22.08-1 6.9L—V-8 Diesel Engine DIESEL ENGINES 22-08-1 6.9L — V-8 Diesel Engine 32-08 ‘APPLIES TO F-250 — F-350, E-250 — E-350 SUBJECT PAGE © SUBJECT PAGE CLEANING AND INSPECTION DIAGNOSIS AND TESTING Bearings 22-08-61 Compression Test 22-08-14 Rod 22-08-61 Camshaft End Play 22-08-17 Main . 22-08-61 Camshaft Lobe Lift 22-0846 Camshat ...... 22-08-60 Crankshaft End Play 2208-17 Connecting Rods 22-08-61 Drive Gear Backlash (All Gears) . = 220847 Crankcase Depression Regulator (COR). «22-08-58 Engine Performance 22-08-18 Crankshaft .. : 22-08-60 Engine Oil Leaks ++ 22-08-11 Crankshaft Vibration Damper 22-08-60 Flywheel Runout 22-08-18 Cylinder Block . 2208-62 ‘Automatic Transmission = 22088 Cylinder Heads 22-08-58 Manual Shift Transmission 22-08-18 Drive Gears 22-08-60 Glow Plug System . 22-08-18 Exhaust Manifolds .... se, 22-08-60 Hydraulic Valve Tappet ........ + 22-08-45 Flywheel ‘, 22-08-60 Oil Cooler internal Leakage Test... 22-08-12 ‘Automatic Transmission 22-08-60 Sialic (Engine Off) Valve Train Analysis ..., 22-08-16 Manual Shift Transmission .. 22-08-60 OVERHAUL Hydraulic Valve Tappets - 22-08-60 Bearings 22-08-49 Intake Manifold 22-08-60 Camshaft .. 22-08-48 Oil Cooler = 22-08-63 Main evo, 2208-53 Oil Pan 22-08-63 od . ++ 20854 ll Pump 22-0863 Camshaft sos 22-0848 Pistons, Pins and Rings 22-08-62 Removal and Installation... = P2088 Pushrods .... 22-08-58 Repair +> 20852 Valve Rocker Arm ‘Assembly 22-08-58 ‘Connecting Rods - 22-08-53 Thermostat “20-08-63 Removal and installation 22-08-63 Core Plugs .. oe 2208-49 DESCRIPTION AND OPERATION Crankshaft = 22-08-47 Coolant Flow = 2208-4 Removal and installation = 22-08-47 Engine 22-08-2 Cylinder Assembly .. 2208-46 Fuel Flow . = 22-084 Cylinder Block ...... 2208-46 Glow Plug Fast Start System 22-08-10 Disassembly and Assembly 2208-46 Injection Pump... 22-08-4 Cylinder Head 22-08-50 Injection Nozzle Assemblies 22.08-4 Pistons and Connecting Rods ..... 2208-46 Lubrication System .......... 22.08-4 Removal and installation 22-08-46 Vehicle and Engine Identification 22-0841 Valves 22-08-5122-08-2 -V-8 Diesel Engine 22-08-2 ae . . IN 6.9L — V-8 Diesel Engine (Cont’d.) 30-08 ‘APPLIES TO F250 — F-350, E-260— £-950 SUBJECT PAGE SUBJECT PAGE REMOVAL AND INSTALLATION REMOVAL AND INSTALLATION (Cont'd) ‘Camshatt Drive Gear ssssscvssss+ 2208-82 Fuel Pump Cam and Spacer... Crankease Depression Regulator (CDR)... 220833 Fuel Supply Pump... + 22-08-35 Crankshaft Drive Gear ssvevess 22-08-30 Injection Nozzles sete eeeteeeesees 2208-88 Crankshaft Front Oi Seal .. ++» 2208-27 Injection Nozzle Fuel Lines... 20-087 CCrankshatt Vibration Damper ++ 22-08-26 Injection Pump ....... ++ 22-0835 Cylinder Heads ....... oss 220842 Injection Pump Drive Gear Engine Assembly... +. 2208-18 ‘and Adapter 22-08-31, Engine Front Cover and Intake Manifold «22-08-39 Crankshatt Oil Seal ++: 22-0827 Oil Cooler 22-08-44 Engine Front Insulator «22-08-22 Oil Filter. 22-08-44 £-250 — E-350. 2208-22 OilPan so... b ses 22084 F-250 — F-350 ++ 22-08-22 Oil Pump and Pick-up Tube .. ws 2208-44 Engine Rear Insulator + 20824 — Pushrod . + 22-08-33 Exhaust Manifolds vv 22-08-40 Rocker Arm . . . E250 — E-950 + 22-08-41 Tappets .. s+ 22-0839 F-250 — F-350 .... os 22-08-40 ‘Thermostat + 22-08-41 Flywheel, Engine Rear Cover Valley Pan 22-08-39 and Oil Seal on + 22-08-29 Valve Cover .. setecseseeeeeees PROB Flywheel Ring Gear ...... 22-08-30 Valve Spring, Retainer and Stem Seal ..... 22-08-34 Front Crankshaft Ol Seal .. ++ 220827 Water Pump... cca In Vehicle .......... 