Engine Replacement Procedures September Removal of the Complete Powertrain Assembly. Replacement Long Block Engine Preparation

Transcription

1 SUBJECT DATE Engine Replacement Procedures September 2015 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change Removal of the Complete Powertrain DDC-SVC-MAN-0081 DD Platform Assembly Replacement Long Block Engine Preparation Installation of the Complete Powertrain Assembly Three new procedures detailing how to remove a complete powertrain from a Freightliner Cascadia, how to prepare a replacement long block engine for installation, and installation of a complete powertrain into a Freightliner Cascadia All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

2 2 Removal of the Complete Powertrain Assembly 2 Removal of the Complete Powertrain Assembly When possible, this is the preferred method for removing an engine for service outside of the chassis Examples could include crankshaft replacement or a long block engine replacement The engine, cooling package and transmission will be removed as an assembly NOTE: The instructions listed below are powertrain removal instructions based on a Freightliner Cascadia 113 or 125 model truck with an EPA07, EPA10 or GHG14 DD engine These instructions will vary some depending on the chassis configuration NOTE: There are several instructional videos posted in DDCSN under Support, Multimedia, DD Platform and Powertrain Removal and Installation that may assist with this repair The videos are also posted on the Aftermarket Resource Center (ARC) website in Access Freightliner Special tools required: Engine Lifting Bar W Remove as follows: WARNING: PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component WARNING: PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked 1 Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables The magnetic switch studs are at battery voltage 2 Disconnect the batteries Refer to the Original Equipment Manufacturer (OEM) procedure 3 Remove the front bumper 4 Remove the hood 5 Remove both side fairings, if equipped, and inner fenders/splash shields NOTICE: The engine coolant can be reused if it is not contaminated and has been properly maintained 6 Drain the engine cooling system Refer to section "Cooling System Drain Procedure" 7 Drain the radiator into a suitable drain pan 8 Remove the rain tray Refer to the OEM procedure 9 On Freightliner Cascadia 113 models, remove the windshield wiper linkage 10 Remove air cleaner assembly and inlet to the turbocharger Install a protective cover over the turbocharger inlet 11 Remove the air cleaner brackets from the rocker cover 12 Disconnect the cab heater hoses from the water manifold 13 Disconnect the Diesel Exhaust Fluid (DEF) coolant lines from the water manifold 14 Evacuate the air conditioning (A/C) system, if equipped Refer to the OEM procedure 15 Disconnect the A/C lines at the junction block 4 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

