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SUBJECT
DATE
Removal and Installation of the Camshaft Housing
February 2013
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0081
Platform
EPA07/10/
GHG14 DD
Platform
Section Title
Removal of the
Camshaft Housing
Installation of the
Camshaft Housing
Change
Corrected fuel component nomenclature. Corrected procedure
references. Added installation procedure steps. Added new fuel
warnings.
All information subject to change without notice.
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2 Removal of the Camshaft Housing
2
Removal of the Camshaft Housing
Remove as follows:
1. Steam clean the engine.
2. Remove the rocker shaft/engine brake and camshaft assemblies. Refer to section "Removal of Camshaft and Rocker
Shaft/Engine Brake Assembly".
WARNING: PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been
shut down for a minimum of 10 minutes before servicing any component within the high pressure
circuit. Residual high fuel pressure may be present within the circuit.
WARNING: PERSONAL INJURY
All parts provided within this kit must be installed in the proper locations, and MUST be fastened to
the specified torque. Failure to properly torque hardware/components will result in failure of a high
pressure fuel feed line, resulting in possible fire and/or personal injury.
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time use components and MUST be replaced any time they are loosened or removed.
NOTICE: Engine size/model year specific service kits, containing all of the necessary parts to replace the high
pressure fuel rail feed lines have been released. Refer to TS letter 12 TS-9 for the high pressure fuel line kit
numbers to repair these engines.
3. Remove and discard the high pressure fuel rail feed lines (2).
For the three-filter fuel system, Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - Three-Filter
System".
For the two-filter fuel system, Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter
System".
4. Remove the high pressure fuel injector lines (3).
For the three-filter fuel system, Refer to section "Removal of the High Pressure Fuel Injector Lines - Three-Filter
System".
For the two-filter fuel system, Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter
System".
5. Remove the PLV banjo bolt (4) from the fuel rail. Discard the PLV banjo bolt sealing washers.
a. Three-filter fuel system shown below.
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All information subject to change without notice.
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b. Two-filter KM63 GEN2 fuel system shown below, two-filter KM59 GEN1 fuel system similar.
6. Disconnect the fuel rail pressure sensor (1) and intake manifold temperature sensor (2).
All information subject to change without notice.
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2 Removal of the Camshaft Housing
7. Disconnect the camshaft position sensor (1) from the camshaft housing (2).
8. Unclip all of the electrical wiring harness attaching points from the camshaft housing.
9. Remove the bolt and the P-clip (2) securing the doser coolant line (1) to the camshaft housing (3).
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All information subject to change without notice.
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10. Remove the remaining two bolts (29 and 30) securing the camshaft housing to the cylinder head.
WARNING: PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is
properly supported and securely attached to an adequate lifting device to prevent the component
from falling.
11. Attach a lifting device to the camshaft housing and lift the camshaft housing off of the cylinder head.
All information subject to change without notice.
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3 Installation of the Camshaft Housing
3
Installation of the Camshaft Housing
Install as follows:
1. Install a new seal into the camshaft housing.
WARNING: PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is
properly supported and securely attached to an adequate lifting device to prevent the component
from falling.
2. Using an appropriate lifting device, install camshaft housing onto the cylinder head.
3. Install the bolt (2) and the P-clip securing the doser coolant line (1) to the camshaft housing (3). Torque 30 N·m (22
lb·ft).
4. Clip all of the electrical wiring harness attaching points on to the camshaft housing.
5. Connect the camshaft position sensor (1) on to the camshaft housing (2).
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All information subject to change without notice.
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6. Connect the fuel rail pressure sensor (1) and intake manifold temperature sensor (2).
7. Install the PLV banjo bolt (4) with new sealing washers. Torque to 30 to 32 N·m (22 to 24 lb·ft).
8. Install the high pressure fuel injector lines (3).
For the three-filter fuel system, Refer to section "Installation of the High Pressure Fuel Injector Lines - Three-Filter
System".
For the two-filter fuel system, Refer to section "Installation of the High Pressure Fuel Injector Lines - Two-Filter
System".
WARNING: PERSONAL INJURY
All hardware/components must be installed in the proper locations, and MUST be fastened to the
specified torque. Failure to properly torque hardware/components will result in failure of a high
pressure fuel feed line, resulting in possible fire and/or personal injury.
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time use components and MUST be replaced any time they are loosened or removed.
All information subject to change without notice.
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3 Installation of the Camshaft Housing
NOTICE: Engine size/model year specific service kits, containing all of the necessary parts to replace the high
pressure fuel rail feed lines have been released. Refer to TS letter 12 TS-9 for the high pressure fuel line kit
numbers to repair these engines.
9. Install the high pressure fuel rail feed lines (2).
For the DD13 three-filter fuel system, Refer to section "Installation of the DD13 High Pressure Fuel Rail Feed Lines Three-Filter System".
For the DD13 two-filter fuel system, Refer to section "Installation of the High Pressure Fuel Rail Feed Lines - TwoFilter System".
For the DD15/16 three-filter fuel system, Refer to section "Installation of the DD15 and DD16 High Pressure Fuel Rail
Feed Lines - Three-Filter System".
For the DD15/16 two-filter fuel system, Refer to section "Installation of the High Pressure Fuel Rail Feed Lines - TwoFilter System".
a. Three-filter fuel system shown below.
b. Two-filter KM63 GEN2 fuel system shown below; two-filter KM59 GEN1 fuel system is similar
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All information subject to change without notice.
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10. Install the rocker shaft/engine brake and camshaft assemblies. Refer to section "Installation of the Camshaft and Rocker
Shaft/Engine Brake Assembly".
11. Prime the fuel system.
For the three-filter fuel system, Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump Three-Filter System".
For the two-filter fuel system, Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - TwoFilter System".
All information subject to change without notice.
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