, keeping the ball in the
2. To disassemble the rocker arm from the fulcrum
detent of the fulcrum plate.
plate; hold rocker arm and fulcrum plate upside
down in the palm of your hand. Push down on
fulcrum plate against rocker arm (relieving force
on ball) while simultaneously pushing rocker away
from ball and fulcrum plate.
Figure 377 Removing the rocker arm clip

1. Fulcrum plate
2. Rocker arm clip
4. Remove and discard the rocker arm clip.
EGES-390
Cleaning and Inspection

1. Clean all parts with a suitable solvent. Use filtered
compressed air to dry parts.
2. Inspect each rocker arm pivot foot and
corresponding valve bridge for pitting or scuffing.
Inspect each rocker arm ball and socket for
scuffing. Replace rocker arms and valve bridges
as required.
3. Inspect rocker arm post ball socket for excessive
wear. Inspect bolts for thread damage. Replace
Figure 379 Installing the rocker arm ball
worn components as required.
1. Fulcrum plate
2. Rocker arm ball
Rocker Arm and Fulcrum Assembly 3. Rocker arm clip
4. Rocker arm
2. Insert the ball onto the fulcrum plate detent. Hold

rocker arm upside down in your palm.
Figure 378 Installing a new rocker arm clip

1. Fulcrum plate
2. Rocker arm clip
Figure 380 Installing the rocker arm clip
NOTE: Disassembly and assembly of dual and single 1. Rocker arm
rocker arm fulcrum plates are similar. 2. Rocker arm clip
3. Fulcrum plate
1. Install a new rocker arm clip onto the fulcrum
plate.
3. Press lower part of the rocker arm against the
rocker arm clip, push up with your palm and push
the upper part of the rocker arm over the rocker
arm ball. Check for freedom of movement of
rocker arm on the fulcrum plate.
EGES-390
4. Position each assembled end rocker fulcrum plate

(intake or exhaust) with a fulcrum bolt spacer onto
rocker carrier assembly. Orient E and I fulcrum
stamping face up. Install bolt (M8 x 45) into each
fulcrum and tighten to the special torque (page
281).
5. Position each assembled dual fulcrum plate
with two fulcrum bolt spacers onto rocker carrier
assembly. Orient E and I stamping face up. Install
two bolts (M8 x 45) into each fulcrum and tighten
to the special torque.
Figure 381 Installing the end fulcrum and

fulcrum bolt spacer
1. Fulcrum plate
2. Fulcrum bolt spacer
Figure 383 Installing the cylinder head to rocker

arm carrier gasket
6. Install a new cylinder head to rocker arm carrier

gasket.
Figure 382 Installing an end rocker fulcrum plate
EGES-390
Installation 2. Lubricate and place each hydraulic cam follower

into its respective roller follower guide.
Hydraulic Cam Follower
1. Clean hydraulic cam followers and roller follower
guide. Use care to maintain roller follower location
and orientation.
NOTE: Verify correct location and orientation of each
reused cam follower and guide during reassembly.
Figure 385 Installing the cam followers and

guide into crankcase
3. Lubricate cam followers with clean engine oil and

install them into their respective bores.
4. Install one M6 x 12 bolt and washer assembly with
roller follower guide (forward guide hole only) and
Figure 384 Installing a cam follower in guide tighten to the standard torque (page 400).
EGES-390
Cylinder Heads
CAUTION: To prevent engine damage, be sure
cylinder head is free of debris or a good seal between
the cylinder head and gasket will not be possible;
leading to oil, coolant, and compression leakage. Do
not apply sealant to head gasket surfaces.
CAUTION: To prevent engine damage, threads in
crankcase bolt holes must be clean and blown dry
with filtered compressed air. Dirt or oil left in holes
may cause binding and false torque reading during
assembly.
1. If not performed already, clean all cylinder head
bolt holes with a Head Bolt Bottoming Tap (page
281) and remove debris with filtered compressed
air.
Figure 387 Cylinder head gasket installation
CAUTION: To prevent engine damage, install a new

cylinder head gasket with part number facing up.
Verify top four bolt holes and cylinder head gasket
push rod holes are all aligned.
NOTE: Use care to avoid scratching blue compound
on cylinder head gaskets.
3. Install new cylinder head gasket over spring dowel
pins and onto crankcase.
Figure 386 Cylinder head spring dowel pins
2. Make sure two cylinder head spring dowel pins

are installed (one at front and one at rear of
crankcase).
EGES-390
Figure 388 Guide pin installation

Figure 389 Cylinder head installation onto
crankcase
4. Install cylinder head installation guide pins (make
locally).
6. Attach hoist hook or lifting sling to lifting bracket.
NOTE: Cam followers cannot be removed or replaced Raise cylinder head and align with guide pins,
when cylinder head is bolted to the crankcase. Be previously installed in crankcase.
sure to complete any required work to cam followers
7. Lower cylinder head onto head gasket.
before installing cylinder head.
8. Install two outer bolts (M8 x 70) across top of
5. Install Cylinder Head Lifting Bracket (page 281)
cylinder head. Run threads down until finger tight.
in center of cylinder head (if removed). Tighten
bracket mounting bolts. 9. Install two inner bolts (M8 x 70) across the top of
the cylinder head. Run threads down until finger
CAUTION: To prevent engine damage, do not drop
tight.
cylinder head on gasket or slide it across gasket.
Either action will damage cylinder head gasket and 10. Remove hoist and cylinder head lifting bracket.
spring dowel pins, resulting in leakage.
EGES-390
Valve Bridges and Push Rods
Figure 391 Installing the valve bridges
Figure 390 Installing push rod

3. Place each of the previously marked valve bridges
onto their respective valve stems.
NOTE: Copper ball on end of each push rod must be CAUTION: To prevent engine damage, make sure
installed into rocker arm socket. the push rods are seated in the hydraulic roller
1. Apply clean engine oil to each end of push rods follower sockets before installing the rocker arm
and insert into previously marked positions. carrier assembly.
2. Coat the end of each valve stem with clean engine

oil.
EGES-390
Rocker Arm Carrier

1. Install dowels in cylinder head.
NOTE: Dowels may still be attached to the
cylinder head.
Figure 393 Installing the rocker arm carrier

assembly
Figure 392 Alignment guides and dowels in

place 5. Place rocker arm carrier onto guides.
1. Alignment guides 6. Remove guides and install two rocker carrier bolts
2. Dowels (M8 x 50). Tighten each bolt alternately while
observing rocker carrier, dowel sleeve bushings
and cylinder head for signs of misalignment.
2. Install cylinder head and rocker carrier alignment Tighten bolts to the standard torque (page 400).
guides (make locally) in position shown prior to
installing rocker arm carrier.
3. Rotate the crankshaft until damper locating dowel
hole is in the six o’clock position. This positions
all pistons below TDC so the valves do not
contact the pistons when tightening the rocker
arm assemblies.
4. Apply engine oil to the top center of each valve
bridge.
EGES-390
Cylinder Head Bolt Torque Sequence
Figure 394 Cylinder head bolt torque sequence
CAUTION: To prevent engine damage, use a 3. Tighten M14 bolts 1 through 8 in sequence to 88
permanent ink marker to identify head bolt torque N·m (65 lbf·ft).
orientation. Do not use paint or other temporary
4. Tighten M14 bolts 1, 3, 5, and 7 in sequence to
marking.
116 N·m (85 lbf·ft).
CAUTION: To prevent engine damage, check to make
5. Tighten M14 bolts 2, 4, 6, and 8 in sequence to
sure all push rods have been seated in their respective
116 N·m (85 lbf·ft).
rocker arm pivot recesses.
6. Tighten M14 bolts 1 through 8 in sequence
CAUTION: To prevent engine damage, all M14 x
clockwise 90 degrees.
193 head bolts must be replaced when installing
cylinder head. Lubricate bolt threads, flanges, and 7. Tighten M14 bolts 1 through 8 in sequence a
mating surfaces with a light coat of clean engine oil. second time clockwise 90 degrees.
Too much oil will cause hydrostatic lock and give
8. Tighten M 14 bolts 1 through 8 in sequence a third
an incorrect torque reading. Do not use anti-seize
time clockwise 90 degrees.
compound, grease, or any other lubricant on cylinder
head bolt threads. 9. Tighten M8 x 70 bolts 9 through 12 in sequence
to 24 N·m (18 lbf·ft).
1. Lightly lubricate new M14 x 193 cylinder head
bolts with clean engine oil. 10. Tighten M8 x 70 bolts 9 through 12 in sequence
to 31 N·m (23 lbf·ft).
2. Install eight M14 head bolts in the head and finger
tighten.
EGES-390
Glow Plugs Valve Covers
Figure 395 Glow plug Figure 396 Valve cover mounting bolts – right
1. Valve cover stud bolt assembly (3)
1. Install six glow plugs in the cylinder heads.
2. Tighten glow plugs to the special torque (page
281). CAUTION: To prevent engine damage, do not use air
tools to install valve covers.
1. Install valve cover gasket and right valve cover
onto right rocker arm carrier.
2. Tighten six valve cover bolts and three valve cover
stud bolts to special torque (page 281).
3. Install valve cover gasket and left valve cover onto
left rocker arm carrier.
4. Tighten seven valve cover bolts and two valve
cover stud bolts to special torque.
5. If removed, install lifting eyes on the rear of each
rocker arm carrier and one on the left front carrier.
Tighten bolts to special torque.
EGES-390
Crankcase Breather Assembly
Figure 398 Crankcase breather and left valve

cover
1. Crankcase breather hose connection
2. M6 x 43 breather bolt (6)
Figure 397 Crankcase breather installation 3. Left valve cover
4. Crankcase breather
1. Install four breather cover opening seals onto 6. Valve cover stud bolt assembly (2)
crankcase breather.
2. Install the crankcase breather onto the left valve

cover.
3. Install and finger tighten six M6 x 43 breather
bolts.
4. Tighten M6 x 43 bolts to special torque (page
281).
a. Reinstall all safety guards, shields and covers
b. Make sure all tools, loose parts, and service
EGES-390
Specifications
Valve Specifications
Face to stem runout (T.I.R. max.) 0.038 mm (0.0015 in)
Stem to guide clearance (max. allowable before replacement) 0.140 mm (0.0055 in)
6.947 to 6.965 mm (0.2735 to
Valve stem diameter
0.2742 in)
Exhaust valve face angle 37.5°
Intake valve face angle 30.0°
Exhaust valve margin (minimum) 1.35 mm (0.053 in)
Intake valve margin (minimum) 1.40 mm (0.055 in)
Valve Spring Specifications

Free length 51.96 mm (2.045 in)
46.30 mm @ 340 ± 17 N (1.82 in @
Compressed* (first test)
76.5 ± 3.8 lbf)
38.30 mm @ 850 ± 43 N (1.51 in @
Compressed* (second test)
191.1 ± 9.7 lbf)
* Spring must be compressed to a solid height before checking test loads.
Cylinder Head Specifications

Gasket surface flatness (maximum) 0.051 mm (0.002 in) per check point
Overall thickness of cylinder head (deck-to-deck) 95 mm (3.74 in)
Valve guide bore runout 0.05 mm (0.002 in)
7.003 to 7.029 mm (0.276 to 0.277
Valve guide inside diameter
in)
Valve guide taper (maximum) 0.10 mm (0.004 in)
0.32 to 0.68 mm (0.0126 to 0.0268
Valve head recession relative to deck (surface of cylinder head)
in)
Valve seat angle (exhaust) 37.5°
Valve seat angle (intake) 30.0°
Valve seat runout (T.I.R. max.) 0.035 mm (0.0014 in)
Valve seat width (exhaust) 1.48 to 2.24 mm (0.058 to 0.088 in)
Valve seat width (intake) 1.80 to 2.56 mm (0.071 to 0.101 in)
Push rod runout (maximum) 0.25 mm (0.01 in)
EGES-390
Special Torque
See Cylinder Head Bolt

Cylinder head bolt torque and sequence Torque Sequence(page
277)
Crankcase breather bolts (M6 x 43) 11 N·m (96 lbf·in)
Fuel rail plug, M12 36 N·m (27 lbf·ft)
Glow plugs 18 N·m (159 lbf·in)
Lifting eye, front (M10 x 30) 41 N·m (30 lbf·ft)
Lifting eye, rear (M10 x 35) 41 N·m (30 lbf·ft)
Rocker arm fulcrum plate (M8 x 45) 31 N·m (23 lbf·ft)
Valve cover bolt assemblies (M6) 9 N·m (84 lbf·in)
Cylinder Head Lifting Bracket ZTSE4661

Cylinder Head Pressure Test Plate ZTSE4534
Dye Penetrant Kit PT-7191
Fuel Gallery Cleaning Brush ZTSE4541
Glow Plug Sleeve Brush (nylon) ZTSE4533
Glow Plug Sleeve Installer ZTSE4532
Glow Plug Sleeve Remover (consists of: tap, bolt and adapter) ZTSE4531
Glow Plug Sleeve Seat Wire Brush ZTSE4589
Head Bolt Bottoming Tap ZTSE4508
Injector Sleeve Brush ZTSE43041
Injector Sleeve Flat Bottom Brush ZTSE43042
Injector Sleeve Installer ZTSE4529
Injector Sleeve Remover (consists of: tap and adapter) ZTSE4528
Loctite® #620 Obtain locally
Magnetic Covers (Cylinder Head Intake Ports) ZTSE4559
Slide Hammer Kit ZTSE4398A
Straightedge Obtain locally
Valve Guide Gauge Tool ZTSE4577
Valve Spring Compressor ZTSE1846
Valve spring tester Obtain locally
EGES-390
EGES-390
REAR COVER AND FLYWHEEL 283
Table of Contents
Exploded Views. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .287
Rear Main Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
CityStar™ Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .289
Stripped Chassis Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .290
Crankshaft Secondary Flange (Stripped Chassis Only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .291
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .292

Measure Rear Cover Face Runout (Stripped Chassis). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .294
Ring Gear Runout Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Clean and Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .295
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Rear Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .296
Crankshaft Secondary Flange (Stripped Chassis). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .299
Rear Main Oil Seal and Wear Sleeve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
CityStar™ Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .300
Stripped Chassis Applications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .302
Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .304
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .305
EGES-390
284 REAR COVER AND FLYWHEEL
EGES-390
Exploded Views
NOTE: There are two different rear cover assemblies
available, depending upon vehicle application.
1 2
21 3 4
20
19
18
17 5
16
15
14
6
7
8
13 9
10
12 11
J06062
Figure 399 Rear cover and related components (stripped chassis)

1. Bolt, M8 x 55 (5), Refer to 8. Rear seal carrier gasket 16. Flywheel assembly
(Figure 413) 9. Rear oil seal carrier assembly 17. Adapter hub
2. Gasket 10. Bolt, M8 x 25 (6) 18. Dowel pin, 0.250 x 0.625 mm
3. O-ring seal 11. Bolt, M8 x 70 (2) 19. Crankshaft rear oil seal
4. Cover 12. Bolt, M10 x 77 (10) assembly (service)
5. Bolt, M8 x 55 (2) 13. Reinforcement ring 20. Dowel pin, 1/4 x 5/8 in.
6. Rear cover (SAE 2) 14. Bolt, M10 x 35 (12) 21. Dowel pin, M8 x 25
7. Crankshaft flange 15. Converter housing adapter
EGES-390
Figure 400 Rear cover and related components (CityStar™)

1. Bolt, M8 x 35 (8) 4. Crankshaft rear oil seal (service) 7. Bolt, M10 x 31 (10)
2. Rear cover 5. Flywheel adapter 8. Dowel sleeve (2)
3. Gasket 6. Flywheel
EGES-390
Removal Flywheel
1. Measure ring gear runout (page 295).



death, use a suitable lifting device to support
the transmission assembly during removal and
installation. Figure 401 Transmission adapter ring bolt
removal (stripped chassis)
death, support engine (if in chassis) before
2. Stripped chassis applications, remove 12 bolts
removing any engine mounting bracket or
(M10 x 35) securing the transmission adapter ring
flywheel housing bolts.
to the rear cover.

EGES-390
CAUTION: (CityStar™ applications only) – To prevent

engine damage, place a heel bar onto the head of a
rear cover bolt to remove the flywheel adapter. This
will prevent cracking the aluminum rear cover.
CAUTION: To prevent engine damage, carefully
remove and store flywheel adapter or adapter hub.
Damage to the adapter sealing surface can result in
a rear oil seal leak.
5. For CityStar™ applications only, place a heel bar
on the head of the rear cover bolt and the hook
under the lip of the flywheel adapter. Alternate
between the two rear cover head bolts to pry off
the flywheel adapter.
Figure 402 Flywheel bolts (typical)
3. Remove and discard 10 flywheel mounting bolts

(M10 x 31 - CityStar™) (M10 x 77 - stripped
chassis).
4. Remove flywheel assembly.
Figure 404 Flywheel adapter removed

(CityStar™)
1. Dowel pin
2. Pin recess
3. Dust seal lip surface
Figure 403 Flywheel adapter removal

(CityStar™)
1. Rear cover bolt head locations
2. Placement of the heel bar
EGES-390
Rear Main Seal and Wear Sleeve

CityStar™ Applications
1. Use an awl or 1/8 inch drill bit to make two small
starter holes approximately 180° apart in the rear
main seal.
Figure 406 Rear Wear Sleeve Remover

(CityStar™)
4. Install threaded shaft and two shell halves of the

Rear Wear Sleeve Remover (page 305).
Figure 405 Rear main oil seal removal

(CityStar™)
2. Thread slide hammer screw into one of the starter

holes. To remove seal evenly, use Slide Hammer
(page 305) on one side then alternate to other
side.
3. Remove and discard rear main oil seal.
NOTE: When removing the rear main oil seal, it should
be noted that production engines not previously Figure 407 Outer ring (CityStar™)
serviced, will not have a wear sleeve. Wear sleeves
are only available as a service item included with the
rear main oil seal service kit. 5. Install the outer ring of the Rear Wear Sleeve
Remover. Make sure wear sleeve remover shells
are securely in place behind wear sleeve before
applying force to threaded shaft.
6. Thread puller shaft tool in and remove wear
sleeve.
EGES-390
Stripped Chassis Applications

1. Use an awl or 1/8 inch drill bit to make two small
starter holes approximately 180° apart in the rear
main seal.
Figure 409 Wear sleeve removal (stripped

chassis)
5. Install the outer ring of the Rear Wear Sleeve

Remover. Make sure wear sleeve removal tool
shells are securely in place behind wear sleeve
Figure 408 Rear main oil seal removal (stripped before applying force to threaded shaft.
chassis)
2. Thread slide hammer screw into one of the starter

holes. To remove seal evenly, use slide hammer
on one side then alternate to other side.
3. Remove and discard rear main oil seal.
NOTE: When replacing the rear main seal, note that
production engines will not have a wear sleeve. Wear
sleeves are only available as a service item included
with the replacement rear main oil seal.
4. Install threaded shaft and two shell halves of the
Rear Wear Sleeve Remover (page 305).
Figure 410 Wear sleeve removed (stripped

chassis)
1. Rear Wear Sleeve Remover
2. Wear sleeve
6. Turn the threaded shaft clockwise until the wear

sleeve is free of the crankshaft flange.
EGES-390
Crankshaft Secondary Flange (Stripped Chassis

Only)
Figure 411 Rear oil seal carrier bolts (stripped

chassis)
Figure 412 Crankshaft secondary flange
1. Bolts, M8 x 25 (6) removal (stripped chassis)
2. Bolts, M8 x 70 (2)
3. Use Gear Puller (page 305) to remove the