3 Remove the Aftertreatment System (ATS) inlet pipe and exhaust bellows pipe from the engine and ATS Refer to section "Removal of the GHG14 1-BOX From the Vehicle" 17 Disconnect the engine cooling fan clutch air line at the fan solenoid, if equipped 18 Disconnect the air compressor governor line and discharge line at the air compressor 19 Remove the air compressor inlet pipe from the engine 20 Disconnect the engine fuel supply and return lines at the fuel filter module Refer to section "Description and Operation of the Fuel Filter Module and Related Parts - Three-Filter System" Refer to section "Description and Operation of the Fuel Filter Module and Related Parts Two-Filter System" NOTICE: The power steering fluid can be reused if it is not contaminated and has been properly maintained 21 Remove the power steering fluid reservoir and reservoir bracket from the frame rail Place a suitable drain pan under power steering fluid reservoir Remove power steering fill line from the reservoir and drain the fluid Move reservoir out of the way and support as necessary 22 Remove power steering pressure line from steering gear box 23 Disconnect the chassis powertrain interface harness from the bulkhead connections The Powertrain Distribution Module (PDM) and harness will be removed with the powertrain The steering shaft may need to be repositioned to allow clearance for removal of the PDM and harness Refer to the OEM procedures 24 Disconnect the driveline from the transmission Remove the front carrier bearing bolts Remove driveline to transmission output bolts Position driveline out of the way and support as necessary 25 Disconnect power, ground, and starter solenoid connections from the starter 26 Remove battery cable brackets from flywheel housing and transmission Position cables out of the way and support as necessary 27 Disconnect the shifter assembly from the transmission, if equipped with a manual transmission 28 Disconnect the shifter cable from the transmission, if equipped NOTE: Do not disconnect electrical connections from the transmission if they are part of the chassis powertrain interface harness, as this will be removed with the assembly 29 Disconnect any chassis air lines or electrical connections from the transmission, if equipped 30 Remove the fuel junction bracket from the top of transmission and support as necessary Do not disconnect the fuel lines from the junction fittings 31 Disconnect DEF coolant lines from the DEF pump and remove any attachments to the chassis The DEF coolant lines will be removed with the powertrain 32 Remove chassis underslung crossmember (under flywheel housing) 33 Drain the engine lubricating oil into a suitable drain pan Reinstall the oil drain plug WARNING: PERSONAL INJURY In order to avoid personal injury from a falling vehicle, never use any engine lifter brackets to raise or lower any part of the vehicle Engine lifter brackets are not designed to bear the weight of the vehicle Always use approved lifting devices to raise and lower the vehicle NOTE: All of the remaining oil left in the oil galleries (approximately one gallon) will drain from the cylinder block when the oil suction manifold is removed Leave the oil pan in place underneath the engine to catch this oil NOTE: It may be necessary to raise and support the front of the vehicle to obtain clearance for removal of the oil pan 34 Lower the oil pan to remove the oil suction manifold, oil lines and oil pump 35 Remove the oil pan Refer to section "Removal of the Oil Pan" 36 Remove chassis front closing crossmember (in front of the cooling package) All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

4 2 Removal of the Complete Powertrain Assembly 37 Remove or disconnect any additional brackets and mounting hardware for air lines, fuel lines, electrical harnesses, electrical cables or hoses that attach to the powertrain and will interfere with complete powertrain removal 38 Secure all lines, harnesses, hoses and cables in preparation for powertrain removal WARNING: FALLING ENGINE To avoid injury from a falling engine, ensure an appropriately rated lifting device with a spreader bar and sling is used to lift the engine Moving the engine without an appropriately rated lifting device could result in the engine falling, which could cause serious personal injury and component damage The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution, all provided lifter brackets must be used 39 Connect engine lifting bar tool (W ) to the engine using all three engine lifting brackets (two at the rear and one at the front) 40 Attach an appropriately rated lifting device (overhead crane or hoist) to W See illustration below showing a DD13 engine in a Freightliner Cascadia 113 model truck The Cascadia 125 will be similar Attachment point for the lifting hook may vary based on the weight distribution of the complete powertrain and desired angle of removal 41 Remove the bolts securing the front engine mount to the frame 42 Remove the bolts securing the rear engine mounts to the frame mounts NOTICE: Use great care when lifting the powertrain assembly and removing it from the chassis to avoid damaging any components Adequate clearance to the heater lines, A/C lines, front wall and floor of the truck cab must be maintained An assistant is recommended for the following steps 43 Place a transmission jack securely under the transmission and raise the rear of the powertrain assembly approximately 3 inches off of the rear frame mounts 44 Raise the powertrain assembly in the front while maintaining clearance to the cab 45 It may be necessary to alternate between the previous two steps before the powertrain is ready for removal 6 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

5 NOTICE: Ensure proper clearance between powertrain assembly and truck cab and chassis before removal 46 Carefully remove the powertrain assembly from the chassis See illustrations below showing removal of a DD13 powertrain assembly from a Freightliner Cascadia 113 model truck The Cascadia 125 will be similar All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION 7

6 2 Removal of the Complete Powertrain Assembly 47 Place complete powertrain assembly on four appropriately rated jack stands to prepare for disassembly or service Place the jack stands under the oil pan rails of the cylinder block and evenly distribute the load so the lifting device can be removed See illustrations below 8 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

