Detroit Diesel EPA07 Workshop Manual Download

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE

To avoid injury from a falling engine, do not use a damaged
lifter bracket when lifting the engine.

To avoid injury from a falling engine, ensure the engine
is securely attached to the engine overhaul stand before
releasing the lifting sling.

All information subject to change without notice.

DDC-SVC-MAN-0081 2010

38-7

Summary of Contents for EPA07

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Page 3: ...D15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2 31 3 CAMSHAFT HOUSING 3 1 REMOVAL OF THE CAMSHAFT HOUSING 3 3 3 2 INSPECTION OF CAMSHAFT HOUSING 3 8 3 3 INSTALLATION OF THE CAMSHAFT HOUSING 3 9 4 CAMSHAFT TIMING 4 1 CAMSHAFT TIMING VERIFICATION 4 3 4 2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED 4 6 5 GEAR TRAIN AND ENGINE TIMING 5 1...

Page 4: ...ER 9 9 9 4 INSTALLATION OF THE DD13 TURBOCHARGER 9 10 9 5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE 9 12 10 DD13 WASTEGATE SOLENOID 10 1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID 10 3 10 2 REMOVAL OF THE DD13 WASTEGATE SOLENOID 10 4 10 3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID 10 6 11 DD15 TURBOCHARGER 11 1 DESCRIPTION AND OP...

Page 5: ...7 14 13 INSPECTION OF VALVE 14 28 14 14 INSTALLATION OF VALVE SPRING SEAL AND VALVE CAP 14 29 14 15 VALVE LASH ADJUSTMENTS 14 31 14 16 SETTING THE ENGINE BRAKE LASH 14 33 15 PISTON AND CONNECTING ROD ASSEMBLY 15 1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS 15 3 15 2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY 15 5 15 3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMB...

Page 6: ... REMOVAL OF THE OIL DIPSTICK TUBE 20 4 20 3 INSTALLATION OF THE OIL DIPSTICK TUBE 20 5 21 OIL PUMP 21 1 DESCRIPTION AND OPERATION OF OIL PUMP AND RELATED COMPONENTS 21 3 21 2 REMOVAL OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 4 21 3 INSPECTION OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 5 21 4 INSTALLATION OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 6 22 CRANKCASE BR...

Page 7: ...0 5 30 3 INSPECTION OF COOLANT THERMOSTAT AND SEAL 30 6 30 4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL 30 7 31 COOLANT FILTER 31 1 DESCRIPTION AND OPERATION OF COOLANT FILTER 31 3 31 2 REMOVAL OF THE COOLANT FILTER 31 4 31 3 INSTALLATION OF THE COOLANT FILTER 31 5 32 COOLANT FILTER SERVICE MODULE 32 1 REMOVAL OF COOLANT FILTER SERVICE MODULE 32 3 32 2 INSTALLATION OF COOLANT FILTER SERVICE MODUL...

Page 8: ... POWER TAKE OFF 38 8 38 3 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE OFF 38 9 38 4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS 38 10 38 5 INSPECTION OF THE ENGINE LIFTER BRACKETS 38 11 38 6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS 38 12 38 7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE OFF 38 13 38 8 INSTALLATION OF THE FRONT EN...

Page 9: ...THE AIR COMPRESSOR 41 5 41 3 INSPECTION OF THE AIR COMPRESSOR 41 6 41 4 INSTALLATION OF THE AIR COMPRESSOR 41 8 42 CYLINDER BLOCK 42 1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS 42 3 42 2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE 42 9 42 3 CLEANING THE CYLINDER BLOCK 42 12 42 4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK 42 16 All information subject to change without...

Page 11: ...VER Section Page 1 1 DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS 1 3 1 2 REMOVAL OF THE ROCKER COVER 1 4 1 3 CLEANING AND INSPECTION OF THE ROCKER COVER 1 6 1 4 INSTALLATION OF THE ROCKER COVER 1 7 ...

Page 13: ...al and uses an elastomer seal 1 which completely encloses the valve operating mechanism including the overhead camshafts brake assemblies and the injector harness 1 Gasket 4 Air Cleaner Bracket 2 Rocker Cover 5 Stud Bolt 3 Bolt Figure 1 1 Rocker Cover All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 1 3 ...

Page 14: ...s follows 1 Steam clean the engine 2 Remove bolts 1 or nuts if equipped from the two air filter housing brackets 2 and remove housings from the rocker cover All information subject to change without notice 1 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 15: ...3 remove rocker cover NOTE Mark the location of the stud bolts The stud bolts must be replaced in their original location during installation 4 Remove rocker cover gasket from the rocker cover All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 1 5 ...

Page 16: ...when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 2 Blow dry with compressed air 3 Check the rocker cover breather passage and seal for damage Replace as necessary 4 Inspect the bolts Replace if damaged All information subject to change without notice 1 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION...

Page 17: ...roove in rocker cover 2 Install bolts 1 or stud bolts 2 if removed and isolators 3 into rocker cover 3 Install rocker cover onto camshaft housing 4 Finger tighten all bolts 1 and stud bolts then torque to 20 N m 14 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 1 7 ...

Page 18: ...he eight nuts to 20 N m 14 lb ft ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 6 Start the engine and check for leaks All information subject to change without notice 1 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 19: ...T ENGINE BRAKE ASSEMBLY 2 7 2 3 INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT ENGINE BRAKE ASSEMBLY 2 15 2 4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT ENGINE BRAKE ASSEMBLY 2 16 2 5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2 26 2 6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILU...

Page 21: ... along with pressurized oil to the engine brake rockers via the engine brake solenoids through the exhaust shaft The camshaft housing is made of aluminium material 1 Camshaft Bearing Cap 6 Intake Rocker Arm 11 Gasket 2 Bolt 120 mm 7 Exhaust Rocker Arm 12 Exhaust Camshaft Lobes 3 Bolt 108 mm 8 Exhaust Camshaft and Gear 13 Exhaust Camshaft Brake Cam Lobe 4 Bolt 63 mm 9 Intake Camshaft and Gear 14 In...

Page 22: ...aking The exhaust valve is first operated toward the completion of the intake stroke closed during the compression stroke and opened a second time when the compression stroke is completed The engine brake system is enabled using the following components For EPA07 engines Engine brake solenoid valve in front of engine applies low engine braking Engine brake solenoid valve in rear of engine applies ...

Page 23: ... 4 Oil Passage for Cylinders 1 and 2 10 Brake Cam Lobe 5 Oil Passage for Cylinders 3 4 5 and 6 11 Engine Brake Solenoid Valve Front 6 Exhaust Rocker Arm Shaft 12 Engine Brake Solenoid Valve Rear Figure 2 2 EPA07 Engine Brake For EPA10 engines Engine brake solenoid valve in front of engine applies low engine braking For medium engine braking both front and rear solenoids are activated For high both...

Page 24: ...enoid Valve Oil for cylinders 4 through 6 are supplied by the Rear Engine Brake Solenoid Valve 1 Exhaust Rocker Arm 7 Exhaust Camshaft 2 Exhaust Rocker Arm with Actuator Piston 8 Actuator Piston 3 Brake Rocker Arm 9 Exhaust Valve 4 Oil Passage for Cylinders 1 2 and 3 10 Brake Cam Lobe 5 Oil Passage for Cylinders 4 5 and 6 11 Engine Brake Solenoid Valve Front 6 Exhaust Rocker Arm Shaft 12 Engine Br...

Page 25: ...cedures 6 Remove the rocker cover Refer to section 1 2 7 Remove the two 14 pin fuel injector harness connectors 1 from the camshaft housing housing 2 NOTE Top Dead Center TDC can be confirmed by installing camshaft timing tool For the DD13 use Camshaft Timing Tool W470589034000 For the EPA07 DD15 use Camshaft Timing Tool W470589054000 For the EPA10 DD15 use Camshaft Timing Tool W470589104000 8 Usi...

Page 26: ...nstall the flywheel housing crankshaft TDC Locating Pin W470589001500 into the CKP sensor hole located in the rear of the flywheel housing The plastic tip will protrude into the cutout in the tone wheel TDC can be verified by the proper installation of the camshaft timing tool All information subject to change without notice 2 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 27: ... is at TDC firing stroke 12 For EPA07 DD13 a Disconnect both 14 pin injector harness connectors 8 b Disconnect the 24 electrical terminals at the fuel injectors 7 c Disconnect two wiring terminals at each engine brake solenoid 6 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 9 ...

Page 28: ...termediate frame 5 to the camshaft housing 1 Remove the intermediate frame 13 For EPA10 engines a Remove the fuel injector electrical harness clips 2 from the 14 pin electrical connectors All information subject to change without notice 2 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 29: ...inside bolts outward in 1 2 turn increments The increment procedure needs to be followed to prevent the rocker shaft from breaking 15 Completely loosen all of the adjusting screws on all of the rocker arms 16 Loosen the seven bolts securing the intake rocker shaft to the camshaft bearing caps NOTICE Make sure that the camshaft housing housing is not damaged during removal of the intake exhaust roc...

Page 30: ...o prevent the rocker shaft from breaking 18 Loosen the seven bolts securing the exhaust rocker shaft to the camshaft caps 19 Using Rocker Arm Lifter Spacer Exhaust W470589074000 for the DD13 or Rocker Arm Lifter Spacer Exhaust W470589004000 for the DD15 remove the exhaust rocker shaft assembly When removing the EPA10 exhaust rocker shaft ensure the rockers are in the up position NOTE The engine br...

Page 31: ... camshaft bearing caps 2 21 Using tool Cam Bearing Cap Puller J 48883 and Injector Unit Pump Puller J 46375 remove the camshaft bearing caps 1 from the camshaft housing All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 13 ...

Page 32: ...Y 22 Remove the intake and exhaust camshaft assemblies 1 2 from the camshaft housing 3 Use care not to damage intake cam tone wheel when handling All information subject to change without notice 2 14 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 33: ... shaft for scoring or scuffing replace if necessary 4 Inspect rocker arms for roller and bushing damage replace if necessary 5 Inspect adjusting screws and buttons replace if necessary 6 Inspect cam caps and cam journals in camshaft housing for damage replace if necessary 7 Inspect the tone wheel on the intake camshaft for cracks bending or any damage If damage is found replace the intake camshaft...

Page 34: ...r number one using TDC Locating Pin W470589001500 installed in crankshaft position sensor CKP hole located in the flywheel housing 2 Install Camshaft Timing Tool W470589054000 1 for EPA07 DD15 W470589104000 for EPA10 DD15 and W470589034000 for EPA10 DD13 to the rear of the camshaft housing Tighten the two bolts All information subject to change without notice 2 16 DDC SVC MAN 0081 2010 Copyright 2...

Page 35: ...ign the marked gear teeth with the marks on the timing tool 6 Install Camshaft Timing Tool W470589054000 1 for EPA07 DD15 W470589104000 for EPA10 DD15 and W470589034000 for EPA10 DD13 to the front of the camshaft housing and into the grooves cut into the camshafts Secure timing tool to the camshaft with a bolt a At this point the front timing tool should slide into the camshaft grooves easily with...

Page 36: ... camshaft caps onto intake and exhaust camshafts 9 The first and seventh camshaft caps hold the engine brake solenoid to camshaft cap Replace the O rings on the solenoid prior to reinstallation Install the engine brake solenoid NOTE There are 30 bolts retaining the DD13 camshaft assemblies shown 14 120 mm M10 bolts seven 108 mm M10 bolts and nine 63 mm M8 bolts The DD15 uses 28 bolts with two exte...

Page 37: ...lts Refer to figure for proper bolt placement 11 Using the torque sequence shown below torque the M10 camshaft cap bolts to the following 20 N m 15 lb ft Then torque to 50 55 N m 37 40 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 19 ...

Page 38: ... Install crankshaft position sensor Refer to section 15 Install a dial indicator onto gear case and zero out the dial indicator 16 Position the stem of dial indicator to rest between the teeth on the camshaft gear 17 Hold the number five idler gear with a screwdriver Check the lash between the camshaft gear and idler gear number five All information subject to change without notice 2 20 DDC SVC MA...

Page 39: ...ry NOTICE The camshaft journal area is lubricated by oil that has to travel through the rocker shaft If the rocker shaft is installed incorrectly oil passages do not line up This results in insufficient lubrication and damage to the camshaft journals Incorrect shaft installation may also result in the engine brakes not functioning and cause damage to the rocker arm bushings All information subject...

Page 40: ...bolts are drawn down from the inside bolts outward in 1 2 turn increments before final torque If the rocker shaft bolt is fully torqued without using the increment procedure the rocker shaft can break NOTE On EPA10 engines the intake and exhaust rocker shafts are marked TOP FRONT and TOP REAR Top front must face towards the front of the engine 19 Remove timing tools All information subject to chan...

Page 41: ...ntake W470589004000 for the DD15 install the intake rocker shaft assembly to the camshaft cap and secure with seven clamping blocks and bolts 21 Using the torque sequence shown below torque the bolts to 50 55 N m 36 41 lb ft 90 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 23 ...

Page 42: ... the torque sequence shown below torque the bolts to 50 55 N m 36 41 lb ft 90 24 Remove timing tools 25 Install the fuel injectors if removed Refer to section 26 Lash the valves and engine brakes Refer to section 14 15 27 Install the fuel injector wiring harness Refer to section 28 Install the rocker cover Refer to section 1 4 29 Reconnect the battery power to the engine Refer to OEM procedures Al...

Page 43: ...efer to OEM procedures 31 Install the turbocharger inlet pipe and hose and air cleaner Refer to OEM procedures 32 Prime lubrication system Refer to section 27 1 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 25 ...

Page 44: ...nt Crossover Pipe 12 Bolt 21 Bolt 4 Bolt 13 Bolt 22 Venturi 5 Support 14 Outlet Nipple 23 Mixer Pipe 6 Coolant Connecting Tube 15 Seal 24 Seal Ring 7 Exhaust Gas Connecting Tube 16 Exhaust Gas Recirculation Cooler Water Manifold Assembly 25 Bolt 8 Gasket 17 Clamps 26 Lifting Bracket Mounting Bolt 9 Seal Ring 18 Hot Pipe 27 Front Lifting Bracket Figure 2 4 EPA10 DD13 EGR Cooler Water Manifold and R...

Page 45: ...ort 14 Outlet Nipple 23 Mixer Pipe 6 Coolant Connecting Tube 15 Seal 24 Seal Ring 7 Exhaust Gas Connecting Tube 16 Exhaust Gas Recirculation Cooler Water Manifold Assembly 25 Bolt 8 Gasket 17 Clamps 26 Bolt 9 Seal Ring 18 Hot Pipe Figure 2 5 EPA10 DD13 EGR Cooler Water Manifold and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CO...

Page 46: ...this procedure could cause severe engine damage 1 Remove the marmon clamps 2 and EGR hot pipe 3 and inspect for any signs of liquid or moisture The EGR hot pipe exhaust pipe and EGR cooler inlet 1 should have a black dry soot residue inside a If liquid or moisture is present in the pipe go to the next step b If there is no sign of liquid or moisture in the pipe or EGR cooler 1 install the hot pipe...

Page 47: ...old boost pipe 2 3 Remove the exhaust gas crossover tube lifting eye 2 and venturi 6 4 Place a towel over the outlet of the EGR cooler and retain it with a zip tie All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 2 29 ...

Page 48: ...d shop air into the individual tubes in the EGR cooler to clear any excess fuel soot and carbon 6 After performing the cleaning procedure refer to section to install the a mixer pipe b exhaust gas crossover tube lifting eye EPA07 engines and exhaust gas crossover tube EPA10 engines c venturi 7 If the cooler has an excessive amount of buildup that cannot be removed replace the EGR cooler Refer to s...