1. Remove eight rear oil seal carrier bolts (M8). crankshaft secondary flange.
2. Remove rear oil seal carrier and discard gasket.
EGES-390
Rear Cover
1
1 1
J06070
Figure 413 Rear cover bolt arrangement
(stripped chassis) Figure 414 Rear cover bolt arrangement
(CityStar™)
1. Bolt, M8 x 55 (5)
2. Bolt, M10 x 60 (4) 1. Bolt, M8 x 35 (8)
3. Bolt, M10 x 70 (2)
CAUTION: To prevent engine damage when

removing the rear cover, cut the sealant where
the crankcase and lower crankcase meet. Cut
sealant where the crankcase, high-pressure oil pump
cover and rear cover meet. Failure to adequately
cut sealant before removing the rear cover can result
in upper and lower crankcase gaskets being pulled
out. Engine removal and disassembly is required to
replace the lower crankcase gasket.
CAUTION: To prevent engine damage, (if
high-pressure oil pump cover is in place), make sure
the high-pressure oil pump cover gasket does not
pull out when removing the rear cover.
1. Stripped Chassis – Remove necessary rear cover
mounting bolts. Refer to (Figure 413) for rear
cover bolt pattern.
CityStar™ Chassis – Remove eight rear cover
mounting bolts (M8 x 35). Refer to (Figure 414)
for rear cover bolt pattern.
EGES-390
5. Use a thin gasket scraper to separate sealant

between the upper and lower crankcase seals
and rear cover assembly. When removing the
rear cover assembly, separate the sealant at all
joints with the rear cover to avoid pulling these
gaskets out.
WARNING: (Stripped chassis applications

only) – To prevent personal injury or death, have
an assistant help with removal of the rear cover
as it is considerably heavier than the CityStar™
chassis version.
6. Remove the rear cover assembly.
Figure 415 Rear cover removal with a rubber

hammer (typical)
2. Use a rubber hammer to help loosen the rear

cover from its seat.
3. When the rear cover becomes loose, pull back on
the rear cover but do not remove completely.
4. Cut the rear cover gasket from under the
high-pressure pump housing in order to remove
the rear cover. Pull the rear cover back, but do
not remove.
Figure 417 Rear cover gasket removal (typical)
7. Remove the rear cover gasket and discard.
Figure 416 Rear cover and lower crankcase

sealant cut location (typical)
EGES-390
Cleaning, Inspection, and Testing

Measure Rear Cover Face Runout (Stripped
Chassis)
Figure 418 Rear Cover face runout measurement
1. Push the crankshaft in by hand to bring crankshaft 5. Slowly rotate crankshaft 360 degrees while
end play to zero. keeping crankshaft end play at zero and observe
dial indicator measurements.
2. Center the magnetic base of a dial indicator set
(page 305) on the end of the crankshaft. 6. Compare the total dial indicator variation (highest
– lowest reading) to rear cover face runout
3. Place the dial indicator tip against the face of the
rear cover.
4. Zero dial indicator.
EGES-390
Ring Gear Runout Measurement Clean and Inspect

1. Check for ring gear damage associated with 1. Clean all foreign material from crankcase and
the starter pinion. If damage is found, replace rear cover gasket surfaces. Use a scraper or
flywheel. wire brush to remove sealant from any gasket
surfaces.
2. Gasket surfaces must be kept oil free for good
adhesion of liquid gasket during assembly. Use
a commercially available, non-caustic brake
cleaner to clean crankcase and rear cover gasket
surfaces.
3. Clean sealant from under the hydraulic oil pump
cover while it is still in place.
4. Wash flywheel, rear cover, flywheel adapter or
adapter hub with a suitable solvent. Dry with
filtered compressed air.
5. Inspect flywheel for evidence of cracking around
Figure 419 Ring gear run out measurement
webbing and ring gear weld locations. Replace
(typical)
flywheel if any evidence of cracking is found.
6. Inspect ring gear teeth and flywheel for damage.
2. Measure flywheel ring gear for surface run out. Replace flywheel is damaged.
NOTE: Keep the crankshaft end play at zero in the
same direction for all measurements.
A. Attach a dial indicator with magnetic base
(page 305) onto engine. Place dial indicator
tip against surface of ring gear.
B. Zero the dial indicator.
C. Rotate crankshaft slowly (clockwise)
and record total indicator runout. See
3. Replace ring gear if total indicator runout is out of
specifications.
EGES-390
Installation
Rear Cover
CAUTION: To prevent engine damage, before
installing the rear cover, replace dowel sleeves in
crankcase if damaged or missing.
Figure 421 RTV locations, upper and lower

crankcase (typical)
CAUTION: To prevent engine damage, do not allow

Liquid Gasket (RTV) to set longer than 5 minutes
before installing components and tightening bolts.
Figure 420 Rear cover gasket (typical) 2. Apply Liquid Gasket (RTV) (page 305) at two
locations, where the crankcase and lower
crankcase join.
1. Install a new rear cover gasket onto rear cover.
EGES-390
Figure 422 Liquid Gasket (RTV) locations under

the high-pressure pump cover (typical)
3. Apply a small amount of RTV under the Figure 424 Rear cover installation (CityStar™)
high-pressure pump cover.
1. Dowel pins (2)
WARNING: (Stripped chassis applications

only) – To prevent personal injury or death, have
an assistant help with installation of the rear
cover.
5. Install rear cover assembly by aligning dowel
sleeves on crankcase with rear cover. Push rear
cover onto dowel sleeves.
Figure 423 High-pressure pump cover gasket

(typical)
4. Apply a small amount of oil to the high-pressure

pump cover gasket.
EGES-390
1 1
Figure 426 Rear cover bolts (stripped chassis)

J06070
1. Bolt, M8 x 55 (5)
2. Bolt, M10 x 60 (4)
Figure 425 Rear cover bolts (CityStar™)
3. Bolt, M10 x 70 (2)
1. Bolt, M8 x 35 (8)
Stripped Chassis, install and tighten rear cover

6. CityStar™ Chassis, install eight rear cover mounting bolts to standard torque (page 400).
mounting bolts (M8 x 35) and tighten to standard
torque (page 400).
EGES-390
Crankshaft Secondary Flange (Stripped Chassis) 4. Install crankshaft secondary flange by alternately
tightening stud nuts until flange is seated on the
crankshaft.
5. Remove studs after flange is completely seated.
Figure 427 Crankshaft secondary flange sealant

location
1. Place a 360° bead of Loctite® Hydraulic Sealant

(page 305) onto the forward edge of the Figure 429 Rear oil seal carrier (stripped
crankshaft secondary flange (primary flange chassis)
mating surface). 1. Gasket
2. Install crankshaft secondary flange by aligning the
dowel pin hole with the crankshaft dowel pin.
6. Install a new gasket onto rear oil seal carrier.
Figure 430 Rear oil seal carrier bolts (stripped

Figure 428 Crankshaft secondary flange chassis)
installation 1. Bolts, M8 x 25 (6)
1. Crankshaft Secondary Flange Installation Studs (2) 2. Bolts, M8 x 70 (2)
3. Install two Crankshaft Secondary Installation 7. Install two M8 x 70 bolts in lower holes (Figure
Studs (page 305) 180° apart into the crankshaft 430). Install six M8 x 25 bolts. Tighten eight bolts
primary flange. Thread studs completely into the to standard torque (page 400).
crankshaft primary flange.
EGES-390
Rear Main Oil Seal and Wear Sleeve

CityStar™ Applications
separate wear sleeve from the new oil seal, damage
to seal and engine will result.
NOTE: When replacing the rear main oil seal it should
be noted that production engines not previously
serviced, will not have a wear sleeve. Wear sleeves
are only available as a service item included with a
rear main oil seal service kit.
1. Clean primary crankshaft flange a with suitable
solvent. Dry with filtered compressed air.
Figure 432 Rear Seal / Wear Sleeve Installer

(CityStar™)
3. Bolt Rear Seal / Wear Sleeve installer onto end

of crankshaft. Make sure crankshaft dowel fits in
installation tool dowel recess hole.
Figure 431 Sealant application to crankshaft

primary flange (CityStar™)

(page 305) onto the rear edge of the crankshaft
primary flange prior to wear sleeve and rear main
oil seal installation.
Figure 433 Rear main oil seal and wear sleeve

1. Dust seal lip
2. Rear main oil seal
3. Crankshaft side (forward)
4. Wear sleeve (internal bevel)
EGES-390
Figure 434 Rear main seal / wear sleeve

installation Figure 435 Flywheel adapter (CityStar™)
1. Rear main oil seal 1. Dowel pin

2. Rear Seal / Wear Sleeve Installer 2. Pin recess
3. Thrust bearing 3. Flywheel adapter
4. Drive nut
CAUTION: To prevent engine damage, do not scratch

4. Position rear main oil seal and wear sleeve crankshaft primary flange sealing surface.
combination on the Rear Seal / Wear Sleeve 7. Place flywheel adaptor onto crankshaft primary
Installer. Make sure the beveled edge of the wear flange. Be sure to line up dowel pin. If necessary,
sleeve is oriented toward the crankshaft. carefully tap with hammer to start and seat.
5. Place thrust bearing and drive nut onto threaded
shaft. Tighten nut until rear main oil seal bottoms
out onto rear oil seal carrier.
6. Remove the Rear Seal/Wear Sleeve Installer tool.
EGES-390
Stripped Chassis Applications

separate wear sleeve from oil seal, damage to the
seal and engine will result.
NOTE: When replacing the rear main oil seal, note
that production engines will not have a wear sleeve.
Wear sleeves are only available as a service item
included with the replacement rear main oil seal.
Figure 437 Rear Seal / Wear Sleeve Installer
2. Bolt Rear Seal / Wear Sleeve Installer (page 305)

onto the end of secondary crankshaft flange.
Make sure crankshaft alignment dowel fits in
dowel recess hole.
Figure 436 Sealant application to crankshaft

secondary flange

onto the rear edge of the crankshaft secondary
flange prior to wear sleeve and rear main oil seal
installation. See Special Service Tools (page
305).
EGES-390
4. Position rear main oil seal and wear sleeve

combination on the Rear Seal / Wear Sleeve
Installer.
Figure 439 Rear main oil seal and wear sleeve

Figure 438 Rear main oil seal and wear sleeve combination
orientation
1. Rear Seal / Wear Sleeve Installer
1. Dust seal lip 2. Rear main oil seal
2. Rear main oil seal 3. Drive nut
3. Crankshaft side (forward) 4. Thrust bearing
4. Wear sleeve (internal bevel)
5. Place thrust bearing and drive nut onto threaded

3. Orient seal as shown in (Figure 438) and slide shaft. Tighten nut until rear main oil seal bottoms
on Rear Seal / Wear Sleeve Installer. Make sure out in rear oil seal carrier.
the beveled edge of the wear sleeve is oriented
toward the crankshaft.
EGES-390
Flywheel
CAUTION: To prevent engine damage, always install
new flywheel mounting bolts when installing the
flywheel.
CAUTION: To prevent engine damage, do not use
anti-seize compounds or grease on flywheel mounting
bolts.
Figure 440 Flywheel torque sequence (typical)
1. Align crankshaft dowel pin with flywheel alignment 4. Measure ring gear runout (page 295).
hole and slide flywheel into place.
5. Stripped chassis only, place converter housing
2. Install 10 new flywheel bolts. adaptor onto rear cover assembly and install 12
bolts (M10 x 35). Tighten bolts to standard torque
• CityStar™ series – M10 x 31
(page 400).
• Stripped chassis – M10 x 77
3. Evenly tighten all flywheel bolts to special torque
(page 305) using the torque sequence illustration
(Figure 440).
EGES-390
Specifications
Max. flywheel ring gear T.I.R. runout 1.27 mm (0.050 in)

Rear cover face maximum runout 0.51 mm (0.020 in)
Special Torque
Flywheel mounting bolts (all applications) new bolts only 94 N·m (69 lbf·ft) see
flywheel torque sequence
(Figure 440)
Crankshaft Secondary Flange Installation Studs (2) ZTSE4720
Gear Puller (for secondary flange) ZTSE4520
1
Rear Seal / Wear Sleeve Installer ZTSE4515B
Rear Wear Sleeve Remover ZTSE4518
1
CityStar™ bolts - M10 x 40, Stripped Chassis bolts - M10 x 70
EGES-390
EGES-390
POWER CYLINDER 307
Table of Contents
Exploded View. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .309
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .310
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
Piston Protrusion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .311
Connecting Rod Side Clearance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Connecting Rod and Piston Assembly Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .312
Piston Disassembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .314
Cleaning, Inspection, and Measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315

Pistons. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .315
Piston Rings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .317
Connecting Rods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .318
Connecting Rod Bore Out-of-Round and Taper Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .319
Connecting Rod Bearing Fit Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .320
Piston Pin Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .321
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Piston Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .322
Connecting Rod and Piston Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .324
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .326
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .327
EGES-390
308 POWER CYLINDER
EGES-390
POWER CYLINDER 309
Exploded View
Figure 441 Piston, rings, and connecting rod

1. Piston 5. Retaining ring (2) 8. Connecting rod bearing
2. Oil control ring 6. Connecting rod (with fractured 9. Piston pin
3. Intermediate compression ring cap mating surfaces)
4. Top compression ring 7. Connecting rod bolt (2)
EGES-390
310 POWER CYLINDER
Removal
WARNING: To prevent personal injury or GOVERNMENT REGULATION: Engine
death, read all safety instructions in the “Safety fluids (oil, fuel, and coolant) may be a threat
Information” section of this manual. to the environment. Recycle or dispose
or bodies of water.
CAUTION: To prevent engine damage, do not allow
WARNING: To prevent personal injury or connecting rod or connecting rod cap fractured mating
death, allow engine to cool before working with surfaces to contact any surface other then its matched
components. fractured surface. Contacting any other surface could
cause misalignment of the mating surface, resulting in
connecting rod bearing and engine failure.

EGES-390
POWER CYLINDER 311
Preliminary Checks
Piston Protrusion
NOTE: Before removing any piston and connecting
rod assemblies, check piston protrusion and
connecting rod side clearance to help identify bent or
twisted connecting rods.
Figure 442 Piston protrusion measurement
NOTE: Piston protrusion readings are performed its maximum outward protrusion at cylinder
at the 3 and 9 o’clock positions. Those positions Top Dead Center (TDC). Read this maximum
are in line with the piston pin, removing the rocking protrusion on dial indicator.
movement of the piston at any other position of
e. Record reading.
measurement.
f. Reposition dial indicator tip on piston head at
1. Check piston protrusion above crankcase as
the 9 o’clock position.
follows:
g. Bar the crankshaft around in the direction
a. Position a dial indicator with magnetic
of normal rotation to raise the piston
base (page 327) close to the piston to be
to its maximum protrusion. Read the
measured.
maximum protrusion (piston height above
b. Zero the dial indicator gauge on crankcase the crankcase) on the dial indicator.
deck surface.
h. Average the two maximum protrusion
c. Position dial indicator tip over the piston head readings and compare to Specifications
at the 3 o’clock position. (page 326). Replace piston and piston rod
as required.
d. Bar the crankshaft around in the direction of
normal rotation. This will raise the piston to
EGES-390
312 POWER CYLINDER
Connecting Rod Side Clearance Connecting Rod and Piston Assembly Removal
CAUTION: To prevent engine damage, remove
carbon ridge, if evident, prior to removing the rod and
piston assemblies from the top of the cylinder bore.
This reduces the chance of piston ring land damage
during removal.
1. Use a razor knife or emery cloth to scrape carbon
ridge from top of cylinder bore.
2. Rotate crankshaft to position journals for removal
of connecting rod assemblies. Mark connecting
rod locations.
CAUTION: To prevent engine damage, check
connecting rod bolts for binding. If binding occurs,
check thread condition carefully during inspection.
Figure 443 Connecting rod side clearance

1. Feeler gauge
2. Connecting rod
1. Lightly pry apart each pair of connecting rods

and insert a feeler gauge (page 327) to check
connecting rod side clearance (page 326).
NOTE: Lack of clearance could indicate a damaged
rod or a rod bearing out of position. Excessive
clearance may require replacement of rods or
crankshaft. Correct as required.
EGES-390
POWER CYLINDER 313
4. Remove piston and connecting rod assemblies

from crankcase as follows:
a. Rotate engine to a vertical position.
b. Use a wooden or plastic handle of a hammer
to push the piston and rod assembly from
cylinder bore.
c. Once piston rings are free of cylinder bore,
remove piston and connecting rod assembly
from top crankcase.
CAUTION: To prevent engine damage, make sure
each connecting rod and cap are marked or tagged
with the cylinder number. This engine uses fractured
connecting rods. Do not alter or damage the fractured
Figure 444 Connecting rod cap mating surfaces of the rod and cap. A cap from
one connecting rod is not interchangeable with other
1. Connecting rod bolts (2 per rod cap) connecting rods. The matching connecting rod and
2. Connecting rod cap (6) cap numbers indicate a matched set.
3. Remove two connecting rod bolts and connecting

rod cap.
Figure 446 Matching cap and rod numbers

1. Matching numbers
Figure 445 Piston and connecting rod removal
CAUTION: To prevent engine damage, do not push

on connecting rod fractured surface.
EGES-390
314 POWER CYLINDER
Piston Disassembly

CAUTION: To prevent engine damage, use
permanent markers to identify internal components
or their orientation. Do not use paint or temporary
markers.
CAUTION: To prevent engine damage, do not stamp
marks on any machined surface of piston. If piston
must be marked with a stamp, place mark on a
non-machined as-cast surface only.
CAUTION: To prevent engine damage, mark each
piston with its cylinder number. Each piston must be
reinstalled into its original cylinder bore, if the pistons Figure 448 Piston pin retaining ring
are being reused.
2. Separate connecting rod from piston as follows:

a. Use pliers to remove both piston pin retaining
rings.
b. Remove piston pin from its bore by hand, and
then separate connecting rod from piston.
Figure 447 Piston ring removal

1. Piston ring expansion pliers
2. Piston
3. Piston ring
CAUTION: To prevent engine damage, only expand

piston rings enough to fit over top of piston.
1. Use Piston Ring Expansion Pliers (page 327) to
remove the piston rings. Remove top ring first,
intermediate ring, and then finally the oil control
ring. Keep rings organized and marked for correct
reassembly.
EGES-390
POWER CYLINDER 315
Cleaning, Inspection, and

Measurement
NOTE: Do not use a caustic solution or a wire brush
for cleaning aluminum pistons. Do not bead blast
pistons.
1. Use a soap and water solution to clean aluminum
pistons. Soak piston first, and then clean piston
with a nonmetallic brush.
2. Clean all piston ring grooves thoroughly.
3. The following disassembled components may be
cleaned using a suitable solvent:
• Piston pins
• Piston pin retainers Figure 449 Top compression ring groove
measurement
• Connecting rods
1. Piston gauge pins (0.082 in)
4. Thoroughly clean all connecting rod bolt holes and
threads.
2. Check top compression ring groove for wear as
follows:
Pistons
NOTE: Top compression ring groove is a
1. Inspect pistons for scuffed or scored skirts,
keystone design which requires measurement
cracked or worn ring lands, and cracked or
over gauge pins to determine ring groove wear.
scuffed pin bores. Replace any pistons showing
such damage. a. Install the Piston Gauge Pins (0.082 in) in
the top ring groove. Piston gauge pins must
be parallel. See Special Service Tools (page
327).
b. Use a 3 - 4 inch outside micrometer to
measure diameter over piston gauge pins.
See Specifications (page 326).
c. If measurement over the gauge pin is not
within specifications, excessive piston groove
wear exists. Replace piston.
EGES-390
316 POWER CYLINDER
Figure 450 Ring groove clearance measurement Figure 451 Piston skirt diameter measurement
(intermediate ring shown)
1. Piston skirt
1. Compression ring groove 2. 3-4 inch micrometer
2. Intermediate compression ring groove
3. Feeler gauge
5. Measure piston skirt diameter under conditions
indicated in the Specifications (page 326).
3. Check side clearance of intermediate ring groove
When considering piston replacement, check
as follows:
each cylinder condition and bore out-of-round
a. Place outer edge of new ring in its respective (page 342). Cylinder boring may be required.
ring groove. Such bore reconditioning will require oversize
service pistons.
b. Roll ring entirely around piston in its
respective groove. Make sure ring is able to NOTE: In addition to the standard size service piston,
move freely in its groove. the following oversize pistons are available.
c. Use a feeler gauge (page 327) to check • 0.254 mm (0.010 in)
side clearance. Excessive side clearance
• 0.508 mm (0.020 in)
indicates ring groove wear and requires
piston replacement. See Specifications • 0.762 mm (0.030 in)
(page 326).
6. If cylinder walls have minor surface damage but
4. Check side clearance of oil control ring groove as are otherwise within specification (out of round),
follows: it may be possible to remove such damage by
honing.
a. Place outer edge of new ring in oil control ring
groove. If cylinder bore is suitable for use without
reconditioning, de-glaze bore using a glaze
b. Roll ring entirely around piston in its
breaker brush, then reassemble. See Crankcase
respective groove. Make sure ring is able to
and Crankshaft section for the correct de-glazing
move freely in groove.
procedure.
c. Use a feeler gauge to check side clearance
of oil control ring in its respective groove.
Excessive side clearance indicates
ring groove wear and requires piston
replacement. See Specifications (page 326).
EGES-390
POWER CYLINDER 317
a. Push piston ring down into cylinder bore.

