Detroit Diesel EPA07 Workshop Manual
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Detroit Diesel EPA07 Workshop Manual

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  • Page 3: Table Of Contents

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE TABLE OF CONTENTS ROCKER COVER DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS ...................... REMOVAL OF THE ROCKER COVER ............ CLEANING AND INSPECTION OF THE ROCKER COVER ....INSTALLATION OF THE ROCKER COVER ..........
  • Page 4 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY ....................6-10 COLD BOOST PIPE (CHARGE AIR PIPE) DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS ..........REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) .....
  • Page 5 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DD15 AXIAL POWER TURBINE GEAR BOX 13.1 DESCRIPTION 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 ..
  • Page 6 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 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 LUBRICATION SYSTEM 18.1...
  • Page 7 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25.2 INSTALLATION OF THE OIL FILLER NECK ........... 25-4 OIL COOLANT MODULE 26.1 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 ........
  • Page 8 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.9 INSTALLATION OF RING GEAR ............. 34-14 FRONT ENGINE MOUNT/RADIATOR SUPPORT 35.1 DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS ......35-3 35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT ..
  • Page 9 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE POLY-V-BELTS 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 AIR COMPRESSOR 41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR ..
  • Page 10 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE All information subject to change without notice. viii DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 11: Rocker Cover

    ROCKER COVER Section Page DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS ...................... REMOVAL OF THE ROCKER COVER ............ CLEANING AND INSPECTION OF THE ROCKER COVER ....INSTALLATION OF THE ROCKER COVER ..........
  • Page 12 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 13: Description And Operation Of Rocker Cover And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS The rocker cover (2) is made of an aluminum or plastic material and uses an elastomer seal (1) which completely encloses the valve operating mechanism including the overhead camshafts, brake assemblies and the injector harness.

  • Page 14: Removal Of The Rocker Cover

    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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 15 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Loosen the bolts (1) or stud bolts (2) (if equipped) and isolators (3); remove rocker cover. NOTE: Mark the location of the stud bolts. The stud bolts must be replaced in their original location during installation.

  • Page 16: Cleaning And Inspection Of The Rocker Cover

    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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 17: Installation Of The Rocker Cover

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE INSTALLATION OF THE ROCKER COVER Install as follows: 1. Install rocker cover gasket into groove in rocker cover. 2. Install bolts (1) or stud bolts (2) (if removed) and isolators (3) into rocker cover.
  • Page 18 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 CORPORATION...

  • Page 19: Camshaft And Rocker Shaft/Engine Brake Assembly

    CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Section Page DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS ....REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY ....................INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY ................. 2-15 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY .................
  • Page 20 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 21: Description And Operation Of Camshaft And Rocker Shaft/Engine Brake Assembly And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS The engine uses a dual overhead camshaft and rocker shaft design. The intake and exhaust camshafts are timed to each other, through a geartrain, to the crankshaft. The camshaft housing houses the camshafts and valve train.
  • Page 22 □ Six exhaust rocker arms with actuator pistons. □ Six brake rocker arms which are actuated by the brake cam lobes. □ Exhaust camshaft has one brake cam lobe per cylinder. All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 23 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE For EPA07 engines, the exhaust rocker arm shaft lubricating oil passages direct pressurized oil to the rocker arms. The exhaust rocker arm has two additional oil passages to operate the engine brakes. Oil for cylinders 1 and 2 is supplied by the Front Engine Brake Solenoid Valve. Oil for cylinders 3 to 6 are supplied by the Rear Engine Brake Solenoid Valve.
  • Page 24 5. Oil Passage for Cylinders 4, 5 and 6 11. Engine Brake Solenoid Valve, Front 6. Exhaust Rocker Arm Shaft 12. Engine Brake Solenoid Valve, Rear Figure 2-3 EPA10 Engine Brake All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 25 (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).
  • Page 26 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 27 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11. When the TDC dot (3) between two teeth on the flywheel aligns with the edge of pointer (2), the engine is at TDC firing stroke. 12. For EPA07 DD13: [a] Disconnect both 14-pin injector harness connectors (8).
  • Page 28 (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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE [b] Remove the bolts securing the two-piece fuel injector electrical harness (1 and 3) and remove the harness from the camshaft housing housing. 14. Remove the engine brake solenoids from the camshaft housing.
  • Page 30 NOTE: The engine brake solenoids do not have to be removed unless damaged. NOTE: Mark cap position for proper reassembly. All information subject to change without notice. 2-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 31 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20. Remove the remaining bolts (1) from the 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.
  • Page 32 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: Inspection Of The Camshaft And Rocker Shaft/Engine Brake Assembly

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY Inspect the camshaft and rocker shaft assemblies as follows: 1. Inspect the camshafts for lobe damage; replace if necessary. 2. Inspect the camshaft gears for damage; replace if necessary.

  • Page 34: Installation Of The Camshaft And Rocker Shaft/Engine Brake Assembly

    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.
  • Page 35 5. Align 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.
  • Page 36 108 mm (M10) bolts and nine 63 mm (M8) bolts. The DD15 uses 28 bolts, with two external bolts at the rear of the camshaft housing. All information subject to change without notice. 2-18 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 37 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10. Install the 30 bolts to camshaft caps; finger tighten the bolts. 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)
  • Page 38 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-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 39 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18. The dial indicator should read 0.051 - 0.257 mm (0.002 - 0.010 in). If the gear lash is excessive between either camshaft gear and the number five idler gear, inspect the number five idler gear spindle, camshaft gear and camshaft housing.
  • Page 40 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 change without notice. 2-22 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 41 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20. Using Rocker Arm Lifter / Spacer Intake (W470589044000) (1) for the DD13 or Rocker Arm Lifter / Spacer Intake (W470589004000) for the DD15, install the intake rocker shaft assembly to the camshaft cap and secure with seven clamping blocks and bolts.
  • Page 42 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. All information subject to change without notice. 2-24 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 43 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30. Install air cleaner housing. Refer 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.

  • Page 44: Dd13 Egr Cooler Cleaning Procedure To Remove Excess

    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 Related Parts All information subject to change without notice. 2-26 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 45 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10. Banjo Union 19. Exhaust Gas Crossover Tube / 1. Clamp Lifting Eye 2. Hose 11. Banjo Bolt 20. Gasket 12. Bolt 21. Bolt 3. Coolant Crossover Pipe 4. Bolt 13. Bolt 22. Venturi 5.
  • Page 46 [b] If there is no sign of liquid or moisture in the pipe or EGR cooler (1), install the hot pipe. No further action is required. All information subject to change without notice. 2-28 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 47 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2. Remove the mixer pipe (1) from the cold 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.
  • Page 48 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 49: Dd15 Egr Cooler Cleaning Procedure To Remove Excess

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE Inspect as follows: 17. Metal Seal 1. Venturi 9. Connecting Tube 2. Bolt 10.Seal Ring 18. Hot Pipe 3.
  • Page 50 15. Metal Seal 23. Seal Ring 7. Connecting Tube 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE Check as follows: NOTICE: This procedure must be followed after replacing an engine brake solenoid due to any failure that could cause high DOC temperature codes, excessive fuel, oil, or coolant to enter the exhaust system.
  • Page 52 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: Camshaft Housing

    CAMSHAFT HOUSING Section Page REMOVAL OF THE CAMSHAFT HOUSING ........... INSPECTION OF CAMSHAFT HOUSING ..........INSTALLATION OF THE CAMSHAFT HOUSING ........
  • Page 54 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 55: Removal Of The Camshaft Housing

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE REMOVAL OF THE CAMSHAFT HOUSING The camshaft housing houses the camshafts and valve train. It has internal oil passages to supply oil from the block to the camshaft and rocker bearings along with pressurized oil to the engine brake rockers via the engine brake solenoids through the exhaust shaft.
  • Page 56 (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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 57 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Disconnect the fuel rail pressure sensor (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.
  • Page 58 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 59 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 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.