Page 49: ...ot Pipe 3 Gasket 11 Banjo Union 19 Water Manifold 4 Bolt 12 Banjo Bolt 20 Support 5 Exhaust Gas Crossover Tube 13 Exhaust Gas Cooler 21 Clamp 6 Bolt 14 Strap 22 Hose 7 Lifting Bracket 15 Shim 23 Mixer Pipe 8 Connecting Tube 16 Clamp 24 Coolant Delivery Pipe 25 Seal Ring Figure 2 6 EPA10 DD15 EGR Cooler and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyrig...

Page 50: ...ust Gas Cooler 19 Clamp 4 Bolt 12 Strap 20 Hose 5 Exhaust Gas Crossover Tube Lifting Eye 13 Shim 21 Mixer Pipe 6 Connecting Tube 14 Clamp 22 Coolant Delivery Pipe 7 Connecting Tube 15 Metal Seal 23 Seal Ring 8 Seal Ring 16 Hot Pipe Figure 2 7 EPA07 DD15 EGR Cooler and Related Parts All information subject to change without notice 2 32 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION...

Page 51: ...Remove the clamps 2 exhaust pipe 4 and gaskets 3 from the EGR cooler 1 and inspect and inspect for any signs of liquid or moisture The EGR hot pipe and EGR cooler inlet should have a black dry soot residue inside a If liquid or moisture is present in the pipe go to the next step b If there is no sign of liquid or moisture in the pipe install the EGR cooler hot pipe No further action is required Re...

Page 52: ...safety goggles and do not exceed 40 psi 276 kPa air pressure 5 Using a rubber tipped blow gun blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel soot and carbon 6 After performing the cleaning procedure refer to section to install the a mixer pipe b exhaust gas crossover tube lifting eye EPA07 engines and exhaust gas crossover tube EPA10 engines c venturi...

Page 53: ...3 CAMSHAFT HOUSING Section Page 3 1 REMOVAL OF THE CAMSHAFT HOUSING 3 3 3 2 INSPECTION OF CAMSHAFT HOUSING 3 8 3 3 INSTALLATION OF THE CAMSHAFT HOUSING 3 9 ...

Page 55: ...ctor harness 1 from the camshaft housing 2 4 Remove the following high pressure fuel line components 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 a High pressure fuel lin...

Page 56: ...to the fuel filter module 4 Refer to section 5 Remove the rocker shaft engine brake and camshaft assemblies Refer to section 2 2 6 Disconnect the intake manifold temperature sensor 2 All information subject to change without notice 3 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 57: ...nsor 1 8 Disconnect the camshaft position sensor 1 from the camshaft housing 2 9 Unclip all of the electrical wiring harness attaching points from the camshaft housing All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 3 5 ...

Page 58: ...using 3 11 Remove the remaining two bolts 29 and 30 securing the camshaft housing to the cylinder head 12 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 3 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 59: ...g 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 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 3 7 ...

Page 60: ...housing replace if damaged 4 Inspect the camshaft housing sealing surfaces for damage Inspect the following sealing surfaces for damage a The camshaft housing to rocker cover b The camshaft housing to cylinder head c The O ring seal on the injector harness d The O ring seal on the engine brake solenoids 5 Inspect the rocker shaft installation surface located inside the camshaft housing for scoring...

Page 61: ...bearing cap dowel pin hole lubricate the camshaft housing camshaft journals 4 Install the camshaft assemblies into the camshaft housing Refer to section 2 4 5 Install the following high pressure fuel line components a High pressure fuel line bracket 1 and high pressure fuel lines from fuel rail to high pressure fuel pump 2 refer to section b High pressure fuel lines from fuel rail to fuel injector...

Page 63: ...4 CAMSHAFT TIMING Section Page 4 1 CAMSHAFT TIMING VERIFICATION 4 3 4 2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED 4 6 ...

Page 65: ...No 1 with the No 6 valve in overlap The dot 2 that is located inside the flywheel tone ring is aligned with the edge of the pointer 1 3 Locate the mark on the camshaft and mark the top of the corresponding gear tooth with a light colored paint pen 4 Remove the Crankshaft Position Sensor CKP from the flywheel housing Refer to section All information subject to change without notice DDC SVC MAN 0081...

Page 66: ...e in the flywheel housing and engage into the flywheel notch 6 Install the rear Camshaft Timing Tool W470589054000 for EPA07 DD15 W470589104000 for EPA10 DD15 and W470589034000 for DD13 1 onto the camshaft housing All information subject to change without notice 4 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 67: ... DD13 1 into the grooves cut into the cams and pin it into the camshaft housing with a bolt 8 Verify that the marks on the gear teeth match the marks on the timing tool If the marks do not match research the root cause of incorrect camshaft timing All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 4 5 ...

Page 68: ...with a light colored paint pin 4 Lubricate the camshafts and camshaft housing journals with clean engine oil NOTE The intake camshaft has the tone wheel and must be installed on the intake side of the engine 5 Install the camshafts into the camshaft housing in their respective locations lining up the marked cam gear teeth with the mark on the timing plate 6 Install the rear Camshaft Timing Tool W4...

Page 69: ...INE installing or removing could indicate the camshafts being out of time Install a bolt into the tool to hold it into place All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 4 7 ...

Page 71: ...D ENGINE TIMING Section Page 5 1 DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS 5 3 5 2 ENGINE GEAR TRAIN INSTALLATION AND TIMING 5 8 5 3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED 5 16 ...

Page 73: ...d at the rear of the engine The gear train consists of intake and exhaust camshaft gears idler gears No 1 2 3 4 and 5 crankshaft gear oil pump gear fuel pump gear air compressor gear and Axial Power Turbine APT gear All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 5 3 ...

Page 74: ...11 Camshaft Gear Exhaust 4 Idler Gear No 4 12 Camshaft Gear Intake 5 Idler Gear No 5 A Level A 6 Air Compressor Gear B Level B 7 Fuel Pump Gear C Level C 8 Axial Power Turbine Gear x To Front of Engine Figure 5 1 DD15 Engine Gear Train All information subject to change without notice 5 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 75: ... helical cut NOTE On the DD13 there is no Axial Power Turbine APT and no Idler gear number four The position of the idler gear number four is covered by a plate and sealed with an O ring Level B The middle gears include idler gear number one which drives the air compressor gear and the idler gear number two Idler gear number two drives the high pressure fuel pump and idler gear number three These ...

Page 76: ...11 Camshaft Gear Exhaust 4 Idler Gear No 4 12 Camshaft Gear Intake 5 Idler Gear No 5 A Level A 6 Air Compressor Gear B Level B 7 Fuel Pump Gear C Level C 8 Axial Power Turbine Gear x To Front of Engine Figure 5 2 DD15 Engine Gear Train All information subject to change without notice 5 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 77: ...M Fuel Pump 1 50 ________ RPM Oil Pump 1 33 ________ RPM APT Gearbox Drive 4 00 ________ RPM APT Turbine Shaft 26 64 ________ RPM Table 5 1 HDEP Geartrain Ratios The power steering pump can be mounted in two places If the engine is equipped with a single cylinder air compressor it will be mounted to the front of the air compressor If the engine is equipped with a two cylinder air compressor then t...

Page 78: ...nter TDC on cylinder number one Install and lock Crankshaft TDC Locating Tool J 48630 into place with bolt 3 Install spindle into idler gear number five 4 Install idler gear number five onto the cylinder head using Shoulder Bolt J 47486 5 Install two bolts into idler gear number five and hand tighten Remove J 47486 Torque to 60 65 N m 44 48 lb ft 6 Install the spindle into idler gear number three ...

Page 79: ...en the teeth on large gear of idler gear No 3 zero out the dial indicator 11 Hold idler gear No 5 with a screw driver to check gear lash 12 The lash reading on the dial indicator should be 0 079 0 305 mm 0 003 0 012 in 13 When correct gear lash is established torque idler gear No 3 to 60 65 N m 44 48 lb ft 14 Install the spindle and gear plate onto the idler gear number two 15 Install the spindle ...

Page 80: ...all the spindle onto the idler gear number four 21 On the DD15 install the assembled thrust washer spindle and idler gear number four onto the cylinder block Torque to 100 N m 73 lb ft NOTE Tool J 47487 should remove with ease If not check gears for proper installation 22 Remove the idler gear number three tool J 47487 23 Check that the idler gear number one is flush with the rear side of the cran...

Page 81: ...mshaft housing with two bolts 28 Install both of the intake and exhaust camshafts into the camshaft housing Refer to section 2 4 29 Rotate the camshafts until the mark on the inside of the gear aligns with the mark on Camshaft Timing Tool W470589054000 for EPA07 DD15 W470589104000 for EPA10 DDl5 and W470589034000 for DD13 All information subject to change without notice DDC SVC MAN 0081 2010 Copyr...

Page 82: ...t housing and secure to the camshaft housing with one bolt 31 Ensure timing marks on the camshaft gears are at TDC and aligned to the marks on the tool 32 Install the seven camshaft caps onto intake and exhaust camshafts NOTE The first and seventh camshaft caps hold the engine brake solenoid to camshaft cap All information subject to change without notice 5 12 DDC SVC MAN 0081 2010 Copyright 2010 ...

Page 83: ...e are 30 bolts retaining the camshaft assemblies fourteen 120 mm M10 bolts seven 108 mm M10 bolts and nine 63 mm M8 bolts 34 Install the thirty bolts to camshaft caps finger tighten the bolts Refer to figure for proper bolt placement All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 5 13 ...

Page 84: ...m and 108 mm M10 camshaft cap bolts to the following 20 N m 15 lb ft Then torque to 50 55 N m 37 40 lb ft 1 Using the torque sequence torque the nine 63 mm M8 bolts to 30 N m 22 lb ft All information subject to change without notice 5 14 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 85: ...till align with the timing tool 3 Remove timing tools from gears and camshaft housing 4 Install the closing cover and two bolts to the rear of the cylinder head Torque the closing cover bolts to 30 N m 22 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 5 15 ...

Page 86: ... Turn idler gear number five counterclockwise viewed from front of engine until 0 lash is present then zero the gauge on the dial indicator 5 Check the gear lash by turning the idler gear number five stop to stop verify that the lash reading on the dial indicator is 0 043 0 165 mm 0 0016 0 0065 in 6 If gear lash is incorrect continue with the following steps to adjust 7 Remove access cover to the ...

Page 87: ...se viewed from front of engine will result in zero lash Rotating idler gear number five clockwise viewed from front of engine will result in maximum lash 10 Install a magnetic base dial indicator gauge on engine block 11 Set the dial indicator on the number five gear tooth All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 5 17 ...

Page 88: ...4 Tighten the two bolts on the number three gear 15 Check gear lash by turning idler gear number five stop to stop verify the lash reading on the dial indicator should be 0 043 0 165 mm 0 0016 0 0065 in 16 If gear lash is OK then final torque idler gear number three bolts to 60 65 N m 44 48 lb ft 17 Install access cover and tighten 18 Install the camshaft housing as needed Refer to section 3 3 All...

Page 89: ...ATER MANIFOLD AND RELATED COMPONENTS 6 3 6 2 REMOVAL OF THE DD15 DD16 WATER MANIFOLD 6 5 6 3 CLEANING AND INSPECTION OF THE DD15 DD16 WATER MANIFOLD 6 7 6 4 INSTALLATION OF THE DD15 DD16 WATER MANIFOLD 6 8 6 5 DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY 6 10 ...

Page 91: ...ched to the cylinder head by a total of nineteen bolts including two that are shared with the coolant outlet elbow Two 3 port gaskets are used between the water manifold and the cylinder head 1 Connecting Pipe 7 Bolt 2 Water Manifold 8 Plug 3 Bolt 9 Bolt 4 Bolt 10 Bolt 5 Coolant Outlet Elbow 11 Gasket 6 Gasket Figure 6 1 DD15 DD16 Water Manifold and Related Parts All information subject to change ...

Page 92: ... Bolt M8 x 40 6 qty 4 Cylinder Head 2 Bolt M8 x 80 5 qty 5 Connecting Pipe 3 Bolt M8 x 100 6 qty 6 Water Manifold Figure 6 2 DD15 DD16 Water Manifold and Related Parts All information subject to change without notice 6 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 93: ... wrench while removing the coolant lines 6 Disconnect and remove doser coolant lines and remove retaining clips 7 Disconnect EGR cooler vent line 8 Disconnect the outlet coolant temperature sensor electrical harness connector 9 Remove EGR actuator coolant outlet line 10 Remove upper radiator hose 11 Remove four coolant outlet elbow bolts 1 and remove the coolant outlet elbow 2 Remove and discard t...

Page 94: ...lts 14 Loosen six lower water manifold bolts 15 Remove two bolts from the retaining strap for the water manifold outlet to the coolant crossover pipe 16 Remove water manifold 17 Remove and discard water manifold gaskets All information subject to change without notice 6 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 95: ...DD16 WATER MANIFOLD Clean and inspect as follows 1 Clean the water manifold 2 Inspect the water manifold for damage or cracks replace if necessary 3 Replace the gaskets All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 6 7 ...

Page 96: ...lling water manifold to the cylinder head 1 Install water manifold gaskets and connecting pipe onto the water manifold 2 Install six lower water manifold bolts and start by a few threads 3 Install water manifold onto cylinder head 4 Install eleven upper water manifold bolts 5 Torque the water manifolds bolts to 30 N m 22 lb ft using the torque sequence illustrated below 6 Install EGR cooler to wat...

Page 97: ...coolant lines Torque to 15 N m 11 lb ft 13 Install the EGR hot pipe Refer to section 14 Install the exhaust manifold heat shields Refer to section 15 Install the air cleaner Refer to OEM procedures 16 Fill engine with coolant to the correct level ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 17 Start the engi...

Page 98: ... section Removal of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly refer to section Inspection of the DD13 EGR Cooler Water Manifold Assembly refer to section Testing and Inspection of the DD13 EGR Cooler Water Manifold Assembly refer to section Installation of the DD13 EGR Cooler Water Manifold Assembly refer to section All information subject to change without notice 6 10 DDC SVC ...

Page 99: ...SCRIPTION AND OPERATION OF COLD BOOST PIPE CHARGE AIR PIPE AND RELATED COMPONENTS 7 3 7 2 REMOVAL OF THE COLD BOOST PIPE CHARGE AIR PIPE 7 4 7 3 INSPECTION OF COLD BOOST PIPE CHARGE AIR PIPE 7 5 7 4 INSTALLATION OF THE COLD BOOST PIPE CHARGE AIR PIPE 7 6 ...

Page 101: ... intake manifold and is a component of the EGR System 1 Bolt 8 Cold Boost Pipe 2 Bracket 9 Spacer 3 Bolt 10 Isolators 4 Adaptor 11 Washer 5 Gasket 12 Bracket to Oil Coolant Module 6 Intake Throttle Valve 13 Bolt 7 Gasket 14 Bolt Figure 7 1 Cold Boost Pipe and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 7 3 ...

Page 102: ...e Air Cooler CAC hose clamp at the CAC 4 Remove the four bolts securing the cold boost pipe to the intake manifold 5 Remove two bolts at cold boost pipe bracket on oil module 6 Remove the cold boost pipe 7 If the Intake Throttle Valve is required to be removed from the Cold Boost Pipe refer to section All information subject to change without notice 7 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT...

Page 103: ...Inspect the cold boost pipe for cracks flange damage blockage and leaks replace if necessary NOTICE If the cold boost pipe is damaged on the interior the pipe needs to be replaced All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 7 5 ...

Page 104: ...old 3 Secure cold boost pipe to intake manifold with four bolts Torque bolts to 30 N m 22 lb ft 4 Attach support bracket to oil module with two bolts 5 Install EGR mixer pipe 6 If removed install seal intake throttle valve and adaptor onto cold boost pipe Torque four bolts to 30 38 N m 22 28 lb ft 7 Connect the sensor harness All information subject to change without notice 7 6 DDC SVC MAN 0081 20...