Make sure the piston ring is square with
cylinder wall. An inverted piston head can be
used to push piston ring to desired location of
measurement (usually at the top of the piston
ring travel).
b. Use a feeler gauge to measure gap between
ends of each piston ring.
Figure 452 Piston skirt clearance in cylinder

bore
1. Piston
2. Crankcase
3. Feeler gauge
7. Check piston skirt clearance (page 326) with a

feeler gauge in the cylinder bore. Correct as
required.
Figure 453 Piston ring end gap clearance in
cylinder bore
Piston Rings
1. Piston ring
NOTE: Faulty rings cannot always be detected by 2. Feeler gauge
visual inspection. Therefore, whenever a piston is 3. Crankcase
removed from a cylinder, replace the piston rings.
1. Inspect new piston rings for cleanliness.
c. If gap does not meet specifications, select
2. Before installing new piston rings on piston, check another ring or recheck cylinder bore wear.
gap for each ring as follows: See Specifications (page 326).
EGES-390
318 POWER CYLINDER
Connecting Rods
CAUTION: To prevent engine damage, the
connecting rod cap fractured mating surfaces must
be assembled onto the original connecting rod and in
the original orientation (matching numbers must be
adjacent to each other).
CAUTION: To prevent engine damage, keep the
fractured mating surfaces clean and free of debris.
Do not allow mating surfaces to rest on any other
surface. Do not bump mating surfaces or drop
the connecting rod or cap. This could cause wear
and chipping of the fractured surface, resulting in Figure 454 Inside diameter of piston pin bushing
improper mating during installation and possible
1. Piston pin bushing
engine damage.
2. Telescoping gauge
1. Inspect connecting rod bolts for nicks or damage.
Replace as required.
3. Inspect connecting rod piston pin bushing for wear
2. Inspect connecting rod and cap mating surfaces
as follows:
and bearing bore for any indication of damage.
Bore must be smooth and free of scoring or nicks. a. Using a Telescoping Gauge and a 1-2
Replace as required. inch micrometer, measure pin bore at two
locations approximately 90° apart. Record
the measurements. See Special Service
Tools (page 327).
b. If inside diameter of piston pin bushing
exceeds specification, replace connecting
rod. See Specifications (page 326).
EGES-390
POWER CYLINDER 319
Connecting Rod Bore Out-of-Round and Taper

Check
CAUTION: To prevent engine damage, check
connecting rod bolts for binding. They should thread
into connecting rod freely when lubricated with clean
engine oil. If they do not, the connecting rod must
be discarded. Connecting rod threads cannot be
re-tapped if binding exists. Check thread condition
carefully during inspection.
1. Lubricate connecting rod bolts with clean engine
oil. Assemble cap to rod without bearing insert.
Tighten bolts to special torque (page 327).
Figure 456 Connecting rod bore taper

measurement
4. Measure connecting rod taper as follows:

a. Insert a Telescoping Gauge near chamfer on
either side. Record the readings. See Special
Service Tools (page 327).
b. Measure inner diameter of connecting rod
bearing bore near chamfer on other side.
Record the readings.
The difference between the two readings is
Figure 455 Connecting rod bearing bore out of the connecting rod bore taper. If connecting
round measurements rod bore taper exceeds specification, replace
connecting rod. See Specifications (page
326).
2. Using a Telescoping Gauge, measure connecting 5. With connecting rod cap removed, inspect surface
rod at two locations, 90° apart. See Special finish of connecting rod bearing bore. Bore must
Service Tools (page 327). be smooth and free of scoring, nicks or burrs.
3. If the difference between dimension A and B Replace as required.
exceeds out-of-round specifications, replace
connecting rod. See Specifications (page 326).
EGES-390
320 POWER CYLINDER
Connecting Rod Bearing Fit Check CAUTION: To prevent engine damage, make sure
connecting rods are installed with their caps in
NOTE: Bearing shells must fit tightly in the bore.
the right direction. If a rod cap is reversed during
When bearing shells are inserted into the connecting
assembly, an obvious offset will be seen at the mating
rod and cap, they protrude above the parting line.
surfaces. If the connecting rod assembly is installed
This protrusion is required to achieve "bearing crush."
on the crankshaft this way, the connecting rod must
Therefore connecting rod caps must be wiped clean
be replaced. Also, check crank pin fillets for damage
prior to installation of the bearing shell.
as such damage would require replacement of the
crankshaft.
Bearing shells across the open ends are slightly
larger than the diameter of the connecting rod bore 1. Lubricate connecting rod bolts with clean engine
into which they are assembled. This condition is oil. Assemble cap to rod with new bearing shells
designed into the bearing shell, causing it to spread installed. Tighten bolts alternately and evenly to
outward at the parting line when "bearing crush" load the special torque (page 327).
is applied by tightening the bolts. Some snap may
2. Using a Telescoping Gauge, measure inside
be lost in normal use, but bearing replacement is not
diameter of connecting rod bearing at two
required because of a nominal loss of snap.
locations 90° apart. Average the two inside
When the assembly is drawn up tight, the bearing is diameters. Record reading. See Special Service
compressed, ensuring a positive contact between the Tools (page 327).
backside of the bearing and the bore.
3. Using a 2–3 inch micrometer, measure each
crankshaft rod journal diameter. Record reading.
4. Subtract the crankshaft rod journal diameter
from the respective connecting rod bearing
inside diameter to obtain connecting rod bearing
running clearance. Repeat for each crankshaft
rod journal.
5. If bearing-to-crankshaft running clearances
exceed specifications because of wear on
crankshaft, replace or grind crankshaft and
install undersize precision type bearing shells.
CAUTION: To prevent engine damage, do not attempt
to reduce journal-to-bearing running clearances by
reworking bearing cap, bearings, or both. Grind or
Figure 457 Offset for incorrect rod cap assembly replace the crankshaft only.
NOTE: Plastigage® may be used as an alternate
method of determining running clearance.
EGES-390
POWER CYLINDER 321
Piston Pin Inspection

1. Inspect piston pins for corrosion or wear. Replace
as required.
Figure 459 Piston pin bore inside diameter

measurement
3. Using a 1-2 inch telescoping gauge and

Figure 458 Piston pin measurement
micrometer, measure each piston pin bore inside
diameter, at two locations 90° apart. Record
reading.
2. Using a 1-2 inch micrometer, measure piston pin
outside diameter at two locations 90° apart. 4. To check piston pin clearance, subtract piston
Measure each end of the pin. Record the pin outside diameter from piston pin bore inside
range of readings. If piston pin wear exceeds diameter measurement. If clearance exceeds
specifications (page 326), replace piston pin. specifications, recheck piston pin, piston, and
connecting rod bushing measurements. Replace
component that is out of Specifications (page
326).
EGES-390
322 POWER CYLINDER
Installation
Piston Assembly

CAUTION: To prevent engine damage, make sure the
connecting rod and piston are assembled correctly.
Figure 461 Proper position of installed

connecting rod
1. Longer leg of connecting rod (cam side)
2. “CAM V8” stamped on cam side of piston crown
1. Connect piston to connecting rod as follows:

a. Lubricate connecting rod piston pin bore,
piston pin bore, and piston pin with clean
Figure 460 Offset for incorrect rod cap assembly
engine oil.
b. Orient the longer leg of the connecting rod
CAUTION: To prevent engine damage, the rod cap with the side of the piston bearing the “CAM
can only be correctly installed on the connecting rod V8” stamped in its crown.
if it is oriented in the correct direction. If the rod
cap is reversed during assembly of the connecting
rod, an obvious offset will be seen at the mating
surfaces. If the connecting rod assembly is installed
on the crankshaft in this manner, the connecting rod
must be replaced. Also check the crank pin fillets for
damage. Such damage will require replacement of
the crankshaft.
Assemble the piston rings, piston, and connecting rod
as follows:
Figure 462 Piston pin retaining ring installation
c. Using pliers, install retaining ring at one end

of piston pin bore.
EGES-390
POWER CYLINDER 323
d. Slide piston pin through bored holes, stopping a. Install expansion spring component of two
at installed retaining ring. piece oil control ring into bottom piston
groove.
e. Install second retaining ring.
b. Install oil scraper component of two piece oil
f. Check to see if the piston slides easily on
control ring over expansion spring.
piston pin from one snap ring to the other.
Figure 463 Piston ring locations Figure 465 Piston ring identification marks (top
1. Top compression ring ring shown)
2. Intermediate compression ring 1. Identification mark
3. Oil control ring
CAUTION: To prevent engine damage, make

sure piston rings are installed correctly.
Both intermediate and compression rings
have the same identification markings. The
intermediate ring has a square cross section.
The top compression ring has a keystone
cross section.
c. Install intermediate ring (rectangular
cross section) into middle piston groove
with identification mark facing up. The
intermediate ring is identified by one ’O’
mark on the top surface of ring.
d. Install compression ring (keystone cross
section) into top piston groove with
identification mark facing up. The
Figure 464 Piston ring installation (typical) compression ring is identified by the ’O’
mark on the top surface of ring.
1. Piston ring expansion pliers
2. Piston 3. Space ring gaps approximately 120° apart after
3. Piston ring (top compression shown) ring installation.
2. Using Piston ring expansion pliers (page 327),

install piston rings as follows:
EGES-390
324 POWER CYLINDER
Connecting Rod and Piston Installation 3. Place piston in Piston Ring Compressor (cope) to
compress rings and ease the installation of piston
1. Turn crankshaft so that the number 1 connecting
and connecting rod assembly into the crankcase.
rod journal is at the bottom of its stroke.
See Special Service Tools (page 327).
NOTE: Before installing piston and connecting rod
NOTE: Make certain that connecting rod and cap
assembly, make sure all piston cooling tubes are in
bearing surfaces have been wiped clean of any oil or
place.
residue.
2. Coat piston and piston rings with clean engine
4. Install bearing shells in connecting rod and cap.
oil. Coat cylinder walls, crankshaft journals, and
Coat bearing shell in connecting rod with clean
piston cope with clean engine oil.
engine oil.
CAUTION: To prevent engine damage, the "CAM V8"
5. Carefully insert connecting rod and start piston
stamped on top of the piston must be oriented towards
into the top end of the cylinder bore until cope is
the camshaft side of the crankcase, toward center of
against the top of the cylinder.
engine.
CAUTION: To prevent engine damage, use caution
NOTE: Pistons are interchangeable between the VT
not to damage piston cooling tubes when installing
365 and MaxxForce™ 5 diesel engines.
connecting rod and piston assemblies.
Figure 467 Piston installation into cylinder bore
6. Once piston and connecting rod assembly have

been inserted in cylinder bore, use the handle
(wood or plastic) of a hammer to tap piston in
crankcase bore. Guide connecting rod in place
on crankshaft.
Figure 466 Piston Ring Compressor
EGES-390
POWER CYLINDER 325
8. Assemble cap to connecting rod with matching

identification code on same crankshaft journal
from which it was removed. Be certain that the
longer leg of the connecting rod and the “CAM
V8” stamp on piston crown are oriented towards
the camshaft.
CAUTION: To prevent engine damage, do not use air
powered tools when installing connecting rod bolts.
This may cause seizure of connecting rod bolts.
Figure 468 Orientation of piston in cylinder bore

1. Cam follower opening
2. Identification mark, “CAM V8”
Figure 470 Torquing the connecting rod cap

bolts
1. Connecting rod bearing cap
2. Connecting rod bolt
9. Install and tighten connecting rod bolts evenly to

the initial and final torque values. See special
torque (page 327).
10. Repeat installation procedure for remaining
Figure 469 Connecting rod and cap matching
connecting rod and piston assemblies.
identification numbers
11. Check connecting rod side clearance with feeler
1. Matching numbers
gauge. See procedure in removal section Piston
and Connecting Rod Checks in this section.
CAUTION: To prevent engine damage, do not alter 12. Complete the engine rebuild and reinstall all
or damage the fractured mating surfaces of the safety guards, shields and covers after servicing
connecting rod and cap. the engine.
7. Apply clean engine oil to connecting rod bolt hole 13. Make sure all tools, covers, loose parts and
threads and bearing shell in cap before installing service equipment are removed from the engine
bolts. area after all work is done.
EGES-390
326 POWER CYLINDER
Specifications
Connecting Rods
Connecting rod length (center to center) 176 mm (6.929 in)
Bushing bore diameter (pin end) 36.98 to 37.02 mm (1.456 to 1.457 in)
34.0140 to 34.0215 mm (1.3391 to 1.3394
Piston pin bushing inside diameter
in)
Bearing bore diameter (crankshaft end) 72.987 to 73.013 mm (2.8735 to 2.8745 in)
Bearing bore maximum out-of-round 0.013 mm (0.0005 in)
Bearing bore maximum taper per 25 mm (1 inch) 0.013 mm (0.0005 in)
Connecting rod bearing inside diameter 69.027 to 69.077 mm (2.7176 to 2.7196 in)
Connecting rod bearing running clearance (diameter) 0.0203 to 0.0837 mm (0.0008 to 0.0033 in)
Connecting rod side clearance 0.3 to 0.6 mm (0.012 to 0.024 in)
Weight (complete rod without bearing) 1201.5 to 1215.5 g (2.649 to 2.679 lb)
Pistons
Material Aluminum Alloy
Skirt diameter 1
94.9460 to 94.9186 mm (3.737 to 3.738 in)
1
Measure 14.68 mm (0.578 in) from bottom, at 90° to the piston pin. Measure only at room temperature
of 19 to 21 °C (66 to 70 °F).
Service Piston:
Standard size 94.9460 to 94.9186 mm (3.737 to 3.738 in)
0.254 mm (0.010 in) oversize 95.1738 to 95.1992 mm (3.747 to 3.748 in)
Top compression ring groove width (measured over 2.08 mm (0.082 in) gauge pins):
Upper limit 94.469 mm (3.7192 in)
Replacement limit 94.290 mm (3.7122 in)
Piston protrusion above crankcase deck 0.900 mm (0.0354 in)
Piston skirt clearance (1 - 8) 0.0441 to 0.0909 mm (0.0017 to 0.0036 in)
EGES-390
POWER CYLINDER 327
Piston Pins
Length 65.073 to 65.327 mm (2.5619 to 2.5719 in)
33.9975 to 34.0025 mm (1.3385 to 1.3387
Diameter
in)
Pin fit at room temperature of 19 to 21 °C (66 to 70 °F):
0.0115 to 0.0240 mm (0.00045 to 0.00094
Clearance in connecting rod (piston pin bushing)
in)
Clearance in piston 0.013 to 0.022 mm (0.0005 to 0.0009 in)
End clearance 0.24 mm (0.009 in)
Piston Rings
Ring diameter (standard): 95 mm (3.74 in)
Ring groove (side clearance):
Intermediate compression 0.051 to 0.102 mm (0.0020 to 0.0040 in)
Oil control 0.038 to 0.084 mm (0.0015 to 0.0033 in)
Ring gap in bore:
Top compression 0.29 to 0.55 mm (0.011 to 0.021 in)

Special Torque
Initial 45 N·m (33 lbf·ft)

Connecting rod cap bolts
Final 68 N·m (50 lbf·ft)

Piston Gauge Pins (0.082 in) ZTSE4513
Piston Ring Compressor (cope) ZTSE4514
Piston ring expansion pliers Obtain locally
Telescoping gauge set Obtain locally
EGES-390
328 POWER CYLINDER
EGES-390
CRANKCASE, CRANKSHAFT, AND CAMSHAFT 329
Table of Contents
Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
Preliminary Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .333
Lower Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .337
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Piston Cooling Tubes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .338
Camshaft / Primary Balancer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .339
Camshaft Bushings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
Coolant Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .340
Cleaning, Inspection and Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341

Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .341
Crankshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .344
Coolant Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .347
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .348
Crankshaft and Timing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .351
Lower Crankcase. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .353
Crankcase Sensors and Coolant Heater. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .358
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .359
Special Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .361
EGES-390
330 CRANKCASE, CRANKSHAFT, AND CAMSHAFT
EGES-390
Figure 471 Crankcase, crankshaft, and camshaft
EGES-390
1. Primary balancer shaft 12. Crankshaft assembly 24. Bolt, M10 x 25

2. Dowel pin 13. Oil level gauge tube assembly 25. Bolt, M6 x 12 (3)
3. Primary balancer gear 14. Nut, M8 26. Primary balancer counterweight
4. Bolt, M8 x 16 (2) 15. Dipstick tube seal 27. Primary thrust plate
5. Camshaft assembly 16. Lower crankcase assembly 28. Coolant heater, right side rear
6. Spring dowel pin (4) 17. Bolt, M8 x 30 (6) (optional)
7. Crankcase assembly 18. Main bearing bolt, M14 x 127 (8) 29. Camshaft bushing (4)
8. Plug, M16 (2) 19. Main bearing bolt, M14 x 114 (8) 30. Primary balancer bushing (2)
9. Crankshaft upper main bearing 20. Crankshaft lower main bearings
(3) (4)
10. Dowel pin 21. Bolt, M8 x 18 (6)
11. Crankshaft upper main thrust 22. Piston cooling tube (6)
bearing (1) 23. Dowel pin (2)
EGES-390
Removal CAUTION: To prevent engine damage, do not remove

the rear primary crankshaft flange bolts. If the flange
WARNING: To prevent personal injury or is removed and reinstalled, it will result in engine
death, read all safety instructions in the “Safety vibration and premature transmission wear.


components.