  • Page 60: Inspection Of Camshaft Housing

    [d] The O-ring seal on the engine brake solenoids. 5. Inspect the rocker shaft installation surface located inside the camshaft housing for scoring or scratches. All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 61: Installation Of The Camshaft Housing

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE INSTALLATION OF THE CAMSHAFT HOUSING Install as follows: 1. Install a new seal into the camshaft housing. 2. Using an appropriate lifting device install camshaft housing onto the cylinder head. PERSONAL INJURY To avoid injury when removing or installing a heavy engine...
  • Page 62 INSTALLATION OF THE CAMSHAFT HOUSING All information subject to change without notice. 3-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 63: Camshaft Timing

    CAMSHAFT TIMING Section Page CAMSHAFT TIMING VERIFICATION ............TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED ..
  • Page 64 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 65: Camshaft Timing Verification

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE CAMSHAFT TIMING VERIFICATION Verify the camshaft timing as follows: 1. Remove the rocker cover. Refer to section 1.2. 2. Bar the engine to top dead center (TDC) with Engine Barring Tool (J-46392) (3) on cylinder No.1 with the No.
  • Page 66 5. Install the flywheel TDC Locating Pin (W470589001500), through the crankshaft position sensor hole 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.
  • Page 67 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install the rear Camshaft Timing Tool (W470589054000) for EPA07 DD15, (W470589104000) for EPA10 DD15, and (W470589034000) for DD13 (1) into the grooves cut into the cams and pin it into the camshaft housing with a bolt.

  • Page 68: Timing The Camshafts With The Gear Train Installed

    1. Bar the crankshaft over to TDC cylinder No. 1 and lock with W470589001500 through the crankshaft position sensor hole. 2. Install the rear Camshaft Timing Tool (W470589054000) for EPA07 DD15, (W470589104000) for EPA10 DD15, and (W470589034000) for DD13 (1) onto the rear of the camshaft housing.
  • Page 69 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 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...
  • Page 70 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 71: Gear Train And Engine Timing

    GEAR TRAIN AND ENGINE TIMING Section Page DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS ...................... ENGINE GEAR TRAIN INSTALLATION AND TIMING ......CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED ................5-16...
  • Page 72 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 73: Description And Operation Of Gear Train And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS The gear train is located 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.
  • Page 74 B. Level B C. Level C 7. Fuel Pump Gear x. To Front of Engine 8. Axial Power Turbine Gear Figure 5-1 DD15 Engine Gear Train All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 75 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE The gear train on the DD Platform engines is located at the rear of the engine and has three levels. Level A consists of the outermost gears (closest to the flywheel), Level B consists of the middle gears, and Level C consists of the innermost gears (closest to the block).
  • Page 76 B. Level B C. Level C 7. Fuel Pump Gear x. To Front of Engine 8. Axial Power Turbine Gear Figure 5-2 DD15 Engine Gear Train All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 77 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE Multiply Crankshaft Speed by Effective Ratio to Attain Individual Component Speed Component Effective Ratio Speed Crankshaft ________ RPM Camshafts 0.50 ________ RPM Idler #1 0.79 ________ RPM Idler #2 0.86 ________ RPM Idler #3 0.75...

  • Page 78: Engine Gear Train Installation And Timing

    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. All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 79 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install Installation Cantilever tool (J-47487) onto idler gear number three. 8. Install two bolts into the spindle and idler gear No. 3; snug the bolts. NOTE: When idler gear No. 3 and timing tool J–47487 are installed to the gear case, timing tool J–47487 should come off of the gear with ease.
  • Page 80 25. Lubricate the camshaft journals and install the camshafts into the camshaft housing. 26. Mark the camshafts TDC indicator triangle located on the inside of the camshaft gear with a suitable marker. All information subject to change without notice. 5-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 81 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 27. Install Camshaft Timing Tool (1) (W470589054000) for EPA07 DD15 - shown, (W470589104000) for EPA10 DDl5, and (W470589034000) for DD13 into the holes at the rear of the camshaft housing and secure to the camshaft housing with two bolts.
  • Page 82 ENGINE GEAR TRAIN INSTALLATION AND TIMING 30. Install Camshaft Timing Tool (1) (W470589054000) for EPA07 DD15 - shown, (W470589104000) for EPA10 DDl5, and (W470589034000) for DD13 into the holes at the slot in the front of the camshaft housing and secure to the camshaft housing with one bolt.
  • Page 83 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 33. Prior to engine brake solenoid installation, replace the O-rings on the engine brake solenoids. NOTE: There are 30 bolts retaining the camshaft assemblies; fourteen 120 mm (M10) bolts, seven 108 mm (M10) bolts and nine 63 mm (M8) bolts.
  • Page 84 □ 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 2. Verify correct camshaft timing by checking that the marks on the camshaft gears still 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).

  • Page 86: Checking And Adjusting Gear Lash With Camshaft Housing Removed

    7. Remove access cover to the idler gear number three bolts. 8. Loosen the two number three idler gear bolts and then snug by hand. All information subject to change without notice. 5-16 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 87 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9. Turning idler gear number five by hand will change gear lash from zero lash to maximum lash. NOTE: Rotating idler gear number five counterclockwise (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.
  • Page 88 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 information subject to change without notice. 5-18 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 89: Description And Operation Of Dd15 & Dd16 Water

    WATER MANIFOLD Section Page DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS .......... REMOVAL OF THE DD15 & DD16 WATER MANIFOLD ......CLEANING AND INSPECTION OF THE DD15 & DD16 WATER MANIFOLD ....................INSTALLATION OF THE DD15 & DD16 WATER MANIFOLD ....DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY ....................
  • Page 90 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 91: Manifold And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS Coolant flows from the cylinder head through an opening next to each exhaust port and into the water manifold in the DD15 engine. The water manifold is attached to the cylinder head by a total of nineteen bolts, including two that are shared with the coolant outlet elbow.
  • Page 92 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 93: Removal Of The Dd15 & Dd16 Water Manifold

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE REMOVAL OF THE DD15 & DD16 WATER MANIFOLD Remove as follows: 1. Disconnect the batteries. 2. Drain the engine coolant. 3. Remove the air cleaner. 4. Remove the exhaust manifold heat shields. 5. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section .
  • Page 94 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 95: Cleaning And Inspection Of The Dd15 & Dd16 Water Manifold

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE CLEANING AND INSPECTION OF THE DD15 & 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.

  • Page 96: Installation Of The Dd15 & Dd16 Water Manifold

    5. Torque the water manifolds bolts to 30 N·m (22 lb·ft), using the torque sequence illustrated below. 6. Install EGR cooler to water manifold and torque to 20 N·m (15 lb·ft). All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 97 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 7. Install coolant outlet elbow (2) with four bolts (1) and torque to 30 N·m (22 lb·ft). 8. Install upper radiator hose. 9. Install EGR actuator coolant outlet line. Torque outlet line to 35 N·m (26 lb·ft).

  • Page 98: Dd13 Exhaust Gas Recirculation Cooler Water Manifold Assembly

    □ 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-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 99 COLD BOOST PIPE (CHARGE AIR PIPE) Section Page DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS ..........REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ..... INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) ....INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ..
  • Page 100 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 101: Description And Operation Of Cold Boost Pipe (Charge Air Pipe) And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS The cold boost pipe (Charge Air Pipe) is installed onto the intake manifold and is a component of the EGR System.

  • Page 102: Removal Of The Cold Boost Pipe (Charge Air Pipe)

    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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 103: Inspection Of Cold Boost Pipe (Charge Air Pipe)

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) 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.

  • Page 104: Installation Of The Cold Boost Pipe (Charge Air 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 105 AIR INTAKE MANIFOLD Section Page DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS ..................REMOVAL OF AIR INTAKE MANIFOLD ..........CLEANING OF THE AIR INTAKE MANIFOLD ........INSPECTION OF THE AIR INTAKE MANIFOLD ........INSTALLATION OF AIR INTAKE MANIFOLD ..........
  • Page 106 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 107: Description And Operation Of Air Intake Manifold And Related Parts

    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 temperature sensor in the intake throttle adaptor.
  • Page 108 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 Related Parts All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 109 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt 9. Flanged Screw, Intake Manifold 17. Bolt, Cold Boost Pipe to Intake to Cylinder Head Manifold 10. Seal Ring, Charge Air Sensor 18. Cold Boost Pipe 2. Adaptor 3. Gasket 11. Clamp, turbocharger outlet pipe 19.