Page 105: ...ESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS 8 3 8 2 REMOVAL OF AIR INTAKE MANIFOLD 8 6 8 3 CLEANING OF THE AIR INTAKE MANIFOLD 8 7 8 4 INSPECTION OF THE AIR INTAKE MANIFOLD 8 8 8 5 INSTALLATION OF AIR INTAKE MANIFOLD 8 9 ...

Page 107: ... to maintain seal under higher boost pressure An intake manifold air temperature sensor is installed to the intake manifold The Exhaust Gas Recirculation EGR mixer intake throttle valve and adaptor installed to the air inlet of the intake manifold CAC ducting is installed on the intake throttle valve adaptor For EPA07 engines there is a pressure combination sensor in the cold boost pipe and a temp...

Page 108: ...anifold Temperature Sensor 7 Cold Boost Pipe 18 Gasket Cold Boost Pipe 8 Flanged Screw Intake Manifold to Cylinder Head 19 Bolt Cold Boost Pipe to Intake Manifold 9 Flanged Screw Intake Manifold to Cylinder Head 20 Bolt 10 Isolator Gasket 21 Shield 11 Intake Manifold 22 Bracket to Oil Coolant Module 23 Charge Air Pressure Sensor EPA10 Combination Sensor Figure 8 1 DD13 Air Intake Manifold and Rela...

Page 109: ... 12 Turbocharger Outlet Pipe 20 Charge Air Pressure Sensor 5 Air Temperature Sensor Guard 13 Intake Manifold Air Temperature Sensor 21 Bracket to Oil Coolant Module 6 Bolt 14 Intake Manifold 22 Shield 7 Bolt Intake Manifold to Cylinder Head 15 Gasket Intake Manifold 23 Air Temperature Sensor I Cooler Out 8 Isolator Gasket 16 Gasket Cold Boost Pipe Figure 8 2 DD15 Air Intake Manifold and Related Pa...

Page 110: ...nes connected to the common rail and output side of the high pressure fuel pump Refer to section 9 Disconnect and remove the fuel line connected to the common rail and base of the fuel filter housing 10 Disconnect and remove the air intake pressure sensor electrical harness connectors from the two air intake sensors 11 Identify the bolt locations prior to removal of bolts 12 Remove the thirteen fl...

Page 111: ...ing surfaces 2 Wash all of the parts in clean fuel oil EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 3 Blow dry with compressed air All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 8 7 ...

Page 112: ...inder head a If the manifold mating surface has imperfections replace the intake manifold b If the manifold mating surface is not damaged reuse part 3 Laying a 0 5 cm 20 in long by 6 mm 1 4 in wide straight edge across the intake manifold check the mating ports surfaces for warping a If all port flange area measurements are less than 0 127 mm 0 005 in the manifold is reusable and can be reinstalle...

Page 113: ...ectrical harness connectors to appropriate sensors 4 Install oil coolant module Refer to section 26 3 5 Install fuel module Refer to section 6 Install cold boost pipe Refer to section 7 4 7 Install exhaust gas recirculation EGR mixer pipe and delivery pipe Refer to section 8 Install the poly V belts Refer to section 40 3 9 Prime fuel system Refer to section 10 Fill the cooling system Refer to OEM ...

Page 115: ...13 TURBOCHARGER AND RELATED PARTS 9 3 9 2 REMOVAL OF THE DD13 TURBOCHARGER 9 5 9 3 INSPECTION OF THE DD13 TURBOCHARGER 9 9 9 4 INSTALLATION OF THE DD13 TURBOCHARGER 9 10 9 5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE 9 12 ...

Page 117: ...e to the charge air cooler The compressed air is cooled in the charge air cooler permitting a more dense charge of air to be delivered to the engine and therefore engine output is increased The charge air then passes from charge air cooler into the intake manifold The turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold The turbocharger is mounted on the exhaust outl...

Page 118: ...cket 9 Stud 15 Turbo Outlet Elbow Pipe 4 Bracket 10 Gasket 16 Heat Shield 5 Stud 6 qty 11 Turbocharger 17 Air Hose 6 Bolt 12 Turbo Inlet Pipe 18 Electronic Proportioning Valve Figure 9 1 EPA10 DD13 Turbocharger and Related Parts All information subject to change without notice 9 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 119: ...nd exhaust ducting Damaged oil drain lines Cracked or deteriorating turbocharger housing External oil leakage or exhaust leaks Replace damaged parts with new parts To remove the turbocharger perform the following NOTICE Do not attempt to remove carbon or dirt buildup on the compressor or turbine wheels without removing the turbocharger from the engine If chunks of carbon are left on the blades an ...

Page 120: ...ove the O ring from the cylinder block 5 Remove the fuel inlet line and coolant inlet and outlet lines from the doser injection valve 6 To prevent coolant from spilling without draining the coolant system cap the banjo bolt inlet and outlet coolant lines with a nut 7 Disconnect the electrical wiring harness from the turbocharger speed sensor All information subject to change without notice 9 6 DDC...

Page 121: ...ng a heavy engine component ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling 12 Attach a chain hoist and a suitable lifting sling to the turbocharger assembly 13 Remove the two bolts from the turbocharger support bracket to the cylinder block 14 Lower the turbocharger assembly away from the exhaust manifold and pla...

Page 122: ...llow the chemical manufacturer s usage handling and disposal instructions Observe all manufacturer s cautions 17 Clean the exterior of the turbocharger with a non caustic cleaning solvent All information subject to change without notice 9 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 123: ...e damage For DD13 refer to section 9 2 a Remove defective turbocharger from the engine b Tag removed turbocharger for remanufacture c Install a new turbocharger to the engine ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 7 Start the engine 8 Run the engine speed to full load 9 Visually inspect the exhaust for...

Page 124: ...s oil and coolant outlet lines and drain openings on the turbocharger 4 Place a new gasket face up with the tab towards outside on the exhaust manifold turbocharger flange 5 Place the turbocharger assembly into position on the exhaust manifold flange studs Tighten the nuts just enough to hold the turbocharger in place 6 Torque the turbocharger exhaust manifold nuts to 50 N m 37 lb ft 7 Install a n...

Page 125: ...ge to the exhaust manifold 13 Install the coolant inlet and outlet lines to the doser injector housing Torque to 15 N m 11 lb ft 14 Install the fuel line to the doser injection valve Torque to 23 25 N m 17 18 lb ft 15 Install the turbocharger heat shields 16 Install the two bolts to the turbocharger support bracket and turbocharger Torque the bolts to 25 N m 18 lb ft 17 Install the compressor elbo...

Page 126: ... 20 Gasket 3 Coolant Delivery Pipe 12 Bolt 21 Bolt 4 Bolt 13 Bolt 22 Venturi 5 Support 14 Coolant Outlet Elbow 23 Mixer Pipe 6 Connecting Tube 15 Gasket 24 O ring 7 Connecting Tube 16 EGR Cooler Water Manifold Assembly 25 Bolt 8 Gasket 17 Clamps 26 Bolt 9 Seal Ring 18 EGR Hot Pipe 27 Front Lifting Eye Figure 9 2 EPA10 DD13 EGR Cooler Water Manifold and Related Parts All information subject to chan...

Page 127: ...ort 14 Outlet Nipple 23 Mixer Pipe 6 Coolant Connecting Tube 15 Seal 24 Seal Ring 7 Exhaust Gas Connecting Tube 16 Exhaust Gas Recirculation Cooler Water Manifold Assembly 25 Bolt 8 Gasket 17 Clamps 26 Bolt 9 Seal Ring 18 Hot Pipe Figure 9 3 EPA07 DD13 EGR Cooler Water Manifold and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CO...

Page 128: ...ng brake chock the wheels and perform any other applicable safety steps 2 Remove the clamps 2 and the EGR hot pipe 3 from the EGR cooler and inspect for any signs of liquid or moisture The hot pipe and EGR cooler inlet should have a black dry soot residue inside Refer to section a If liquid or moisture is present in the pipe go to the next step b If there is no sign of liquid or moisture in the pi...

Page 129: ...rom the cold boost pipe 1 Refer to section 4 Remove the Exhaust Gas Crossover Tube 2 gasket 4 venturi 6 lifting eye 8 and connecting tube 1 from the EGR cooler All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 9 15 ...

Page 130: ... a rubber tipped blow gun blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel soot and carbon 7 After performing the cleaning procedure refer to section to install the a mixer pipe b exhaust gas crossover tube lifting eye EPA07 engines and exhaust gas crossover tube EPA10 engines c venturi 8 If the cooler has an excessive amount of buildup that cannot be r...

Page 131: ...D13 WASTEGATE SOLENOID Section Page 10 1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID 10 3 10 2 REMOVAL OF THE DD13 WASTEGATE SOLENOID 10 4 10 3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID 10 6 ...

Page 133: ...ol the turbocharger wastegate The MCM uses a PWM signal to activate the wastegate solenoid to control the available air pressure to the wastegate on the turbocharger There are many operating conditions that require use of the wastegate solenoid All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 10 3 ...

Page 134: ...emove as follows 1 Disconnect the electrical harness connector 1 from the wastegate solenoid 2 Remove the hose clamp 2 and remove the air line 1 from the wastegate solenoid All information subject to change without notice 10 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 135: ... air supply 1 to the wastegate solenoid 4 Remove the bolt 3 and the nut 2 from the stud 1 and remove the wastegate solenoid from the cylinder block All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 10 5 ...

Page 136: ...k boss Torque the stud to 10 N m 7 4 lb ft 2 Install the wastegate solenoid on the cylinder block 3 Install the bolt 3 and the nut 2 Torque each to 30 N m 22 lb ft 4 Install the vehicle air supply 1 to the wastegate solenoid Torque to 25 N m 18 lb ft All information subject to change without notice 10 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 137: ...ENGINE 5 Install the air line to the wastegate solenoid and tighten hose clamp 6 Connect the wastegate solenoid connector All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 10 7 ...

Page 139: ...TURBOCHARGER AND RELATED PARTS 11 3 11 2 REMOVAL OF DD15 TURBOCHARGER 11 5 11 3 INSPECTION OF DD15 TURBOCHARGER 11 7 11 4 INSTALLATION OF DD15 TURBOCHARGER 11 8 11 5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE 11 10 ...

Page 141: ...ipe to the charge air cooler The compressed air is cooled in the charge air cooler permitting a more dense charge of air to be delivered to the engine and therefore engine output is increased The charge air then passes from charge air cooler into the intake manifold The turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold The turbocharger is mounted on the exhaust ou...

Page 142: ...M10 x 20 mm 20 Bolt 28 Turbo Speed Sensor 5 Gear Box 13 Axial Power Turbine 21 Gasket 29 Clamp 6 Bolt M10 x 65 mm 14 Clamp 22 Turbocharger 30 Turbo Outlet Elbow 7 Gasket Seal 15 Bolts 23 Clamp 31 Heat Shield 8 O ring 16 Air Line 24 Turbo Inlet Elbow 32 Heat Shield Mounting Bolt Figure 11 1 EPA07 and EPA10 DD15 Turbocharger and Related Parts All information subject to change without notice 11 4 DDC...

Page 143: ...housings External oil leakage or exhaust leaks Replace damaged parts with new parts To remove the turbocharger perform the following NOTICE Do not attempt to remove carbon or dirt buildup on the compressor or turbine wheels without removing the turbocharger from the engine If chunks of carbon are left on the blades an unbalanced condition will exist and subsequent failure of the bearings will resu...

Page 144: ...mponent is properly supported and securely attached to an adequate lifting device to prevent the component from falling 10 Attach a chain hoist and a suitable lifting sling to the turbocharger assembly NOTICE Turbocharger must be supported when removing the mounting bolts to avoid damage to the turbocharger 11 Lift the turbocharger assembly away from the engine and place it on a bench 12 Cover tur...

Page 145: ...ble damage Refer to section 11 2 a Remove defective turbocharger from the engine b Tag removed turbocharger for remanufacture c Install a new turbocharger to the engine ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 7 Start the engine 8 Run the engine speed to full load 9 Visually inspect the exhaust for exces...

Page 146: ...ant inlet and drain lines and the oil and coolant inlet and drain openings on the turbocharger 8 Install new turbocharger flange gasket with the tab facing the rear of the engine NOTICE The turbocharger must be supported after it has been installed to the exhaust manifold flange to avoid damage to the turbocharger 9 Secure the turbocharger to the exhaust flange Hand tighten bolts NOTE Do not use a...

Page 147: ... the drain line that runs to the cylinder block Torque the bolts to 30 38 N m 22 28 lb ft 15 Install turbocharger oil supply line Torque line to 30 N m 22 lb ft 16 Install heat shields 17 Install compressor elbow and charge air compressor plumbing Torque clamps to 6 N m 4 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 11 9 ...

Page 148: ...Bolt 11 Banjo Union 20 Support 3 Gasket 12 Banjo Bolt 21 Clamp 4 Bolt 13 Exhaust Gas Cooler 22 Hose 5 Exhaust Gas Crossover Tube 14 Strap 23 Mixer Pipe 6 Bolt 15 Shim 24 Coolant Crossover Pipe 7 Lifting Eye 16 Clamp 25 Seal Ring 8 Coolant Connecting Tube 17 Seal Washer 9 Connecting Tube 18 EGR Hot Pipe Figure 11 2 EPA10 DD15 EGR Cooler and Related Parts All information subject to change without no...

Page 149: ... Strap 20 Hose 5 Exhaust Gas Crossover Tube Lifting Eye 13 Shim 21 Mixer Pipe 6 Connecting Tube 14 Clamp 22 Coolant Delivery Pipe 7 Connecting Tube 15 Metal Seal 23 Seal Ring 8 Seal Ring 16 Hot Pipe Figure 11 3 EPA07 DD15 EGR Cooler and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 11 11 ...

Page 150: ...ke chock the wheels and perform any other applicable safety steps 2 Remove the EGR hot pipe 4 and gaskets 3 and inspect for any signs of liquid or moisture The hot pipe and EGR cooler inlet should have a black dry soot residue inside a If liquid or moisture is present in the pipe go to the next step b If there is no sign of liquid or moisture in the pipe or EGR cooler install the hot pipe No furth...

Page 151: ...si air pressure 6 Using a rubber tipped blow gun blow compressed shop air into the individual tubes in the EGR cooler to clear any excess fuel soot and carbon 7 After performing the cleaning procedure refer to section to install the a mixer pipe b exhaust gas crossover tube lifting eye EPA07 engines and exhaust gas crossover tube EPA10 engines c venturi 8 If the cooler has an excessive amount of b...

Page 152: ...OOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE All information subject to change without notice 11 14 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 153: ... Page 12 1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS 12 3 12 2 REMOVAL OF DD15 AXIAL POWER TURBINE 12 5 12 3 INSPECTION OF THE DD15 AXIAL POWER TURBINE 12 6 12 4 INSTALLATION OF DD15 AXIAL POWER TURBINE 12 7 ...

Page 155: ... hydrodynamic clutch impeller is a part of the hydrodynamic clutch housing The vanes on the impeller generate an oil flow in the hydrodynamic clutch which sets the turbine wheel of the hydrodynamic clutch into rotation and the output gear is driven over a shaft The generated torque is transferred through the idler gear number four to the crankshaft gear It is also possible to ensure via the hydrod...

Page 156: ...0 mm 12 Bolt M10 x 20 mm 20 Bolt 28 Turbo Speed Sensor 5 Gear Box 13 Axial Power Turbine 21 Gasket 29 Clamp 6 Bolt M10 x 65 mm 14 Clamp 22 Turbocharger 30 Turbo Outlet Elbow 7 Gasket Seal 15 Bolts 23 Clamp 31 Heat Shield 8 O ring 16 Air Line 24 Turbo Inlet Elbow 32 Heat Shield Mounting Bolt Figure 12 1 Axial Power Turbine and Related Parts All information subject to change without notice 12 4 DDC ...

Page 157: ...S pipe from APT outlet by removing the marmon clamp 5 Remove the EGR hot pipe Refer to section 6 Remove the turbocharger and interstage duct Refer to section 11 2 7 Remove the air line from the air seal pressure regulator valve or from the compressor housing of the turbocharger 8 Remove four bolts securing the gear box to the axial power turbine 9 Remove four bolts from the APT support bracket 10 ...

Page 158: ... TURBINE Inspect as follows 1 Inspect axial power turbine for damage to the turbine and housing replace if necessary 2 Inspect the gear box for damage replace if necessary All information subject to change without notice 12 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 159: ...gear box ensure gears are aligned by viewing through exhaust port and rotating impeller Damage to gear box and axial power turbine will occur if not installed correctly 6 Install the front bolt through the APT into the gear box and hand tighten the bolt 7 Install two bolts through the bracket into the axial power turbine then install two bolts through the bracket into the cylinder block Install th...

Page 161: ...SCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS 13 3 13 2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX 13 5 13 3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX 13 6 13 4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX 13 7 ...

Page 163: ...F DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS The gear box is located on the right side of the engine between the axial power turbine and cylinder block All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 13 3 ...

Page 164: ...lt M10 x 90 mm 12 Bolt M10 x 20 mm 20 Bolt 28 Turbo Speed Sensor 5 Gear Box 13 Axial Power Turbine 21 Gasket 29 Clamp 6 Bolt M10 x 65 mm 14 Clamp 22 Turbocharger 30 Turbo Outlet Elbow 7 Gasket Seal 15 Bolts 23 Clamp 31 Heat Shield 8 O ring 16 Air Line 24 Turbo Inlet Elbow 32 Heat Shield Mounting Bolt Figure 13 1 Gear Box and Related Parts All information subject to change without notice 13 4 DDC S...

Page 165: ... 11 2 2 Remove the Axial Power Turbine APT Refer to section 12 2 3 Remove the oil line from cylinder block to gear box 4 Remove four bolts from the axial power turbine gear box to the cylinder block and remove the axial power turbine gear box All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 13 5 ...

Page 166: ...URBINE GEAR BOX 13 3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX Inspect the gear box for damage replace if necessary All information subject to change without notice 13 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 167: ... 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 for the bolt installed in the upper location near the cylinder block is 35 mm 1 37 in The correct length for the bolt located in the lower position of the gear box is 120 mm 4 72 in 2 Install four bolts into gear box and cylinder bloc...

Page 169: ...F CYLINDER HEAD 14 18 14 7 INSTALLATION OF THE DD15 CYLINDER HEAD 14 19 14 8 REMOVAL OF VALVE SPRING CYLINDER HEAD INSTALLED 14 22 14 9 REMOVAL OF THE VALVE SPRING CYLINDER HEAD REMOVED 14 24 14 10 REMOVAL OF INTAKE AND EXHAUST VALVES 14 25 14 11 CLEANING OF VALVES AND RELATED PARTS 14 26 14 12 INSPECTION OF VALVE SPRINGS 14 27 14 13 INSPECTION OF VALVE 14 28 14 14 INSTALLATION OF VALVE SPRING SEA...

Page 171: ...e The valve train assembly needs to be removed in order to access the cylinder head bolts The cylinder head has a split coolant jacket the coolant flows around the cylinder to the inlet side of the head and then to the exhaust side The coolant flows in the lower level of the cylinder head around the injectors and the valve seat rings The coolant then flows around in the upper level of the cylinder...

Page 172: ...er Head 2 Water Return Openings from Cylinder Head to Cylinder Block Figure 14 2 Water Hole Location on Fire Deck of Cylinder Head 1 Upper Cooling Level 2 Lower Cooling Level Figure 14 3 Cooling Levels All information subject to change without notice 14 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 173: ...at treated alloys with precision ground heads and stems Stem ends are hardened to minimize wear in contact with the valve rocker buttons All valves are retained by valve spring caps and two piece tapered valve locks Valve stem oil seals are installed on both intake and exhaust valves to provide controlled valve stem lubrication while limiting oil consumption All information subject to change witho...

Page 174: ... face 1 Exhaust Rocker Arm 8 Valve Spring 2 Exhaust Rocker Arm with Actuator 9 Intake Rocker Arm 3 Brake Rocker Arm 10 Intake Rocker Arm Shaft 4 Exhaust Rocker Arm Shaft 11 Drive Gear for Intake Camshaft 5 Drive Gear for Exhaust Camshaft 12 Intake Camshaft 6 Exhaust Camshaft 13 Intake Valve 7 Exhaust Valve 14 Camshaft Housing Figure 14 5 Valves Rocker Arms and Related Parts All information subject...

Page 175: ...Intake Valve Spring 5 Intake Valve 14 Water Jacket Cover Plug 6 Cylinder Head 15 Water Jacket Seal Ring Plug 7 Washer 16 Water Protection Sleeve Seal Ring 8 Valve Guide 17 Injector Cup 9 Valve Stem Seal 18 Cylinder Head to Cylinder Block Bolt Figure 14 6 Valves and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 14 7 ...

Page 176: ...aust Rocker Arm with Actuator 3 Exhaust Rocker Arm 6 Exhaust Rocker Arm Figure 14 7 Exhaust Valve Assembly 1 Intake Valves 3 Drive Gear and Timing Wheel for Intake Camshaft 2 Valve Springs Figure 14 8 Intake Valve Assembly All information subject to change without notice 14 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 177: ...M WORKSHOP MANUAL ENGINE 1 Inlet Valves 2 Exhaust Valves Figure 14 9 Intake and Exhaust Valve Location All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 14 9 ...

Page 178: ...fold Air Temperature sensor d Throttle Valve e Intake Air Temperature sensor 9 Remove the removal of high pressure fuel injector lines Refer to section 10 Remove high pressure fuel lines from fuel rail to high pressure fuel pump Refer to section 11 Remove amplifier return line needle return line and pressure limiting valve PLV lines Refer to section 12 Disconnect fuel injector harness from the fue...

Page 179: ...valve bracket remove the clip attaching it 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 22 Using Cylinder Head Engine Lifting Bar tool W470589006200 remove the cylinder head from the cylinder block 23 Remove and discard the met...

Page 180: ...section 16 5for cylinder liner protrusion specifications 3 Install cylinder head guide studs W471589016100 4 Position a new cylinder head gasket onto the cylinder block 1 Engine Oil Feed Hole 4 Coolant Return Opening 2 Engine Oil Return Opening 5 Opening for Blow by Duct to Crankcase Vent 3 Coolant Feed Hole PERSONAL INJURY To avoid injury when removing or installing a heavy engine component ensur...

Page 181: ...ws a 200 N m 147 lb ft b 90 torque turn c 90 torque turn 11 Torque the small bolts 39 and 40 to 60 N m 44 lb ft 12 Check and adjust the gear lash as needed Refer to section 5 2 13 Install the turbocharger flange bolts 14 Install the EGR crossover tube Refer to section 15 Install the EGR actuator harness connector linkage and the heat shield 16 Install the coolant lines to EGR actuator 17 Install t...

Page 182: ...emperature sensor harness 29 Install the turbocharger inlet pipe 30 Install any components that were removed and fill with required fluids as recommended Refer to OEM guidelines 31 Set the valve lash and engine brake Refer to section 14 15 ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 32 Install the rocker co...

Page 183: ...er to OEM procedure 3 Drain the fuel system Refer to section 4 Drain the oil Refer to OEM procedure 5 Drain the coolant Refer to OEM procedure 6 Remove the turbocharger inlet pipe Refer to OEM procedure 7 Remove the rocker cover Refer to section 1 2 8 Disconnect the following electrical harness connections a Coolant Outlet Temperature sensor harness from the water manifold b Delta p sensor c Intak...

Page 184: ...emove the turbocharger flange bolts 21 Remove the EGR crossover tube Refer to section 22 Remove the two bolts attaching the cold boost pipe to the support bracket 23 Using the Flywheel and Main Pulley Socket tool J 45390 remove the 40 bolts securing the cylinder head to the cylinder block PERSONAL INJURY To avoid injury when removing or installing a heavy engine component ensure the component is p...

Page 185: ... it has been stripped 4 Clean the head in a de scaling bath EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 5 Clean the valves springs and rocker shafts in fuel oil and blow dry with compressed air 6 Clean the rocker arm assemblies All information subject to change witho...

Page 186: ...g sealant such as Loctite 620 or equivalent on the cup plugs Use Cup Plug Installation Set J 35653 2 Ensure that all cup plugs on the front face of the cylinder head are flush or below the surface 3 Install valves valve stem seals valve springs and keepers All information subject to change without notice 14 18 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 187: ...stalling the cylinder head 3 Install Cylinder Head Guide Studs tool J 35784 4 Position a new cylinder head gasket onto engine block 1 Engine Oil Feed Hole 4 Coolant Return Opening 2 Engine Oil Return Opening 5 Opening for Blow by Duct to Crankcase Vent 3 Coolant Feed Hole PERSONAL INJURY To avoid injury when removing or installing a heavy engine component ensure the component is properly supported...

Page 188: ...arge bolts in four steps to a 50 N m 37 lb ft b 250 N m 184 lb ft c 90 torque turn d 90 torque turn 12 Torque the small bolts 39 and 40 to 60 N m 44 lb ft 13 Install camshaft housing Refer to section 3 3 14 Install camshaft assemblies Refer to section 2 4 15 Time camshaft assembly Refer to section 4 2 16 Install rocker shaft assembly Refer to section 2 4 17 Set the valve lash and engine brake Refe...

Page 189: ...the engine in a well ventilated area Engine exhaust is toxic 20 Prime engine lubrication system Refer to section 27 1 21 Start the engine and check for fuel coolant or oil leaks 22 Shut down the engine All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 14 21 ...

Page 190: ...ad Center TDC After servicing a cylinder turn the crankshaft to TDC for the next cylinder being serviced 7 Remove the fuel injector from the appropriate cylinder Refer to section 8 Using Engine Barring Tool J 46392 bar the engine over until the cylinder is at Top Dead Center TDC EYE INJURY To avoid injury from flying debris when using compressed air wear adequate eye protection face shield or safe...

Page 191: ...TICE Do not contact the valve with the compressor tool 11 Compress the valve spring and remove the valve locks using a small magnet to prevent the locks from falling into the cylinder head oil return galleries 12 Release the spring and remove the valve cap and valve spring If the valve stem oil seal is to be replaced remove the seal and discard it All information subject to change without notice D...

Page 192: ...p and valve spring 3 Remove the valve stem oil seal and discard the seal 4 Remove the valve spring seat 5 As parts are removed mark or segregate them according to their original position for possible reuse 6 Mark the location of each intake and exhaust valve in accordance to its cylinder number and whether it is an intake or an exhaust valve 7 Flip the cylinder head over and carefully remove the v...

Page 193: ...ve as follows 1 Remove the cylinder head a For the DD13 ONLY Refer to section 14 2 b For the DD15 ONLY Refer to section 14 4 2 Remove the valve spring s Refer to section 14 9 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 14 25 ...

Page 194: ...1 Using proper eye protection clean all of the disassembled parts with fuel oil and dry with compressed air 2 Clean the carbon from the valve stems and wash the valves with fuel oil 3 Clean the valve guide bore to remove all gum and carbon deposits use bore brush J 5437 or equivalent for this procedure NOTICE If a valve is removed through a stem seal the stem seal must be replaced All information ...

Page 195: ...e entire spring should be inspected When a broken spring is replaced the spring retainer and valve locks for that valve and spring should also be replaced NOTE If a valve is removed through a stem seal the stem seal must be replaced All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 14 27 ...

Page 196: ...s normal and is acceptable as long as no leak paths are evident If leak paths exist re face the valves or install new valves If the valve heads are warped or the valve stem is bent replace the valves See Figures 14 10 and 14 11 Figure 14 10 Exhaust Valve Figure 14 11 Intake Valve All information subject to change without notice 14 28 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 197: ... seal down on the valve stem using the seal installer J 47490 When the installer tool contacts the cylinder head the seal is correctly positioned Be sure the installer is square against the cylinder head Remove the seal installer and protector cap 7 Install the valve spring and retainer If reusing parts install them to their original positions NOTE Always install new valve stem locks when installi...

Page 198: ... opened and fill the cooling system Purge the air from the system using the vent in the thermostat housing Complete filling of the cooling system is essential for proper engine operation ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 14 Start the engine and check for leaks All information subject to change wit...

Page 199: ...gradual degrading of engine performance and reduced fuel combustion efficiency Adjust the valves as follows 1 Turn engine OFF key OFF engine OFF 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 5 Remove air cleaner housing 6 Remove the rocker cover Refer to section 1 2 7 Bar the engine ...

Page 200: ...392 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 Refer to section 14 16 All information subject to change without notice 14 32 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION...

Page 201: ...ee six two then four 4 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 Using Engine Brake Adjustment tool W470589022300 set the lash to 4 1 mm 0 1614 in 5 Lash the engine brakes in the following firing order 1 5 3 6 2 and 4 6 Torque the locknut valve adjusting screw to 50 N m 37 lb f...

Page 203: ...D RELATED PARTS 15 3 15 2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY 15 5 15 3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY 15 7 15 4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY 15 8 15 5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY 15 9 15 6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY 15 11 ...

Page 205: ... rod bushing is pressed into the small end of the connecting rod 1 Connecting Rod Bolt 2 qty 6 Oil Control Ring 2 Connecting Rod Bushing 7 Compression Ring 3 Retaining Ring 2 qty 8 Fire Ring 4 Piston Pin 9 Connecting Rod 5 Piston Figure 15 1 Piston and Connecting Rod Assembly All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 15 3 ...

Page 206: ...g 8 1 Piston Skirt 8 Fire Ring 2 Cover Plate EPA07 pistons only 9 Cooling Galley 3 Piston Pin 10 Combustion Bowl 4 Retaining Clip 11 Piston Dome 5 Piston Boss 12 Top Land 6 Oil Control Ring 13 Second Land 7 Compression Ring Figure 15 2 Piston All information subject to change without notice 15 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 207: ...9 2 4 Remove the camshaft housing and associated parts Refer to section 3 1 5 Remove the cylinder head and gasket a For DD13 ONLY refer to section 14 2 b For DD15 ONLY refer to section 14 4 6 Use Scotch Brite pads to remove any carbon deposits from the upper inner surface of the cylinder liner 1 Carbon Deposits in Cylinder Liners All information subject to change without notice DDC SVC MAN 0081 20...

Page 208: ...ap will occur if it is placed on end the connecting rod assembly will need to be replaced if the cap is damaged 10 Remove the piston and connecting rod assembly through the top of the cylinder liner 11 Assemble the connecting rod bearing cap and lower bearing shell to the connecting rod after removal If not already marked match mark the rod and cap on the tang side with the cylinder number from wh...

Page 209: ... NOTICE Stamping cylinder numbers on the piston assembly will damage the components Disassemble piston and connecting rod assembly as follows 1 Place the piston dome down on the table 2 Using appropriate flat nosed pliers remove the retaining rings from the piston boss 3 Slide out the piston wrist pin and remove the connecting rod from piston All information subject to change without notice DDC SV...

Page 210: ...SSEMBLY Inspect as follows 1 Inspect the connecting rod and bearing cap for damage replace as necessary 2 Inspect the piston wrist pin and piston rings for damage replace as necessary All information subject to change without notice 15 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 211: ...o a retaining ring recess in the piston Orient the retaining ring gap 1 to either the 12 o clock or 6 o clock position 2 Liberally lubricate the piston pin bore the piston pin and the connecting rod bushing in the small end of the connecting rod with 80 90w oil or equivalent All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 15 9 ...

Page 212: ...e rod until it rests against the previously installed retaining ring 5 Using the appropriate flat nosed pliers install the other retaining ring into the retaining ring recess in the piston boss to lock the pin in place Orient the retaining ring gap to either the 12 o clock or 6 o clock position All information subject to change without notice 15 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIES...

Page 213: ...he top groove 2 Allowable new ring end gaps for A B and C are shown below Ring Ring End Gap Fire Ring A 0 35 0 75 mm 0 024 0 030 in Compression Ring B 0 7 0 9 mm 0 027 0 035 in Oil Control Ring C 0 4 0 6 mm 0 016 0 024 in Table 15 1 Allowable Ring End Gaps 3 Add clean engine oil to a clean pan at least 305 mm 12 in in diameter until the level reaches approximately 76 mm 3 in 4 Place the piston and...

Page 214: ...gs and ring lands 7 Coat the inside diameter of the piston ring compression tool with clean engine oil a For the DD13 use Piston Ring Compressor tool W470589005900 b For the DD15 use Piston Ring Compressor tool J 47386 All information subject to change without notice 15 12 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 215: ... with the piston and connecting rod assembly NOTICE Failure to orient the piston and connecting rod assembly properly during piston installation may result in the bearing end of the rod striking the nozzle causing damage to the nozzle or loosening it from the block A damaged bent or loosened nozzle may cause a loss of main gallery pressure In these cases piston overheating or lack of adequate lubr...

Page 216: ...ylinder liner Therefore care must be taken during the installation of the piston to prevent damage 14 With care and moderate pressure press the piston into the liner 15 Remove the ring compressor 16 Push or tap the piston and connecting rod within the liner until the upper rod bearing is firmly seated on the appropriate crankshaft journal 17 Lubricate the lower bearing shell with clean engine oil ...

Page 217: ...3 DD15 DD16 190 N m 140 lb ft 90 torque turn 115 N m 85 lb ft 180 torque turn 115 N m 85 lb ft 180 torque turn Bearing Cap to Rod Bolt Cap Bolt Maximum Length DD13 DD15 DD16 79 mm 3 11 in 82 3 mm 3 240 in 82 3 mm 3 240 in All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 15 15 ...

Page 218: ...nd rod assemblies in the same manner NOTICE Ensure when installing the piston spray nozzles that damage to the nozzle does not occur Damaged oil spray nozzles could result in a loss of oil pressure to cool the pistons which may cause engine damage 22 Install new piston spray nozzles 1 at the base of the cylinder bores Torque each piston spray nozzle bolt to 30 N m 22 lb ft 23 Using a dial gauge an...

Page 219: ...following a Inspect piston piston pin boss and piston pin for wear or damage If damaged repair as necessary b Inspect connecting rod checking for bent rod piston pin bore wear or damage If damaged repair as necessary c Inspect connecting rod bearings for wear or damage If damage is found replace rod bearings d Inspect crankshaft for damage to rod journal or evidence of spun bearing If damaged repa...

Page 220: ... other engine assembly as necessary 31 After the engine has been completely assembled refill the oil pan to the proper oil level on the dipstick 32 Prime engine lubrication system Refer to section 27 1 33 Close the drain cocks and fill the engine with the recommended coolant NOTE Coolant system maintenance is very important Bleed off all the air from the system and top off 34 Verify repairs made t...

Page 221: ...16 1 DESCRIPTION AND OPERATION OF CYLINDER LINER AND RELATED PARTS 16 3 16 2 REMOVAL OF CYLINDER LINER 16 4 16 3 INSPECTION OF CYLINDER LINER 16 5 16 4 CLEANING OF THE CYLINDER LINER 16 7 16 5 INSTALLATION OF THE CYLINDER LINER 16 8 ...

Page 223: ...he cylinder block Each cylinder liner has 2 sealing rings the upper sealing ring sealed by the upper coolant jacket to the cylinder block bore and the lower sealing ring sealed by the lower coolant jacket to the cylinder block bore 1 Cylinder Liner 5 Lower Coolant Jacket 2 Compression Seal Surface 6 Lower Collar 3 Upper Sealing Ring 7 Lower Sealing Ring 4 Upper Coolant Jacket 8 Bottom Stop Balcony...

Page 224: ...prior to installation always store them in an upright position until ready for use Liners left on their side for any length of time can become egg shaped and distorted making installation in cylinder bores difficult or impossible If the cylinder liners are to be reused they should be marked for cylinder location and engine orientation a paint mark can be used to indicate the front of the engine so...

Page 225: ...o the cylinder and result in major engine damage due to water in the oil or hydraulic lockup b Check the cylinder liner for cavitation If indication of cavitation is present replace the liner c Check for bore polishing if detected replace the cylinder liner 2 Inspect the outside diameter of the liner a Check the liner for fretting b If any fretting is found remove it from the surface of the liner ...

Page 226: ...1 97 to 141 95 mm 5 589 to 5 588 in 148 95 to 148 97 mm 5 864 to 5 865 in 148 95 to 148 97 mm 5 864 to 5 865 in Table 16 1 Acceptable Cylinder Liner Diameters b If the liner does not meet specification replace with a new part 5 Inspect the cylinder liner a Check the two seal ring grooves for burrs or sharp edges b If any are detected smooth with a Scotch Brite pad All information subject to change...

Page 227: ...2 Dry the liner with compressed air NOTICE If the liners are not to be installed at this time oil them lightly with clean engine lubricating oil and store them upright in a clean dry area Do not let the liners rest on their sides and do not store anything on top of the liners 3 Coat the bore of the liner with clean engine lubricating oil 4 Allow the liner to sit for 10 minutes to allow the oil to ...

Page 228: ...es can cause the liner to seat improperly Clean with a wire brush 2 Install the two new seal rings 1 3 onto the cylinder liner 2 NOTE Ensure when installed the seal rings are properly seated in the proper grooves locations 1 and 3 3 Lubricate the seal rings with clean engine oil 4 Install the cylinder liner in cylinder block bore using cylinder liner installation tool J 45876 All information subje...

Page 229: ...l J 47407 128 for the DD13 6 Install the cylinder liner protrusion tool J 47415 onto the cylinder block Thread four cylinder head bolts through the tool and into a head bolt hole and alternately torque the four bolts to 10 N m 7 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 16 9 ...

Page 230: ... liner protrusion exceeds the maximum allowable remove the piston and connecting rod assembly if installed and then remove the liner to check for debris under the liner flange b If the liner protrusion is below the minimum specification contact Detroit Diesel Customer Support Center 313 592 5800 All information subject to change without notice 16 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIE...

Page 231: ... CRANKSHAFT 17 6 17 3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS 17 9 17 4 INSTALLATION OF CRANKSHAFT 17 10 17 5 REMOVAL OF CRANKSHAFT REAR OIL SEAL 17 14 17 6 INSTALLATION OF THE REAR OIL SEAL 17 15 17 7 REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL 17 17 17 8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL 17 18 ...

Page 233: ...e There are oil holes located at the crankshaft bearing journal and the connecting rod journal through which the crankshaft bearing and connecting rod bearing are lubricated NOTE The DD13 engine has four counterweights the DD15 and DD16 each have eight counterweights NOTE The crankshaft throws on the DD16 are longer than on the DD15 crankshaft 1 Crankshaft Bearing Journals 3 Counterweights number ...

Page 234: ...ibration Damper 7 Bolt 3 Cover Plate 8 Flywheel 4 Crankshaft Bearings 9 Ring Gear 5 Connecting Rod Bearings 10 Crankshaft Figure 17 2 DD15 DD16 Crankshaft and Related Parts All information subject to change without notice 17 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 235: ...r Crankshaft Bearing Shells 9 Thrust Washer 4 Lower Connecting Rod Bearing Shells 10 Crankshaft 5 Upper Connecting Rod Bearing Shells 11 Thrust Washer 6 Cylinder Block Figure 17 3 DD13 Crankshaft and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 17 5 ...

Page 236: ...ly supported and securely attached to an adequate lifting device to prevent the component from falling 4 Attach Cylinder Head Engine Lifting Bar tool W470589006200 with hooks to the three engine lifter brackets one at the front and two at the rear Remove all engine to base attaching bolts and remove the engine from its chassis FALLING ENGINE To avoid injury from a falling engine ensure the engine ...

Page 237: ...ley and vibration assembly If the damper is allowed to fall damage to the internal components of the damper may result 10 Loosen and remove two of the crankshaft pulley retaining bolts and hardened washers 180 degrees apart and install Flywheel Guide Studs tool J 36235 in their place Then loosen and remove the remaining six pulley retaining bolts and hardened washers 11 Remove the vibration damper...

Page 238: ...ng caps so that they can be installed to their respective original positions The main bearing caps must be kept in sequence so that they are installed to their original positions 16 Remove the thrust washers from each side of the No 6 main bearing cap 17 Remove the crankshaft All information subject to change without notice 17 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 239: ...surfaces will result in oil leakage at these points If excessively scored replace the crankshaft 6 Check the crankshaft thrust surfaces for excessive wear or grooving If excessively worn replace the crankshaft 7 Inspect the crankshaft gear for damage Replace if necessary 8 Check the crankshaft journal run out Set journals number 1 and number 7 on a pair of V blocks Rotate crankshaft and measure jo...

Page 240: ...oves with petroleum jelly and install with the oil grooved sides facing away from the saddle 4 Apply clean engine oil 360 degrees around all crankshaft bearing journals and install the crankshaft 5 Install the lower main bearing shells in the main bearing caps as follows a Align the tang on the lower main bearing shell with the groove in the main bearing cap Install the bearing shell to the main b...

Page 241: ... pry bar on the other side of the bearing cap Force the crankshaft in the opposite direction and note the amount of end play on the dial c The end play should be 0 099 0 419 mm 0 0039 0 0165 in Insufficient end play can be the result of a misaligned No 6 main bearing a misaligned upper thrust washer or a burr or dirt on the inner face of one or more of the thrust washers 11 For the DD13 torque all...

Page 242: ...a For DD13 ONLY Refer to section 14 3 b For DD15 ONLY refer to section 14 7 15 If removed install the camshaft housing Refer to section 3 3 16 If removed install the gear train Refer to section 5 2 17 Install the flywheel housing Refer to section 34 3 18 Replace the rear crankshaft seal with new seal Refer to section 17 6 19 Install the flywheel Refer to section 34 6 20 Install the oil pump inlet ...

Page 243: ...of the engine and remove the engine from the overhaul stand 25 Remove the overhaul stand adaptor plate from the engine block 26 Install any accessories that were removed 27 Install the engine to the equipment from which it was removed 28 Fill the cooling system Refer to OEM specifications 29 Prime engine lubrication system Refer to section 27 1 30 After replacing the main or connecting rod bearing...

Page 244: ...rill is straight and perpendicular to the seal Failure to drill the holes straight could result in damage to the seal bore resulting in replacement of the flywheel housing NOTE When drilling the holes for screws make sure to coat the drill bit with grease to catch the shavings 2 Drill 3 174 mm 0 125 in pilot holes in the seal 2 use the sheet metal screws and the Rear Crankshaft Seal Installer Remo...

Page 245: ...ear If it is scored or worn replace it 2 Install the new rear seal 2 onto the Rear Crankshaft Seal Installer Remover tool W470589004300 NOTE For ease of installation into the flywheel housing apply a light coating of a soapy water solution to the outer diameter 2 of the seal 3 Position the seal into the flywheel housing 1 All information subject to change without notice DDC SVC MAN 0081 2010 Copyr...

Page 246: ...n the end of the crankshaft 5 Remove tool W470589004300 and visually check the seal and sealing lip for correct installation 6 Install the flywheel into the flywheel housing 1 Refer to section 34 6 All information subject to change without notice 17 16 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 247: ...t the drill is straight and perpendicular to the seal Failure to drill the hole straight could result in damage to the seal bore resulting in the replacement of the front cover NOTE When drilling the holes for screws make sure to coat the drill bit with grease to catch the shavings NOTE Handle the new seal with care Do not bend the seal lip bending the lip will damage the seal and cause it to leak...

Page 248: ...protection face shield or safety goggles and do not exceed 276 kPa 40 psi air pressure 1 Use air to clean the sealing surfaces on the cover and crankshaft NOTE Seal lip should face outward for proper installation NOTE For ease of installation into the front cover apply a light coating of a soapy water solution to the outer diameter 1 of the seal 2 Install a new seal onto plastic seal installation ...

Page 249: ...taller Remover tool W541589023300 to the crankshaft 5 Install the seal by turning the forcing screw until the tool bottoms out on the end of the crankshaft 6 Remove the tool and visually check the seal and sealing lip for correct installation The seal lip should face outward when installed correctly All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESE...

Page 250: ...e vibration damper pulley and torque the eight bolts to 200 N m 147 5 lb ft Refer to section 36 2 8 Install the poly V belts Refer to section 40 3 All information subject to change without notice 17 20 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 251: ...18 LUBRICATION SYSTEM Section Page 18 1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS 18 3 ...

Page 253: ...e Figure 18 2 1 Engine Brake 6 Backflow Valve 11 Oil Refill 2 Turbocharger 7 Suction Pipe 12 Intake Rocker Arm Supply Spindle 3 Crankcase Breather 8 Oil Spray Nozzle 13 Engine Brake Supply 4 Oil Pump 9 Oil Cooler and Housing 14 Exhaust Rocker Arm Supply Spindle 5 Pressure Valve 10 Oil Filter 15 Gear Train Oil Supply 16 Main Bearing Supply Figure 18 1 DD13 Oil Flow Schematic All information subject...

Page 254: ...nkcase Breather 13 Intake Rocker Arm Spindle Supply 5 Oil Pump 14 Engine Brake Supply 6 Pressure Valve 15 Exhaust Rocker Arm Spindle Supply 7 Backflow Valve 16 Gear Train Oil Supply 8 Suction Pipe 17 Main Bearing Supply 9 Oil Spray Nozzle Figure 18 2 DD15 Oil Flow Schematic All information subject to change without notice 18 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 255: ... RELATED COMPONENTS 19 3 19 2 REMOVAL OF OIL PAN 19 4 19 3 CLEANING OF OIL PAN 19 5 19 4 INSPECTION OF OIL PAN 19 6 19 5 REMOVAL OF THREADED INSERT PLASTIC OIL PAN ONLY 19 7 19 6 INSTALLATION OF THREADED INSERT PLASTIC OIL PAN ONLY 19 8 19 7 INSTALLATION OF OIL PAN 19 9 ...

Page 257: ... pan The oil pan seal has high sealing reliability and noise reduction In order to determine the engine oil level there is a conventional oil dipstick 1 Bolt Isolator 5 Bolt 9 Bolt 13 Dipstick Tube 17 Threaded Insert 2 Oil Pan 6 Nut 10 Bolt 14 Clamp 18 Seal Ring 3 Gasket 7 Bracket 11 Bracket 15 Adapter 19 Connecting Nut 4 Bolt 8 Clamp 12 Bracket 16 Seal 20 Seal Ring 21 Drain Plug Figure 19 1 Oil P...

Page 258: ...pan Refer to section 20 2 5 Remove bolt at harness P clamp on front center of oil pan 6 Loosen the eighteen oil pan bolts Bolts will remain installed to the pan 7 Remove the oil pan taking care not to damage the oil pump inlet pipe and screen 8 Remove the oil pan seal and check for damage All information subject to change without notice 19 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORP...

Page 259: ...uate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure 2 Dry with compressed air NOTICE Do not use solvents to clean gaskets Damage to the gasket will result 3 Clean the surfaces the cylinder block all four T joints front cover oil pan and flywheel housing where they mate All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 ...

Page 260: ... for dents cracks or damage Replace as necessary 3 Inspect threaded inserts for cracks or damage Replace as necessary 4 Clean seals and lubricate seal grooves if applicable with clean fuel oil and inspect for cracks or tears If damage is found replace oil pan All information subject to change without notice 19 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 261: ... PLASTIC OIL PAN ONLY Remove as follows 1 Remove oil pan Refer to section 19 2 2 Remove threaded insert using Snap On tool GLD139 or equivalent Discard O ring All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 19 7 ...

Page 262: ... as follows 1 Install new O ring on threaded insert 2 Install threaded insert into oil pan 3 Install threaded insert connecting nut and torque to 100 N m 73 lb ft 4 Install the oil pan Refer to section 19 7 All information subject to change without notice 19 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 263: ...his manner halving the distance and seating the seal 2 For the aluminum pan place the gasket on the top of the pan 3 Reapply Loctite 5970 or equivalent to the four corner squares in gasket 4 Install the eighteen oil pan bolts and sleeve assemblies through the pan rail into the holes in the gasket 5 Ensure the joint surfaces of the gear case the cylinder block and front cover are cleaned and there ...

Page 264: ... to pan M20x1 5 60 N m 44 lb ft Fitting to pan M22x1 5 70 N m 51 lb ft Fitting to pan M27x1 5 90 N m 66 lb ft Fitting to pan M30x1 5 100 N m 73 lb ft Table 19 1 Torque Specs for Pan Fittings 11 Install dipstick tube on fitting and tighten clamp Refer to section 20 3 12 Install dipstick 13 Install oil filter and cap Torque to 55 N m 40 lb ft 14 If oil pump was removed follow section 21 4 15 Prime t...

Page 265: ...njury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 17 Start the engine and inspect for leaks All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 19 11 ...

Page 267: ...0 OIL DIPSTICK TUBE Section Page 20 1 DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND RELATED COMPONENTS 20 3 20 2 REMOVAL OF THE OIL DIPSTICK TUBE 20 4 20 3 INSTALLATION OF THE OIL DIPSTICK TUBE 20 5 ...

Page 269: ...stick bracket and hose clamp secure the assembly to the cylinder block The oil dipstick tube and oil pan adaptor allow the dipstick to extend into the oil The oil level is observed by removing the dipstick and reading the oil level 1 Upper Dipstick Stabilizing Bracket DD15 only 4 Oil Dipstick Tube 2 Dipstick 5 Hose Clamp 3 Lower Dipstick Bracket 6 Oil Pan Adaptor All information subject to change ...

Page 270: ...mp 6 attaching oil dipstick tube 2 to the oil pan adaptor 2 Remove all P clips 4 attaching oil dipstick tube to bracket 1 and upper bracket on the DD15 and DD16 3 Remove oil dipstick tube from engine All information subject to change without notice 20 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 271: ...pstick tube 2 onto the oil pan adaptor 2 Attach all P clips 4 to the bracket 1 and upper bracket on DD15 and DD16 3 Tighten the hose clamp 6 attaching the oil dipstick tube to the adaptor All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 20 5 ...

Page 273: ...N OF OIL PUMP AND RELATED COMPONENTS 21 3 21 2 REMOVAL OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 4 21 3 INSPECTION OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 5 21 4 INSTALLATION OF THE OIL PUMP OIL SUCTION MANIFOLD AND OIL LINES 21 6 ...

Page 275: ...he oil pump pressure line and then through the return flow check valve to the main oil duct into the engine oil circuit The pressure regulator valve regulates engine oil pressure The pressure regulator valve has the oil pressure applied to it from the engine oil in the main oil duct Excess engine oil is fed by the pressure regulator valve to the suction side according to the oil pressure in the ma...

Page 276: ...on 19 2 3 Remove the four bolts 2 securing the oil suction manifold 1 to the engine block 3 4 Remove the oil suction manifold 1 oil lines 6 and 11 and O rings 5 and 10 Discard the O rings 5 Remove the three bolts 7 securing the oil pump 9 to the engine block 3 and remove the oil pump assembly 8 and 9 from the engine block All information subject to change without notice 21 4 DDC SVC MAN 0081 2010 ...

Page 277: ... wear adequate eye protection face shield or safety goggles and do not exceed 40 psi 276 kPa air pressure 1 Wash all parts in clean fuel oil and dry them with compressed air 2 Clean the suction and pressure pipe and screen in clean fuel oil and blow dry with compressed air All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 21 5 ...

Page 278: ...r block so that the drive gear of the oil pump meshes with the crankshaft gear 3 Install oil pump with three bolts Torque the bolts to 30 N m 22 lb ft 4 Install oil lines with new O rings on each end 5 Install four bolts and secure the oil intake manifold to the cylinder block Torque the bolts to 60 N m 44 lb ft 6 Install the oil pan Refer to section 19 7 All information subject to change without ...

Page 279: ...EATHER Section Page 22 1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER 22 3 22 2 REMOVAL OF THE CRANKCASE BREATHER 22 5 22 3 INSPECTION OF THE CRANKCASE BREATHER 22 6 22 4 INSTALLATION OF THE CRANKCASE BREATHER 22 7 ...

Page 281: ...e centrifuge The centrifuge drive gear is driven by pressurized engine oil causing the centrifuge to turn The centrifugal force that is created causes the blow by gas to be pushed against the inside wall of the housing The engine oil contained in the blow by gas runs along the inside wall downwards and flows to the outlet for the engine oil that has been separated back into the oil pan The cleaned...

Page 282: ...Breather Housing 8 O ring 3 Gasket 9 Screw 4 Threaded Fitting 10 Speed Sensor 5 Breather Pipe 11 O ring 6 Screw Figure 22 2 EPA10 Crankcase Breather and Related Parts All information subject to change without notice 22 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 283: ... NOTE Note orientation of bracket located on top bolt 2 On EPA07 engines remove the two bolts and gasket from the breather pipe Discard gasket 3 On EPA10 engines disconnect the quick connect fitting at the cylinder block 4 Remove the four bolts and gasket from the crankcase breather and remove crankcase breather from the cylinder block Discard the gasket All information subject to change without n...

Page 284: ...r to installation of crankcase breather 2 Inspect the tubes clamps and hoses for wear or damage replace if necessary 3 Inspect the crankcase breather for cracks or damage replace if necessary 4 Inspect the sensor and replace if necessary All information subject to change without notice 22 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 285: ...void injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm Always start and operate an engine in a well ventilated area If operating an engine in an enclosed area vent the exhaust ...

Page 287: ...23 OIL FILTER Section Page 23 1 REPLACEMENT OF THE OIL FILTER 23 3 ...

Page 289: ... care to prevent foreign objects from entering the filter housing 2 Remove the filter element by pressing and twisting the side and detaching it from the cap Discard the filter element 3 Remove the oil filter O ring and discard Lightly coat a new O ring with clean engine oil and install it on the filter cap 4 Check the filter housing for any debris and remove if necessary 5 Insert a new filter ele...

Page 291: ...24 OIL SAMPLE VALVE Section Page 24 1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE 24 3 24 2 REMOVAL OF OIL SAMPLE VALVE 24 4 24 3 INSTALLATION OF OIL SAMPLE VALVE 24 5 ...

Page 293: ...valve as follows 1 Using a 17 mm Allen tool remove the Allen head plug from the oil priming port on the oil coolant module 2 Install the oil sample valve onto the oil coolant module Torque to 80 N m 59 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 24 3 ...

Page 294: ...24 2 REMOVAL OF OIL SAMPLE VALVE Remove as follows Remove the oil sample valve and washer from the oil coolant module All information subject to change without notice 24 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 295: ...TION OF OIL SAMPLE VALVE Install as follows Install the oil sample valve and washer onto the oil coolant module and torque to 80 N m 59 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 24 5 ...

Page 297: ...25 OIL FILLER NECK Section Page 25 1 REMOVAL OF THE OIL FILLER NECK 25 3 25 2 INSTALLATION OF THE OIL FILLER NECK 25 4 ...

Page 299: ...HE OIL FILLER NECK 1 Remove three bolts 5 from the oil filler neck 2 2 Remove oil filler neck 2 from the oil coolant module 6 3 Discard O ring 1 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 25 3 ...

Page 300: ...L FILLER NECK 1 Install new O ring 1 2 Install oil filler neck 2 on the oil coolant module 6 3 Install three bolts 5 and torque to 27 31 N m 20 22 lb ft All information subject to change without notice 25 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 301: ... 1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE 26 3 26 2 REMOVAL OF THE OIL COOLANT MODULE 26 5 26 3 INSTALLATION OF THE OIL COOLANT MODULE 26 7 26 4 REMOVAL OF THE OIL THERMOSTAT 26 9 26 5 INSTALLATION OF THE OIL THERMOSTAT 26 11 ...

Page 303: ...to the main oil stream feed into the oil filter unit Oil flows into the oil filter unit from outside of the oil coolant module through the oil filter element to the support dome where it is cleaned The cleaned engine oil flows to the support dome and main oil flow drain back into the oil circuit 1 Coolant Pump 4 Oil Filter Unit 2 Oil Coolant Module 5 Oil Fill 3 Oil Water Heat Exchanger Figure 26 1...

Page 304: ...ater Pump Seal 2 Pulley 6 Oil Cooler Module 3 Bolt 7 Thermostat Seal 4 Water Pump 8 Thermostat 9 Bolt Figure 26 2 Oil Coolant Module and Related Parts All information subject to change without notice 26 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 305: ...lant module Inspect the coolant coupler hose for damage Discard if damage is found 6 Disconnect the coolant line from the fuel module to the oil coolant module 7 Remove the poly V belt from the water pump pulley Refer to section 40 1 8 Remove the radiator hose from the thermostat housing NOTE Ensure any remaining coolant is drained from the oil coolant module and from the cylinder block to prevent...

Page 306: ...26 2 REMOVAL OF THE OIL COOLANT MODULE 12 Remove and discard the gasket All information subject to change without notice 26 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 307: ... N m 44 47 lb ft 6 Remove tool J 36107 Install the remaining two bolts into the oil cooler module Torque the bolts to the following 10 N m 7 lb ft Final torque the bolts to 60 65 N m 44 47 lb ft 7 Install the dipstick tube and two bolts and torque to 15 N m 11 lb ft 8 Install the radiator support strut bracket Torque to 100 N m 74 lb ft 9 Install water pump if removed Refer to section 29 4 10 Inst...

Page 308: ...lant delivery pipe bolts to the oil coolant module and torque to 30 N m 22 lb ft 17 Install cold boost pipe and four bolts to intake manifold Torque bolts to 12 N m 9 lb ft 18 If removed install mixer tube to cold boost pipe with three bolts Torque 30 N m 22 lb ft 19 If removed install the intake throttle valve to cold boost pipe Torque bolts to 30 N m 22 lb ft 20 Fill the coolant system 21 Prime ...

Page 309: ...nt module 2 Unclip electrical harness from the oil thermostat cover 3 Remove four bolts 2 attaching the oil thermostat cover 1 to the oil coolant module 3 4 Using tool W470589030900 remove the thermostat from the oil coolant module housing All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 26 9 ...

Page 310: ...26 4 REMOVAL OF THE OIL THERMOSTAT 5 Discard the seal 3 and the O ring 4 All information subject to change without notice 26 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 311: ...ll as follows 1 Install a new O ring 4 on the oil thermostat 5 2 Using tool W470589030900 install the thermostat to the oil coolant module housing Torque to 50 N m 37 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 26 11 ...

Page 312: ...the oil coolant module 3 using four bolts 2 Torque the bolts to 30 N m 22 lb ft 4 Connect the electrical harness to the sensor 5 Clip electrical harness to the oil thermostat cover All information subject to change without notice 26 12 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 313: ...27 PRIMING THE LUBRICATION SYSTEM Section Page 27 1 PRIMING THE ENGINE LUBRICATION SYSTEM 27 3 ...

Page 315: ... Allen tool remove the Allen head plug from the oil priming port on the oil coolant module NOTE Tool J 49181 is used to adapt the J 45299 priming pump 2 If equipped with an oil sample valve remove the valve and washer All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 27 3 ...

Page 316: ...rts of oil 6 Open the valve on the primer and start pumping until the container is empty 7 Fill the container with an additional eight quarts of oil and pump until the canister is empty 8 The oil system is now primed with sixteen quarts of oil Pour the remaining oil into the oil filler until the correct full level is obtained All information subject to change without notice 27 4 DDC SVC MAN 0081 2...

Page 317: ...plug or oil sample valve to the module and torque to 70 80 N m 51 59 lb ft ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 12 Start the engine and monitor the oil pressure 13 After the engine oil pressure stabilizes shut the engine down and check the oil per the oil check guidelines All information subject to c...

Page 319: ...28 COOLING SYSTEM Section Page 28 1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS 28 3 ...

Page 321: ...A97 EGR Actuator V Coolant Feed 4 Cylinder Head 13 Coolant Filter B65 1 Inlet Temp Sensor VA Clt EGR to Clr Actuator 5 Water Manifold 14 Heat Exchanger B65 2 Outlet Temp Sensor VH Clt Heat Exchanger 6 Compressor 15 Filling Valve B Coolant Fill Line VM Clt to Doser 7 EGR Cooler 16 Pressure Control Valve E De aeration 8 Fuel Cooler 17 Oil Coolant Module KK Radiator Circuit 9 Thermostat 18 Trans Cool...

Page 322: ... Cylinder Block 4 Coolant Return Flow 11 Air Compressor 5 Coolant Outlet to Cooler Circuit 12 Fuel Cooler 6 Exhaust Gas Recirculation Cooler 13 Oil Water Heat Exchanger 7 Coolant Return Flow 14 Thermostat Figure 28 2 Cooling System Components All information subject to change without notice 28 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 323: ... ENGINE WATER PUMP Section Page 29 1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP 29 3 29 2 REMOVAL OF THE WATER PUMP 29 4 29 3 INSPECTION OF THE WATER PUMP 29 5 29 4 INSTALLATION OF THE WATER PUMP 29 6 ...

Page 325: ... with five bolts The water pump is driven by the poly V belt that is installed onto the water pump pulley The rotary motion of the pulley is transmitted by the hub to the shaft The shaft drives the impeller which causes the coolant to circulate in the coolant circuit 1 Bolt 4 Water Pump 2 Water Pump Pulley 5 Water Pump Seal 3 Bolt 6 Oil Coolant Module Figure 29 1 Water Pump and Related Parts All i...

Page 326: ... and fingers from the spring loaded auto belt tensioner violently snapping back do not cut the belt to remove it 4 Remove the accessory drive belt Refer to section 40 1 5 Remove the five bolts 1 securing the coolant pulley 2 to the water pump 4 and remove pulley from water pump 6 Remove nine bolts 3 from the water pump and remove from the oil coolant module 6 All information subject to change with...

Page 327: ...e Belt Noise section in the Troubleshooting Manual to correctly determine the cause of the belt noise 1 Clean the water pump and surrounding area 2 Drain the cooling system 3 Remove the water pump 4 Inspect the inside of the water pump 1 for cavitations or corrosion replace pump if damaged 5 Inspect the blades 3 on the water pump for cracks or damage replace the pump if damaged 6 Inspect the beari...

Page 328: ...th five bolts 1 and finger tighten and install belt 4 Install the poly V belt Refer to section 40 3 5 Torque the water pump pulley bolts to 25 N m 18 lb ft 6 Fill the coolant system 7 Reconnect the batteries ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 8 Start the engine and inspect for leaks All information...

Page 329: ...ection Page 30 1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT 30 3 30 2 REMOVAL OF COOLANT THERMOSTAT AND SEAL 30 5 30 3 INSPECTION OF COOLANT THERMOSTAT AND SEAL 30 6 30 4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL 30 7 ...

Page 331: ...rmostat and Related Parts The coolant thermostat regulates coolant flow from the engine to the radiator The thermostat regulates coolant flow to control the temperature of the coolant within the coolant circuit The following benefits result from regulating the coolant at the inlet temperature of the engine Reduced thermal cycling of the engine Operating temperature is reached faster Emissions are ...