2206-27 SPECIFICATIONS .............. = 22-08-64 DESCRIPTION AND OPERATION Engine Description Refer to Figs. 1 through 5. The 6.9L diesel engine is a four cycle naturally aspirated V-8 with o valves. The right bank of cylinders are numbered 1, 3, 5, 7, with number 1 being at the front. The firing order is '1-2-7-3-4-5-6-8, The crankcase has been especially designed to withstand the loads of diesel operation and utlizes a four ‘bolt main bearing to assure a strong support for the rotating parts. The crankcase also has internal piston oil cooling jets which direct oll to the underside of the piston. The crankshaft isa fve main bearing uit with fore and att thrust controlled atthe center (NO. 2) bearing. Heavy- duty forged steel connecting rods are attached to the crankshatf, two to each beering throw. The piston pin is a free floating ype permiting the pinto move or float freely in piston and rod. The pin is held in place with pin retaining snap-rings. The camshatt is supported by five insert-type bearings pressed into the block ands driven by a drive gear keyed to the crankshaft. The end thrust of the camshaft is controlled by a thrust flange located between the front ‘camshaft journal and the camshaft drive gear. The aluminum-alioy pistons are fitted with two ‘compression rings and one oil ring. The hydraulic valve tappets minimize engine noise id maintain zero valve lash or tappet clearance, This iminates the need for periodic adjustment. The hydraulic valve tappets also incorporate camshaft roller followers for improved camshaft wear characteristics. The cylinder head assemblies feature pre-combustion chambers which provide superior combustion characteristics. The cylinder heads used on the engine: fre equipped with positive valve-rolating mechanisms,22-08-4 6.9L=V-8 Diesel Engine 22-08-64 located at the bottom of the intake and exhaust valve springs. The engine is equipped with a fully closed crankcase ventilation system. The crankcase depression regulator (CDR) valve is mounted on the intake manifold and provides a connection between the valley pan and the Intake manifold, to regulate crankcase pressur ‘The rotary.type injection pump is located between the cylinder heads in a recess in the front of the engine. The ‘engine governor is integral with the fuel injection pump. ‘Operating principles and service instructions for the fuel ‘system components are also provided in this Section. Coolant Flow Coolant flows from the water pump to the engine right and ie banks (Fig. maine Circulation of the coolants from the front tothe rear of the crank-case. Coolant flows from crankcase to the cylinder head via positive cooling passages and through one p tthe rear bulkhead of the cylinder head, and one at the front, Coolant flows between the pr ‘combustion chambers and valve seats and towards the front. Coolant exits the cylinder head into a common cavity which runs across the front of the crankcase th to the thermostat housing. When the thermostat is closed, coolant bathes the thermostat and runs through the bypass orifice which is located below the thermostat. No coolant is allowed to leave the crankcase. ‘Also when the thermostat is closed, the heater coolant flow assembly (Fig. 6, View A) reduces coolant low and pressure to the heater core, This provides for quick nt reaches. 105°C bypass orifice, the volume of coolant allowed to bypass is decreased, and coolant is allowed to return to the radiator. Lubrication System Lubrication oll is drawn out of the sump through 1 pick up screen and oil pick up tube to the oll pump (Fig. 7), Ol pump flow is 45.4 liters (12 gallons) per minute at tated speed and a preseure of 414 kPa, From the ol pump oil is passed via driled passageways In the Erancase fo fhe of cooler adapter then through the ol cooler. Oil flows around the outside of the heat ‘exchanger tubes. (Coolant flows through the tubes). The oll passes around the tubes rearward to the oil titer header, At the oil fiter header the oll meets the pressure 38 the oll pressure to the oil 38. The rear oil fiter header ich will open if the oll fter should become clogged. Five cross passages distribute oll to verticle passages which feed crankshaft main bearings, camshaft