  • Page 110: Removal Of Air Intake Manifold

    12. Remove the thirteen flanged screws and isolator gaskets securing the air intake manifold to cylinder head. 13. Remove the air intake manifold and six gaskets from the cylinder head. Discard gaskets. All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 111: Cleaning Of The Air Intake Manifold

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE CLEANING OF THE AIR INTAKE MANIFOLD Clean as follows: 1. Remove loose gasket material from the cylinder head and intake manifold mating surfaces. 2. Wash all of the parts in clean fuel oil.

  • Page 112: Inspection Of The Air Intake Manifold

    [a] If all port flange area measurements are less than 0.127 mm (0.005 in), the manifold is reusable and can be reinstalled with new gaskets. [b] If the manifold does not meet this requirement, the manifold must be replaced. All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 113: Installation Of Air Intake Manifold

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE INSTALLATION OF AIR INTAKE MANIFOLD Install as follows: 1. Install six gaskets to the air intake manifold. 2. Install thirteen flanged screws and isolator gaskets to the air intake manifold. Secure air intake manifold to cylinder head. Torque the bolts to 25 N·m (18 lb·ft).
  • Page 114 INSTALLATION OF AIR INTAKE MANIFOLD All information subject to change without notice. 8-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 115: Dd13 Turbocharger

    DD13 TURBOCHARGER Section Page DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS ................REMOVAL OF THE DD13 TURBOCHARGER ........INSPECTION OF THE DD13 TURBOCHARGER ........INSTALLATION OF THE DD13 TURBOCHARGER ........ 9-10 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE ....
  • Page 116 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 117: Description And Operation Of The Dd13 Turbocharger And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS Compression of air in the turbocharger causes an air mass to flow into the combustion chamber. The turbocharger consists of a turbine and a compressor which are attached to a shaft. The exhaust gas flows to the turbine wheel and causes it to turn.
  • Page 118 5. Stud (6 qty.) 11. Turbocharger 17. Air Hose 12. Turbo Inlet Pipe 18. Electronic Proportioning Valve 6. Bolt Figure 9-1 EPA10 DD13 Turbocharger and Related Parts All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 119: Removal Of The Dd13 Turbocharger

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE REMOVAL OF THE DD13 TURBOCHARGER Cleaning the turbocharger is necessary before removal. PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. PERSONAL INJURY...
  • Page 120 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 121 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. For EPA10 DD13 engines, remove the clamp (2) from the Electronic Proportioning Valve (EPV) air hose to the turbocharger and remove the hose (1) from the EPV. NOTE: Leave the air hose (1) connected to the turbocharger.
  • Page 122 To avoid injury from improper use of chemicals, follow 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. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 123: Inspection Of The Dd13 Turbocharger

    [a] If the engine exhaust emission appears normal, no further troubleshooting is required. Shut down the engine. [b] If the engine exhaust emission is excessive, shut down the engine. Call Detroit Diesel Customer Support Center (313-592-5800). All information subject to change without notice.

  • Page 124: Installation Of The Dd13 Turbocharger

    30-38 N·m (22-28 lb·ft). 8. Install the turbocharger oil drain line. 9. Install the turbocharger oil supply line. Torque line to 30 N·m (22 lb·ft). All information subject to change without notice. 9-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 125 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 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.

  • Page 126: Egr Cooler Cleaning Procedure To Remove Excess Fuel

    8. Gasket 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 change without notice. 9-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 127 Cooler Water Manifold Assembly 8. Gasket 17. Clamps 26. Bolt 18. Hot Pipe 9. Seal Ring Figure 9-3 EPA07 DD13 EGR Cooler Water Manifold and Related Parts All information subject to change without notice. 9-13 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 128 [b] If there is no sign of liquid or moisture in the pipe, install the EGR cooler hot pipe. No further action is required. Refer to section . All information subject to change without notice. 9-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 129 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Remove the EGR Mixer Pipe (2) from 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.
  • Page 130 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.

  • Page 131: Dd13 Wastegate Solenoid

    DD13 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 132 All information subject to change without notice. 10-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 133: Description And Operation Of The Dd13 Wastegate Solenoid

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10.1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID For EPA10, the DD13 uses an wastegate solenoid to control 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.

  • Page 134: Removal Of The Dd13 Wastegate Solenoid

    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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Remove the vehicle 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.

  • Page 136: Installation Of The Dd13 Wastegate Solenoid

    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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - 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. 10-7 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 138 10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID All information subject to change without notice. 10-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 139: Dd15 Turbocharger

    DD15 TURBOCHARGER Section Page 11.1 DESCRIPTION AND OPERATION OF 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 ..
  • Page 140 All information subject to change without notice. 11-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 141: Description And Operation Of Turbocharger And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11.1 DESCRIPTION AND OPERATION OF TURBOCHARGER AND RELATED PARTS Compression of air in the turbocharger causes an air mass to flow into the combustion chamber. The turbocharger consists of a turbine and a compressor which are attached to a shaft. The exhaust gas flows to the turbine wheel and causes it to turn.
  • Page 142 16. Air Line 24. Turbo Inlet Elbow 32. Heat Shield Mounting 8. O-ring Bolt Figure 11-1 EPA07 and EPA10 DD15 Turbocharger and Related Parts All information subject to change without notice. 11-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 143: Removal Of Dd15 Turbocharger

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11.2 REMOVAL OF DD15 TURBOCHARGER Cleaning the turbocharger is necessary before removal. PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. PERSONAL INJURY...

  • Page 144: Removal Of Dd15 Turbocharger

    To avoid injury from improper use of chemicals, follow the chemical manufacturer’s usage, handling, and disposal instructions. Observe all manufacturer’s cautions. 13. Clean the exterior of the turbocharger with a non-caustic cleaning solvent. All information subject to change without notice. 11-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 145: Inspection Of Dd15 Turbocharger

    [a] If the engine exhaust emission appears normal, no further troubleshooting is required. Shut down the engine. [b] If the engine exhaust emission is excessive, shut down the engine. Call Detroit Diesel Customer Support Center (313-592-5800). All information subject to change without notice.
  • Page 146 11. Torque the turbocharger-to-exhaust manifold bolts to 50 N·m (37 lb·ft). 12. Tighten the interstage duct clamp to 12 N·m (9 lb·ft). 13. Torque turbine housing bracket bolts to 25 N·m (18 lb·ft). All information subject to change without notice. 11-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 147 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14. Install the turbocharger oil drain line, using a new gasket and O-ring between the opening in the bottom side of the turbocharger center housing and the drain line that runs to the cylinder block.

  • Page 148: Egr Cooler Cleaning Procedure To Remove Excess Oil From Egr Cooler After Dd15 Turbocharger Failure

    7. Lifting Eye 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 notice. 11-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 149 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Venturi 9. Banjo Union 17. Water Manifold 10. Banjo Bolt 18. Support 2. Bolt 3. Gasket 11. Exhaust Gas Cooler 19. Clamp 4. Bolt 12. Strap 20. Hose 13. Shim 21. Mixer Pipe 5.
  • Page 150 [b] If there is no sign of liquid or moisture in the pipe or EGR cooler, install the hot pipe. No further action is required. 3. Remove the mixer pipe (4) from the cold boost pipe (1). Refer to section . All information subject to change without notice. 11-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 151 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.
  • Page 152 11.5 EGR COOLER 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: Description And Operation Of Dd15 Axial Power Turbine

    DD15 AXIAL POWER TURBINE Section 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 ......
  • Page 154 All information subject to change without notice. 12-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 155: And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS The Axial Power Turbine (APT) increases the efficiency and the economy of the engine by converting the thermal energy in the exhaust flow from the turbocharger into mechanical energy, delivering the resulting torque to the crankshaft.
  • Page 156 7. Gasket Seal 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-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 157: Removal Of Dd15 Axial Power Turbine

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.2 REMOVAL OF DD15 AXIAL POWER TURBINE Remove as follows: NOTICE: Ensure turbocharger and axial power turbine are supported prior to removal. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

  • Page 158: Inspection Of The Dd15 Axial Power Turbine

    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: Installation Of Dd15 Axial Power Turbine

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE Install as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. If removed, install the gear box to cylinder block with four bolts. Torque bolts to 55–60 N·m (41–45 lb·ft).
  • Page 160 12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE All information subject to change without notice. 12-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 161: Dd15 Axial Power Turbine Gear Box

    DD15 AXIAL POWER TURBINE GEAR BOX Section Page 13.1 DESCRIPTION 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 ....
  • Page 162 All information subject to change without notice. 13-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 163: Description And Operation Of Dd15 Axial Power Turbine Gear Box And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.1 DESCRIPTION AND OPERATION OF 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.
  • Page 164 7. Gasket Seal 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-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 165: Removal Of The Dd15 Axial Power Turbine Gear Box

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX Remove as follows: 1. Remove the turbocharger. Refer to section 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.