Page 332: ... F to and less than 95 C 203 F the circulating thermostat opens partially and the coolant flows at the same time through the engine radiator and the radiator bypass to the coolant thermostat Radiator operation When the coolant inlet temperature is above 95 C 203 F the circulating thermostat is completely open The coolant flows through the radiator to the coolant thermostat None of the flow passes ...

Page 333: ...n and boots Remove the cap slowly to relieve pressure 1 Drain the cooling system 2 Remove the plug on the cylinder block below the oil coolant module to drain the remaining coolant 3 Loosen hose clamp at the thermostat 4 Remove the four thermostat housing to oil cooler module attaching bolts 5 Remove the thermostat housing assembly from the oil coolant module and hose 6 Remove the thermostat housi...

Page 334: ... is not found reuse parts 2 Visually inspect thermostat body seal for damage cracks or nicks a If any damage is noted replace seal b If no damage is found reuse parts 3 Visually inspect the tip of the thermostat for wear or damage a If wear or damage is found replace parts b If wear or damage is not found reuse parts All information subject to change without notice 30 6 DDC SVC MAN 0081 2010 Copyr...

Page 335: ...le 1 3 Torque four bolts to 30 N m 22 lb ft 4 Tighten clamp at the hose 5 Fill engine with coolant to the correct level ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 6 Start the engine and check for leaks All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORP...

Page 337: ...31 COOLANT FILTER Section Page 31 1 DESCRIPTION AND OPERATION OF COOLANT FILTER 31 3 31 2 REMOVAL OF THE COOLANT FILTER 31 4 31 3 INSTALLATION OF THE COOLANT FILTER 31 5 ...

Page 339: ...RATION OF COOLANT FILTER DD Platform engine cooling systems are protected by a coolant filter element that may contain supplemental corrosion inhibitors All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 31 3 ...

Page 340: ...lows 1 Using a 36 mm wrench remove the cap 1 from the oil coolant module 4 2 Pull the coolant filter 3 out of the oil coolant module 3 Discard the O ring 2 in the cap All information subject to change without notice 31 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 341: ... 1 Install a new O ring 2 onto the cap 2 Install a new coolant filter 3 into the cap 1 3 Install coolant filter and cap into the oil coolant module 4 Torque cap to 55 60 N m 41 44 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 31 5 ...

Page 343: ...32 COOLANT FILTER SERVICE MODULE Section Page 32 1 REMOVAL OF COOLANT FILTER SERVICE MODULE 32 3 32 2 INSTALLATION OF COOLANT FILTER SERVICE MODULE 32 4 ...

Page 345: ...Drain coolant 2 Remove hose clamps and remove hoses 3 Remove ten bolts from the Coolant Filter Service Module and remove service module from engine 4 Discard the O rings 3 and 4 and the seals 5 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 32 3 ...

Page 346: ... oil cooler module 3 Install the ten bolts and torque to 37 N m 27 lb ft 4 Install hoses and hose clamps 5 Fill coolant to appropriate level ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 6 Start engine and check for leaks All information subject to change without notice 32 4 DDC SVC MAN 0081 2010 Copyright 20...

Page 347: ...33 COOLANT INLET ELBOW Section Page 33 1 REMOVAL OF THE COOLANT INLET ELBOW 33 3 33 2 INSTALLATION OF THE COOLANT INLET ELBOW 33 4 ...

Page 349: ... follows 1 Drain coolant 2 Remove two bolts from the coolant inlet elbow 3 Remove the coolant inlet elbow from the coolant service filter module 4 Remove and discard the O ring All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 33 3 ...

Page 350: ...service module with two bolts 3 Torque bolts to 30 N m 22 lb ft 4 Fill coolant to appropriate level ENGINE EXHAUST To avoid injury from inhaling engine exhaust always operate the engine in a well ventilated area Engine exhaust is toxic 5 Start engine and check for leaks All information subject to change without notice 33 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 351: ...4 2 REMOVAL OF FLYWHEEL HOUSING 34 6 34 3 INSTALLATION OF FLYWHEEL HOUSING 34 7 34 4 REMOVAL OF THE FLYWHEEL 34 9 34 5 INSPECTION OF FLYWHEEL 34 10 34 6 INSTALLATION OF FLYWHEEL 34 11 34 7 INSPECTION OF FLYWHEEL HOUSING AND REAR OIL SEAL AREA OF CRANKSHAFT 34 12 34 8 REMOVAL OF RING GEAR 34 13 34 9 INSTALLATION OF RING GEAR 34 14 ...

Page 353: ...kshaft with twelve bolts The bolt holes in the crankshaft and flywheel are equally spaced 34 1 2 Ring Gear The steel ring gear and flywheel is a two piece assembly Prior to assembly the ring gear is heated to expand its diameter It is then installed onto the flywheel and allowed to cool After the ring gear cools it contracts onto the flywheel locking it in place 1 Steel Ring Gear 2 Flywheel All in...

Page 354: ...ut removing the housing The power steering pump on some applications may be mounted on the flywheel housing An engine barring or locking device can be attached at the opening on the bottom of the flywheel housing This allows the engine to be barred or locked for maintenance or repair work 1 Gasket 6 Nut 2 Seal 7 Flywheel Housing 3 Stud 8 Cover 4 Stud 9 Bolt 2 5 Access Hole Cover Figure 34 1 Rear o...

Page 355: ... x 90 6 qty 11 Gasket 4 Bolt M10 x 45 6 qty 12 Stud 1 qty 5 Gasket 1 qty 13 Nut M12 10 1 qty 6 Cover 1 qty 14 Cover 7 Bolt M8 x 30 2 qty 15 Bolt 2 qty 8 Bolt M14 x 1 5 x 180 1 qty Figure 34 2 Front of Flywheel Housing and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 34 5 ...

Page 356: ...e tapped holes in the side of the flywheel housing and attach a suitable lifting sling to the eye bolts 9 Thread two guide stud tools J 43431 for the 14 mm bolts into the cylinder block 10 Remove the remainder of the bolts that secure the flywheel housing to the cylinder block BODILY INJURY To avoid injury from a falling component ensure a proper lifting device is used Never stand beneath a suspen...

Page 357: ...ket BODILY INJURY To avoid injury from a falling component ensure a proper lifting device is used Never stand beneath a suspended load 3 Using a lifting sling support the flywheel housing and position it onto the cylinder block 4 Install all of the housing bolts in their proper location finger tighten them All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROI...

Page 358: ...equence and torque shown 7 Inspect the crankshaft rear main oil seal If any damage is found replace as necessary 8 Install the flywheel Refer to section 34 6 9 For the DD15 install the exhaust pipe and bracket to the flywheel housing and axial power turbine Install two bolts into the bracket and flywheel housing Install a clamp onto the exhaust pipe and axial power turbine Refer to section 12 4 10...

Page 359: ...e to the flywheel 5 Attach a chain hoist to the lifting tool 6 Loosen but do not remove the last flywheel attaching bolt FALLING FLYWHEEL To avoid injury from a falling flywheel when removing the last bolt hold the flywheel against the crankshaft by hand to prevent it from slipping off the crankshaft The flywheel is not doweled to the crankshaft 7 Lift lightly on flywheel using lifting device and ...

Page 360: ...tch contact face shows cracks 2 Inspect the ring gear a Check ring gear for excessively worn or damaged gear teeth b If damaged gear teeth are detected replace the ring gear 3 Inspect crankshaft and flywheel contact surface a Check the butt end of the crankshaft and flywheel contact surface for damage b Lightly stone the contact surface to remove any fretting brinelling or burrs All information su...

Page 361: ...e crankshaft bolt holes Be sure to line up the locating pin hole with the pin on the crankshaft 3 Remove the flywheel lifting tool and guide studs 4 Apply clean engine oil to the threads and to the bolt head contact area underside of the remaining bolts Any excess must be wiped off NOTE Clean engine oil must never be used between two surfaces where maximum friction is desired as between the cranks...

Page 362: ...racks and any other damage a Check sealing surface for damage b Check flywheel housing for cracks c If damaged or cracked repair is not possible replace the part 2 Inspect the flywheel where the rear oil seal makes contact Check for groove in flywheel if grooved replace flywheel All information subject to change without notice 34 12 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 363: ...cable safety steps 2 Remove the transmission 3 Remove the flywheel 4 Using an acetylene torch cut the ring gear 1 2 to 3 4 of the way through without allowing the flame to touch the flywheel 5 The uncut portion will now yield Tap the ring gear to remove it from the flywheel All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 34 13 ...

Page 364: ... Use of these crayons will ensure against overheating the gear 2 Rest the gear on a flat metal surface Heat the gear uniformly with an acetylene torch keeping the torch moving around the gear to avoid hot spots 3 Use a pair of tongs to place the gear on the flywheel with the chamfer if any facing the same direction as on the gear just removed 4 Tap the gear in place against the shoulder of the fly...

Page 365: ...N AND OPERATION OF FRONT ENGINE MOUNT RADIATOR SUPPORT AND RELATED PARTS 35 3 35 2 REMOVAL OF THE FRONT ENGINE MOUNT RADIATOR SUPPORT 35 4 35 3 INSPECTION OF THE FRONT ENGINE MOUNT RADIATOR SUPPORT 35 5 35 4 INSTALLATION OF THE FRONT ENGINE MOUNT RADIATOR SUPPORT 35 6 ...

Page 367: ...The front engine mount radiator support is mounted to the cylinder block with four bolts 1 Front Engine Mount Radiator Support 3 Engine Block 2 Bolts Figure 35 1 Front Engine Mount Radiator Support and Related Parts All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 35 3 ...

Page 368: ...r Refer to OEM procedures 2 Remove the charge air cooler CAC hoses 3 Remove the air cooling components Refer to OEM guidelines 4 Remove the four bolts securing the front engine mount radiator support and remove front engine mount radiator support All information subject to change without notice 35 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 369: ...INSPECTION OF THE FRONT ENGINE MOUNT RADIATOR SUPPORT Inspect the front engine mount radiator support for damage replace as necessary All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 35 5 ...

Page 370: ...the front engine mount radiator support to the cylinder block with four bolts Torque bolts to 250 N m 184 lb ft 2 Install CAC hoses 3 Install air cooling components refer to OEM guidelines 4 Fill with coolant to the appropriate levels All information subject to change without notice 35 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 371: ...36 VIBRATION DAMPER Section Page 36 1 REMOVAL OF THE VIBRATION DAMPER 36 3 36 2 INSTALLATION OF THE VIBRATION DAMPER 36 4 ...

Page 373: ...y V belt Refer to section 40 1 2 Remove the eight bolts 1 attaching the vibration damper 2 to the crankshaft 4 3 Using guide studs tool J 43431 remove the vibration damper 4 Remove the splash ring 3 All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 36 3 ...

Page 374: ...2 Using guide studs tool J 43431 install the vibration damper onto the crankshaft 3 Install the eight bolts attaching the vibration damper to the crankshaft Torque to 200 N m 147 5 lb ft Refer to section 36 2 4 Install the poly V belt Refer to section 40 3 All information subject to change without notice 36 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 375: ...OVER Section Page 37 1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE COVER 37 3 37 2 REMOVAL OF THE FRONT ENGINE COVER 37 4 37 3 INSPECTION OF THE FRONT ENGINE COVER 37 5 37 4 INSTALLATION OF THE FRONT ENGINE COVER 37 6 ...

Page 377: ...oil leaks at the crankshaft 1 Front Mounting Bracket Bolt 4 qty 7 Front Cover Mounting Bolts 10 qty 2 Front Mounting Bracket 8 Front Cover 3 Vibration Damper Mounting Bolts 8 qty 9 Front Cover Gasket 4 Vibration Damper 10 Oil Pan Gasket 5 Splash Ring 11 Oil Pan 6 Front Radial Seal 12 Oil Pan Mounting Bolts 18 qty Figure 37 1 Front Engine Cover and Related Components All information subject to chan...

Page 378: ...ching the vibration damper to the crankshaft Refer to section 36 1 4 Remove the splash ring NOTE The oil pan must be completely removed to clean the gasket and groove to prevent potential oil leaks 5 Remove the oil pan Refer to section 19 2 6 Remove the ten mounting bolts attaching the front engine cover to the cylinder block and remove the front engine cover All information subject to change with...

Page 379: ...nspect as follows 1 Inspect the front cover housing for leaks cracks or any other signs of damage Replace as necessary 2 Clean the front engine cover with clean engine oil All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 37 5 ...

Page 380: ... sequence shown 3 Install the oil pan to cylinder block Refer to section 19 7 4 Install the splash ring on the front of the crankshaft 5 If the front crankshaft seal is damaged and requires replacement replace as necessary Refer to section 17 8 6 Install the vibration damper and pulley to the crankshaft Refer to section 36 2 7 Install the poly V belt Refer to section 40 3 All information subject t...

Page 381: ...F THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE OFF 38 9 38 4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS 38 10 38 5 INSPECTION OF THE ENGINE LIFTER BRACKETS 38 11 38 6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS 38 12 38 7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE OFF 38 13 38 8 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGI...

Page 383: ...front which is part of the Exhaust Gas Recirculation EGR system crossover tube 1 Venturi 7 Exhaust Gas Crossover Tube Lifting Eye 13 Cylinder Head 2 Bolt 8 Exhaust Gas Connecting Tube 14 Bolt 3 Gasket 9 Bolt 15 Rear Lifting Bracket Left Side 4 Mounting Bolt 10 Plate 16 Rear Lifting Bracket Right Side 5 Bolt 6 qty 11 EGR Cooler Water Manifold Assembly 17 Mixer Pipe 6 Bolt 12 Coolant Crossover Tube ...

Page 384: ... 14 Bolt 5 Bolt 15 Rear Lifting Bracket Left Side 6 Bolt 6 qty 16 Rear Lifting Bracket Right Side 7 Exhaust Gas Crossover Tube 17 Mixer Pipe 8 Exhaust Gas Connecting Tube 18 Clamp 9 Bolt 19 Connector Hose 10 Plate 20 Lifting Bracket Figure 38 2 DD13 EPA10 Lifting Bracket Locations All information subject to change without notice 38 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 385: ... 6 qty 15 Bolt 6 Bolt 16 Rear Lifter Bracket Left Side 7 Exhaust Gas Crossover Tube Lifting Eye 17 Rear Lifter Bracket Right Side 8 Exhaust Gas Connector Tube 18 Mixer Pipe 9 Bolt 19 Clamp 10 Plate 20 Connector Hose Figure 38 3 DD15 EPA07 Lifting Bracket Location All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 38 5 ...

Page 386: ... Bracket Left Side 6 Bolt 6 qty 17 Rear Lifter Bracket Right Side 7 Exhaust Gas Crossover Tube 18 Mixer Pipe 8 Exhaust Gas Connector Tube 19 Clamp 9 Bolt 20 Connector Hose 10 Plate 21 Lifter Bracket 11 Exhaust Gas Recirculation Cooler Figure 38 4 DD15 EPA10 Lifting Bracket Location All information subject to change without notice 38 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION...

Page 387: ...ged lifter bracket when lifting the engine To avoid injury from a falling engine ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 38 7 ...

Page 388: ...NGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE OFF For EPA10 engines remove as follows 1 Remove the two bolts 1 from the front engine lifter bracket 2 Remove the front engine lifter bracket All information subject to change without notice 38 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 389: ...gas crossover tube lifting eye to the cylinder head 5 Remove the bolt attaching the exhaust gas crossover tube lifting eye to the coolant crossover tube 6 Remove the bolt attaching the coolant crossover tube to the exhaust gas crossover tube lifting eye 7 Slide the exhaust gas crossover tube lifting eye off the exhaust gas connector tube and remove from engine 8 Remove the exhaust gas connector tu...