Figure 472 Rear primary crankshaft flange bolts
WARNING: To prevent personal injury or (do not remove)
Preliminary Checks
WARNING: To prevent personal injury or Measure the following:
• Crankshaft gear to camshaft gear
with soap and water. Wash or discard clothing • Primary balancer gear to crankshaft gear
• Crankshaft end play
• Camshaft end play
• Primary balancer shaft end play
or bodies of water.
EGES-390
Figure 473 Primary balancer gear-to-crankshaft Figure 474 Camshaft-to-crankshaft gear

gear backlash backlash
1. Check and record primary balancer 2. Check and record camshaft gear-to-crankshaft
gear-to-crankshaft gear backlash as follows: gear backlash as follows:
NOTE: Crankshaft gear must be fixed, not NOTE: Crankshaft gear must be fixed, not
allowed to rotate. Only the primary balance gear allowed to rotate. Only the camshaft gear should
should be allowed to rotate, otherwise the reading be allowed to rotate, otherwise the reading will
will not be valid. not be valid.
a. Mount dial indicator with magnetic base (page a. Mount dial indicator with magnetic base (page
361) onto rear of engine. 361) onto rear of engine.
b. Position dial indicator tip onto a primary b. Position dial indicator tip onto a cam gear
balancer gear tooth and remove lash. tooth and remove lash.
c. Zero dial indicator. c. Zero dial indicator.
d. Rotate gear by hand and read indicator. d. Rotate gear by hand and read indicator.
Record backlash. Record backlash.
e. If backlash exceeds Specifications (page e. If backlash exceeds Specifications (page
359), replace primary balance gear. 359), replace camshaft gear.
EGES-390
4. Remove the balance shaft counterweight bolt

(M10 x 25).
Figure 475 Primary balance shaft end play
3. Check and record primary balance shaft end play Figure 477 Balance shaft thrust plate bolts
as follows:
a. Reposition dial indicator tip to balance shaft, 5. Remove three balance shaft thrust plate bolts (M6
not gear. x 12).
b. Push camshaft towards the front of the
engine.
c. Zero dial indicator.
d. Place a small pry bar between the primary
balance gear and crankcase. Lightly pry
primary balance gear toward indicator.
Compare dial indicator reading with
Figure 478 Balance shaft counterweight and

thrust plate
Figure 476 Balance shaft counterweight bolt
6. Remove balance shaft counterweight and thrust
plate.
EGES-390
b. Push camshaft towards the front of the

engine.
c. Zero dial indicator.
d. Place a small pry bar or screwdriver
between the camshaft gear and crankcase.
Lightly pry camshaft gear towards indicator.
Compare dial indicator measurement with
Figure 479 Balance shaft removal
7. Carefully remove balance shaft from the inside of

the camshaft.
Figure 481 Crankshaft end play

1. Crankshaft gear
2. Dial indicator
3. Pry bar or screwdriver
9. Check crankshaft end play as follows:

a. Mount dial indicator on crankcase with
indicator tip on the end of crankshaft flange
Figure 480 Camshaft end play
as shown.
b. Pry crankshaft forward with pry bar and zero
NOTE: Check camshaft end play only after the dial indicator.
balance shaft has been removed.
c. Pry crankshaft back and forth while reading
8. Check and record camshaft end play as follows: dial indicator. Record end play measurement.
a. Reposition dial indicator tip onto camshaft,
not gear.
EGES-390
Lower Crankcase 4. Remove all lower crankcase main bearing bolts

(inboard and outboard).
1. Remove oil gauge tube assembly if not done so
already. Remove dipstick tube seal and discard. NOTE: There are three different bolt sizes supporting
the lower crankcase:
2. Remove retaining bolt (M6 x 14) from CKP sensor
installed in the front lower right of the crankcase. • Eight lower crankcase main bearing bolts (M14 x
127 - inboard)
• Eight lower crankcase main bearing bolts (M14 x
114 - outboard)
• Six lower crankcase outer bolts (M8 x 30)
5. Remove six lower crankcase bolts (M8 x 30).
Figure 482 Crankcase Position (CKP) sensor
3. Remove CKP sensor from lower crankcase.

Discard O-ring seal.
Figure 484 Lower crankcase removal
6. Carefully lift lower crankcase away from

crankshaft. Discard seal.
CAUTION: To prevent engine damage, use
permanent marker to identify internal engine
components and their orientation. Do not use paint
or temporary markers.
7. Remove main bearing shells from lower
crankcase by pushing them out of bearing
saddles. Mark each lower bearing shell with
numbers 1 to 4, beginning from the front.
Figure 483 Lower crankcase main bolts
EGES-390
Crankshaft CAUTION: To prevent engine damage, use

permanent marker to identify internal engine
WARNING: To prevent personal injury or components and their orientation. Do not use paint
death, use an appropriately size lifting sling and or temporary markers.
hoist equipped with a safety latch on hook. 3. Remove bearings from upper main bearing
1. Install a bolt into each end of the crankshaft. saddles by pushing them out. Mark upper
bearings and put them with their respective lower
bearings for proper inspection.
Piston Cooling Tubes

CAUTION: To prevent engine damage, the piston
cooling tubes use a special patch mounting bolt. Do
not substitute.
Figure 485 Crankshaft removal from crankcase

1. Bolts threaded into crankshaft
2. Lifting sling
2. Attach lifting sling to crankshaft over bolts

installed in crankshaft. Lift crankshaft straight
up and out of crankcase.
Figure 487 Piston cooling tube
1. Piston cooling tube
2. Piston cooling tube mounting bolt
Remove each piston cooling tube by removing its

special patch mounting bolt (M6 x 18). The bolts are
reusable, add Loctite® #242 to bolt threads before
installation.
Figure 486 Upper main bearings (thrust bearing

shown)
EGES-390
Camshaft / Primary Balancer 3. Remove two camshaft thrust plate mounting bolts
(M8 x 16).
1. Remove the Camshaft Position (CMP) sensor
retaining bolt (M6 x 14) located at front of engine, NOTE: If the engine is mounted on a revolving stand,
lower left. rotate engine so rear of engine is facing up (in vertical
position). This position allows for easy removal of
camshaft assembly.
Figure 488 CMP sensor
Figure 490 Camshaft assembly

2. Remove the CMP sensor and discard both sensor
O-rings.
4. Remove camshaft from crankcase by lifting
assembly straight up and out.
NOTE: The camshaft gear is assembled to the
camshaft with a shrink fit and can be removed with a
hydraulic press if required.
Figure 489 Camshaft thrust plate mounting

bolts
1. Camshaft thrust plate mounting bolt (2)
EGES-390
Camshaft Bushings backup nut until collet fits snug in camshaft

bushing. To avoid nicks on bushings, be careful
1. Determine necessity of replacing bushings based
when inserting or removing threads of pulling
on running clearance (Camshaft Bushings, page
screw.
347).
4. Attach pulling plate, thrust bearing and drive
2. If bushings require replacement, use existing
nut on pulling screw. Tighten nut against thrust
Camshaft Bushing Kit in conjunction with
bearing and pulling plate. Continue to thread nut
Camshaft Bushing Remover / Installer (expanding
on pulling screw until camshaft bushing is free
collet) to remove all camshaft bushings. Install
from crankcase.
Camshaft Bushing Remover / Installer (expanding
collet in collapsed state) into camshaft bushing. NOTE: Hold wrench on the end of the pulling screw to
See Special Service Tools (page 361). prevent it from turning.
Coolant Heater
Figure 491 Camshaft bushing removal

1. Camshaft bushing
2. Camshaft Bushing Remover/Installer (expanding Figure 492 Coolant heater removal
collet)
3. Pulling screw (from camshaft bushing kit)
Remove coolant heater from right rear side of engine
block and discard O-ring seal.
3. Assemble pulling screw in Camshaft Bushing
Remover/Installer (expanding collet) and tighten
EGES-390
Cleaning, Inspection and Testing

Crankcase
NOTE: The best way to clean the crankcase during
an engine overhaul is in a chemical bath or hot tank.
This procedure removes all carbonized material and
mineral deposits which collect in coolant passages.
When a hot tank is not available, use the following
procedure:
NOTE: Thoroughly clean and inspect crankcase
before and after reconditioning.
Figure 494 Cleaning the main oil gallery
2. Clean main galleries with an Oil Gallery Cleaning

Brush (page 361).
3. Spray or wipe main oil gallery cup plug bores with
an appropriate cleaning solvent. The bores must
be free of any oily residue for the sealant to adhere
and be effective.
4. Coat edges of new oil gallery cup plugs and
crankcase joints with Loctite® #620 (page 361)
prior to installing cup plugs.
Figure 493 Oil gallery cup plug removal 5. Use an Oil Gallery Plug Driver to install new oil
gallery cup plugs. It should be flush with the
1. Hammer crankcase surface to approximately 1.50 mm
2. Punch (0.060 in) below surface. See Special Service
3. Oil gallery cup plug (5) Tools (page 361).
6. Use non-metallic stiff bristle brushes and scrapers
1. To remove main oil gallery cup plug (16 mm) to clean gasket material from machined surfaces
located in rear of crankcase, use a punch and of crankcase.
hammer near the edge of the plug and strike 7. Clean cylinder bore with soap, water, and a nylon
with hammer. Remove plug from crankcase and stiff bristle brush.
discard.
8. Clean lower crankcase in solvent. Dry with filtered
compressed air.
EGES-390
CAUTION: Do not resurface the crankcase. Surface

defects beyond those listed above cannot be
corrected.
CAUTION: To prevent engine damage, threads in the
crankcase bolt holes must be clean and blown dry
with filtered compressed air. Dirt or oil left in holes
may cause binding and a false torque reading during
assembly.
Figure 495 Deck flatness measurement

1. Straightedge
2. Feeler gauge
9. Use a Straightedge (page 361) to check the

crankcase top surface for flatness. Insert a
Feeler gauge between the Straightedge and
crankcase head surface.
Figure 496 Crankcase head bolt holes
a. Measure the total deck surface, if any gap
exceeds Specifications (page 359), the
crankcase must be replaced. 10. Clean all cylinder head bolt holes with Head Bolt
b. Divide the deck surface into areas of Bottoming Tap (page 361). Blow out holes with
approximately 150 mm2. Measure each filtered compressed air.
area and if any gap exceeds specifications, 11. After cleaning, inspect crankcase for cracks,
the crankcase must be replaced. See scoring, roughness or wear at cylinder bores.
12. If cylinder walls have minor surface damage, but
c. Divide the deck surface into areas of are otherwise within out-of-round specifications,
approximately 25 mm2. Measure each it may be possible to remove such damage by
area and if any gap exceeds specifications, honing.
the crankcase must be replaced. See
EGES-390
Figure 497 Cylinder bore out-of-round Figure 498 De-glazing hone

measurement
17. De-glaze cylinder as follows:

13. Use a Cylinder Bore Gauge (page 361) to check
a. Attach a De-glazing hone (page 361) to a
cylinder bore for out-of-round.
variable speed electric or air powered drill.
a. Measure diameter of cylinder bore at top of
NOTE: A speed of approximately 100 to 120
piston ring travel. Be sure to measure at a
rpm is required. Speed adjustment is required
right angle to the center line of crankshaft
for the procedure to be successful.
(dimension A). Record reading.
b. De-glaze cylinder wall for about 15 seconds.
b. Measure each bore so gauge reading
Stroke bore up and down at a rate of one
coincides with center line of crankshaft
complete up and down stroke per second.
(dimension B). Record reading.
c. Withdraw de-glazing hone from cylinder
c. The difference between dimension A and
bore while brush is rotating. Wipe portion of
dimension B is the out-of-round condition at
cylinder wall and inspect cross hatch pattern.
the top of the cylinder bore.
NOTE: The cross hatch pattern left by the
14. Repeat the same procedure at the bottom of ring
abrasive tool should be approximately 45°.
travel to check for out-of-round condition.
d. If pattern is “flatter” than required, increase
CAUTION: To prevent engine damage, if cylinder
up and down stroke speed or slow down drill
bores are deeply scored, out-of-round or exceed
rotation as required.
specifications, all cylinders must be bored oversize.
e. Continue de-glazing cylinder bore for 10 to 15
15. If cylinder bore is within specifications, standard
seconds or 20 to 25 strokes.
size pistons and rings may be used. If cylinder
bore is suitable for use without reconditioning, f. Wipe cylinder bore clean and inspect bore for
de-glaze the cylinder bore before assembling. proper 45° cross hatch pattern.
18. After de-glazing, thoroughly clean cylinder bores
NOTE: If cylinder bores are to be de-glazed, all piston with soft bristle brush, soap and water. Dry with
cooling tubes must be removed. filtered compressed air. Lubricate bore with clean
engine oil.
16. Spray both the cylinder to be de-glazed and
the de-glazing hone with penetrating fluid or
equivalent. This spray contains colloidal graphite
and works well for this application.
EGES-390
Crankshaft
1. Clean and inspect the crankshaft and main
bearings as follows:
a. Clean crankshaft with a suitable solvent and
dry with compressed air.
b. Use a stiff nylon brush to clean all internal
oil passages of crankshaft. Loosen all
accumulated dirt, sludge, and deposits.
Flush oil passages with a suitable solvent.
c. Inspect crankshaft journals (main and
connecting rod) for scratches, grooves, and
scoring.
2. Inspect crankshaft bearings (main and connecting
rod) for scratches, grooves, scoring, pitting, and Figure 500 Crankshaft connecting rod journal
inconsistent coloring. measurement
5. Measure diameter of each crankshaft connecting

rod journal at two points 90 degrees from each
other using a 2-3 inch micrometer. Move the
micrometer over the entire width of the journal at
each measurement point. Measure and record
readings for each of the six connecting rod
journals.
6. Compare connecting rod journal measurements
to crankshaft Specifications (page 359).
Piston Cooling Tubes
Figure 499 Crankshafts main journal 1. With the piston cooling tubes removed, run an
measurement appropriate size wire through the tube to ensure
there is no blockage.
2. Use dry filtered compressed air to blow out any
NOTE: If crankshaft journals exceed maximum debris that remains from cleaning.
out-of-round or other specifications the crankshaft
must be reground or replaced. 3. Replace any cracked or bent tubes.
3. Measure diameter of each crankshaft main

journal at two points 90 degrees from each other
using a 3-4 inch micrometer (page 361). Move
the micrometer over the entire width of the journal
at each measurement point. Measure and record
readings for each of the seven main journals.
4. Compare main journal measurements to
crankshaft Specifications (page 359).
EGES-390
Camshaft / Primary Balancer a. Use a 2-3 inch micrometer (page 361) to

measure camshaft main bearing journals and
1. Wash camshaft / primary balancer assembly
then again at 90°. Record measurements
in cleaning solvent with a soft brush. Dry
for later use in camshaft bushing inspection.
components with filtered compressed air.
Compare with specifications, and if worn
2. Inspect camshaft. If any lobes are scuffed, scored beyond limits replace the camshaft.
or cracked, replace camshaft.
NOTE: This engine uses hydraulic valve tappets
with roller followers. Roller follower guides
are used to maintain proper roller to cam lobe
orientation. Normal clearance between the valve
tappet and guide allows for slight tracking of the
roller across the cam lobe. Typical wear patterns
on cam lobes will have tracks from side to side
and have wide and narrow areas from the loading
and unloading of the follower. The visual wear
pattern (tracking) is normal and does not require
camshaft replacement.
3. Beyond visual inspection, evaluate camshaft main
journal and lobe condition as follows:
NOTE: When measuring the camshaft with a
micrometer, always take two measurements at
Figure 502 Camshaft intake and exhaust lobe
approximately 90° apart.
measurement
1. Camshaft assembly
2. Micrometer
b. To check camshaft intake and exhaust lobes,

measure across (A to C) and across (B to
D). Subtract (B to D) from (A to C). This will
give cam lobe lift. Replace camshaft when
cam lobe wear exceeds specifications. See
4. Inspect thrust plate for wear, cracks or distortion.
Use a micrometer to measure thrust plate
thickness. Replace thrust plate if worn or
damaged. See Specifications (page 359).
Figure 501 Camshaft main bearing journal 5. Inspect camshaft drive gear for worn or damaged
measurement teeth.
EGES-390
Figure 503 Primary balance shaft bushing Figure 504 Primary balancer shaft outside
inside diameter measurement diameter measurement
6. Using a telescoping gauge (page 361), measure 7. Measure the primary balance shaft outside
the primary balance shaft bushing inside diameter diameter at each end of shaft (bushing location).
in each end of the camshaft.
8. Subtract primary balance shaft outside diameter
from primary balance shaft bushing inside
diameter. This will give the balance shaft bearing
clearance. Refer to Specifications (page 359).
Replace camshaft as necessary.
EGES-390
Camshaft Bushings 2. Measure telescoping gauge with a 2-3 inch

micrometer and record measurement.
Inspect the four camshaft bushings for wear and
proper running clearance as follows: 3. To determine running clearance for each bushing
and journal, subtract previous camshaft journal
diameter reading from camshaft bushing inside
diameter reading. See Specifications (page 359).
4. If maximum allowable running clearance is
exceeded, replace camshaft bushings. See
camshaft bushing removal and installation
procedures within this section. Also, see
5. Inspect each bushing bore in crankcase for burrs
or debris that could potentially damage new
bushings.
6. Remove burrs and clean bores thoroughly before
installing new camshaft bushings.
Figure 505 Camshaft bushing measurement Coolant Heater

1. Using a volt-ohm meter, inspect heater for
1. Using a telescoping gauge (page 361), measure electrical continuity.
camshaft bushing inside diameter with bushings 2. Check element sealant around terminals for
installed in crankcase. evidence of cracking.
3. Replace O-ring whenever heater is removed.
Figure 506 Measurement of telescoping gauge

1. Outside micrometer
2. Telescoping gauge
EGES-390
Installation 3. To aid alignment of bushing and crankcase oil

holes, use a marker to indicate oil hole location
Camshaft Bushings
on backup nut of installation tool. Repeat for each
CAUTION: To prevent engine damage, use the camshaft bushing.
correct Camshaft Bushing Remover / Installer
4. Install camshaft bushings through rear of
(expanding collet). See Special Service Tools (page
crankcase. Pull bushings in place at rear of
361).
crankcase by turning pulling nut on pulling screw.
Remove Camshaft Bushing Remover/Installer
and inspect oil hole alignment.
Figure 508 Camshaft bushings measurement