  • Page 166: Inspection Of Dd15 Axial Power Turbine Gear Box

    INSPECTION OF DD15 AXIAL POWER TURBINE 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: Installation Of The Axial Power Turbine Gear Box

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX Install as follows: NOTICE: Ensure the gear box gear and idler gear located in the gear case housing are meshed. Failure to mesh gears correctly will cause damage.
  • Page 168 13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX All information subject to change without notice. 13-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 169: Description And Operation Of Cylinder Head And Related Parts

    CYLINDER HEAD Section Page 14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS ...................... 14-3 14.2 REMOVAL OF THE DD13 CYLINDER HEAD ......... 14-10 14.3 INSTALLATION OF THE DD13 CYLINDER HEAD ........14-12 14.4 REMOVAL OF THE DD15 CYLINDER HEAD ......... 14-15 14.5 CLEANING OF THE CYLINDER HEAD ..........
  • Page 170 All information subject to change without notice. 14-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 171: Description And Operation Of Cylinder Head And Related

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS This section explains the description(s) and operation(s) of the following systems within the cylinder head: □ Cylinder Head □ Valve Springs and related components □...
  • Page 172 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Holes for Installing the Intake Manifold 2. Inlet Ducts Figure 14-4 Cylinder Head Inlet Duct Location 14.1.2 Intake and Exhaust Valves There are four valves per cylinder; two intake valves and two exhaust valves.
  • Page 174 5. Drive Gear for Exhaust 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 to change without notice. 14-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 175 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Cylinder Head Gasket 10. Valve Keeper 2. Exhaust Valve Seat Ring 11. Exhaust Valve Spring 12. Spring Retainer 3. Intake Valve Seat Ring 4. Exhaust Valve 13. Intake Valve Spring 5. Intake Valve 14.
  • Page 176 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1.Inlet Valves 2. Exhaust Valves Figure 14-9 Intake and Exhaust Valve Location All information subject to change without notice. 14-9 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 178: Removal Of The Dd13 Cylinder Head

    Refer to section . 12. Disconnect fuel injector harness from the fuel injectors and engine brake solenoids. [a] EPA07 Engines: For Removal of One-Piece Fuel Injector Wiring Harness refer to section . [b] EPA10 Engines: For Removal of Two-Piece Fuel Injector Wiring Harness refer to section .
  • Page 179 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18. Remove the EGR crossover tube. Refer to section . 19. Remove the two bolts attaching the cold boost pipe to the support bracket. 20. Using Flywheel and Main Pulley Socket tool (J-45390), remove the 40 bolts securing the cylinder head to the cylinder block.

  • Page 180: Installation Of The Dd13 Cylinder Head

    5. Install four lift hooks onto the cylinder head. All information subject to change without notice. 14-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 181 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Lift the cylinder head into position using Cylinder Head/Engine Lifting Bar tool (W470589006200). Lower cylinder head into place over the guide studs and dowel pins until it is seated on the engine block.
  • Page 182 34. Prime engine lubrication system. Refer to section 27.1. 35. Start the engine and check for fuel, coolant or oil leaks. 36. Shut down the engine. All information subject to change without notice. 14-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 183: Removal Of The Dd15 Cylinder Head

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.4 REMOVAL OF THE DD15 CYLINDER HEAD Because optional and accessory equipment varies with the engine application, this procedure covers only the basic engine. If the engine is equipped with accessories that affect cylinder head removal, note the mounting details of each to assure correct installation at reassembly.
  • Page 184 24. Using Cylinder Head/Engine Lifting Bar tool (W470589006200), remove the cylinder head from the cylinder block. 25. Remove and discard the metallic gasket from the cylinder block. All information subject to change without notice. 14-16 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 185: Cleaning Of The Cylinder Head

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.5 CLEANING OF THE CYLINDER HEAD Clean the cylinder head as follows: 1. Keep parts segregated according to original position to assure proper reassembly, if parts are to be reused. 2. Remove all plugs.

  • Page 186: Assembly Of Cylinder Head

    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: Installation Of The Dd15 Cylinder Head

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.7 INSTALLATION OF THE DD15 CYLINDER HEAD Install the cylinder head as follows: 1. Inspect the head bolt holes in both block and head for the presence of oil, water, dirt, or damaged threads, clean or re-tap as necessary. Ensure piston domes and the cylinder head and cylinder block deck surfaces are clean and free of foreign matter.
  • Page 188 17. Set the valve lash and engine brake. Refer to section 14.15. 18. Install any components that were removed and fill with required fluids as recommended. Refer to OEM guidelines. 19. Fill the cooling system. All information subject to change without notice. 14-20 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 189 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate 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.

  • Page 190: Removal Of Valve Spring (Cylinder Head Installed)

    9. Install the adaptor (J-47411) into the cylinder and torque to 20 N·m (14 lb·ft) plus 90 degrees with the injector hold-down clamp and bolt, connect shop air to compression adaptor. All information subject to change without notice. 14-22 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 191 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 10. Position the spring compressor cage portion of the valve spring compressor(J–47406) directly over the valve spring to be compressed. Engage the dowel of the cage in the closest slot of the valve spring compressor handle.

  • Page 192: Removal Of The Valve Spring (Cylinder Head Removed)

    7. Flip the cylinder head over and carefully remove the valves from the cylinder head. All information subject to change without notice. 14-24 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 193: Removal Of Intake And Exhaust Valves

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.10 REMOVAL OF INTAKE AND EXHAUST VALVES Remove 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.

  • Page 194: Cleaning Of Valves And Related Parts

    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 subject to change without notice. 14-26 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 195: Inspection Of Valve Springs

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.12 INSPECTION OF VALVE SPRINGS Inspect the valve springs and replace any that are pitted or cracked. The 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.

  • Page 196: Inspection Of Valve

    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: Installation Of Valve, Spring, Seal And Valve Cap

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.14 INSTALLATION OF VALVE, SPRING, SEAL AND VALVE CAP Install as follows: 1. Position the cylinder head on a work bench for valve installation, if removed. Lubricate the valve stems with clean engine lubricating oil and slide them into their respective valve guides and against the valve seats.
  • Page 198 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 without notice. 14-30 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 199: Valve Lash Adjustments

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.15 VALVE LASH ADJUSTMENTS Accurate adjustment of clearance between intake and exhaust valves is important if maximum performance and economy are to be obtained. NOTE: Every time the valve lash is adjusted the engine brake lash will also need to be set.
  • Page 200 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: Setting The Engine Brake Lash

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 14.16 SETTING THE ENGINE BRAKE LASH Set the brake lash as follows: 1. Set the lash on all the exhaust adjusting screws first (all the adjusting screws in direct contact with the exhaust valves).
  • Page 202 14.16 SETTING THE ENGINE BRAKE LASH All information subject to change without notice. 14-34 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 203: Piston And Connecting Rod Assembly

    PISTON AND CONNECTING ROD ASSEMBLY Section Page 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 ASSEMBLY ..15-7 15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY ..
  • Page 204 All information subject to change without notice. 15-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 205: Description And Operation Of Piston And Connecting Rod And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS The connecting rods are forged from a high strength steel. A connecting rod bushing is pressed into the small end of the connecting rod.
  • Page 206 4. Retaining Clip 11. Piston Dome 12. Top Land 5. Piston Boss 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY Remove the piston and connecting rod assembly as follows: 1. Drain the engine cooling system. 2. Drain the engine oil. 3. Remove the oil pan. Refer to section 19.2 4.

  • Page 208: Removal Of Piston And Connecting Rod Assembly

    When removed, the bearing cap and the bearing shell must be assembled to its original connecting rod before another connecting rod bearing cap is removed. All information subject to change without notice. 15-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 209: Disassembly Of Piston And Connecting Rod Assembly

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY Piston assembly components should be segregated by cylinder and match-marked during disassembly to ensure they are assembled in the same position and orientation. NOTICE: Stamping cylinder numbers on the piston assembly will damage the components.