7 Disconnect the lifting device from the engine lifting bar tool 49 Remove the engine lifting bar tool from the engine lifting brackets 50 If the engine is being replaced with a warranty long block (WLB) or ¾ engine, refer to the section "Replacement Long Block Engine Preparation" All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

8 3 Replacement Long Block Engine Preparation 3 Replacement Long Block Engine Preparation The instructions listed below explain how to remove the necessary components from a failed engine and install them onto a replacement warranty long block or ¾ engine assembly These are specifically written for a Freightliner Cascadia 113 or 125 model truck equipped with an EPA07, EPA10 or GHG14 DD engine where the complete powertrain was removed as an assembly and will be reinstalled as an assembly NOTE: The most efficient shop setup for this procedure is to have both the failed engine and replacement engine in close proximity to each other A table or bench close to the work site for temporary engine component storage is also highly recommended When possible, it is best to remove and install components as assemblies to minimize customer downtime NOTE: New gaskets and seals should be used when reusing original parts or installing new components Special tools required: Engine Lifting Bar W NOTE: If the powertrain assembly is still in the chassis, refer to section "Removal of the Complete Powertrain Assembly" Remove components from the failed engine as follows: 1 Remove the chassis powertrain interface harness from the engine and transmission 2 Remove the radiator support rods and brackets 3 Remove the cooling package from the powertrain assembly Keep the cooling package as complete as possible for ease of re-installation Place the cooling package in a suitable location, standing upright 4 Remove the engine cooling fan 5 Remove the drive belts from the engine Refer to section "Removal of the Poly-V-Belts" 6 Remove the engine cooling fan hub 7 Remove the belt drive idler pulleys and idler pulley bracket 8 Remove vibration damper, if replacement engine is a warranty long block Refer to section "Removal of the Vibration Damper" 9 Remove the front engine mount Refer to section "Removal of the Front Engine Mount/Radiator Support" 10 Remove the front engine lifter bracket/exhaust Gas Recirculation (EGR) crossover and EGR venturi pipe as an assembly 11 Remove the Diesel Exhaust Fluid (DEF) coolant lines from the powertrain 12 Remove the transmission cooler lines, if equipped 13 Remove the transmission assembly 14 Remove the transmission clutch assembly Refer to section "Removal of the Clutch" 15 Remove the hydrocarbon dosing line 16 Remove the rear engine lifter brackets 17 Remove the rear engine mounts 18 Remove the cold boost pipe as an assembly 19 Remove the coolant crossover pipe 20 Remove the air compressor coolant lines 21 Remove the oil dipstick and tube 22 Remove the fuel filter module Refer to section "Removal of the Fuel Filter Module - Three-Filter System" Refer to section "Removal of the Fuel Filter Module Two-Filter System" 23 Remove the left-hand radiator support rod bracket 24 Remove the engine sensor harness 25 Remove the oil coolant module Refer to section "Removal of the Oil Coolant Module" 26 Remove the Motor Control Module (MCM) 27 Remove the air compressor and power steering pump as an assembly 28 Remove the high pressure fuel lines (high pressure fuel pump to fuel rail and fuel rail to fuel injectors) 10 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