Figure 507 Camshaft bushing installation
1. Oil supply hole 5. Using a telescoping gauge (page 361), measure
2. Pulling screw camshaft bushing inside diameter with bushings
3. Backup nut installed in crankcase.
4. Camshaft Bushing Remover/Installer (expanding
collet)
6. Measure telescoping gauge with a 2-3 inch
5. Camshaft bushing
micrometer and record measurement.
6. Camshaft bushing oil supply slot 7. To determine running clearance for each bushing
/ journal, subtract previous camshaft journal
diameter reading from camshaft bushing inside
CAUTION: To prevent engine damage, and to ensure diameter reading. See Specifications (page 359).
proper oil circulation through the crankcase, make
sure all camshaft bushing oil slots are aligned with 8. If maximum allowable running clearance is
corresponding oil supply holes machined in the exceeded, measure cam journal outside diameter
crankcase. and cam bushing inside diameter again and
compare with Specifications (page 359). See
1. Slide a new bushing onto the Camshaft Bushing camshaft bushing removal and installation
Remover / Installer (expanding collet). See procedures within this section.
9. Lubricate new camshaft bushings and crankcase
2. Thread pulling screw, backup nut, and Camshaft bores with clean engine oil.
Bushing Remover / Installer together. Tighten
expanding collet by turning backup nut until
bushing is held securely on the Camshaft Bushing
Remover/Installer.
EGES-390
Piston Cooling Tubes NOTE: Do not nick or scratch camshaft bushings with
cam lobes.
CAUTION: To prevent engine damage, the piston
cooling tubes use a special patch mounting bolt. Do
not substitute.
NOTE: The bolt-on piston cooling tubes are
self-aligning.
1. Place piston cooling tubes on crankcase mounting
pad.
2. When installing the piston cooling tube bolts, use
either:
• A new piston cooling tube mounting bolts
(patch type)
• Remove oil residue with a suitable solvent
and apply Loctite® #242 to the threads of
existing piston cooling tube bolts (patch type).
See Special Service Tools (page 361). Figure 510 Camshaft assembly installation
2. Position crankcase with rear of engine facing up

on engine stand and carefully install camshaft
assembly.
Figure 509 Piston cooling tube

1. Piston cooling tube
2. Piston cooling tube mounting bolt, M6 x 18 (patch
type)
Figure 511 Camshaft thrust plate mounting bolts

3. Install and tighten piston cooling tube bolts (M6 x 1. Camshaft thrust plate mounting bolts (2)
18) to the standard torque (page 400).
3. Install two camshaft thrust plate mounting bolts

(M8 x 16). Tighten bolts to the standard torque
Camshaft / Primary Balancer (page 400).
1. Coat camshaft lobes and bushing journals with
clean engine oil.
EGES-390
Figure 512 Camshaft end play measurement Figure 514 Balance shaft thrust plate bolts
4. Verify that camshaft end play is within 6. Install three balance shaft thrust plate bolts (M6 x
specifications. See Specifications (page 359). 12) and tighten to the standard torque (page 400).
Figure 513 Primary balance shaft installation Figure 515 Balance shaft counterweight bolt
5. Coat primary balance shaft with clean engine oil 7. Install the balance shaft counterweight bolt (M10 x
and install inside camshaft. 25) and tighten to the standard torque (page 400).
EGES-390
Crankshaft and Timing

NOTE: Make sure the crankshaft has been inspected
per instructions found within this section prior to
proceeding.
1. Use a lint-free cloth to wipe the crankcase bearing
supports free of oil.
2. Inspect each bearing. Replace all bearings that
are scored, chipped, or worn.
NOTE: When inserting main bearings in the
crankcase, be sure that there is no oil between
the back side of the bearing and crankcase bearing
saddles.
Figure 517 Crankshaft Timing Tool
5. Align index marks on both camshaft gear and

primary balancer gear so that they are adjacent
to each other. Install Crankshaft Timing Tool
through machined holes in both balancer gear
and camshaft gear as well as the machined hole
in crankcase. See Special Service Tools (page
361).
Figure 516 Upper crankshaft main bearings

(thrust bearing shown)
3. Place upper main bearings in the crankcase.

Make sure locking tabs on bearings are snapped
in the crankcase saddle and oil holes in bearings
line up with oil holes in crankcase.
NOTE: Crankshaft thrust bearing is installed at
the number 3 upper main bearing journal.
4. Lubricate the upper main bearings with clean
engine oil. Figure 518 Installing crankshaft into crankcase
1. Bolts threaded into crankshaft
2. Lifting sling
6. Place a bolt in each end of the crankshaft. Attach

hoist and lifting sling around crankshaft bolts and
carefully lower onto the four main bearings.
EGES-390

death, use an appropriately sized lifting sling and
hoist equipped with a safety latch on hook.
1
3
4
5
6
7
J03029
Figure 519 Crankshaft / camshaft / primary balancer timing alignment

1. Flywheel alignment pin 4. Primary balancer gear timing 6. Camshaft gear
2. Crankshaft gear (1 of 2) mark 7. Timing tool thru hole
3. Crankshaft gear timing mark 5. Primary balancer gear
7. Install crankshaft so that index mark aligns with 8. Remove Camshaft Timing Tool.
both camshaft and primary balancer index marks.
EGES-390
Lower Crankcase 3. Install bearings into the lower crankcase, making

sure bearing alignment tab is fitted into machined
1. Make sure the lower crankcase sealing recesses
notch.
are free of any dirt and oil.
4. Apply clean engine oil to all lower bearing inserts,
crankshaft journals and lower crankcase bolts.
CAUTION: To prevent engine damage, make sure
the longer main cap bolts (M14 x 127) are installed
inboard and the shorter bolts (M14 x 114) are installed
outboard.
Figure 520 Lower crankcase seal installation
2. Install two new lower crankcase seals.

NOTE: Make certain that the lower crankcase
machined bearing surfaces are free of all dirt and Figure 522 Lower crankcase installation
oil.
5. Install the lower crankcase over the crankshaft

being careful not to bump crankshaft and knock
any bearings out.
Figure 521 Lower crankcase bearing installation
EGES-390
Lower Crankcase Torque Sequence
10 2 8 16
9 1 7 15
11 3 5 13
12 4 6 14
J07006
Figure 523 Lower crankcase main bearing bolt torque sequence
6. Install all 16 lower crankcase main bearing b. Increase torque for bolts to 163 N·m (120
mounting bolts. Tighten main cap bolts to the lbf·ft) in the numerical sequence shown in
special torque as follows using the sequence "Lower crankcase main bearing mounting bolt
shown in the "Lower crankcase main bearing tightening sequence" (Figure 523).
mounting bolt tightening sequence" (Figure 523):
c. Increase torque for bolts to a final value of 231
a. Initially torque bolts to 122 N·m (90 lbf·ft) in N·m (170 lbf·ft) in the numerical sequence
the numerical sequence shown in "Lower shown in "Lower crankcase main bearing
crankcase main bearing mounting bolt mounting bolt tightening sequence" (Figure
tightening sequence" (Figure 523). 523).
EGES-390
4 1 5
3 2 6
J07007
Figure 524 Lower crankcase outer bolt torque sequence
7. Install six bolts (M8 x 30) around outside of lower crankcase outer bolt tightening sequence" (Figure
crankcase. Tighten bolts to the standard torque 524).
(page 400) using the sequence shown in "Lower
EGES-390
Figure 525 Crankshaft end play measurement Figure 526 Camshaft-to-crankshaft gear
backlash
1. Pry bar or screwdriver
2. Crankshaft flange
3. Dial indicator
9. Check and record camshaft gear-to-crankshaft
gear backlash as follows:
8. Check crankshaft end play as follows: NOTE: Crankshaft gear must be fixed, not
allowed to rotate, only the camshaft gear should
a. Mount dial indicator on crankcase with
be allowed to rotate, otherwise the reading will
indicator tip on the end of crankshaft flange
be invalid.
as shown.
a. Mount Dial Indicator with Magnetic Base onto
b. Pry crankshaft forward with pry bar and zero
rear of engine. See Special Service Tools
dial indicator.
(page 361).
c. Pry crankshaft back and forth while reading
b. Position dial indicator tip onto a gear tooth and
dial indicator. Record end play.
remove any lash.
c. Zero dial indicator index.
d. Rotate gear by hand and read indicator.
Record backlash.
e. If backlash exceeds specified limits, replace
camshaft gear. See Specifications (page
359).
EGES-390
Figure 527 Primary balancer gear-to-crankshaft Figure 528 Primary balancer shaft end play
gear backlash
11. Check and record the primary balancer shaft end

10. Check and record primary balancer play as follows:
gear-to-crankshaft gear backlash as follows:
a. Reposition dial indicator tip to balance shaft,
NOTE: Crankshaft gear must be fixed, not not gear.
allowed to rotate, only the primary balancer gear
b. Push camshaft to the front of the engine.
should be allowed to rotate, otherwise the reading
will be invalid. c. Zero dial indicator index.
a. Mount dial indicator with magnetic base (page d. Place a small pry bar between the primary
361) onto rear of engine. balance gear and crankcase. Lightly pry
primary balancer gear toward indicator.
b. Position dial indicator tip on primary balancer
Compare dial indicator reading with
gear tooth and remove lash.
specifications. See Specifications (page
c. Zero dial indicator index. 359).
d. Rotate gear by hand and read indicator. 12. Slide a new dipstick tube seal onto oil level gauge
Record backlash. assembly and install into lower crankcase, making
certain that the seal is fully seated within the lower
e. If backlash exceeds specified limits, replace
crankcase.
primary balancer gear. See Specifications
(page 359).
EGES-390
Crankcase Sensors and Coolant Heater 5. Install CKP sensor into lower crankcase.
1. Place two new O-rings onto CMP sensor. 6. Install retaining bolt (M6 x 14) to CKP sensor
located on the front of the engine, lower right.
Tighten bolt to the standard torque (page 400).
7. Lubricate a new O-ring and install onto the coolant
heater.
Figure 529 CMP sensor
2. Lubricate sensor O-rings with clean engine oil and

install CMP sensor into crankcase.
3. Secure sensor with bolt (M6 x 16) and tighten to Figure 531 Coolant heater
the standard torque (page 400).
4. Place a new lubricated O-ring seal onto the 8. Install coolant heater element into crankcase and
crankshaft position sensor. tighten to the special torque (page 361).
a. Reinstall all safety guards, shields and covers
b. Make sure all tools, loose parts and service
Figure 530 CKP sensor
EGES-390
Specifications
Crankshaft
Crankshaft end play (maximum) 0.222 mm (0.0087 in)
Crankshaft gear backlash (maximum) 0.32 mm (0.012 in)
Crankshaft connecting rod journal out-of-round 0.006 mm (0.00024 in)
Crankshaft connecting rod journal taper (maximum per inch) 0.0076 mm (0.0003 in)
Crankshaft main journal out-of-round 0.006 mm (0.00024 in)
Crankshaft main journal taper (maximum per inch) 0.0076 mm (0.0003 in)
Main bearing thrust face maximum runout 0.051 mm (0.002 in)
Oil seal journal maximum runout 0.025 mm (0.001 in)
Vibration damper mounting area maximum runout 0.05 mm (0.002 in)
Flywheel mounting surface maximum runout 0.05 mm (0.002 in)
Main bearing to crankshaft running clearance 0.025 to 0.076 mm (0.001 to 0.003
in)
Main Bearing Journal Diameter
• Standard size 80.987 to 81.012 mm (3.188 to
3.150 in)
• 0.254 mm (0.010 in) under size 80.733 to 80.758 mm (3.178 to
3.140 in)
3.130 in)
3.120 in)
Connecting Rod Journal Diameter
68.99 to 69.01 mm (2.716 to 2.717
• Standard size
in)
68.73 to 68.75 mm (2.706 to 2.707
• 0.254 mm (0.010 in) under size
in)
68.48 to 68.50 mm (2.696 to 2.697
in)
68.23 to 68.25 mm (2.686 to 2.687
in)
EGES-390
Camshaft and Bushings

Camshaft bushing inside diameter 62.05 to 62.14 mm (2.443 to 2.446 in)
Camshaft end play 0.051 to 0.211 mm (0.002 to 0.008 in)
Camshaft gear backlash 0.179 to 0.315 mm (0.007 to 0.012 in)
Camshaft lobe wear (max) 0.51 mm (0.02 in)
Camshaft journal diameter (all journals) 61.987 to 62.013 mm (2.440 to 2.441
in)
Camshaft thrust plate thickness 3.589 to 3.649 mm (0.1413 to 0.1436
in)
Journal and bushing running clearance 0.037 to 0.153 mm (0.0015 to 0.0060
in)
Primary balance shaft bearing clearance (max) 0.123 mm (0.005 in)
Primary balance shaft end play 1.77 mm (0.070 in)
Primary balance gear backlash 0.184 to 0.306 mm (0.007 to 0.012 in)
Camshaft lobe lift (maximum)
• Intake 5.820 mm (0.2291 in)
• Exhaust 5.906 mm (0.2325 in)
Valve timing no. 1 cylinder (top of lobe)
• Intake open 16.2° BTDC
• Intake closed 50.4° ABDC
• Exhaust open 47.5° BBDC
• Exhaust closed 14.9° ATDC
Crankcase
Cylinder block top surface of crankcase flatness Total deck surface: 0.10 mm (0.004 in)
150 mm2 (36 in2) area: 0.05 mm (0.02
in)
25 mm2 (1 in2) area: 0.025 mm
(0.001in)
85.99 to 86.01 mm (3.3854 to 3.3862
Crankcase main bearing bore diameter
in)
Crankcase cam bearing bore diameter 65.98 to 66.02 mm (2.597 to 2.599 in)
Roller follower bore diameter 23.44 to 23.48 mm (0.923 to 0.924 in)
Roller follower outside diameter 23.39 to 23.41 mm (0.921 to 0.923 in)
94.991 to 95.001 mm (3.740 to 3.741
Cylinder bore diameter
in)
Cylinder bore maximum out-of-round 0.008 mm (0.0003 in)
Cylinder stroke 105 mm (4.13 in)
EGES-390
Coolant heater element rating 1,000 watts, 120 volts

Main Bearings
Material Steel backed copper/lead
Number of main bearings 4
Thrust bearing location No. 3 main upper
Lower crankcase Four bolts per main journal
Special Torque
Lower crankcase main bearing cap bolts See tightening procedure

and sequence (page 354)
Coolant heater element or plug 41 N·m (30 lbf·ft)
Crankcase coolant drain plug / O-ring, M16 20 N·m (15 lbf·ft)
Camshaft Bushing Kit ZTSE2893B

Camshaft Bushing Remover/Installer (expanding collet) ZTSE4489
Crankshaft Timing Tool ZTSE4687
Cylinder bore gauge Obtain locally
De-glazing hone (four-inch) Obtain locally
Freeze Plug Installer ZTSE4509
Loctite® #242 Threadlocker Obtain locally
Loctite® #620 Compound Obtain locally
Micrometer, 2-3 in Obtain locally
Oil Gallery Cleaning Brush ZTSE4511
Oil Gallery Plug Driver ZTSE4512
EGES-390
EGES-390
IN-CHASSIS SERVICE - ROCKER ARM REPLACEMENT 363
Table of Contents
Rocker Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .365
EGES-390
364 IN-CHASSIS SERVICE - ROCKER ARM REPLACEMENT
EGES-390
Rocker Arm Replacement CAUTION: To prevent engine damage, position shop

towels or rubber hose into each of the cylinder head
Before performing rocker arm replacement, the
oil drain holes before fuel injector removal. This will
following components must be removed as outlined
ensure small parts (or broken pieces) will not get into
elsewhere in this engine service manual:
the oil. Potentially damaging components include:
• Turbocharger inlet air ducting
• ⅜" rocker arm pivot balls
• Valve cover(s)
• Rocker arm pivots and pivot retainers
• High-pressure oil rail(s)
Account for all parts (or pieces of) before removing
shop towels or rubber hose after rocker arm has been
installed.
Information” section of this manual. 1. Locate dowel hole in vibration damper. The hole
is located between two of the four bolt heads.

components.


Limit compressed air pressure to 207 kPa (30 psi). Figure 532 Dowel hole in vibration damper
WARNING: To prevent personal injury or 2. Rotate crankshaft until the dowel hole is at the
death, do not let engine fluids stay on your skin. 12:00 O’clock position.
with soap and water. Wash or discard clothing Wiggle both rocker arms at the #1 cylinder. If the
and rags contaminated with engine fluids. rockers do not move freely, rotate crankshaft one
complete revolution (360°). The #1 cylinder
rocker arms should now feel free of valve
train loading. Rocker arm replacement can
GOVERNMENT REGULATION: Engine be performed at cylinders 1, 2, and 4.
fluids (oil, fuel, and coolant) may be a threat Rotate crankshaft one additional revolution (360°)
to the environment. Recycle or dispose to service both rocker arms for cylinders 3, 5, and
of engine fluids and filters according to 6.
fluids in the trash, on the ground, in sewers 3. Disconnect and remove the fuel injector electrical
or bodies of water. connection at the rocker arm carrier using the
Injector Connector Remover. See Special Service
Tools (page 369).
EGES-390
4. Remove the fuel injector hold down clamp

assembly using a T45 Torx bit socket (page
369).
5. Place injector into a closable container, cover with
oil, and close container.
CAUTION: To prevent engine damage, place a
clean paper towel inside the injector sleeve to
prevent entrance of foreign material.
Figure 534 Hold down clamp and base

1. Locating notch / index feature
6. Using the On Engine Valve Spring Compressor

Tool, insert the Valve Spring Compressor Base
into injector hold down clamp, making sure the
notch in the base aligns with index feature on hold
down clamp.
Figure 533 On Engine Valve Spring Compressor

Tool
1. Valve Spring Compressor Plate
2. Valve Spring Compressor Base
3. Valve Spring Compressor Bolt
EGES-390
8. Install Valve Spring Compressor Plate onto the

top of each valve bridge, locating the small point
of plate between the exhaust rocker and valve
bridge.
a. If exhaust rocker is severely worn, insert a
small pry bar between the exhaust rocker arm
and valve bridge. Compressing the valve
bridge down and raising the rocker slightly
should give enough clearance to rotate the
small point of the Valve Spring Compressor
Plate between the two components.
Figure 535 Valve Spring Compressor Base

installed
7. Install assembly between valve bridges as if

installing an injector. While centering Valve
Spring Compressor Base between the two valve
bridges, lightly tighten injector hold down clamp
bolt, but do not torque.
Figure 537 Valve Spring Compressor Plate

installed
1. Plate properly positioned on top of valve bridges
2. Exhaust rocker arm
b. Once the Valve Spring Compressor Plate is in

position, install the Valve Spring Compressor
Bolt through the Valve Spring Compressor
Plate and into Valve Spring Compressor
Base.
Figure 536 Creating clearance between rocker CAUTION: To prevent engine damage, do not
arm and valve bridge use power tools.
1. Valve Spring Compressor Plate c. Using a hand wrench, tighten bolt to
2. Valve bridge (2) compress valve springs until Valve Spring
3. Small pry bar Compressor Plate contacts top of Valve
Spring Compressor Base.
EGES-390
9. Disengage rocker arm from push rod while opening and rotating clip until snapping around
rotating rocker arm and compressing rocker fulcrum plate.
arm clip simultaneously. Repeat procedure for
adjacent rocker arm.
CAUTION: To prevent engine damage, account
for the two ⅜" rocker arm pivot balls. If balls fall
onto cylinder head, use a magnet to retrieve them.
CAUTION: To prevent engine damage, account
for each rocker arm pivot and pivot retainer.
Failure to account for broken pieces would 1 2
require the removal of the oil pan to retrieve, if
shop towels or hoses were not placed within the
oil drain holes.
D08152
10. With rocker arms removed, back out Valve