  • Page 210: Inspection Of Piston And Connecting Rod Assembly

    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: Assembly Of Piston And Connecting Rod Assembly

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY Assemble as follows: 1. Using appropriate flat-nosed pliers, install one of the retaining rings into a retaining ring recess in the piston. Orient the retaining ring gap (1) to either the 12 o'clock or 6 o'clock position.
  • Page 212 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 DIESEL CORPORATION...

  • Page 213: Installation Of Piston And Connecting Rod Assembly

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY Install as follows: 1. If the rings have been removed, install them into the grooves of the piston and rotate 120° apart as follows: [a] Install the oil ring expander in the lowest groove in the piston.
  • Page 214 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE [c] For the DD15, Piston Ring Compressor tool (W470589015900) may also be used. 8. Place piston on a bench with dome side down, install piston ring compressor tool. 9. Once the ring compressor is clamped, ensure the piston can rotate freely. If rotation is hindered, remove the compressor and reposition the dome and rings, or inspect for ring damage.
  • Page 216 17. Lubricate the lower bearing shell with clean engine oil. 18. With the number on the cap and rod on the same side and the arrow facing forward, install the bearing cap. All information subject to change without notice. 15-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 217 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19. Torque the connecting rod bolts alternately to the following: Connecting Rod Bolt Torque DD13 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°...
  • Page 218 30 N·m (22 lb·ft). 23. Using a dial gauge and holder, measure the piston protrusion relative to cylinder block top dead center at all the pistons. All information subject to change without notice. 15-16 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 219 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24. Allowable piston protrusion (A) is in the table below: 1. Piston 2. Cylinder Liner A. Allowable Piston Protrusion Engine Minimum Maximum DD13 -0.201 mm (-0.0079 in) 0.2215 mm (0.0087 in.) DD15 -0.213 mm (-0.0090 in.) 0.2075 mm (0.0081 in.)
  • Page 220 34. Verify repairs made to the piston and connecting rod assembly. If new parts such as pistons, rings, cylinder liners or bearings were installed, operate the engine on the run-in schedule. All information subject to change without notice. 15-18 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 221: Cylinder Liner

    CYLINDER LINER Section Page 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 222 All information subject to change without notice. 16-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 223: Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.1 DESCRIPTION AND OPERATION OF CYLINDER LINER AND RELATED PARTS The cylinder liners feature a “bottom stop” design, which means that the cylinder liners are installed with a lower collar in the cylinder block. This design allows for a shorter distance between cylinders and a more compact design for the cylinder block.
  • Page 224 4. Remove the two seal rings (1, 3) from the cylinder liner (2) and discard them. All information subject to change without notice. 16-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 225 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.3 INSPECTION OF CYLINDER LINER Inspect as follows: 1. Inspect the cylinder liner. [a] Check the cylinder liner for cracks or scoring. If cracks or scoring are present, replace the liner. NOTICE: Cavitation is due to poor cooling system maintenance.
  • Page 226 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 without notice. 16-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 227 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 16.4 CLEANING OF THE CYLINDER LINER Clean as follows: NOTE: If using de-greasing solution to clean cylinder liner when finished, an application of clean engine oil will need to be applied to protect the cylinder liner from corrosion.
  • Page 228 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 subject to change without notice. 16-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 229 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5. Seat the liner into the block using cylinder liner installation tool J-47407 for the DD15, for the and tool 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).
  • Page 230 (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.
  • Page 231 CRANKSHAFT Section Page 17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS ...................... 17-3 17.2 REMOVAL OF 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 ..........
  • Page 232 All information subject to change without notice. 17-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 233: Description And Operation Of Crankshaft And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS The crankshaft is made out of induction-hardened steel. The crankshaft bearing journals and connecting rod journals are hardened in the boundary layer and then are ground. In order to avoid vibrations, counterweights are cast onto the guide-ways.
  • Page 234 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt 7. Vibration Damper 2. Main Bearing Caps 8. Upper Crankshaft Bearing Shells 3. Lower Crankshaft Bearing Shells 9. Thrust Washer 4. Lower Connecting Rod Bearing Shells 10. Crankshaft 5. Upper Connecting Rod Bearing Shells 11.

  • Page 236: Removal Of Crankshaft

    FALLING 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. 17-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 237 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 5. Remove and inspect all of the accessories and assemblies with their attaching parts, as necessary, to permit the engine block adaptor to be bolted to the intake (left) side of the cylinder block. Mount the engine to the overhaul stand (J–29109) with adaptor (J–35635–A).
  • Page 238 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: Inspection Of The Crankshaft And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS Inspect as follows: 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.

  • Page 240: Installation Of Crankshaft

    200.5 mm (7.894 in.) Table 17-2 Maximum Main Bearing Cap Bolt Length 7. Install the main bearing caps together with lower bearing shells in place. All information subject to change without notice. 17-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 241 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. Apply a small quantity of clean engine oil to the bolt threads and underside of the bolt heads. Install the main bearing cap bolts and draw them up snug. 9. Torque main bearing cap bolt torque to 50 N·m (36 lb·ft).
  • Page 242 21. Replace the front crankshaft oil seal with new seal. Refer to section 17.8. 22. Install the crankshaft pulley and vibration damper assembly. Refer to section 36.2. All information subject to change without notice. 17-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 243 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 23. Install the oil pan. Refer to section 19.7. 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.

  • Page 244: Removal Of Crankshaft Rear Oil Seal

    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 & Remover tool (W470589004300); remove the seal (2) and discard the seal. All information subject to change without notice. 17-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 245: Installation Of The Rear Oil Seal

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.6 INSTALLATION OF THE REAR OIL SEAL Install as follows: NOTE: The standard size rear oil seal has an inside diameter of 138 mm (5.433 in.). 1. Inspect the contact area of the flywheel for damage and wear. If it is scored or worn, replace it.
  • Page 246 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: Removal Of The Crankshaft Front Oil Seal

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.7 REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL To remove the front crankshaft oil seal, use Front Crankshaft Seal Installer/Remover tool (W541589023300). Remove as follows: 1. Remove the poly-V-belts. Refer to section 40.1.

  • Page 248: Installation Of The Crankshaft Front Oil Seal

    2. Install a new seal onto plastic seal installation tool. NOTE: The plastic seal installation tool is a one time use item; discard after using. All information subject to change without notice. 17-18 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 249 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 3. Install seal (1) and plastic installation tool (2) into the front cover (3) and crankshaft; remove plastic seal installation tool (2) and discard. 4. Install Front Crankshaft Seal Installer/Remover tool (W541589023300) to the crankshaft.
  • Page 250 7. Install the 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: Lubrication System

    LUBRICATION SYSTEM Section Page 18.1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS .............. 18-3...
  • Page 252 All information subject to change without notice. 18-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 253 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 18.1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS A schematic of the lubrication system in the following illustration shows the oil flow to the engine components. For the DD13 engine, see Figure18-1. For the DD15 engine, see Figure 18-2.
  • Page 254 16. Gear Train Oil Supply 7. Backflow Valve 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 OIL PAN Section Page 19.1 DESCRIPTION AND OPERATION OF OIL PAN AND 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 —...
  • Page 256 All information subject to change without notice. 19-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 257: Description And Operation Of Oil Pan And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.1 DESCRIPTION AND OPERATION OF OIL PAN AND RELATED COMPONENTS Depending on manufacturer, the oil pan is either glass fiber reinforced plastic or aluminum. Sealing of the oil pan takes place using a metal elastomer pre-formed gasket for the aluminum pan or an elastomer gasket for the plastic pan.

  • Page 258: Removal Of Oil 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 CORPORATION...

  • Page 259: Cleaning Of Oil Pan

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.3 CLEANING OF OIL PAN Clean as follows: 1. Clean the oil pan and attaching hardware with clean fuel oil or solvent. To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  • Page 260: Inspection Of Oil Pan

    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: Removal Of Threaded Insert - Plastic Oil Pan Only

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.5 REMOVAL OF THREADED INSERT — 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.