bearings and two tappet galleries. The piston cooling jets are fed from the same passage as the valve tappets, The connecting rod bearings are tod from, the main bearings via driled passages in the ‘crankshaft. The timing gears are lubricated by oil splash ‘Oil passes through the hydraulic tappet rollers and up the hollow pushrods to lubricate the rocker arm assemblies and valve stems. Fuel Flow Fuel from the tank (under suction) is routed through the fuel water separator to the fuel pump (Fig. 8). It then passes through a fuel heater which reduces the formation of wax while the engine is running. This allows the use of more economical winter blend number 2 diesel fuel in coo! weather. Fuel then passes through the engine fuel fier Property filtered diesel fuel cannot be overemphasized. It is essential for long component fe and reliability. ‘The Fuel Shut-Off solenoid controls the flow of fue! into the injection pump. With the ignition switch in Start or Fun the solenoids anergized and ful is alowod to flow to the injection pump. With the ignition switch Off, fuel flow to the injection pump stops. Fuel entering the injection pump is metered and delivered undirhigh pressure through injection lines to i injection nozzles (Fig. 3). The nozzies atomize this fuel into the cylinders tor ‘combustion. On each nozzle fuel return fitting that returns excess fuel to the fuel tank. Injection Pump The function of the diesel fuel injection pump is to accurately meter and deliver fuel to a nozzle in each cylinder at high pressure and at precisely timed intervals. The injection pump is an opposed plunger, inlet metered, positive displacement, distributor type pump. ‘The pumip Incorporates a single pumping chamber, an integral fuel transfer pump and governor, and’ an ‘automatic injection advance mechanism. On-off control is provided by means of an electric solenoid located in the housing cover. Operating principles of the pump can be understood by following the fuel circuit through a complete pump gycle (Fig. 8), Fuel flows. into the. injection pump inlet through the iniet filter screen (1). Fuel then flows to the vane type fuel transfer pump (2). Excess fuel from the transfer pump is bypassed through the pressure Fegulator assembly (3) to the suction side. Fuel under transfer pump pressure flows through t Center of the transfer pump rotor, past the rotor retainers (4) into the hydraulic head. it’ then flows through a Gannectin passage (6) in the head to the automatic advance (6) and up through a racial passage (8) to the metering valve. The position of the metering valve, Controlled by the governor, regulates flow of the tua Inte the radial charging passage (8) which incorporates the head charging ports. As the rotor revolves, the two rotor iniet passages (10) align with the charging ports in the raulic head, allowing fuel to flow into the pumping chamber. With further rotation, the inlet passages move out of alignment and the discharge port of the rotor aligns with one of the head outlets, While the discharge Port is opened, the rollers (11) contact the cam lobes forcing the plungers together. Fuel trapped between the plungers is then pressurized and delivered by the nozzle to the combustion chamber. In addition, an air vant passage (12) in the hydraulic head connects the outlet side of the transter pump with the pump housing. This allows air and some fuel to be bled back to the fuel tank via the return line. The fuel thus, bypassed fills the housing, lubricates the internal components, cools and carries off any small air bubbles. Injection Nozzle Assemblies Description __The Injection nozzles are of the inwardly opening, differential, hydraulically operated, pintie type, Their function is to direct a metered amount of fuel, under high Pressure from the fuel injection pump, into’ the engine ‘combustion chamber. hl