9 Remove the low pressure fuel return lines (needle, amplifier and pressure limiting valve) Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter System" Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines Two-Filter System" 30 Remove the hydrocarbon doser block assembly 31 Remove the rocker cover 32 Bar the engine to Top Dead Center (TDC) on cylinder number one, if possible 33 Remove the high pressure fuel pump Refer to section "Removal of the High Pressure Fuel Pump - Three-Filter System" Refer to section "Removal of the High Pressure Fuel Pump Two-Filter System" 34 Remove the fuel rail, if the replacement engine is a warranty long block Refer to section "Removal of the Fuel Rail - Three-Filter System" Refer to section "Removal of the Fuel Rail - Two-Filter System" 35 Remove the air intake manifold Refer to section "Removal of the Air Intake Manifold" 36 Remove the starter 37 Remove the alternator 38 Remove the air conditioning compressor, if equipped 39 Remove the accessory mounting bracket and belt tensioner as an assembly 40 Remove the right-hand radiator support rod bracket 41 Remove the turbocharger and Axial Power Turbine (APT) heat shields, if equipped 42 Remove the crankcase breather Refer to section "Removal of the Crankcase Breather" 43 Remove the EGR hot pipe Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe" Refer to section "Removal of the GHG14 DD15 AT Exhaust Gas Recirculation Valve/Hot Pipe" 44 Remove the EGR actuator 45 Remove the hydrocarbon doser valve coolant lines 46 Remove the turbocharger 47 Remove the interstage duct, if equipped 48 Remove the exhaust S-pipe and hydrocarbon doser valve, if a turbocompound (TC) engine 49 Remove the APT, if equipped 50 Remove the APT gear box, if equipped 51 Remove the cylinder block cover plate, if equipped 52 Remove the exhaust manifold as an assembly 53 Remove the EGR cooler, water manifold and water outlet elbow as an assembly 54 Remove the fuel injector harnesses 55 Remove the fuel injectors, if the replacement engine is a warranty long block 56 Remove the intake rocker arm assembly 57 Remove the exhaust rocker arm assembly 58 Verify the following parts of the replacement engine match the original engine configuration: Flywheel housing (standard or rear engine power take-off) Flywheel ( manual transmission or automatic transmission or DT12 transmission) Oil coolant module (coolant filter or no coolant filter) Water pump (standard or variable speed) Intake camshaft (12 lobe or 6 lobe) Oil pan (front or rear sump, plastic or aluminum) NOTICE: If the oil pan configuration is different on the replacement engine and the oil pan from the original engine is used, the original oil suction manifold must also be used Serious engine damage will occur if the correct oil suction manifold is not used 59 If there are any parts on the replacement engine that do not match the original engine configuration, they must be replaced to maintain the same engine functions 60 Install the intake and exhaust rocker arm assemblies Refer to section "Installation of the Rocker Shafts" 61 Install the fuel rail For a three filter system, Refer to section "Installation of the Fuel Rail - Three-Filter System" For a two filter system, Refer to section "Installation of the Fuel Rail Two-Filter System" All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

10 3 Replacement Long Block Engine Preparation NOTE: Install components onto the replacement engine as follows: 62 Install the fuel injectors, if replacement engine is a warranty long block, using the following procedure for each injector 63 Install a new copper washer with the recess facing UP toward the fuel injector and the flat side of the washer facing DOWN 64 Apply a thin coat of acid-free grease or clean engine oil to the fuel injector seal rings and then use J (Fuel Injector O-ring Installer) to install them in the fuel injector nut ring grooves Make sure they are properly seated 65 Install the fuel injector and clamp as an assembly into its respective fuel injector bore Align the clamp over the bolt hole, install the new bolt into fuel injector clamp and snug until the fuel injector fully seats, then release the fuel injector bolt DO NOT torque 66 Install the high pressure fuel injector feed lines 67 Torque the fuel injector hold-down bolt to 20 N m (15 lb ft) + 90 degree torque turn 68 Install the fuel injector harnesses 69 Install the rocker cover Install and hand tighten all mounting bolts; then torque to 20 N m (14 lb ft) 70 Install the EGR cooler, water manifold and water outlet elbow as an assembly Install and hand tighten the seventeen water manifold assembly mounting bolts Torque the bolts to 30 N m (22 lb ft) in the sequence shown below NOTE: The illustration below shows a DD13 EGR cooler water manifold assembly The torque sequence and values are the same for DD15 and DD16 engines 71 Install the exhaust manifold as an assembly For EPA07, EPA10 and GHG14 TC engines Refer to section "Installation of the Exhaust Manifold" For GHG14 AT engines Refer to section "Installation of the GHG14 DD15 Asymmetrical Turbocharger Exhaust Manifold" 72 Install the cylinder block cover plate, if equipped Torque the mounting bolts to 60 N m (44 lb ft) 73 Install the axial power turbine gear box, if equipped Refer to section "Installation of the DD15 and DD16 Axial Power Turbine Gear Box" 74 Install the axial power turbine, if equipped Refer to section "Installation of the DD15 and DD16 Axial Power Turbine" 75 Install the exhaust S-pipe and hydrocarbon doser valve, if this is a TC engine Refer to section "Installation of the DD15 and DD16 Exhaust S-pipe" 76 Loosely install the interstage duct, if equipped 77 Install the turbocharger For DD13 engines, Refer to section "Installation of the DD13 Turbocharger" For DD15 and DD16 TC engines, Refer to section "Installation of the DD15 and the DD16 Turbocharger" For DD15 AT engines, Refer to section "Installation of the GHG14 DD15 Asymmetrical Turbocharger" 12 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