  • Page 262: Installation Of Threaded Insert - Plastic Oil Pan Only

    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: Installation Of Oil Pan

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 19.7 INSTALLATION OF OIL PAN Install as follows: 1. When a plastic pan is used, insert the raised lip portion of the seal into the groove in the oil pan. Press down on the isolator seal and insert it completely around the oil pan. Be careful not to stretch or bunch the seal.
  • Page 264 14. If oil pump was removed, follow section 21.4. 15. Prime the lubrication system. Refer to section 27.1. 16. Refill the oil pan with lubricating oil. (refer to specs for oil quantities). All information subject to change without notice. 19-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 265 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 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 engine and inspect for leaks. All information subject to change without notice.
  • Page 266 19.7 INSTALLATION OF OIL PAN All information subject to change without notice. 19-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 267: Oil Dipstick Tube

    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 268 All information subject to change without notice. 20-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 269: Description And Operation Of Oil Dipstick Tube And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20.1 DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND RELATED COMPONENTS DD Platform engines share a similar oil dipstick tube design. The dipstick inserts into the oil pan through the dipstick guide tube and oil pan adaptor. A lower dipstick bracket and hose clamp secure the assembly to the cylinder block.

  • Page 270: Removal Of The Oil Dipstick Tube

    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: Installation Of The Oil Dipstick Tube

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 20.3 INSTALLATION OF THE OIL DIPSTICK TUBE 1. Install oil dipstick tube (2) onto the oil pan adaptor. 2. Attach all P-clips (4) to the bracket (1) and upper bracket on DD15 and DD16.
  • Page 272 20.3 INSTALLATION OF THE OIL DIPSTICK TUBE All information subject to change without notice. 20-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 273: Oil Pump

    OIL PUMP Section Page 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 .......................
  • Page 274 All information subject to change without notice. 21-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 275: Description And Operation Of Oil Pump And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 21.1 DESCRIPTION AND OPERATION OF OIL PUMP AND RELATED COMPONENTS The oil pump supplies all of the engine oil circuits with engine oil. The oil pump ensures that engine oil is available under all operating conditions, in adequate quantities, at the required pressure, and to the respective locations.

  • Page 276: Removal Of The Oil Pump, Oil Suction Manifold, And Oil Lines

    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 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 277: Inspection Of The Oil Pump, Oil Suction Manifold, And Oil Lines

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 21.3 INSPECTION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES Inspect as follows: To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air pressure.

  • Page 278: Installation Of The Oil Pump, Oil Suction Manifold, And Oil Lines

    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 notice. 21-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 279: Crankcase Breather

    CRANKCASE BREATHER 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 280 All information subject to change without notice. 22-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 281: Description And Operation Of Crankcase Breather

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 22.1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER The crankcase breather is located below the turbocharger on DD Platform engines, next to the starter on the right hand side of the cylinder block. The crankcase breather has the primary task of regulating the pressure in the crankcase as well as cleaning discharged blow-by gases.
  • Page 282 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: Removal Of The Crankcase Breather

    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.

  • Page 284: Inspection Of The 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: Installation Of The Crankcase Breather

    NOTE: Bracket is installed on top bolt. 2. On EPA07 engines, install the breather pipe and new gasket to the engine block. Torque the two bolts to 30 N·m (22 lb·ft). 3. On EPA10 engines, snap the breather pipe to the fitting on the cylinder block.
  • Page 286 22.4 INSTALLATION OF THE CRANKCASE BREATHER All information subject to change without notice. 22-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 287: Oil Filter

    OIL FILTER Section Page 23.1 REPLACEMENT OF THE OIL FILTER ............ 23-3...
  • Page 288 All information subject to change without notice. 23-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 289: Replacement Of The Oil Filter

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 23.1 REPLACEMENT OF THE OIL FILTER “Oil Filter Removal Video” Remove as follows: 1. Using a 36-mm socket, unscrew the oil filter cap (1) and filter (3), and allow the oil to drain into the housing.
  • Page 290 23.1 REPLACEMENT OF THE OIL FILTER All information subject to change without notice. 23-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 291: Oil Sample Valve

    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 292 All information subject to change without notice. 24-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 293: Replacing Oil Plug With Oil Sample Valve

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24.1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE Replace oil plug with oil sample 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.

  • Page 294: Removal Of Oil Sample Valve

    REMOVAL OF OIL SAMPLE VALVE 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: Installation Of Oil Sample Valve

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 24.3 INSTALLATION 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.
  • Page 296 24.3 INSTALLATION OF OIL SAMPLE VALVE All information subject to change without notice. 24-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 297: Oil Filler Neck

    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 298 All information subject to change without notice. 25-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 299: Removal Of The Oil Filler Neck

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25.1 REMOVAL OF THE 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).

  • Page 300: Installation Of The Oil Filler Neck

    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 OIL COOLANT MODULE Section Page 26.1 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 ..........
  • Page 302 All information subject to change without notice. 26-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 303: Description And Operation Of The Oil Coolant Module

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE The oil filter unit is an integral part of the oil coolant module. The oil coolant module is located on the left side of the engine. The oil filter unit ensures engine oil filtering.
  • Page 304 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: Removal Of The Oil Coolant Module

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.2 REMOVAL OF THE OIL COOLANT MODULE Remove as follows: 1. Drain coolant from the radiator. Refer to OEM procedures. 2. Open the drain plug (1) on the cylinder block located next to the oil coolant module and t.
  • 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: Installation Of The Oil Coolant Module

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.3 INSTALLATION OF THE OIL COOLANT MODULE Install as follows: 1. Install thermostat to oil coolant module with four bolts. Torque to 20-25 N·m (15-19 lb·ft). 2. Install Exhaust Manifold Guide Studs tool (J–36107) into the cylinder block to assist in guiding the oil coolant module onto the cylinder block.
  • Page 308 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 engine lubrication system. Refer to section 27.1. All information subject to change without notice. 26-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 309: Removal Of The Oil Thermostat

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.4 REMOVAL OF THE OIL THERMOSTAT Remove as follows: 1. Place a suitable oil capturing device under the oil coolant 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).
  • 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: Installation Of The Oil Thermostat

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 26.5 INSTALLATION OF THE OIL THERMOSTAT Install 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.
  • Page 312 (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: Priming The Lubrication System

    PRIMING THE LUBRICATION SYSTEM Section Page 27.1 PRIMING THE ENGINE LUBRICATION SYSTEM ........27-3...
  • Page 314 All information subject to change without notice. 27-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 315: Priming The Engine Lubrication System

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 27.1 PRIMING THE ENGINE LUBRICATION SYSTEM Prime the oil system as follows: 1. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port on the oil coolant module.
  • Page 316 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 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 317 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 9. Close the valve and loosen the fitting; do not completely remove it from the adaptor. 10. Remove the priming adaptor (1) from the oil coolant module (2) with the line attached to keep the oil from flowing out of the module.
  • Page 318 27.1 PRIMING THE ENGINE LUBRICATION SYSTEM All information subject to change without notice. 27-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 319: Cooling System

    COOLING SYSTEM Section Page 28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS ..............28-3...
  • Page 320 All information subject to change without notice. 28-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 321: Description And Operation Of Cooling System And Related Components

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS A schematic of the cooling system in the following illustration shows the coolant flow to the engine components. 1. Coolant Pump 10. Fan 19.
  • Page 322 5. Coolant Outlet to Cooler Circuit 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

    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 324 All information subject to change without notice. 29-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 325: Description And Operation Of Engine Water Pump

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 29.1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP The water pump is located on the left side of the engine, mounted on the front of the oil coolant module. The water pump circulates the coolant in the cooling circuit.

  • Page 326: Removal Of The Water Pump

    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 without notice. 29-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 327: Inspection Of The Water Pump

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 29.3 INSPECTION OF THE WATER PUMP Slight weeping from the weep hole in the bottom of water pump is normal. The water pump should only be replaced if there is a heavy leak from the weep hole. The water pump should only be replaced after all of the following inspections have been performed.

