Detroit-Diesel-Dd-Series-Workshop-Manual-Abby 13

Power Service Literature Page 1 of 1
1 California Proposition 65 Warning and Engine Idle Notice
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth
defects, and other reproductive harm.
CALIFORNIA
Engine Idle Limiting Standard Notice
Vehicles with engines certified by the State of California are
equipped with software features making them compliant
with the California Engine Idle Regulations. In order to meet
this regulation, the engine control strategy is generally
configured to automatically shut down the engine after five
minutes of continuous idle operation. This shutdown
feature is not an engine malfunction and is required to meet
the California emission regulations.
Printed Sat Feb 19 07:29:49 2011
Copyright © 2011 by Detroit D iesel Corporation. All rights reserved.
Generated on 02-18-2011
HOC
From the library of Barrington Diesel Club
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070100.htm 2/19/2011

2.1 Description and Operation of Rocker Cover and Related Parts
The rocker cover is made of an aluminum or plastic material and uses an elastomer seal which
completely encloses the valve operating mechanism including the overhead camshafts, brake assemblies
and the injector harness.
dO10030a
1. Elastomer Seal (Gasket)

2. Rocker Cover
3. Bolt
4. Air Filter Housing Bracket
5. Stud (Bolt)
etc

2.2 Removal of the Rocker Cover
Remove as follows:
1. Steam clean the engine.

2. Remove bolts (1) or nuts (if equipped) from the two air filter housing brackets (2) and remove housings
from the rocker cover.
Note: Mark the location of the stud bolts. The stud bolts must be replaced in their original location
during installation.
3. Loosen the bolts (1) or stud bolts (2) (if equipped) and isolators (3); remove rocker cover.
4. Remove rocker cover gasket from the rocker cover.
| Printed Sat Feb 19 08:47:41 20111
Copyright © 2011 by Detroit Diesel Corporation. All rights reserved.
8DC

2.3 Cleaning and Inspection of the Rocker Cover
Clean and inspect as follows:
1. Remove the sealing gasket from the rocker cover.

2. Clean the rocker cover and sealing gasket in clean solvent or fuel.
^ ^ W A R N IN G ;
EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye
protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air
pressure.
3. Blow dry with compressed air.

4. Check the rocker cover, breather passage and seal for damage. Replace as necessary.
5. Inspect the bolts. Replace if damaged.

2.4 Installation of the Rocker Cover
2. Install bolts (1) or stud bolts (2) (if removed) and isolators (3) into rocker cover.
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3. Install the rocker cover onto the camshaft housing.

4. Finger tighten all bolts (1) and stud bolts; then torque to 20 N m (14 lb ft).
5. Install the two air filter housing brackets (2) (if equipped), onto the rocker cover and torque the
eight nuts to 20 N m (14 lbft).
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1070204.htm 2/19/2011
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-
ventilated area. Engine exhaust is toxic.
6. Start the engine and check for leaks.
6DC

3.1 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. 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. The camshaft housing is made of aluminum material.
1. Camshaft Bearing Cap

2. Bolt 120 mm
3. Bolt 108 mm
4. Bolt 63 mm
5. Engine Brake Solenoid
6. Intake Rocker Arm
7. Exhaust Rocker Arm
8. Exhaust Camshaft and Gear
9. