Category Archives: Tips & Tricks

DD15 EPA10 GHG14 TEMPORARILY BYPASS DPF/DEF DERATE

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This is will work on Freightliner Cascadia’s with DD15 engines(EPA10 or GHG14)

1. Confirm derate is due to active ACM fault (DPF/DOC/SCR related). Turn off engine.
2. Open hood
3. Find PNDB fuse box (located to the left of the steering shaft coming out the firewall). Fuse box has 2 yellow locks & flashing red light
4. Open cover & remove green 30amp mini fuse (labelled ACM)
5. Once removed. Close fuse box & hood.
6. Start engine
7. Truck will have engine stop warning(Ignore)
8. Find the “engine overide” button on the dash (typically located beside regen button)
9. Hold down button and drive unit.
10. Truck will now drive @55mph (95km/hr). But driver will have to continue to hold down the button.

THIS IS A TEMPORARY FIX. THIS WILL ALLOW DRIVER TO MAKE IT TO THE YARD/REPAIR SHOP.

DD15 Torque Values (Cylinder Head, Main bearings, Rod bearings)

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Using the sequence shown below, torque the 38 large bolts in four steps to:
◦50 N·m (37 lb·ft).
◦250 N·m (184 lb·ft).
◦ 90° torque turn.
◦90° torque turn

DD15 CYLINDER HEAD TORQUE

 

The end play specification is 0.099 to 0.419 mm (0.0039 to 0.0165 in.). Insufficient end play can be the result of a misaligned No. 6 main bearing, a misaligned upper thrust washer or debris on the inner face of one or more of the thrust washers.
Correct the end play, if necessary.

NOTE: If the main bearings have been installed properly, the crankshaft will turn freely with all of the main bearing cap bolts drawn to the specified torque.
For the DD13: torque all of the main bearing cap bolts, in three steps, using the sequence shown below. Torque the main bearing cap bolts to:

1. 150 N·m (111 lb·ft)
2. 300 N·m (221 lb·ft)
3. 90° torque turn

For the DD15 and DD16; torque all of the main bearing cap bolts, in four steps, using the sequence shown below. Torque the main bearing cap bolts to:

1. 150 N·m (111 lb·ft)
2. 250 N·m (184 lb·ft)
3. 1st 90° torque turn
4. 2nd 90° torque turn

DD15 MAIN BEARING TORQUE

Using new bolts, install the bearing cap (3) on the rod (1) with the numbers (2) on the same side.
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Torque the connecting rod bolts alternately to the following:
For the DD13: 180 N·m (133 lb·ft) + 90° torque turn
For the DD15: 115 N·m (85 lb·ft) + 180° torque turn
For the DD16: 115 N·m (85 lb·ft) + 180° torque turn

DD15 CONNECTING ROD TORQUE

DD15 Tune Up Procedure/ Valve Lash

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1. Turn engine OFF, (key OFF, engine OFF).

 

Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage.

DD15 TUNE UP
2. Steam clean the engine.
3. Disconnect the starting power for the engine. Refer to OEM procedures.
4. Remove the air cleaner and the turbocharger inlet pipe and hose. Refer to OEM procedures.
5. Remove air cleaner housing. Refer to OEM procedures.
6. Remove the rocker cover. Refer to section “Removal of the Rocker Cover”
7. Using special tool (J-46392 or W904589046300), bar the engine over until cylinder number one is at Top Dead Center (TDC) compression stroke.
8. Using a feeler gauge (1), lash intake valves one, two and four to 0.4 mm (0.016 in.).1. Figure below displays the old style intake camshaft with 12 lobes and the old style rocker arms. These components were utilized on DD13 engines built before engine serial number HDE0079072 and on the DD15 & DD16 engines built before HDE0077481.
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2. Figure below displays the new style intake camshaft with 6 lobes and bridged rocker arms. These components were installed on DD13 engines beginning with engine serial number HDE0079072 and on the DD15 &DD16 engines beginning with engine serial number HDE0077481. The components are not backwards compatible.
d050015a

DD15 VALVE ADJUSTMENT

9. Using a feeler gauge (1), lash exhaust valves one, three and five to 0.6 mm (0.024 in.).
10. Using special tool (J-46392 or W904589046300), bar the engine over 360° until cylinder number six is at TDC compression stroke.
11. Lash intake valves three, five, and six to 0.4 mm (0.016 in.).
12. Lash exhaust valves two, four and six to 0.6 mm (0.024 in.).
13. Torque the locknut valve adjusting screw to 50 N·m (37 lb·ft).
14. Remove any tools used for this procedure.
15. Set the engine brake lash.