  • Page 328: Installation Of The Water Pump

    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 subject to change without notice. 29-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 329: Coolant Thermostat

    COOLANT THERMOSTAT Section 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 330 All information subject to change without notice. 30-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 331: Description And Operation Of Coolant Thermostat

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT The coolant thermostat is located on the left side of the engine on the oil coolant module. The coolant thermostat regulates the coolant inlet temperature in a range from 87°C (188° F) to 95°C (203°F).
  • Page 332 These loops include the flow through the vehicle cab heater, vehicle bunk heater, the EGR actuator, and the doser. All information subject to change without notice. 30-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 333: Removal Of Coolant Thermostat And Seal

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.2 REMOVAL OF COOLANT THERMOSTAT AND SEAL Remove as follows: HOT COOLANT To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap while the engine is at operating temperature.

  • Page 334: Inspection Of Coolant Thermostat And Seal

    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 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 335: Installation Of Coolant Thermostat And Seal

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL Install as follows: 1. Install seal (2) onto thermostat housing (3). 2. Install thermostat into hose and onto oil cooler module (1). 3. Torque four bolts to 30 N·m (22 lb·ft).
  • Page 336 30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL All information subject to change without notice. 30-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 337: Coolant Filter

    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 338 All information subject to change without notice. 31-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 339: Description And Operation Of Coolant Filter

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 31.1 DESCRIPTION AND OPERATION 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. 31-3...

  • Page 340: Removal Of The Coolant Filter

    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: Installation Of The Coolant Filter

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 31.3 INSTALLATION OF THE COOLANT FILTER Install as follows: 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).
  • Page 342 31.3 INSTALLATION OF THE COOLANT FILTER All information subject to change without notice. 31-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 343: Coolant Filter Service Module

    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 344 All information subject to change without notice. 32-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 345: Removal Of Coolant Filter Service Module

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 32.1 REMOVAL OF COOLANT FILTER SERVICE MODULE Remove as follows: 1. 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.

  • Page 346: Installation Of Coolant Filter Service Module

    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 © 2010 DETROIT DIESEL CORPORATION...

  • Page 347: Coolant Inlet Elbow

    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 348 All information subject to change without notice. 33-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 349: Removal Of The Coolant Inlet Elbow

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 33.1 REMOVAL OF THE COOLANT INLET ELBOW Remove as 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.

  • Page 350: Installation Of The Coolant Inlet Elbow

    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: Flywheel And Flywheel Housing

    FLYWHEEL AND FLYWHEEL HOUSING Section Page 34.1 DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS ............34-3 34.2 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 ..............
  • Page 352 All information subject to change without notice. 34-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 353: Description And Operation Of Flywheel, Flywheel

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.1 DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS This section explains the description(s) and operation(s) of the following components: □ Flywheel □ Ring Gear □ Flywheel Housing 34.1.1 Flywheel The flywheel is attached to the rear end of the crankshaft with twelve bolts. The bolt holes in the crankshaft and flywheel are equally spaced.
  • Page 354 7. Flywheel Housing 3. Stud 8. Cover 4. Stud 9. Bolt (2) 5. Access Hole Cover Figure 34-1 Rear of Flywheel Housing and Related Parts All information subject to change without notice. 34-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 355 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Bolt M10 x 90 (3 qty.) 9. Bolt M8 x 45 (2 qty.) 10. Flywheel Housing 2. Bolt M14 x 1.5 x 70 (1 qty.) 3. Bolt M14 x 1.5 x 90 (6 qty.) 11.

  • Page 356: Removal Of Flywheel Housing

    12. Remove and discard the flywheel housing gasket. 13. Remove all sealing material from the flywheel housing. All information subject to change without notice. 34-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 357: Installation Of Flywheel Housing

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.3 INSTALLATION OF FLYWHEEL HOUSING Install as follows: 1. Thread two guide studs (J–43431) for 14 mm bolts, into the cylinder block to guide the housing in place. 2. Install a new gasket.
  • Page 358 10. Install the crankshaft position sensor. Refer to section . 11. Install the oil pan and fill the engine with new oil. 12. Prime the lubrication system. Refer to section 27.1 All information subject to change without notice. 34-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 359: Removal Of The Flywheel

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.4 REMOVAL OF THE FLYWHEEL Pre-cleaning is not necessary. Remove as follows: 1. Remove the crankshaft position sensor (CKP). Refer to section . 2. Remove eleven of the twelve flywheel attaching bolts, leaving one bolt at the 12 o'clock position.

  • Page 360: Inspection Of Flywheel

    [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 subject to change without notice. 34-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 361: Installation Of Flywheel

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.6 INSTALLATION OF FLYWHEEL Install as follows: 1. Install two flywheel guide studs (J–36235) into two of the tapped holes in the crankshaft at the 3 and 9 o'clock position. NOTICE: Maximum flywheel bolt length for reuse is 88mm, if bolt length exceeds this, replace the used bolts with new bolts.

  • Page 362: Inspection Of Flywheel Housing And Rear Oil Seal Area Of Crankshaft

    [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: Removal Of Ring Gear

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 34.8 REMOVAL OF RING GEAR Remove the ring gear as follows: 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Remove the transmission.

  • Page 364: Installation Of Ring Gear

    5. Once the ring gear is installed, install the flywheel. 6. Install the transmission. All information subject to change without notice. 34-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 365: Front Engine Mount/Radiator Support

    FRONT ENGINE MOUNT/RADIATOR SUPPORT Section Page 35.1 DESCRIPTION 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 ....................
  • Page 366 All information subject to change without notice. 35-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 367: Description And Operation Of Front Engine Mount/Radiator Support And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 35.1 DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS 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.
  • Page 368 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

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 35.3 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. 35-5 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 370: Installation Of The Front Engine Mount/Radiator

    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: Vibration Damper

    VIBRATION DAMPER Section Page 36.1 REMOVAL OF THE VIBRATION DAMPER ..........36-3 36.2 INSTALLATION OF THE VIBRATION DAMPER ........36-4...
  • Page 372 All information subject to change without notice. 36-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 373: Removal Of The Vibration Damper

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 36.1 REMOVAL OF THE VIBRATION DAMPER Remove as follows: 1. Remove the poly-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.

  • Page 374: Installation Of The Vibration Damper

    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: Front Engine Cover

    FRONT ENGINE COVER 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 376 All information subject to change without notice. 37-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 377: Description And Operation Of The Front Engine Cover

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 37.1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE COVER The front cover housing seals the cylinder block to the oil pan, while also holding the front radial seal to the machined surface of the crankshaft nose. The front radial seal prevents oil leaks at the crankshaft.

  • Page 378: Removal Of The Front Engine Cover

    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 without notice. 37-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 379: Inspection Of The Front Engine Cover

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 37.3 INSPECTION OF THE FRONT ENGINE COVER Inspect 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.

  • Page 380: Installation Of The Front Engine Cover

    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 to change without notice. 37-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 381: Engine Lifter Brackets

    ENGINE LIFTER BRACKETS Section Page 38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS ................38-3 38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF ............. 38-8 38.3 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF ..............
  • Page 382 All information subject to change without notice. 38-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 383: Description And Operation Of Engine Lifter Brackets And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS The engine lifter brackets on the DD Platform engines are utilized when removing or replacing an engine. All DD Platform engines have two lifting brackets that are located on the rear of the engine, bolted to the cylinder head.
  • Page 384 18. Clamp 8. Exhaust Gas Connecting Tube 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 11. Exhaust Gas Recirculation Cooler 1. Venturi 12. Water Manifold 2. Bolt 3. Gasket 13. Coolant Crossover Tube 4. Bolt 14. Cylinder Head 15. Bolt 5. Bolt (6 qty.) 6. Bolt 16. Rear Lifter Bracket — Left Side 7.
  • Page 386 8. Exhaust Gas Connector Tube 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 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.

  • Page 388: Removal Of The Front Engine 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: Removal Of The Front Engine Lifter Bracket With Front Engine Power Take-Off

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.3 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF For EPA07 engines, remove as follows: 1. Loosen the two hose clamps on the venturi to mixer pipe hose. 2. Slide the connector hose fully on the mixer pipe. If hose is cut, torn, or cracked, then remove and discard it.

  • Page 390: Removal Of The Rear Engine Lifter Brackets

    38.4 REMOVAL 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: Inspection Of The Engine Lifter Brackets

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.5 INSPECTION OF 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.

  • Page 392: Installation Of The Rear Engine Lifter 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: Installation Of The Front Engine Lifter Bracket Without Front Engine Power Take-Off

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 38.7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET 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).