Spring Compressor Bolt and remove Valve Figure 539 Retaining clip in correct position
Spring Compressor Plate to gain access to valve 1. Fulcrum plate
bridges. 2. Rocker arm retaining clip
11. Replace valve bridges as necessary. Compress
valves again to enable installation of new rocker
arms. 15. Refer to illustration (Figure 539) for correctly
installed clip. Repeat procedure with adjacent
12. Place a dab of wheel bearing grease onto new rocker arm.
rocker arm socket (to hold new ⅜” ball in place
while installing rocker arm). 16. Remove Valve Spring Compressor Bolt making
sure rocker arm remains in place and ⅜” ball has
13. Position ⅜” ball and rocker arm underneath not fallen out. Repeat procedure on remaining
fulcrum and rotate rocker arm into place making cylinders for this crankshaft position session.
sure push rod is seated within rocker arm.
17. After all desired rocker arms and valve bridges
have been replaced for cylinders 1, 2, and 4, the
1 crankshaft can be rotated one complete revolution
(360°) to service rocker arms at cylinders 3, 5 and
A 6.
18. Install a new O-ring seal kit onto each of the fuel
2 injectors as outlined in Cylinder Head and Valve
B Train section of this manual.
19. Remove paper towels from injector bores and
install injectors.
20. Look for small broken particles (visually and using
D08151
a magnet) before removing shop towels or rubber
hose from oil drain holes.
Figure 538 Position "A" in first then slide "B" 21. Continue to install the following components as
around fulcrum plate outlined in this engine service manual:
1. Fulcrum plate
• High-pressure oil rail(s)
2. Rocker arm retaining clip
• Valve cover(s)
• Turbocharger inlet air ducting
14. Install new plastic rocker arm retaining clip (Figure
538) by positioning top of clip to top of rocker arm
EGES-390

Quick Release Tool kit ZTSE4454
On Engine Valve Spring Compressor Tool ZTSE4697
EGES-390
EGES-390
ABBREVIATIONS AND ACRONYMS 371
Table of Contents
Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .373
EGES-390
372 ABBREVIATIONS AND ACRONYMS
EGES-390
Abbreviations and Acronyms CKPO – Crankshaft Position Out

cm – Centimeter
Abbreviations and Acronyms
CMP – Camshaft Position
A or amp – Ampere CMPO – Camshaft Position Out
ABDC – After Bottom Dead Center CO – Carbon Monoxide
ABS – Antilock Brake System COO – Cruise On / Off switch
AC – Alternating Current CPU – Central Processing Unit
A/C – Air Conditioner CTC – Coolant Temperature Compensation
ACC – Air Conditioner Control Cyl – Cylinder
ACCEL – Accelerate
DB – Decibel
ACD – Air Conditioner Demand
DCA – Diesel Coolant Additive
ACT PWR GND – Actuator Power Ground
DDI – Digital Direct Fuel Injection
AF – Air to Fuel ratio
DDS – Driveline Disengagement Switch
AFT – Aftertreatment
DLC – Data Link Connector
AIT – Air Intake Temperature
DME – Dimethyl Ether
Amb – Ambient
DMM – Digital Multimeter
amp or A – Ampere
DOC – Diesel Oxidation Catalyst
AMS – Air Management System
DPF – Diesel Particulate Filter
API – American Petroleum Institute
DT – Diesel Turbocharged
APS – Accelerator Position Sensor
DTC – Diagnostic Trouble Code
APS/IVS – Accelerator Position Sensor / Idle
DTRM – Diesel Thermo Recirculation Module
Validation Switch
ASTM – American Society for Testing and Materials EBP – Exhaust Back Pressure
ATA – American Trucking Association EBPD – Exhaust Back Pressure Desired
ATDC – After Top Dead Center ECI – Engine Crank inhibit
AWG – American Wire Gauge ECL – Engine Coolant Level
ECM – Electronic Control Module
B+ or VBAT – Battery Voltage
ECM PWR – Electronic Control Module Power
BAP – Barometric Absolute Pressure
ECT – Engine Coolant Temperature
BBDC – Before Bottom Dead Center
EFP – Engine Fuel Pressure
BCP – Brake Control Pressure
EFRC – Engine Family Rating Code
BCS – Boost Control Solenoid
EFT – Engine Fuel Temperature
BDC – Bottom Dead Center
EG – Ethylene Glycol
bhp – Brake Horsepower
EGC – Electronic Gauge Cluster
BNO – Brake Normally Open
EGDP – Exhaust Gas Differential Pressure
BOO – Brake On / Off
EGR – Exhaust Gas Recirculating
BPS – Brake Pressure Switch
EGRH – Exhaust Gas Recirculation High control
BSV – Brake Shut-off Valve
EGRL – Exhaust Gas Recirculation Low control
BTDC – Before Top Dead Center
EGRP – Exhaust Gas Recirculation Position
BTU – British Thermal Unit
EGT1 – Exhaust Gas Temperature 1
C – Celsius EGT2 – Exhaust Gas Temperature 2
CAC – Charge Air Cooler EGT3 – Exhaust Gas Temperature 3
CAN – Controller Area Network EMI – Electromagnetic Interference
CAP – Cold Ambient Protection EOP – Engine Oil Pressure
CARB – California Air Resources Board EOT – Engine Oil Temperature
cc – Cubic centimeter EPA – Environmental Protection Agency
CCA – Cold Cranking Ampere EPR – Engine Pressure Regulator
CID – Cubic Inch Displacement ESC – Electronic System Controller
cfm – Cubic feet per minute ESN – Engine Serial Number
cfs – Cubic feet per second EST – Electronic Service Tool
CKP – Crankshaft Position EWPS – Engine Warning Protection System
EGES-390
F – Fahrenheit ITVL – Intake Throttle Valve Low control

FCV – Fuel Coolant Valve ITVP – Intake Throttle Valve Position
FEL – Family Emissions Limit IVS – Idle Validation Switch
fhp – Friction horsepower
JCT – Junction (electrical)
FMI – Failure Mode Indicator
FPC – Fuel Pump Control kg – Kilogram
FPCV – Fuel Pressure Control Valve km – Kilometer
fpm – Feet per minute km/h – Kilometers per hour
fps – Feet per second km/l – Kilometers per liter
FRP – Fuel Rail Pressure KOEO – Key-On Engine-Off
ft – Feet KOER – Key-On Engine-Running
FVCV – Fuel Volume Control Valve kPa – Kilopascal
GND – Ground (electrical) L – Liter
gal – Gallon L/h – Liters per hour
gal/h – U.S. Gallons per hour L/m – Liters per minute
gal/min – U. S. Gallons per minute L/s – Liters per second
GCW – Gross Combined Weight lb – Pound
GCWR – Gross Combined Weight Rating lbf – Pound force
GPC – Glow Plug Control lb/s – Pounds per second
GPD – Glow Plug Diagnostic lbf ft – Pounds of force per foot
GPR – Glow Plug Relay lbf in – Pounds of force per inch
GVW – Gross Vehicle Weight lbm – Pound mass
LSD – Low Sulfur Diesel
H2O – Water
HC – Hydrocarbons m – Meter
HFCM – Horizontal Fuel Conditioning Module m/s – Meters per second
Hg – Mercury MAF – Mass Air Flow
hp – Horsepower MAG – Magnetic
HPFP – High-Pressure Fuel Pump MAP – Manifold Absolute Pressure
hr – Hour MAT – Manifold Air Temperature
Hyd – Hydraulic mep – Mean effective pressure
mi – Mile
IAT – Intake Air Temperature
mm – Millimeter
IAHC – Inlet Air Heater Control
mpg – Miles per gallon
IAHD – Inlet Air Heater Diagnostic
mph – Miles per hour
IAHR – Inlet Air heater Relay
MPR – Main Power Relay
IC – Integrated Circuit
MSDS – Material Safety Data Sheet
ICP – Injector Control Pressure
MSG – Micro Strain Gauge
ID – Inside Diameter
MSM – Multiplex System Module
IDM – Injector Drive Module
MY – Model Year
IGN – Ignition
ILO – Injector Leak Off NC – Normally closed (electrical)
in – Inch NETS – Navistar Electronics Technical Support
inHg – Inch of mercury Nm – Newton meter
inH2O – Inch of water NO – Normally Open (electrical)
INJ – Injector NOX – Nitrogen Oxides
IPR – Injection Pressure Regulator
OAT – Organic Acid Technology
ISIS – International® Service Information System
OCC – Output Circuit Check
IST – Idle Shutdown Timer
OCP – Overcrank Protection
ITP – Internal Transfer Pump
OD – Outside Diameter
ITV – Intake Throttle Valve
OL – Over Limit
ITVH – Intake Throttle Valve High control
EGES-390
ORH – Out-of-Range High SIG GRD – Signal Ground

ORL – Out-of-Range Low S/N – Serial Number
OSHA – Occupational Safety and Health SW – Switch (electrical)
Administration SYNC – Synchronization
OWL – Oil/Water Lamp
TACH – Tachometer output signal
PID – Parameter Identifier TBD – To Be Determined
P/N – Part Number TCAPE – Truck Computer Analysis of Performance
ppm – Parts per million and Economy
PROM – Programmable Read Only Memory TDC – Top Dead Center
psi – Pounds per square inch TCM – Transmission Control Module
psia – Pounds per square inch absolute TTS – Transmission Tailshaft Speed
psig – Pounds per square inch gauge
ULSD – Ultra Low Sulfur Diesel
pt – Pint
UVC – Under Valve Cover
PTO – Power Takeoff
PWM – Pulse Width Modulate V – Volt
PWR – Power (voltage) VBAT or B+ – Battery Voltage
VC – Volume Control
qt – Quart
VEPS – Vehicle Electronics Programming System
RAM – Random Access Memory VGT – Variable Geometry Turbocharger
RAS – Resume / Accelerate Switch (speed control) VIGN – Ignition Voltage
REPTO – Rear Engine Power Takeoff VIN – Vehicle Identification Number
RFI – Radio Frequency Interference VOP – Valve Opening Pressure
rev – Revolution VRE – Vehicle Retarder Enable
rpm – Revolutions per minute VREF – Reference Voltage
RPRE – Remote Preset VSO – Vehicle Speed Output
RSE – Radiator Shutter Enable VSS – Vehicle Speed Sensor
RVAR – Remote Variable
WEL – Warn Engine Lamp
SAE – Society of Automotive Engineers® WIF – Water In Fuel
SCA – Supplemental Cooling Additive WTEC – World Transmission Electronically Controlled
SCCS – Speed Control Command Switches automatic transmissions (Allison)
SCS – Speed Control Switch
XMSN – Transmission
SHD – Shield (electrical)
SID – Subsystem Identifier
EGES-390
EGES-390
TERMINOLOGY 377
Table of Contents
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .379
EGES-390
378 TERMINOLOGY
EGES-390
TERMINOLOGY 379
Terminology output of an engine, sometimes-called flywheel

horsepower is less than the indicated horsepower by
Terms
the amount of friction horsepower consumed in the
Accessory work – The work per cycle required engine.
to drive engine accessories (normally, only those
Brake Horsepower (bhp) net – Net brake
essential to engine operation).
horsepower is measured with all engine components.
Actuator – A device that performs work in response The power of an engine when configured as a fully
to an input signal. equipped engine. (SAE J1349 JUN90)
Aeration – The entrainment of air or combustion gas Calibration – The data values used by the strategy
in coolant, lubricant, or fuel. to solve equations and make decisions. Calibration
values are stored in ROM and put into the processor
Aftercooler (Charge Air Cooler) – A heat exchanger
during programming to allow the engine to operate
mounted in the charge air path between the
within certain parameters.
turbocharger and engine intake manifold. The
aftercooler reduces the charge air temperature by Catalyst – A substance that produces a chemical
transferring heat from the charge air to a cooling reaction without undergoing a chemical change itself.
medium (usually air).
Catalytic converter – An antipollution device in the
Ambient temperature – The environmental air exhaust system that contains a catalyst for chemically
temperature in which a unit is operating. In general, converting some pollutants in the exhaust gases
the temperature is measured in the shade (no solar (carbon monoxide, unburned hydrocarbons, and
radiation) and represents the air temperature for other oxides of nitrogen) into harmless compounds.
engine cooling performance measurement purposes.
Cavitation – A dynamic condition in a fluid system that
Air entering the radiator may or may not be the same
forms gas-filled bubbles (cavities) in the fluid.
ambient due to possible heating from other sources
or recirculation. (SAE J1004 SEP81) Cetane number – 1. The auto-ignition quality of
diesel fuel.
Ampere (amp) – The standard unit for measuring the
strength of an electrical current. The flow rate of a 2. A rating applied to diesel fuel similar to octane
charge in a conductor or conducting medium of one rating for gasoline.
coulomb per second. (SAE J1213 NOV82)
3. A measure of how readily diesel fuel starts to burn
Analog – A continuously variable voltage. (self-ignites) at high compression temperature.
Analog to digital converter (A/D) – A circuit in the Diesel fuel with a high cetane number self-ignites
ECM processing section that converts an analog shortly after injection into the combustion chamber.
signal (DC or AC) to a usable digital signal for the Therefore, it has a short ignition delay time. Diesel
microprocessor. fuel with a low cetane number resists self-ignition.
Therefore, it has a longer ignition delay time.
American Trucking Association (ATA) Datalink –
A serial datalink specified by the American Trucking Charge air – Dense, pressurized, heated air
Association and the SAE. discharged from the turbocharger.
Boost pressure – 1. The pressure of the charge air Charge Air Cooler (CAC) – See Aftercooler.
leaving the turbocharger.
Closed crankcase – A crankcase ventilation that
2. Inlet manifold pressure that is greater than recycles crankcase gases through a breather, then
atmospheric pressure. Obtained by turbocharging. back to the clean air intake.
Bottom Dead Center (BDC) – The lowest position of Closed loop operation – A system that uses a sensor
the piston during the stroke. to provide feedback to the ECM. The ECM uses the
sensor to continuously monitor variables and adjust
Brake Horsepower (bhp) – The power output from
to match engine requirements.
an engine, not the indicated horsepower. The power
EGES-390
380 TERMINOLOGY
Cloud point – The point when wax crystals occur in Disable – A computer decision that deactivates a
fuel, making fuel cloudy or hazy. Usually below -12 °C system and prevents operation of the system.
(10 °F).
Displacement – The stroke of the piston multiplied by
Cold cranking ampere rating (battery rating) – The the area of the cylinder bore multiplied by the number
sustained constant current (in amperes) needed to of cylinders in the engine.
produce a minimum terminal voltage under a load of
Driver (high side) – A transistor within an electronic
7.2 volts per battery after 30 seconds.
module that controls the power to an actuator circuit.
Continuous Monitor Test – An ECM function that
Driver (low side) – A transistor within an electronic
continuously monitors the inputs and outputs to
module that controls the ground to an actuator circuit.
ensure that readings are within set limits.
Duty cycle – A control signal that has a controlled
Coolant – A fluid used to transport heat from one point
on/off time measurement from 0 to 100%. Normally
to another.
used to control solenoids.
Coolant level switch – A switch sensor used to
Engine lamp – An instrument panel lamp that comes
indicate low coolant level.
on when DTCs are set. DTCs can be read as flash
Crankcase – The housing that encloses the codes (red and amber instrument panel lamps).
crankshaft, connecting rods, and allied parts.
Engine OFF tests – Tests that are done with the
Crankcase breather – A vent for the crankcase to ignition switch ON and the engine OFF.
release excess interior air pressure.
Engine rating – Engine rating includes Rated hp and
Crankcase pressure – The force of air inside the Rated rpm.
crankcase against the crankcase housing.
Engine RUNNING tests – Tests done with the engine
Current – The flow of electrons passing through a running.
conductor. Measured in amperes.
Exhaust brake – A brake device using engine
Damper – A device that reduces the amplitude of exhaust back pressure as a retarding medium.
torsional vibration. (SAE J1479 JAN85)
Exhaust manifold – Exhaust gases flow through the
Deaeration – The removal or purging of gases (air or exhaust manifold to the turbocharger exhaust inlet and
combustion gas) entrained in coolant or lubricating oil. are directed to the EGR cooler.
Deaeration tank – A separate tank in the cooling Fault detection/management – An alternate control
system used for one or more of the following functions: strategy that reduces adverse effects that can be
caused by a system failure. If a sensor fails, the ECM
• Deaeration
substitutes a good sensor signal or assumed sensor
• Coolant reservoir (fluid expansion and afterboil) value in its place. A lit amber instrument panel lamp
signals that the vehicle needs service.
• Coolant retention
Filter restriction – A blockage, usually from
• Filling
contaminants, that prevents the flow of fluid through
• Fluid level indication (visible) a filter.
Diagnostic Trouble Code (DTC) – Formerly called Flash code – See Diagnostic Trouble Code (DTC).
a Fault Code or Flash Code. A DTC is a three digit
Fuel inlet restriction – A blockage, usually from
numeric code used for troubleshooting.
contaminants, that prevents the flow of fluid through
Digital Multimeter (DMM) – An electronic meter that the fuel inlet line.
uses a digital display to indicate a measured value.
Fuel pressure – The force that the fuel exerts on the
Preferred for use on microprocessor systems because
fuel system as it is pumped through the fuel system.
it has a very high internal impedance and will not load
down the circuit being measured.
EGES-390
TERMINOLOGY 381
Fuel strainer – A pre-filter in the fuel system that • High idle is maximum rpm at no load.
keeps larger contaminants from entering the fuel
Intake manifold – A collection of tubes through which
system.
the fuel-air mixture flows from the fuel injector to the
Fully equipped engine – A fully equipped engine intake valves of the cylinders.
is an engine equipped with only those accessories
International NGV Tool Utilized for Next
necessary to perform its intended service. A fully
Generation Electronics (INTUNE) – The
equipped engine does not include components
diagnostics software for chassis related components
that are used to power auxiliary systems. If these
and systems.
components are integral with the engine or for any
reason are included on the test engine, the power Low speed digital inputs – Switched sensor inputs
absorbed may be determined and added to the net that generate an on/off (high/low) signal to the ECM.
brake power. (SAE J1995 JUN90) The input to the ECM from the sensor could be from
a high input source switch (usually 5 or 12 volts) or
Fusible link (fuse link) – A fusible link is a special
from a grounding switch that grounds the signal from
section of low tension cable designed to open the
a current limiting resistor in the ECM that creates a low
circuit when subjected to an extreme current overload.
signal (0 volts).
(SAE J1156 APR86)
Lubricity – Lubricity is the ability of a substance
Gradeability – The maximum percent grade which
to reduce friction between solid surfaces in relative
the vehicle can transverse for a specified time at a
motion under loaded conditions.
specified speed. The gradeability limit is the grade
upon which the vehicle can just move forward. (SAE Lug (engine) – A condition when the engine is
J227a) operating at or below maximum torque speed.
Gross Combined Weight Rating (GCWR) – Manometer – A double-leg liquid-column gauge, or a
Maximum combined weight of towing vehicle single inclined gauge, used to measure the difference
(including passengers and cargo) and the trailer. between two fluid pressures. Typically, a manometer
The GCWR indicates the maximum loaded weight records in inches of water.
that the vehicle is allowed to tow.
MasterDiagnostics® (MD) – The diagnostics
Gross brake horsepower – The power of a complete software for engine related components and systems.
basic engine, with air cleaner, without fan, and
Microprocessor – An integrated circuit in a
alternator and air compressor not charging.
microcomputer that controls information flow.
Hall effect – The development of a transverse electric
Nitrogen Oxides (NOx) – Nitrogen oxides form by
potential gradient in a current-carrying conductor or
a reaction between nitrogen and oxygen at high
semiconductor when a magnetic field is applied.
temperatures and pressures in the combustion
Hall effect sensor – Generates a digital on/off signal chamber.
that indicates speed and timing.
Normally closed – Refers to a switch that remains
High speed digital inputs – Inputs to the ECM from closed when no control force is acting on it.
a sensor that generates varying frequencies (engine
Normally open – Refers to a switch that remains open
speed and vehicle speed sensors).
when no control force is acting on it.
Horsepower (hp) – Horsepower is the unit of work
Ohm (Ω) – The unit of resistance. One ohm is the
done in a given period of time, equal to 33,000 pounds
value of resistance through which a potential of one
multiplied by one foot per minute. 1hp = 33,000 lb x
volt will maintain a current of one ampere. (SAE J1213
1 ft /1 min.
NOV82)
Hydrocarbons – Unburned or partially burned fuel
On demand test – A self test that the technician
molecules.
initiates using the EST and is run from a program in
Idle speed – the processor.
• Low idle is minimum rpm at no load.
EGES-390
382 TERMINOLOGY
Output Circuit Check (OCC) – An On demand test Reference voltage (VREF) – A 5 volt reference supplied
done during an Engine OFF self test to check the by the ECM to operate the engine sensors.
continuity of selected actuators.
Reserve capacity – Time in minutes that a fully
pH – A measure of the acidity or alkalinity of a solution. charged battery can be discharged to 10.5 volts at 25
amperes.
Particulate matter – Particulate matter includes
mostly burned particles of fuel and engine oil. Signal ground – The common ground wire to the
ECM for the sensors.
Piezometer – An instrument for measuring fluid
pressure. Speed Control Command Switches (SCCS) – A set
of switches used for cruise control, Power TakeOff
Power – Power is a measure of the rate at which work
(PTO), and remote hand throttle system.
is done. Compare with Torque.
Steady state condition – An engine operating
Power TakeOff (PTO) – Accessory output, usually
at a constant speed and load and at stabilized
from the transmission, used to power a hydraulic
temperatures and pressures. (SAE J215 JAN80)
pump for a special auxiliary feature (garbage packing,
lift equipment, etc). Strategy – A plan or set of operating instructions
that the microprocessor follows for a desired goal.
Pulse Width Modulate (PWM) – The time that an
Strategy is the computer program itself, including
actuator, such as an injector, remains energized.
all equations and decision making logic. Strategy is
Random Access Memory (RAM) – Computer always stored in ROM and cannot be changed during
memory that stores information. Information can calibration.
be written to and read from RAM. Input information
Stroke – Stroke is the movement of the piston from
(current engine speed or temperature) can be stored
Top Dead Center (TDC) to Bottom Dead Center
in RAM to be compared to values stored in Read Only
(BDC).
Memory (ROM). All memory in RAM is lost when the
ignition switch is turned off. Substrate – Material that supports the washcoating
or catalytic materials.
Rated gross horsepower – Engine gross
horsepower at rated speed as declared by the System restriction (air) – The static pressure
manufacturer. (SAE J1995 JUN90) differential that occurs at a given air flow from air
entrance through air exit in a system. Usually
Rated horsepower – Maximum brake horsepower
measured in inches (millimeters) of water. (SAE
output of an engine as certified by the engine
J1004 SEP81)
manufacturer. The power of an engine when
configured as a basic engine. (SAE J1995 JUN90) Tachometer output signal – Engine speed signal for
remote tachometers.
Rated net horsepower – Engine net horsepower at
rated speed as declared by the manufacturer. (SAE Thermistor – A semiconductor device. A sensing
J1349 JUN90) element that changes resistance as the temperature
changes.
Rated speed – The speed, as determined by the
manufacturer, at which the engine is rated. (SAE Thrust load – A thrust load pushes or reacts through
J1995 JUN90) a bearing in a direction parallel to the shaft.
Rated torque – Maximum torque produced by an Top Dead Center (TDC) – The uppermost position of
engine as certified by the manufacturer. the piston during the stroke.
Ratiometric Voltage – In a Micro Strain Gauge Torque – A force having a twisting or turning effect.
(MSG) sensor pressure to be measured exerts force For a single force, the cross product of a vector from
on a pressure vessel that stretches and compresses some reference point to the point of application of the
to change resistance of strain gauges bonded to force within the force itself. Also known as moment of
the surface of the pressure vessel. Internal sensor force or rotation moment. Torque is a measure of the
electronics convert the changes in resistance to a ability of an engine to do work.
ratiometric voltage output.
EGES-390
TERMINOLOGY 383
Truck Computer Analysis of Performance and Viscosity – The internal resistance to the flow of any
Economy (TCAPE) – Truck Computer Analysis of fluid.
Performance and Economy is a computer program
Viscous fan – A fan drive that is activated when a
that simulates the performance and fuel economy of
thermostat, sensing high air temperature, forces fluid
trucks.
through a special coupling. The fluid activates the fan.
Turbocharger – A turbine driven compressor
Volt (v) – A unit of electromotive force that will move
mounted to the exhaust manifold. The turbocharger
a current of one ampere through a resistance of one
increases the pressure, temperature and density of
Ohm.
intake air to charge air.
Voltage – Electrical potential expressed in volts.
Variable capacitance sensor – A variable
capacitance sensor is measures pressure. The Voltage drop – Reduction in applied voltage from the
pressure forces a ceramic material closer to a thin current flowing through a circuit or portion of the circuit
metal disc in the sensor, changing the capacitance of current multiplied by resistance.
the sensor.
Voltage ignition – Voltage supplied by the ignition
Vehicle Electronic System Programming System – switch when the key is ON.
The computer system used to program electronically
Washcoat – A layer of alumina applied to the
controlled vehicles.
substrate in a monolith-type converter.
Vehicle Retarder Enable/Engage – Output from the
ECM to a vehicle retarder.
Vehicle Speed Sensor (VSS) – Normally a magnetic
pickup sensor mounted in the tailshaft housing of the
transmission, used to indicate ground speed.
EGES-390
384 TERMINOLOGY
EGES-390
APPENDIX A – SPECIFICATIONS 385
Table of Contents
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Dual Stage Turbocharger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Manifolds and Exhaust Gas Recirculation (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
High-pressure Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .387
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388
Oil Cooler and Filter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .388
Front Cover, Vibration Damper, Oil Pump, and Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .389
Cylinder Head and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .391
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
Power Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .392
Crankcase, Crankshaft, and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .394
EGES-390
386 APPENDIX A – SPECIFICATIONS
EGES-390
Specifications
Engine Electrical
Glow plugs 10.9 V to 11.1 V