11 Install the EGR actuator For DD13 engines, Refer to section "Installation of the DD13 Exhaust Gas Recirculation Valve Actuator" For DD15 and DD16 TC engines, Refer to section "Installation of the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator" For DD15 and DD16 TC engines with the Sonceboz EGR actuator, Refer to section "Installation of the DD15 and DD16 Sonceboz Exhaust Gas Recirculation Valve Actuator" For DD15 AT engines, Refer to section "Installation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve Actuator" 79 Install the EGR hot pipe For all engines except GHG14 DD15 AT, Refer to section "Installation of the Exhaust Gas Recirculation Hot Pipe" For GHG14 DD15 AT engines, install the EGR valve/hot pipe Refer to section "Installation of the GHG14 DD15 AT Exhaust Gas Recirculation Valve/Hot Pipe" 80 Install the crankcase breather assembly to the engine block with a new gasket and four bolts Torque the bolts to 60 N m (44 lb ft) 81 For EPA07 engines, install the breather pipe and new gasket to the engine block Torque the two bolts to 30 N m (22 lb ft) 82 For EPA10 engines, snap the breather pipe to the fitting on the cylinder block 83 Connect electrical harness, if equipped 84 Install the turbocharger and axial power turbine heat shields, if equipped 85 Install the right-hand radiator support rod bracket and torque mounting bolts to 68 N m (51 lb ft) 86 Install the accessory mounting bracket and belt tensioner as an assembly Torque the six mounting bolts to 60 N m (44 lb ft) 87 Install the alternator Refer to the OEM procedure 88 Install the air conditioning compressor, if equipped Refer to the OEM procedure 89 Install the starting motor Refer to the OEM procedure 90 Remove the oil coolant module from the replacement engine Discard the mounting gasket 91 Install the air intake manifold Install the thirteen flanged screws and isolator gaskets to the air intake manifold 92 Secure the air intake manifold to the cylinder head Torque the mounting screws to 25 N m (18 lb ft) starting at the center of the manifold and then outward until all screws are torqued 93 Install the oil coolant module Ensure gasket mounting surfaces on cylinder block and oil coolant module are clean and dry 94 Install new oil coolant module mounting gasket onto the guide pins 95 Install the oil coolant module onto the cylinder block with the eleven mounting bolts 96 Torque the oil coolant module mounting bolts to the following specifications using the torque sequence below: First pass torque the bolts to 10 N m (7 lb ft) Final pass torque the bolts to 60 to 65 N m (44 to 48 lb ft) All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