  • Page 394: Installation Of The Front Engine Lifter Bracket With Front Engine Power Take-Off

    30 N·m (22 lb·ft). 8. Slide hose onto venturi using soap and water for ease of installation. 9. Install two clamps onto hose and tighten. All information subject to change without notice. 38-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 395: Belt Drive Tensioner System

    BELT DRIVE TENSIONER SYSTEM Section Page 39.1 DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS ..................39-3 39.2 REMOVAL OF THE BELT TENSIONER ..........39-5 39.3 INSTALLATION 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...
  • Page 396 All information subject to change without notice. 39-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 397: Description And Operation Of Belt Drive Tensioner And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.1 DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS The engine uses two poly-V-belts. Since this type of belt is very flexible, a number of major assemblies can be driven by one poly-V-belt. The alternator, refrigerant compressor, and coolant pump are driven by one eight-ribbed poly-V-belt.
  • Page 398 5. Poly-V-Belt for Alternator, Refrigerant Compressor and Coolant Pump 12. Water Pump 13. Idler Pulley Bracket 6. Tensioner Pulley 7. Refrigerant Compressor 14. Idler Pulley All information subject to change without notice. 39-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 399: Removal Of The Belt Tensioner

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.2 REMOVAL OF THE BELT TENSIONER 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.

  • Page 400: Installation Of The Belt Tensioner

    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: Removal Of The Idler Pulley And Idler Pulley Bracket

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET Remove as follows: 1. Remove 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.

  • Page 402: Installation Of The Idler Pulley And Idler Pulley Bracket

    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: Removal Of Non-Bracketed Idler Pulley

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.6 REMOVAL OF NON-BRACKETED IDLER PULLEY 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.

  • Page 404: Installation Of Non-Bracketed Idler Pulley

    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: Removal Of The Accessory Mounting Bracket

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 39.8 REMOVAL OF THE ACCESSORY MOUNTING BRACKET Remove as follows: 1. Remove the two poly-V-belts. Refer to section 40.1. 2. Remove the three bolts from the belt tensioner. 3. Remove the belt tensioner from the accessory mounting bracket.

  • Page 406: Installation Of The Accessory Mounting 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-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 407: Poly-V-Belts

    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 408 All information subject to change without notice. 40-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 409: Removal Of The Poly-V-Belts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 40.1 REMOVAL OF THE POLY-V-BELTS Remove as follows: NOTICE: Use a half-inch socket tool (with extension) is used. Do not use more than a 6 inch extension on the socket tool to reduce the danger of cracking the tensioner.
  • Page 410 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 DETROIT DIESEL CORPORATION...
  • Page 411 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 8. Insert an M10x80 bolt (or equivalent pin), into the bracket hole in the non-grooved pulley idler arm (2). 9. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position.

  • Page 412: Inspection Of The Poly-V-Belts

    Inspect 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 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE MISALIGNMENT GRAVEL PENETRATION 2. Inspect the bearings in the idler pulleys and accessories by rotating the pulleys to look for bearing slop or choppy feeling bearings. NOTE: Inspect the area for oil leaking at the spring area. Change the assembly if oil is present.
  • Page 414 [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: Installation Of The Poly-V-Belts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 40.3 INSTALLATION OF THE POLY-V-BELTS Install as follows: NOTE: If tensioners are pre-tensioned, start at step 9. 1. Install a half-inch extension into the square hole on the grooved pulley idler arm. 2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100 N·m (66-73 lb·ft).
  • Page 416 40.3 INSTALLATION OF THE POLY-V-BELTS All information subject to change without notice. 40-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 417: Air Compressor

    AIR 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 418 All information subject to change without notice. 41-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 419: Description And Operation Of The Air Compressor

    The air compressor is designed to permit direct installation of the compressor onto the gear case. Detroit Diesel offers two sizes of air compressors. The single cylinder has a displacement 360 and the twin cylinder has a displacement 650 cm .
  • Page 420 7. Coolant Return Line Assembly 15. Intake Line (OEM provided) 16. Bolt 8. Coolant Inlet Line Assembly 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: Removal Of The Air Compressor

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 41.2 REMOVAL OF THE AIR COMPRESSOR 1. Disconnect the batteries. 2. Drain the coolant from radiator. Refer to OEM procedures. NOTICE: Ensure the air pressure has been released from the air lines before removing the lines from the air compressor.

  • Page 422: Inspection Of The Air Compressor

    [a] If the engine crankcase pressure remained the same, check for a defective turbocharger. Refer to section . [b] If the engine crankcase pressure decreased, replace the air compressor. Refer to section 41.2. All information subject to change without notice. 41-6 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 423 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Remove the air compressor from the engine. Refer to section 41.2. To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

  • Page 424: Installation Of The Air Compressor

    4. Install the air lines to and from the air compressor. Refer to OEM specifications. 5. Fill the cooling system. Refer to OEM specifications. 6. Start the engine and check for leaks. All information subject to change without notice. 41-8 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 425 CYLINDER BLOCK Section Page 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 426 All information subject to change without notice. 42-2 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

  • Page 427: Description And Operation Of Cylinder Block And Related Parts

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS The cylinder block is the basic engine structure, establishing and maintaining the alignment of all engine working parts. The cylinder block is made from an iron material. High strength and low noise are features of the cylinder block, and is a result of the vertical and horizontal reinforcements and the design of the oil return ducts.
  • Page 428 This allows for a superior sealing pressure between the gasket, cylinder head and cylinder block. The cylinder block uses replaceable, wet-type cylinder liners. All information subject to change without notice. 42-4 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 429 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 1. Coolant Return for Cylinder Head Coolant Manifold 5. Coolant Connection for EGR Cooler 2. Coolant Feed for Oil Water Heat Exchanger 6. Coolant Transfer Hole to Cylinder Head 3. Coolant Connection for Fuel Heat Exchanger 7.
  • Page 430 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-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 431 EPA07/10 DD PLATFORM WORKSHOP 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. 42-7 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 432 1. Oil Feed Hole for Main Bearing and Connecting 2. Oil Feed Hole for Oil Spray Nozzles Rod Bearing 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: Removal And Disassembly Of Engine From The Vehicle

    EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE Before mounting an engine on an overhaul stand, it must be disconnected from the transmission. Details for removing an engine will vary from one application to another. However, the following steps will be necessary, regardless of application: 1.
  • Page 434 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 information subject to change without notice. 42-10 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 435 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 25. With the engine mounted on the overhaul stand, remove all of any remaining subassemblies and parts from the cylinder block. [a] Remove the rocker cover. Refer to section 1.2. [b] Remove the engine lifter brackets. Refer to section 38.2.

  • Page 436: Cleaning The Cylinder Block

    Aluminum parts, such as flywheel housing, air intake manifold, oil filter adaptor and the camshaft gear access cover should NOT be cleaned in this manner. Mention will be made of special procedures when necessary. All information subject to change without notice. 42-12 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 437 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6. Be certain that all water passages and oil galleries have been thoroughly cleaned and dried. Install new cup plugs using a coating of good grade non-hardening sealant such as Loctite® 620 or equivalent."...
  • Page 438 0.0001 in increments. Set the cylinder bore gauge on zero in master setting fixture. NOTE: Dial bore master setting fixture should be used to zero the cylinder bore gauge. All information subject to change without notice. 42-14 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 439 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 42.3.3 General Inspection Check all machined surfaces for nicks or burrs that could affect the fit of mating parts. Clean up as necessary by stoning. Also inspect all tapped holes for thread damage and re-tap or install helical thread inserts as necessary.

  • Page 440: Reassembly And Installation Of Cylinder Block

    3. Also stamp the position numbers on the main bearing caps and the position of the No. 1 bearing on the cooler side of the oil pan mounting flange of the block. All information subject to change without notice. 42-16 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...
  • Page 441 EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 4. Install the main bearing caps in their original positions. NOTICE: Always check to make sure cooling nozzles are open and aligned after piston installation. An obstructed, misaligned, bent, or damaged nozzle may not provide proper piston cooling.
  • Page 442 7. Transfer the engine to a suitable engine dynamometer test stand. Operate the engine on a dynamometer following the Run-in procedure. 8. Install the engine in the equipment from which it was removed. All information subject to change without notice. 42-18 DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION...

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