Page 390: ...AL OF THE REAR ENGINE LIFTER BRACKETS Remove as follows 1 Remove the bolts securing the lifter brackets to the engine 2 Remove lifter bracket All information subject to change without notice 38 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 391: ...F THE ENGINE LIFTER BRACKETS Inspect the lifter brackets for cracks bending or other damage Replace the bracket if any of these conditions exist All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 38 11 ...

Page 392: ...IFTER BRACKETS Install the rear lifter brackets as follows 1 Install the two rear lifter brackets with four bolts to the cylinder head 2 Torque the bolts to 180 N m 132 lb ft All information subject to change without notice 38 12 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 393: ...WITHOUT FRONT ENGINE POWER TAKE OFF For EPA10 engines install as follows 1 Install the front engine lifter bracket to the engine 2 Install the two bolts Torque to 160 N m 110 lb ft All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 38 13 ...

Page 394: ...rossover tube Torque to 30 N m 22 lb ft 4 Install bolt attaching the coolant crossover tube to the exhaust gas crossover tube lifting eye Torque to 30 N m 22 lb ft 5 Tighten six exhaust gas crossover tube lifting eye bolts to cylinder head Torque to 60 N m 44 lb ft 6 Slide mixer pipe onto hose with soap and water for ease of installation 7 Install venturi to exhaust gas crossover tube lifting eye ...

Page 395: ...ATION OF THE BELT TENSIONER 39 6 39 4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET 39 7 39 5 INSTALLATION OF THE IDLER PULLEY AND IDLER PULLEY BRACKET 39 8 39 6 REMOVAL OF NON BRACKETED IDLER PULLEY 39 9 39 7 INSTALLATION OF NON BRACKETED IDLER PULLEY 39 10 39 8 REMOVAL OF THE ACCESSORY MOUNTING BRACKET 39 11 39 9 INSTALLATION OF THE ACCESSORY MOUNTING BRACKET 39 12 ...

Page 397: ...rant compressor and coolant pump are driven by one eight ribbed poly V belt The fan clutch and the engine fan are driven by one ten ribbed poly V belt The belt tensioners are firmly bolted onto the accessory bracket The tensioning arms with tensioner pulleys are turned counterclockwise by the force of the springs to provide the required tension in the belts All information subject to change withou...

Page 398: ... the inner poly V belt 1 Crankcase Damper 8 Accessory Mounting Bracket 2 Poly V Belt for the Fan 9 Belt Tensioner 3 Alternator 10 Fan Clutch 4 Pulley 11 Pulley and Spacer 5 Poly V Belt for Alternator Refrigerant Compressor and Coolant Pump 12 Water Pump 6 Tensioner Pulley 13 Idler Pulley Bracket 7 Refrigerant Compressor 14 Idler Pulley All information subject to change without notice 39 4 DDC SVC ...

Page 399: ...ONER Remove as follows 1 Remove the two poly V belts Refer to section 40 1 2 Remove the three bolts from the tensioner 3 Remove the tensioner from the bracket All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 39 5 ...

Page 400: ...1 Install the tensioner to the bracket 2 Install the three bolts attaching the tensioner to the bracket Torque to 60 N m 44 lb ft 3 Install the two poly V belts Refer to section 40 3 All information subject to change without notice 39 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 401: ...move the two poly V belts Refer to section 40 1 2 Remove the idler pulley from the idler pulley bracket 3 Remove the two bolts from the idler pulley bracket and remove the idler pulley bracket from the engine All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 39 7 ...

Page 402: ...ler pulley bracket to the engine 2 Install the two bolts to the idler pulley bracket Torque to 60 N m 44 lb ft 3 Install the idler pulley to the idler pulley bracket Torque to 60 N m 44 lb ft 4 Install the two poly V belts Refer to section 40 3 All information subject to change without notice 39 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 403: ...Y Remove as follows 1 Remove the two poly V belts Refer to section 40 1 2 Remove the bolt from the idler pulley Remove the idler pulley and spacer from the engine block All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 39 9 ...

Page 404: ...Y Install as follows 1 Insert bolt through idler pulley and spacer 2 Install bolt to engine block Torque to 60 N m 44 lb ft 3 Install the two poly V belts Refer to section 40 3 All information subject to change without notice 39 10 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 405: ...3 Remove the belt tensioner from the accessory mounting bracket 4 Remove the air conditioner compressor Refer to OEM procedures 5 Remove the alternator Refer to OEM procedures 6 Remove the six bolts attaching the accessory mounting bracket to the engine 7 Remove the accessory mounting bracket All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPO...

Page 406: ...gine Torque to 60 N m 44 lb ft 3 Install the alternator Refer to OEM procedures 4 Install the air conditioner compressor Refer to OEM procedures 5 Install the accessory mounting to the belt tensioner bracket 6 Install the three bolts to the belt tensioner Torque to 60 N m 44 lb ft 7 Install the two poly V belts Refer to section 40 3 All information subject to change without notice 39 12 DDC SVC MA...

Page 407: ...40 POLY V BELTS Section Page 40 1 REMOVAL OF THE POLY V BELTS 40 3 40 2 INSPECTION OF THE POLY V BELTS 40 6 40 3 INSTALLATION OF THE POLY V BELTS 40 9 ...

Page 409: ...rooved pulley idler arm before the grooved idler pulley arm is pre tensioned NOTE Never turn the pulley idler arms clockwise NOTE When removing the poly V belts always remove the belt driving the fan first and then remove the belt driving the alternator refrigerant compressor and coolant pump NOTE Do not use any type of cleaning solvent to the rubber parts on the tensioner 1 Install a half inch ex...

Page 410: ...ease the idler arm The grooved pulley idler arm is now locked in a pre tensioned position 5 Remove the belt 6 Install a half inch extension into the square hole V on the non grooved pulley idler arm 1 7 Turn the non grooved pulley idler arm counterclockwise Maximum allowable torque is 90 100 N m 66 73 lb ft All information subject to change without notice 40 4 DDC SVC MAN 0081 2010 Copyright 2010 ...

Page 411: ...d pulley idler arm 2 9 Release the idler arm The non grooved pulley idler arm is now locked in a pre tensioned position 10 Remove the belt from the pulleys then remove the alternator and refrigerant compressor All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 40 5 ...

Page 412: ...ct as follows 1 Inspect the belt contact surfaces for chips flaking cracks and discoloration ABRASION CHUNK OUT IMPROPER INSTALL CRACKING PILLING UNEVEN RIB WEAR All information subject to change without notice 40 6 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 413: ...ea for oil leaking at the spring area Change the assembly if oil is present 3 Inspect the springs on the tensioner If the rubber is damaged or if the spring is damaged change the assembly 4 Inspect the pulleys for damage and excessive wear If pulleys or the belts are damaged change the damaged pulley and the belt All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010...

Page 414: ... pulleys a If wear pattern location is incorrect A change the pulley and bracket b If wear pattern location is correct B idler and bracket can be reused All information subject to change without notice 40 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 415: ...um allowable torque is 90 100 N m 66 73 lb ft 7 Insert an M10x80 bolt or equivalent pin into the bracket hole on the non grooved pulley idler arm 8 Release the idler arm The non grooved pulley idler arm is now locked in a pre tensioned position 9 Install the poly V belts onto the pulleys 10 Ensure the belts are properly installed on the pulleys 11 Install a half inch extension into the square hole...

Page 417: ...COMPRESSOR Section Page 41 1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR 41 3 41 2 REMOVAL OF THE AIR COMPRESSOR 41 5 41 3 INSPECTION OF THE AIR COMPRESSOR 41 6 41 4 INSTALLATION OF THE AIR COMPRESSOR 41 8 ...

Page 419: ...ar case Detroit Diesel offers two sizes of air compressors The single cylinder has a displacement 360 cm3 and the twin cylinder has a displacement 650 cm3 Both compressors are installed with an Energy Saving System ESS to save fuel 1 Bolt 8 Gear 2 Cover 9 Nut 3 O ring 10 Clamp OEM provided 4 Coolant Return Line Assembly 11 Bolt OEM provided 5 Coolant Inlet Line Assembly 12 Intake Line OEM provided...

Page 420: ...Nut 5 Cover 13 Clamp OEM provided 6 O ring 14 Bolt OEM provided 7 Coolant Return Line Assembly 15 Intake Line OEM provided 8 Coolant Inlet Line Assembly 16 Bolt Figure 41 2 Two Cylinder Air Compressor and Related Parts All information subject to change without notice 41 4 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 421: ...t the air lines to and from the compressor 5 Disconnect and drain the coolant supply and return lines at the air compressor 6 Remove the four bolts that secure the air compressor to the cylinder block NOTICE Do not contact the drive gear to the engine block during removal damage to the seal surface will cause oil leaks 7 Slide the air compressor forward and remove from engine 8 Discard air compres...

Page 422: ...form a crankcase pressure test and record the test results using the following test procedure refer to section Crankcase pressure Full load maximum KPa in H2 O operating limits Rated speed 1 25 KPa 5 0 in H2 O column 3 Disconnect the air outlet line 2 from the air compressor 4 Repeat the first step and record the test results 5 Compare the results of test one with test two a If the engine crankcas...

Page 423: ...d 7 Start and run the engine 8 Perform a crankcase pressure test Refer to section a If the engine crankcase pressure exceeds 1 25 kPa 5 in H2 O check for a defective turbocharger Refer to section Shut down the engine b If the engine crankcase pressure is less than 1 25 kPa 5 in H2 O shut down the engine no further troubleshooting is required All information subject to change without notice DDC SVC...

Page 424: ...olant lines are installed that there is an O ring and an O ring retainer installed on both ends of the coolant lines Ensure that the air compressor retainer is installed on the coolant line and is pushed down to lock the lines onto the inlet and outlet ports to the cylinder block fuel filter module and air compressor A leak will occur if the lines are incorrectly installed and the coolant line ret...

Page 425: ...e 42 1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS 42 3 42 2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE 42 9 42 3 CLEANING THE CYLINDER BLOCK 42 12 42 4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK 42 16 ...

Page 427: ...er collar design allows for a shorter distance between cylinders and a more compact design for the cylinder block Each cylinder bore is sealed to a cylinder liner with two sealing rings the upper sealing ring seals the upper coolant jacket to the cylinder block bore and the lower sealing ring seals the lower coolant jacket to the cylinder block bore 1 Cylinder Liner 5 Lower Coolant Jacket 2 Top of...

Page 428: ...Coolant Drain Plug 6 Expansion Plug Front Oil Duct Outlet 18 Dowel Pin 7 Expansion Plug Connector Front Oil Duct Outlet 19 Dowel Pin Crankshaft Bearing Cap 8 Bottom Cylinder Liner Seal Ring 20 Piston Oil Spray Nozzle 9 Cylinder Liner 21 Bolt Oil Spray Nozzle 10 Top Cylinder Liner Seal Ring 22 Main Bearing Cap 11 Expansion Plug Connector Crankcase Ventilation 23 Bolt Crankshaft Bearing Cap to Cylin...

Page 429: ...t Feed for Oil Water Heat Exchanger 6 Coolant Transfer Hole to Cylinder Head 3 Coolant Connection for Fuel Heat Exchanger 7 Coolant Return from Cylinder Head 4 Coolant Connection for Air Compressor Figure 42 3 Cylinder Block All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 42 5 ...

Page 430: ...nection for Cylinder Block Ventilation 4 Oil Return for Oil Filter Change 11 Oil Feed Connection Turbocharger 5 Oil Return Connection from Oil Water Heat Exchanger 12 Oil Hole 6 Oil Feed Connection to Oil Water Heat Exchanger 13 Oil Transfer Holes to the Cylinder Head 7 Oil Hole 14 Oil Return from Cylinder Head Figure 42 4 Cylinder Block All information subject to change without notice 42 6 DDC SV...

Page 431: ...OP MANUAL ENGINE 1 Oil Return to Oil Pan 2 Oil Feed Bore Figure 42 5 Bottom of Cylinder Block Oil Hole Location All information subject to change without notice DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION 42 7 ...

Page 432: ... Oil Feed Hole for Main Bearing and Connecting Rod Bearing 2 Oil Feed Hole for Oil Spray Nozzles Figure 42 6 Bottom of Cylinder Block Oil Hole Location All information subject to change without notice 42 8 DDC SVC MAN 0081 2010 Copyright 2010 DETROIT DIESEL CORPORATION ...

Page 433: ... from the cranking motor and remove cranking motor 11 Disconnect the alternator and other electrical equipment as necessary 12 Disconnect the air compressor air lines as necessary 13 Disconnect and remove the coolant hoses 14 Remove the charge air cooler radiator fan guard and other cooling system related parts as necessary to remove the engine 15 Connect Cylinder Head Engine Lifting Bar tool W470...

Page 434: ...on 20 Remove high pressure pump Refer to section 21 Use engine overhaul stand J 29109 for support when stripping an engine cylinder block 22 Rotate engine in either direction and lock it into position 23 Remove the inlet and outlet fuel lines connected to the Motor Control Module MCM if equipped 24 Remove any electrical components accessories connectors or wiring looms from the engine All informat...

Page 435: ...emove the oil pan Refer to section 19 2 j Remove the piston and connecting rod assembly Refer to section 15 2 k Remove cylinder liners Refer to section 16 2 l Remove the crankshaft Refer to section 17 2 NOTICE Before removing main bearing caps be sure each is stamped or punch marked in numerical order beginning with No 1 at the front to ensure installation in their original position Mark all caps ...

Page 436: ...k to remain in the acid bath until the bubbling action stops approximately 30 minutes c Lift the block drain it and immerse it again in the same acid solution for 10 more minutes Repeat until all scale is removed from the water jacket area d Rinse the block in clear hot water to remove the acid solution e Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath ...

Page 437: ... dial indicator calibrated in 0 0001 in increments 3 Measure cylinder block bore at the positions on axis 90 degrees apart If the diameter does not exceed the dimensions the block may be reused NOTE The above measurements are average gauge readings at each position Also the out of round must not exceed 0 0254 mm 0 001 in Location DD13 DD15 DD16 A 159 mm to 159 04 mm 6 259 to 6 261 in 167 to 167 04...

Page 438: ...to 50 N m 37 lb ft 3 Torque the main cap bolts again to 150 N m 103 lb ft 4 For the DD13 final torque the main cap bolts to 300 N m 221 lb ft Then torque turn the bolts an additional 90 5 For the DD15 final torque the main cap bolts to 250 N m 184 lb ft Then torque turn the bolts an additional 90 and again torque turn the bolts an additional 90 6 Measure the main bearing bores using dial bore gaug...

Page 439: ...pection if the cylinder block is not to be used immediately spray the machined surfaces with engine oil NOTICE Castings free of grease or oil will rust when exposed to the atmosphere Rust on machined surfaces may result in leakage If the block is to be stored for an extended period of time spray or dip it in a polar type rust preventive such as Tectyl 502 C from Valvoline Oil Company or equivalent...

Page 440: ...nditioned or new service replacement cylinder block is used steam clean it to remove the rust preventive and blow out the oil galleries with compressed air 2 If a new service replacement block is used stamp the engine serial number and model number on the pad provided on the front left side of the block 3 Also stamp the position numbers on the main bearing caps and the position of the No 1 bearing...

Page 441: ... such as Loctite 620 or equivalent Apply a thin coat of sealant just inside the chamfer where the plug is to be installed and install using cup plug installation tool set J 35653 6 With the engine mounted on the overhaul stand install all of any remaining subassemblies and parts on the cylinder block a Install the crankshaft main bearings Refer to section 17 4 b Install the crankshaft Refer to sec...

Page 442: ...ine Lifting Bar tool W470589006200 to the engine FALLING ENGINE To avoid injury from a falling engine an adequate lifting device with a spreader bar and sling should be used to lift the engine 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 r Remove ...

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