12 3 Replacement Long Block Engine Preparation 97 Install the high pressure fuel pump Ensure flywheel is positioned at Top Dead Center (TDC) on cylinder number one a If a new or remanufactured high pressure fuel pump is being installed, install the high pressure fuel pump drive gear onto the high pressure fuel pump Refer to section "Installation of the High Pressure Fuel Pump Drive Gear Three-Filter System" b If the high pressure fuel pump is being reused, clean mounting surface of high pressure fuel pump and O-ring groove c If the high pressure fuel pump is being reused, install a new O-ring seal onto the high pressure fuel pump 98 Lightly lubricate the high pressure fuel pump O-ring seal with clean engine oil 99 Clean and inspect the flywheel housing bore for any burrs or other sharp edges; remove as necessary NOTE: The high pressure fuel pump should slide into the flywheel housing without binding The mounting bolt holes on the high pressure fuel pump housing should align closely with the mounting holes on the flywheel housing NOTE: If high pressure fuel pump binds when being installed or if there is misalignment in the mounting bolt holes, remove the high pressure fuel pump and verify the timing mark is at the 12 o'clock position and the engine is at TDC on cylinder number one 100 Install the high pressure fuel pump to the cylinder block Install the four mounting bolts securing the high pressure pump to the cylinder block Torque to 60 N m (44 lb ft) NOTICE: Ensure the correct bolt length is used when installing the high pressure pump If an incorrect bolt length (long) is used, the cup plugs installed in the cylinder block can be pushed out into the gear train causing severe damage to the gear train The correct bolt size is M10 X 35 mm (137 in) 101 Loosely install the high pressure fuel pump bracket, and install the two nuts securing the high pressure fuel pump to the bracket Torque to 30 N m (22 lb ft) 102 Install the two bolts securing the high pressure fuel pump bracket to the cylinder block Torque to 100 N m (74 lb ft) 103 Install the air compressor If removed, install the air compressor gear to the air compressor shaft and secure with nut Thread is left-handed; torque nut to 210 to 250 N m (155 to 185 lb ft) 14 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

13 Clean all foreign material from the mating surfaces of the air compressor and the cylinder block NOTICE: Ensure the correct bolt length is used when the air compressor is installed If an incorrect bolt length (too long) is used, the cup plugs installed in the cylinder block can be pushed out into the gear train causing severe damage to the gear train The correct bolt length is 35 mm (137 in) 105 Install a new O-ring seal on the air compressor hub and a new O-ring seal on the oil supply, and then install the air compressor to the cylinder block Torque the four bolts to 60 N m (44 lb ft) 106 Install support bracket if two-cylinder air compressor is used Hand-tighten all bolts first so that the bracket touches the engine block and compressor, then torque the bolt to the compressor to 50 N m (37 lb ft) and the two bolts to the cylinder block to 30 N m (22 lb ft) NOTE: Do not ground the MCM housing This can result in false codes being logged 107 Install the motor control module (MCM) to the cylinder block with four bolts and isolators Torque the MCM-to-engine bolts to 15 N m (11 lb ft) 108 Install the left-hand radiator support rod bracket and torque mounting bolts to 68 N m (51 lb ft) 109 Install the fuel filter module and torque the mounting bolts to 60 N m (44 lb ft) 110 Install the hydrocarbon fuel doser block assembly and torque the mounting bolts to 32 to 36 N m (24 to 27 lb ft) 111 Install all low pressure and high pressure fuel lines 112 Install engine wiring harness 113 Install air compressor coolant lines 114 Install coolant crossover pipe Install the bolts connecting the support bracket from the coolant crossover pipe to the water manifold Torque bolts to 30 N m (22 lb ft) 115 Install the bolts connecting the coolant crossover pipe to the exhaust crossover tube Torque bolts to 30 N m (22 lb ft) 116 Install the clamps above the oil coolant module Torque clamps to 35 N m (31 lb in) 117 Install the cold boost pipe assembly Loosely secure cold boost pipe to intake manifold with four bolts 118 Attach the support bracket to the oil module with two bolts Torque bolts to 30 N m (22 lb ft) 119 Torque cold boost pipe-to-air intake manifold bolts to 30 N m (22 lb ft) 120 Install the rear engine mounts Refer to the OEM procedure 121 Install the rear engine lifter brackets Torque the bolts to 180 N m (132 lb ft) 122 Install the hydrocarbon doser valve fuel feed line Torque the banjo bolt at the doser block for GHG14 DD15 AT to 15 N m (11 lb ft) and for all others models 25 N m (19 lb ft) 123 Torque the fitting at the doser valve to 18 N m (124 lb ft) Hold the fuel doser injector valve with a wrench while torquing 124 Install and tighten doser fuel line mounting clamp bolts 125 Install a new pilot bearing into the crankshaft, if equipped Refer to the OEM procedure 126 Install the clutch assembly, if equipped Refer to the OEM procedure 127 Install the transmission assembly Refer to the OEM procedure All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