 

DD15 ENGINE BRAKE/ JAKE BRAKE LASH ADJUSTMENT

1. Set the lash on all the exhaust adjusting screws first (all the adjusting screws in direct contact with the exhaust valves).
2. Rotate the engine until a given cylinder is at maximum intake lift. When this is reached, the brake lash can be set on this cylinder.
3. When the engine brake rocker arm is in contact with the exhaust valve, set the lash between the engine brake rocker arm adjusting screw and the actuator piston stem.1. DD15 & DD16 engines built before HDE0077481 use Engine Brake Adjustment tool W470589022300; set the lash to 4.1 mm (0.1614 in.).
2. DD 15 & DD16 engines built starting with HDE0077481 use Engine Brake Adjustment tool W470589042300; set the lash to 4.6 mm (0.1811 in.).
3. DD13 engines built before HDE0079072 use Engine Brake Adjustment Tool W470589022300; set the lash to 4.1 mm (0.1614 in.).
4. DD13 engines built starting with HDE0079072 use Engine Brake Adjustment tool W470589042300; set the lash to 4.6 mm (0.1811 in.).

4. Lash the engine brakes in the following firing order: 1, 5, 3, 6, 2, and 4.
5. Torque the locknut valve adjusting screw to 50 N·m (37 lb·ft).
6. Install the rocker cover

NORMAL FUEL SYSTEM PRESSURES – THREE FILTER SYSTEM

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Normal and abnormal fuel system pressures are listed in the following tables. The pressures can vary slightly due to different chassis fuel line configurations, fuel temperatures, fuel filter condition, and fuel viscosity.

Normal Fuel System Pressures
Port Engine 600 RPM Engine 1800 RPM
LPP Inlet (in Hg) -4 to -8 -11 to -14
LPP Outlet (PSI) 72 to 80 100 to 126
HPP Inlet (PSI) 69 to 77 92 to 112
HPP Outlet (PSI) 1 to 2.5 4 to 7
Priming Port (PSI) 72 to 80 100 to 120
Fuel Compensation pressure w/ doser regulator 75 to 85 80 to 95

If the LPPI is greater than the specified range, check for inlet restrictions.

If the high pressure pump Inlet pressure is lower than the acceptable pressure, check the pressure difference across the low pressure pump outlet pressure sensor and fuel compensation pressure sensor. If engine does not have a low pressure pump outlet pressure sensor, install J-48876 and use priming port pressure.

DD15 Engine Sensor Descriptions

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Factory-installed Sensors

The sensors integrated into the factory-installed Engine Harness are listed below.

Sensor Type Description
Camshaft Position (CMP) sensor Indicates a specific cylinder in the firing order.
Crankshaft Position (CKP) sensor Senses crankshaft position and engine speed for functions such as fuel control strategy.
Diesel Particulate Filter (DPF) inlet pressure sensor Sensor measures pressure between the Diesel Oxidation Catalyst (DOC) and the Diesel Particulate Filter (DPF) in the aftertreatment assembly located in the exhaust system of the vehicle.
DPF outlet pressure sensor Sensor measures pressure on the outlet of the after-treatment device in the exhaust system of the vehicle. Located after the DPF that is within the aftertreatment device.
DPF outlet temperature sensor Temperature measured at the outlet of the after-treatment system that is installed within the exhaust system of the vehicle. Located after the DPF that is within the aftertreatment device.
Diesel Oxidation Catalyst (DOC) inlet temperature sensor Temperature measured at the inlet of the aftertreatment device in the exhaust system of the vehicle. Located before the DOC that is within the aftertreatment device.
DOC outlet temperature sensor Temperature measured between the DOC and the DPF in the aftertreatment assembly located in the exhaust system of the vehicle.
Exhaust Gas Recirculation (EGR) Delta Pressure (Delta P) sensor Senses EGR pressure for EGR control.
EGR temperature sensor Senses EGR exhaust temperature after EGR cooler. Used for EGR system diagnosis.
Engine Coolant Temperature (ECT) sensor Senses coolant temperature for functions such as engine protection, fan control and engine fueling.
Engine Oil Pressure (EOP) sensor Senses gallery oil pressure for functions such as engine protection.
Engine Oil Temperature (EOT) sensor Senses oil temperature for functions such as reducing variation in fuel injection and fan control.
Fuel compensation pressure sensor Compensates fuel line pressure.
Fuel rail pressure sensor Senses high pressure fuel in the fuel rail
Intake Manifold Pressure (IMP) sensor Senses turbocharger boost for functions such as smoke control and engine protection.
Intake Manifold Temperature (IMT) sensor Senses boost temperature.
Low pressure fuel sensor Senses pressure in the low pressure fuel circuit
Supply fuel temperature sensor Senses fuel temperature for functions such as engine fueling.
Turbocharger compressor temperature out sensor Senses turbocharger out air temperature.
Turbocharger Speed Sensor (TSS) Monitors turbocharger speed.
Water-in-Fuel (WIF) sensor Detects water in the fuel filter that alerts the owner/driver that the fuel filter needs to be dried out.

OEM-installed Sensors

All sensors must be of the proper type and continuously monitor vehicular and environmental conditions, so the MCM can react to changing situations. The OEM is responsible for installing the sensors listed in this table.

Sensor Function
Ambient Air Temperature (AAT) sensor Senses ambient air temperature specifically for the ambient air temperature override disable feature or for Optimized Idle (OI).
Engine Coolant Level (ECL) sensor Senses coolant level for engine protection.
Turbocharger compressor inlet temperature sensor Senses the temperature of the turbocharger compressor inlet.
Vehicle Speed Sensor (VSS) Senses vehicle speed for cruise control and vehicle speed limiting.