Intake Air Heater (IAH) 60 Amps
Camshaft Position (CMP) sensor operating speed 30 rpm to 3000 rpm
Crankshaft Position (CKP) sensor operating actuator speed 15 rpm to 2000 rpm
Maximum turbine shaft axial end play (LP turbocharger) 0.091 mm (0.0036 in)
Maximum turbine shaft radial shaft movement (clearance) (LP turbocharger) 0.5 mm (0.02 in)
Maximum turbine shaft axial end play (HP turbocharger) 0.091 mm (0.0036 in)
Maximum turbine shaft radial shaft movement (clearance) (HP turbocharger) 0.5 mm (0.02 in)
Manifolds and Exhaust Gas Recirculation (EGR)
Exhaust Manifolds
Intake Manifold
High-pressure Oil System
Injection Control Pressure (ICP) sensor operating pressure range 0 to 30 MPa (0 to 4,350 psi)
Injection Pressure Regulator (IPR) valve relief pressure 31 MPa (4,500 psi)
IPR valve maximum pressure 38 MPa (5,500 psi)
EGES-390
Fuel System

Electric heater 150 W
Rated flow capacity 98 L/hr (26 gph @ 60 psi)
Secondary Fuel Filter
Maximum fuel pressure in secondary filter 400 kPa (58 psi @ 35 gph)
Valve unseating pressure 310 ± 28 kPa (45 ± 4 psi)
Injection Pressure Regulator (IPR) valve
-40 °C to 220 °C (-40 °F to 428
Operating temperature range
°F)
Maximum operating pressure 28 MPa (4,061 psi)
Oil Cooler and Filter Housing
Oil Cooler
Type Full-flow: oil, coolant
Location Engine valley (forward)
Oil Filter
Type Cartridge, full flow - disposable
Filter bypass location Oil filter return tube assembly
EGES-390
Front Cover, Vibration Damper, Oil Pump, and

Cooling System
Vibration Damper
Face runout (maximum) 0.635 mm (0.025 in)
Rubber bulging (maximum) 1.5 mm (0.060 in)
Lubricating Oil Pump and Pressure Regulator
Type Gerotor
Drive Crankshaft
Gerotor oil pump housing (front
Location
cover)
Oil Pressure:
• Engine oil pressure, low idle (min. @ 110 °C (230 °F) oil temp.) 69 kPa (10 psi)
• Engine oil pressure, high idle (min. @ 110 °C (230 °F) oil temp.) 276 kPa (40 psi)
• Oil pump discharge pressure (2,500 rpm) 483 to 621 kPa (70 to 90 psi)
0.025 to 0.095 mm (0.001 to 0.004
Oil pump end clearance (inner and outer rotor to housing)
in)
Oil pump radial clearance (between outer rotor and housing) 0.15 to 0.28 mm (0.006 to 0.011 in)
Oil pressure regulator bore 18.81 ± 0.02 mm (0.741 0.001)
Thermostat
Type Balanced pressure, wax pellet
Full open temperature, >10 mm (0.394 in) stroke 104 °C (219 °F)
EGES-390
1 2
10
12 7
11
8
6
J05016
Figure 540 Accessories drive belt routing

1. Alternator 5. Flat idler 9. Tensioner square
2. Drive belt 6. Power steering pump 10. Tensioner pulley
3. Flat idler 7. Water pump 11. AC compressor or non AC pulley
4. Grooved idler 8. Crankshaft damper 12. Grooved idler
EGES-390
Cylinder Head and Valve Train
Valve Specifications
Face to stem runout (T.I.R. max.) 0.038 mm (0.0015 in)
Stem to guide clearance (max. allowable before replacement) 0.140 mm (0.0055 in)
6.947 to 6.965 mm (0.2735 to
Valve stem diameter
0.2742 in)
Exhaust valve face angle 37.5°
Intake valve face angle 30.0°
Exhaust valve margin (minimum) 1.35 mm (0.053 in)
Intake valve margin (minimum) 1.40 mm (0.055 in)
Valve Spring Specifications

Free length 51.96 mm (2.045 in)
46.30 mm @ 340 ± 17 N (1.82 in @
Compressed* (first test)
76.5 ± 3.8 lbf)
38.30 mm @ 850 ± 43 N (1.51 in @
Compressed* (second test)
191.1 ± 9.7 lbf)
* Spring must be compressed to a solid height before checking test loads.
Cylinder Head Specifications

7.003 to 7.029 mm (0.276 to 0.277
Valve guide inside diameter
in)
Valve guide bore runout 0.05 mm (0.002 in)
Valve guide taper (maximum) 0.10 mm (0.004 in)
Valve seat width (intake) 1.80 to 2.56 mm (0.071 to 0.101 in)
Valve seat width (exhaust) 1.48 to 2.24 mm (0.058 to 0.088 in)
Valve seat angle (intake) 30.0°
Valve seat angle (exhaust) 37.5°
Valve seat runout (T.I.R. max.) 0.035 mm (0.0014 in)
Gasket surface flatness (maximum) 0.051 mm (0.002 in) per check point
Overall thickness of cylinder head (deck-to-deck) 95 mm (3.74 in)
0.32 to 0.68 mm (0.0126 to 0.0268
Valve head recession relative to deck (surface of cylinder head)
in)
Push rod runout (maximum) 0.25 mm (0.01 in)
EGES-390
Rear Cover
Max. flywheel ring gear T.I.R. runout 1.27 mm (0.050 in)

Rear cover face maximum runout 0.51 mm (0.020 in)
Power Cylinder
Connecting Rods
Connecting rod length (center to center) 176 mm (6.929 in)
Bushing bore diameter (pin end) 36.98 to 37.02 mm (1.456 to 1.457 in)
34.0140 to 34.0215 mm (1.3391 to 1.3394
Piston pin bushing inside diameter
in)
Bearing bore diameter (crankshaft end) 72.987 to 73.013 mm (2.8735 to 2.8745 in)
Bearing bore maximum out-of-round 0.013 mm (0.0005 in)
Bearing bore maximum taper per 25 mm (1 inch) 0.013 mm (0.0005 in)
Connecting rod bearing inside diameter 69.027 to 69.077 mm (2.7176 to 2.7196 in)
Connecting rod bearing running clearance (diameter) 0.0203 to 0.0837 mm (0.0008 to 0.0033 in)
Connecting rod side clearance 0.3 to 0.6 mm (0.012 to 0.024 in)
Weight (complete rod without bearing) 1201.5 to 1215.5 g (2.649 to 2.679 lb)
Pistons
Material Aluminum Alloy
Skirt diameter 1
94.9460 to 94.9186 mm (3.737 to 3.738 in)
1
Measure 14.68 mm (0.578 in) from bottom, at 90° to the piston pin. Measure only at room temperature
of 19 to 21 °C (66 to 70 °F).
Service Piston:
Standard size 94.9460 to 94.9186 mm (3.737 to 3.738 in)
Top compression ring groove width (measured over 2.08 mm (0.082 in) gauge pins):
Upper limit 94.469 mm (3.7192 in)
Replacement limit 94.290 mm (3.7122 in)
Piston protrusion above crankcase deck 0.900 mm (0.0354 in)
Piston skirt clearance (1 - 8) 0.0441 to 0.0909 mm (0.0017 to 0.0036 in)
EGES-390
Piston Pins
Length 65.073 to 65.327 mm (2.5619 to 2.5719 in)
33.9975 to 34.0025 mm (1.3385 to 1.3387
Diameter
in)
Pin fit at room temperature of 19 to 21 °C (66 to 70 °F):
0.0115 to 0.0240 mm (0.00045 to 0.00094
Clearance in connecting rod (piston pin bushing)
in)
Clearance in piston 0.013 to 0.022 mm (0.0005 to 0.0009 in)
End clearance 0.24 mm (0.009 in)
Piston Rings
Ring diameter (standard): 95 mm (3.74 in)
Ring groove (side clearance):
Ring gap in bore:
Top compression 0.29 to 0.55 mm (0.011 to 0.021 in)

EGES-390
Crankcase, Crankshaft, and Camshaft
Crankshaft
Crankshaft end play (maximum) 0.222 mm (0.0087 in)
Crankshaft gear backlash (maximum) 0.32 mm (0.012 in)
Crankshaft connecting rod out-of-round 0.006 mm (0.00024 in)
Crankshaft connecting rod journal taper (maximum per inch) 0.0076 mm (0.0003 in)
Crankshaft main journal out-of-round 0.006 mm (0.00024 in)
Crankshaft main journal taper (maximum per inch) 0.0076 mm (0.0003 in)
Main bearing thrust face maximum runout 0.051 mm (0.002 in)
Oil seal journal maximum runout 0.025 mm (0.001 in)
Vibration damper mounting area maximum runout 0.05 mm (0.002 in)
Flywheel mounting surface maximum runout 0.05 mm (0.002 in)
Main bearing to crankshaft running clearance 0.025 to 0.076 mm (0.001 to 0.003 in)
Main Bearing Journal Diameter
• Standard size 80.987 to 81.012 mm (3.188 to 3.150 in)
• 0.254 mm (0.010 in) under size 80.733 to 80.758 mm (3.178 to 3.140 in)
Connecting Rod Journal Diameter
• Standard size 68.99 to 69.01 mm (2.716 to 2.717 in)
Camshaft and Bushings

Camshaft journal diameter (all journals) 61.987 to 62.013 mm (2.440 to 2.441 in)
Bushing inside diameter 62.05 to 62.14 mm (2.443 to 2.446 in)
Journal and bushing running clearance 0.037 to 0.153 mm (0.0015 to 0.0060 in)
Camshaft end play 0.051 to 0.211 mm (0.002 to 0.008 in)
Camshaft gear backlash 0.179 to 0.315 mm (0.007 to 0.012 in)
Maximum permissible cam lobe wear 0.51 mm (0.02 in)
Camshaft thrust plate thickness 3.589 to 3.649 mm (0.1413 to 0.1436 in)
Balance shaft end play 1.77 mm (0.070 in)
Balance shaft gear backlash 0.184 to 0.306 mm (0.007 to 0.012 in)
Balance shaft bearing clearance 0.123 mm (0.005 in)
EGES-390
Camshaft lobe lift (maximum)

• Intake 5.820 mm (0.2291 in)
• Exhaust 5.906 mm (0.2325 in)
Valve timing no. 1 cylinder (top of lobe)
• Intake open 16.2° BTDC
• Intake closed 50.4° ABDC
• Exhaust open 47.5° BBDC
• Exhaust closed 14.9° ATDC
Crankcase
Cylinder block top surface of crankcase flatness Total deck surface: 0.10 mm (0.004 in)
150 mm2 (36 in2) area: 0.05 mm (0.02
in)
25 mm2 (1 in2) area: 0.025 mm (0.001in)
Crankcase main bearing bore diameter 85.99 to 86.01 mm (3.3854 to 3.3862 in)
Crankcase cam bearing bore diameter 65.98 to 66.02 mm (2.597 to 2.599 in)
Roller follower bore diameter 23.44 to 23.48 mm (0.923 to 0.924 in)
Roller follower outside diameter 23.39 to 23.41 mm (0.921 to 0.923 in)
Cylinder bore diameter 94.991 to 95.001 mm (3.740 to 3.741 in)
Cylinder bore maximum out-of-round 0.008 mm (0.0003 in)
Cylinder stroke 105 mm (4.13 in)
Coolant heater element rating 1,000 watts, 120 volts
Main Bearings
Material Steel backed copper/lead
Number of main bearings 4
Thrust bearing location No. 3 main upper
Lower crankcase Four bolts per main journal
EGES-390
EGES-390
APPENDIX B – TORQUES 397
Table of Contents
General Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399

Bolt Identification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .399
General Torque Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Standard Torque Charts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .400
Using a Torque Wrench Extension. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .401
Special Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402

Mounting Engine on Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .402
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .403
Front Cover, Vibration Damper, Oil Pump, and Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .404
Rear Cover and Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
Power Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
Crankcase, Crankshaft and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .405
EGES-390
398 APPENDIX B – TORQUES
EGES-390
General Torque
Bolt Identification
Figure 541 Classification and Identification – Metric Fasteners
Figure 542 Classification and Identification – Special Use Fasteners
EGES-390
General Torque Guidelines Standard Torque Charts