14 3 Replacement Long Block Engine Preparation 128 Install the front engine lifter bracket/egr crossover with the EGR venturi pipe as an assembly Torque the mounting bolts to 60 N m (44 lb ft) 129 Install the front engine mount/radiator support to the cylinder block with four bolts in two steps as follows: Torque the bolts to 125 N m (92 lb ft) 90 torque turn 130 Install the vibration damper, if the replacement engine is a warranty long block Install the splash ring with cup-side toward end of crankshaft 131 Using guide studs J install the vibration damper onto the crankshaft 132 Install the eight bolts attaching the vibration damper to the crankshaft Torque to 200 N m (1475 lb ft) in a crisscross pattern 133 Install the engine cooling fan hub Refer to the OEM procedure 134 Install the engine cooling fan Refer to the OEM procedure 135 Install the idler pulley and idler pulley bracket to the cylinder block 136 Install the two bolts to the idler pulley bracket Torque to 60 N m (44 lb ft) 137 Install the idler pulley to the idler pulley bracket Torque to 60 N m (44 lb ft) 138 Install the non-bracketed idler pulley Insert bolt through idler pulley and spacer 139 Install bolt to cylinder block Torque to 60 N m (44 lb ft) 140 Install the poly-v-belts 141 Install the cooling package Refer to the OEM procedure 142 Install the radiator support rods Refer to the OEM procedure 143 Install the transmission cooler lines, if equipped Refer to the OEM procedure 144 Install the DEF coolant lines Refer to the OEM procedure 145 Install the chassis powertrain interface harness onto the engine and transmission 146 The complete powertrain assembly is now ready to be installed in the chassis Refer to section "Installation of the Complete Powertrain Assembly" 16 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

15 Installation of the Complete Powertrain Assembly NOTE: When possible, this is the preferred method for installing a complete powertrain into the chassis after the engine has been serviced or replaced The engine, cooling package and transmission will be installed as an assembly NOTE: The instructions listed below are powertrain installation instructions based on a Freightliner Cascadia 113 or 125 model truck with an EPA07, EPA10 or GHG14 DD engine These will vary some depending on the chassis configuration NOTE: There are several instructional videos posted in DDCSN under Support, Multimedia, DD Platform and Powertrain Removal and Installation that may assist with this repair The videos are also posted on the Aftermarket Resource Center (ARC) website in Access Freightliner Special tools required: Engine Lifting Bar W WARNING: FALLING ENGINE To avoid injury from a falling engine, ensure an appropriately rated lifting device with a spreader bar and sling is used to lift the engine Moving the engine without an appropriately rated lifting device could result in the engine falling, which could cause serious personal injury and component damage The sling and spreader bar should be adjusted so the lifting hooks are vertical to prevent bending the lifter brackets To ensure proper weight distribution, all provided lifter brackets must be used Install as follows: 1 Connect engine lifting bar tool W to the engine using all three lifting brackets (two at the rear and one at the front) 2 Attach an appropriately rated lifting device (overhead crane or hoist) to W NOTICE: Use great care when lifting the powertrain assembly and installing in the chassis to avoid damaging any components Adequate clearance to the heater lines, A/C lines, front wall and floor of the truck cab must be maintained An assistant is recommended for the following steps 3 Carefully lift the complete powertrain assembly from the jack stands and place it into the chassis Use a transmission jack under the transmission to lift the rear of the powertrain for proper installation onto the rear frame mounts and front crossmember See illustrations below All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

16 4 Installation of the Complete Powertrain Assembly 4 Install and tighten the bolts securing the rear engine mounts to the frame mounts Refer to the Original Equipment Manufacturer (OEM) procedure 5 Install and tighten the bolts securing the front engine mount to the crossmember Refer to the OEM procedure 6 Disconnect lifting device and remove engine lifting tool W from the engine lifting brackets 7 Install the chassis front closing crossmember Refer to the OEM procedure 18 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

17 WARNING: PERSONAL INJURY In order to avoid personal injury from a falling vehicle, never use any engine lifter brackets to raise or lower any part of the vehicle Engine lifter brackets are not designed to bear the weight of the vehicle Always use approved lifting devices to raise and lower the vehicle NOTE: It may be necessary to raise and support the front of the vehicle for clearance to install the oil pan 8 Install oil pump, oil suction manifold, oil lines and oil pan Refer to section "Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines" 9 Install oil dipstick tube and dipstick 10 Install chassis underslung crossmember Refer to the OEM procedure 11 Install Diesel Exhaust Fluid (DEF) coolant lines to the DEF pump Refer to the OEM procedure 12 Install fuel line junction bracket onto the transmission Refer to the OEM procedure 13 Uncap and connect fuel supply and return lines to the fuel line junction fittings Refer to the OEM procedure 14 Connect any chassis air lines and electrical connections to the transmission, if equipped Refer to the OEM procedure 15 Connect the shifter cable to the transmission, if equipped Refer to the OEM procedure 16 Connect the shifter assembly to the transmission, if equipped with a manual transmission Refer to the OEM procedure 17 Install battery cable brackets and cables to the transmission and flywheel housing 18 Connect power, ground, and starter solenoid connections to the starter 19 Connect the driveline to the transmission Refer to the OEM procedure 20 Install driveline front carrier bearing bolts Refer to the OEM procedure 21 Route and connect chassis powertrain interface harness to the bulkhead and any other chassis connection points The steering shaft may have to be repositioned for harness and Powertrain Distribution Module (PDM) installation 22 Connect power steering pressure line to the steering gear 23 Reposition and install power steering fluid reservoir and bracket Refer to the OEM procedure 24 Install power steering fill line to power steering fluid reservoir NOTICE: The power steering fluid can be reused if it is not contaminated and has been properly maintained 25 Fill the power steering reservoir to the proper level 26 Connect fuel supply and return lines to the fuel filter module Refer to the OEM procedure 27 Install air compressor inlet pipe and connect the pipe to the air compressor 28 Connect air compressor governor line and discharge line to the air compressor 29 Connect engine cooling fan clutch air line to the fan solenoid, if equipped 30 Install the Aftertreatment System (ATS) inlet pipe and exhaust bellows pipe onto the engine and ATS Refer to the OEM procedure 31 Connect the air conditioning (A/C) lines at the junction block, if equipped Refer to the OEM procedure 32 Connect the cab heater hoses to the water manifold 33 Connect DEF coolant lines to the water manifold 34 Install any additional brackets and mounting hardware for air lines, fuel lines, electrical harnesses, electrical cables or hoses that attach to the powertrain 35 Install air cleaner mounting brackets to the rocker cover and torque the eight mounting nuts to 20 N m (14 lb ft) 36 Remove protective cover from the turbocharger inlet, if previously installed 37 Install the air cleaner and inlet to the turbocharger Refer to the OEM procedure 38 On Freightliner Cascadia 113 models, install the windshield wiper linkage Refer to the OEM procedure 39 Install the rain tray Refer to the OEM procedure 40 Prime the lubrication system Refer to section "Priming the Engine Lubrication System" NOTICE: The engine coolant can be reused if it is not contaminated and has been properly maintained 41 Fill the cooling system Refer to section "Cooling System Fill Procedure" 42 Charge the A/C system Refer to the OEM procedure 43 Install both inner fenders/splash shields and side fairings, if equipped Refer to the OEM procedure 44 Install the hood Refer to the OEM procedure 45 Install the front bumper Refer to the OEM procedure All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION

18 4 Installation of the Complete Powertrain Assembly 46 Connect the batteries Refer to the OEM procedure 20 All information subject to change without notice Copyright 2015 DETROIT DIESEL CORPORATION