Standard Torques – Pipe Thread
substitute fasteners. Original equipment standard
hardware is defined as Class 10.9 metric or Grade 8 Thread Size Torque
standard coarse thread bolts and nuts and hardened
1/8 in NPT 11 N·m (90 lbf·in)
flat washers (Rockwell "C" 38-45), all phosphate
coated. 1/4 in NPT 14 N·m (120 lbf·in)
The standard torque charts provide the tightening 3/8 in NPT 20 N·m (180 lbf·in)
torque for general purpose applications using original 1/2 in NPT 34 N·m (25 lbf·ft)
equipment standard hardware as listed in the Parts
Catalog for the application involved. 3/4 in NPT 41 N·m (30 lbf·ft)
NOTE: Visually inspect parts for cleanliness and

obvious defects prior to assembly. Standard Torques – Class 10.9 Metric Bolts and
Studs
Many conditions affect torque and the results of
torque applications. The major purpose in tightening Thread Thread Pitch
Torque
a fastener to a specified torque is to obtain tension Diameter (mm/thread)
in the fastener (bolt and nut), which in turn develops 6 mm 1 13 N·m (115 lbf·in)
a clamping load which exceeds any possible loading
8 mm 1.25 31 N·m (23 lbf·ft)
imposed on parts.
10 mm 1.5 62 N·m (45 lbf·ft)
New phosphate coated fasteners do not require oil
lubrication during assembly and torque application. 12 mm 1.75 107 N·m (79 lbf·ft)
Reused fasteners (even if originally phosphate 14 mm 2 172 N·m (127 lbf·ft)
coated) do require oil lubrication to threads and under
head area for proper torque application. 15 mm 2 216 N·m (159 lbf·ft)
Threads that are dry, excessively rough, battered or 16 mm 2 266 N·m (196 lbf·ft)
filled with dirt require considerable effort just to rotate. 18 mm 2.5 368 N·m (272 lbf·ft)
Then when the clamping load is developed or the
bolt tension is applied, the torque reading mounts 20 mm 2.5 520 N·m (384 lbf·ft)
rapidly (due to thread friction) to the specified torque
value. However, the desired bolt tension and correct Standard Torques – Class 12.9 Metric Bolts and
clamping load is not achieved. This condition can Studs
lead to failure of the fastener to maintain component
Thread Thread Pitch
integrity. The proper bolt tension and clamping load Torque
Diameter (mm/thread)
can never be attained if the fastener is dry. The
fastener threads must be new condition or have a 6 mm 1 15 N·m (132 lbf·in)
film of clean lubricant (engine oil) to be considered
8 mm 1.25 36 N·m (27 lbf·ft)
lubricated.
10 mm 1.5 72 N·m (53 lbf·ft)
12 mm 1.75 126 N·m (93 lbf·ft)
14 mm 2 201 N·m (148 lbf·ft)
15 mm 2 252 N·m (186 lbf·ft)
16 mm 2 311 N·m (230 lbf·ft)
18 mm 2.5 430 N·m (317 lbf·ft)
20 mm 2.5 608 N·m (448 lbf·ft)
EGES-390
Using a Torque Wrench Extension

Occasionally an extension, crowfoot, or other type
of adapter is necessary to use with a torque wrench
to torque a bolt or line fitting. Adding adapters or
extensions will alter the torque on the faster from what
the torque wrench reads. Use the following formula to
calculate the correct torque wrench setting to achieve
a specific torque value.
Figure 543 Torque wrench extension
• F – Force applied by technician Example:

• L – Total length through which force is applied to A component requires a specified torque value of
fastener 65 lbf·ft and a 6 inch extension is required to reach
it. What should the torque wrench setting (TS) be to
• TW – Torque applied at end of torque wrench
compensate for the extension?
• Torque wrench length (LW) = 12 inches
TS = TE (LW / (LW + LE)
• Length of extension LE = 6 inches
• TS – Torque wrench setting
TS = 65 lbf·ft (12 in / (12 in + 6 in)
• TE – Torque applied at fastener
TS = 65 lbf·ft (12 in / 18 in)
• LW – Length of torque wrench
TS = 65 lbf·ft (0.666)
• LE – Length of extension
TS = 43.3 lbf·ft
EGES-390
Special Torques
Mounting Engine on Engine Stand
Oil pan drain plug 44 N·m (32 lbf·ft)

Crankcase coolant drain plug 20 N·m (15 lbf·ft)
Engine Electrical
Alternator M10 x 80 mounting bolts 48 N·m (35 lbf·ft)

Alternator power connector nut 8 N·m (71 lbf·in)
Engine Coolant Temperature (ECT) sensor 17.5 N·m (154 lbf·in)
Engine Oil Pressure (EOP) sensor 14 N·m (124 lbf·in)
Engine Oil Temperature (EOT) sensor 17.5 N·m (154 lbf·in)
Exhaust Back Pressure (EBP) sensor 20 N·m (178 lbf·in)
Injection Control Pressure (ICP) sensor 17 N·m (150 lbf·in)
Intake Air Heater (IAH) element 61 N·m (45 lbf·ft)
Intake Air Heater (IAH) element M5 cable nut 4 N·m (35 lbf·in)
Intake Air Temperature (IAT) sensor 14 N·m (124 lbf·in)
Manifold Absolute Pressure (MAP) sensor 11.5 N·m (101 lbf·in)
Manifold Air Temperature (MAT) sensor 14 N·m (124 lbf·in)
Air inlet duct worm gear clamp 5 N·m (48 lbf·in)

Bango bolt, M12 24 N·m (18 lbf·ft)
Boost Control Solenoid mounting bolt, M6 x 30 9 N·m (79 lbf·in)
See Turbocharger and
Exhaust tubing to exhaust manifold, M8 x 50 Exhaust Tube Torque
Sequence (page 122).
Low-pressure turbine exhaust outlet studs 22 N·m (16 lbf·ft)
V-band clamp (crossover tube) 7 N·m (62 lbf·in)
V-band clamp (turbine mating) 10 N·m (88 lbf·in)
EGES-390
Coolant deaeration fitting 10 N·m (90 lbf·in)

EGR cooler mounting bolt assembly, M6 x 25 11 N·m (97 lbf·in)
EGR cooler to manifold stud bolts, M6 x 55 x 20 11 N·m (97 lbf·in)
1
Exhaust manifold bolts, M8 x 40 See Exhaust Manifolds
(page 140) torque
sequence
Intake manifold bolts, M6 bolts and stud bolts 11 N·m (97 lbf·in) See
intake manifold bolt torque
sequence (Figure 171)
1
Apply anti-seize compound to bolt threads before assembly
Branch tube adaptor jam nut 72 N·m (53 lbf·ft)

Case-to-head tube and rail port plug 82 N·m (60 lbf·ft)
Injection Pressure Regulator (IPR) 50 N·m (37 lbf·ft)
Prime port plug, M8 8 N·m (71 lbf·in)
High-pressure pump plug, M12 35 N·m (26 lbf·ft)
Fuel System
Banjo bolt, 12 mm (fuel supply tube to each cylinder head) 38 N·m (28 lbf·ft)
Fuel filter cap (secondary) 14 N·m (124 lbf·in)
Secondary fuel filter housing mounting screws, M6 x 25 10 N·m (88 lbf·in)
Fuel injector hold down clamp bolt 35 N·m (26 lbf·ft)
Fuel supply hollow screw, M14 35 N·m (26 lbf·ft)
Fuel pump mounting screws, self tapping #10 5 N·m (44 lbf·in)
Fuel return fitting, M16 46 N·m (34 lbf·ft)
Fuel return to HFCM tube fitting 25 N·m (19 lbf·ft)
Fuel return tube assembly mounting screws, 8/32 x 3/8 2-3 N·m (20-25 lbf·in)
HFCM cover plate screws 5 N·m (44 lbf·in)
HFCM housing mounting nuts (M8) 15 N·m (132 lbf·in)
Left and right cylinder head supply tube fittings at filter, M12 25 N·m (18 lbf·ft)
Plug assembly, M12 (rear of cylinder head) 36 N·m (27 lbf·ft)
Primary fuel filter cap 25 N·m (18 lbf·ft)
EGES-390
Oil filter base assembly screws (M6 x 25) 10 N·m (85 lbf·in)
Oil filter base assembly bolt (M8 x 45) 11 N·m (97 lbf·in)
Oil filter base assembly screws (M8 x 23) 23 N·m (17 lbf·ft)
Oil bypass / filter inlet guide valve screws (M5 x 18) 7 N·m (62 lbf·in)
Oil filter housing mounting screws (M6 x 25) 15 N·m (132 lbf·in)
Diagnostic port 16 N·m (144 lbf·in)
EGR coolant supply elbow, M6 screw 9.7 N·m (85 lbf·in)
Oil filter cap 25 N·m (18 lbf·ft)
Front Cover, Vibration Damper, Oil Pump, and

Cooling System
Water pump / fan drive pulley bolts 36 N·m (26 lbf·ft)

Front cover bolts, M8 x 35 24 N·m (18 lbf·ft)
Nut (heater feed to lifting eye), M10 41 N·m (35 lbf·ft)
Oil pressure regulator end cap 27 N·m (240 lbf·in)
Gerotor oil pump cover bolts, M6 x 25 13 N·m (110 lbf·in)
Thermostat stud bolts, M8 x 30 x 19 22 N·m (200 lbf·in)
New bolts only: 68 N·m
Vibration damper mounting bolts, M12 x 59
(50 lbf·ft) + 90° rotation
Water pump mounting bolts 23 N·m (17 lbf·ft)
See Cylinder Head Bolt

Cylinder head bolt torque and sequence Torque Sequence(page
277)
Crankcase breather bolts (M6 x 43) 11 N·m (96 lbf·in)
Fuel rail plug, M12 36 N·m (27 lbf·ft)
Glow plugs 18 N·m (159 lbf·in)
Lifting eye, front (M10 x 30) 41 N·m (30 lbf·ft)
Lifting eye, rear (M10 x 35) 41 N·m (30 lbf·ft)
Rocker arm fulcrum plate (M8 x 45) 31 N·m (23 lbf·ft)
Valve cover bolt assemblies (M6) 9 N·m (84 lbf·in)
EGES-390
Rear Cover and Flywheel
Flywheel mounting bolts (all applications) new bolts only 94 N·m (69 lbf·ft) see
flywheel torque sequence
(Figure 440)
Power Cylinder
Initial 45 N·m (33 lbf·ft)

Connecting rod cap bolts
Final 68 N·m (50 lbf·ft)
Crankcase, Crankshaft and Camshaft
Lower crankcase main bearing cap bolts See tightening procedure

and sequence (page 354)
Coolant heater element or plug 41 N·m (30 lbf·ft)
Crankcase coolant drain plug / O-ring, M16 20 N·m (15 lbf·ft)
EGES-390
EGES-390
APPENDIX C – SPECIAL SERVICE TOOLS 407
Table of Contents

Mounting Engine on Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .409
Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
Front Cover, Vibration Damper, and Gerotor Oil Pump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .410
Rear Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .411
Power Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
Crankcase, Crankshaft and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
In Chassis Service. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .412
Special Tool Photos. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .413

Photos of Essential Tools from MaxxForce™ 5 Essential Tool Kit, ZTSE5010. . . . . . . . . . . . . . . . . . . .413
Photos of Essential Tools from VT 365 Essential Tool Kit, ZTSE5000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .415
Photos of Essential Tools from T 444E Essential Tool Kit, ZTSE4350. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .418
EGES-390
408 APPENDIX C – SPECIAL SERVICE TOOLS
EGES-390

Special tools for the MaxxForce™ 5 engine can be
ordered from the SPX Corporation, 1-800-520-2584.
Mounting Engine on Stand
Engine Stand Mounting Bracket ZTSE4507

Engine Stand OTC1750A
Engine Electrical
Glow Plug Connector Remover / Installer ZTSE4670

Intake Guard ZTSE4293
Turbo Crossover Tube Seal Remover / Installer ZTSE4676
Anti-seize compound Obtain locally

EGR Cooler Pressure Test Plates ZTSE4707
EGR Valve Puller ZTSE4669
Intake Manifold Pressure Test Plates ZTSE4527
Intake Manifold Pressure Test Plug ZTSE4888
Intake Manifold Pressure Test Cap ZTSE4682
Magnetic Covers for Cylinder Head Intake Ports ZTSE4559
EGES-390
Anti-rotation Handle (branch tube adaptor) ZTSE4876–1

Branch tube adaptor installation depth gauge ZTSE4876–2
Case-to-head Tube Removal Tool ZTSE4694
IPR Removal / Installation Tool ZTSE4666
Liquid Gasket (RTV, 6 oz. tube) 1830858C1
Crowfoot, flare nut, 15/16 inch, 12-point Obtain locally
Fuel System

Fuel Injector Tip Cleaning Brush ZTSE4301
Turbocharger Inlet Guard ZTSE4293
Magnetic Covers ZTSE4557

Oil Cooler Pressure Test Plate ZTSE4525
Front Cover, Vibration Damper, and Gerotor Oil

Pump

Fan Hub Wrench (2 inch) ZTSE43972
Fan Wrench (pulley bolts) ZTSE4587
Front Seal / Wear Sleeve Installer ZTSE4680
Front Wear Sleeve Remover ZTSE4517
EGES-390
Cylinder Head Lifting Bracket ZTSE4661

Cylinder Head Pressure Test Plate ZTSE4534
Dye Penetrant Kit PT-7191
Fuel Gallery Cleaning Brush ZTSE4541
Glow Plug Sleeve Brush (nylon) ZTSE4533
Glow Plug Sleeve Installer ZTSE4532
Glow Plug Sleeve Remover (consists of: tap, bolt and adapter) ZTSE4531
Glow Plug Sleeve Seat Wire Brush ZTSE4589
Injector Sleeve Brush ZTSE43041
Injector Sleeve Flat Bottom Brush ZTSE43042
Injector Sleeve Installer ZTSE4529
Injector Sleeve Remover (consists of: tap and adapter) ZTSE4528
Intake Port Covers on Heads ZTSE4559
Loctite® #620 Obtain locally
Slide Hammer Kit ZTSE4398A
Valve Guide Gauge Tool ZTSE4577
Valve Spring Compressor ZTSE1846
Valve spring tester Obtain locally
Rear Cover
Crankshaft Secondary Flange Installation Studs (2) ZTSE4720

Gear Puller (secondary flange) ZTSE4520
1
Rear Seal / Wear Sleeve Installer ZTSE4515A
Rear Wear Sleeve Remover ZTSE4518
1
CityStar™ bolts - M10 x 40, Stripped Chassis bolts - M10 x 70
EGES-390
Power Cylinder

Piston Gauge Pins (0.082 in) ZTSE4513
Piston Ring Compressor (Cope) ZTSE4514
Piston ring expansion pliers Obtain locally
Crankcase, Crankshaft and Camshaft
Camshaft Bushing Kit ZTSE2893B

Camshaft Bushing Remover/Installer (expanding collet) ZTSE4489
Crankshaft Timing Tool ZTSE4687
Cylinder bore gauge Obtain locally
De-glazing hone (four-inch) Obtain locally
Feeler Gauge Obtain locally
Freeze Plug Installer ZTSE4509
Loctite® #242 Threadlocker Obtain locally
Loctite® #620 Compound Obtain locally
Oil Gallery Cleaning Brush ZTSE4511
Oil Gallery Plug Driver ZTSE4512
In Chassis Service

Quick Release Tool kit ZTSE4454
On Engine Valve Spring Compressor Tool ZTSE4697
EGES-390
Special Tool Photos

Photos of Essential Tools from MaxxForce™ 5
Essential Tool Kit, ZTSE5010
Figure 546 IPR Valve Socket, ZTSE4666
Figure 544 Injector Connector Remover, Figure 547 Glow Plug Connector Remover,
ZTSE4650 ZTSE4670
Figure 548 Turbo Crossover Tube Seal Remover

and Installer, ZTSE4676
Figure 545 Cylinder Head Lifting Bracket,
ZTSE4661
EGES-390
Figure 549 Front Seal Installer / Wear Sleeve

Installer, ZTSE4680
Figure 551 Intake Manifold Pressure Test Cap,

ZTSE4682
Figure 550 Quick Release Tool (#8 and #10) ,

ZTSE4581
Figure 552 Crankshaft Timing Tool, ZTSE4687
EGES-390
Figure 553 Case-to-head Tube Removal Tool,

Figure 556 Front Wear Sleeve Remover,
ZTSE4694
ZTSE4517
Photos of Essential Tools from VT 365 Essential

Tool Kit, ZTSE5000
Figure 557 Crankshaft Rear Wear Sleeve

Remover, ZTSE4518
Figure 554 Piston Gauge Pins (0.082 in),

ZTSE4513
Figure 555 Crankshaft Rear Seal / Wear Sleeve

Installer, ZTSE4515A Figure 558 Oil Cooler Test Plate / Pressure
Adapter, ZTSE4525
EGES-390
Figure 559 Intake Manifold Test Plates,

ZTSE4527
Figure 562 Glow Plug Sleeve Remover,
ZTSE4531
Figure 563 Glow Plug Sleeve Installer, ZTSE4532
Figure 564 Glow Plug Sleeve Brush (nylon),

Figure 560 Injector Sleeve Remover, ZTSE4528
ZTSE4533
Figure 565 Cylinder Head Pressure Test Plate,

ZTSE4534
Figure 561 Injector Sleeve Installer, ZTSE4529
EGES-390
Figure 566 Oil Cooler Reservoir / High-pressure

Pump Magnetic Covers, ZTSE4557
Figure 567 Magnetic Covers for Cylinder Head

Intake Ports, ZTSE4559
Figure 570 V - Engines Supplemental Service

Tool Kit, ZTSE4721
Figure 568 Fan Wrench (pulley bolts), ZTSE4587
Figure 571 Crankshaft Secondary Flange

Installation Studs, ZTSE4720
Figure 569 Slide Hammer Kit ⅝ in, ZTSE4398A
EGES-390
Figure 574 Injector Sleeve Brush, ZTSE43041
Figure 575 Injector Sleeve Flat Bottom Brush,

ZTSE43042
Figure 572 On Engine Valve Spring Compressor,
ZTSE4697
Photos of Essential Tools from T 444E Essential

Tool Kit, ZTSE4350
Figure 576 Fan Hub Wrench (2 inch), ZTSE43972
Figure 573 Injector Tip Cleaning Brush,

ZTSE4301
EGES-390
Printed in the United States of America

EGES390

Uploaded by

Copyright:

Available Formats

You might also like

EGES390

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

EGES390

Uploaded by

Copyright:

Available Formats

SERVICE MANUAL

ENGINE SERVICE MANUAL

Mounting Engine on Engine Stand. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Engine Electrical. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Dual Stage Turbocharger Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Manifolds and Exhaust Gas Recirculation (EGR). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .125

High-pressure Oil System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Fuel System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .161

Oil Cooler and Filter Housing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

Oil Pan and Oil Pickup Tube. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .207

Cylinder Head and Valve Train. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .241

Rear Cover and Flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .283

Power Cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .307

Crankcase, Crankshaft, and Camshaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .329

In-Chassis Service - Rocker Arm Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .363

Abbreviations and Acronyms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .371

Appendix A – Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .385

Appendix B – Torques. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .397

Appendix C – Special Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .407

Foreword subscribers. If a technical publication is ordered, the

Service Diagnosis • Knowledge of the principles of operation for

Safety Information Protective measures

Warning: A warning describes actions necessary to 2. Type B — Flammable liquids

Safety equipment • Wear hearing protection.

Air Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Fuel Supply System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

Fuel Management System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Engine Lubrication System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Electronic Control System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Fuel Pump Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Glow Plug System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Inlet Air Heater System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .50

Figure 2 Example of U.S. Environmental

The EPA exhaust emission label is on top of the

Engine Description, Specifications, and Features

Table 1 International® MaxxForce™ 5 Description and Specifications

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

Table 2 International® MaxxForce™ 5 Standard and Optional Features

Engine Description Fuel System

Engine Systems Interaction Diagram

Figure 8 Engine systems interactions

Air Management System

Figure 9 Air management system components and flow

Exhaust Gas Recirculation (EGR) System

Figure 11 EGR valve

The EGR valve assembly consists of three major

Dual Stage Turbocharger Assembly

Figure 12 Dual stage turbocharger

Aftertreatment (AFT) System • Provides heat for exhaust system warm-up

Fuel Supply System

Figure 13 Fuel supply system

Figure 14 Fuel supply system flow

Figure 16 HFCM - fuel flow

Secondary Fuel Filter Assembly

Figure 17 Secondary fuel filter assembly - fuel flow

Figure 18 Fuel lines connected to the secondary

The fuel pressure regulator is a spring loaded poppet

Fuel Management System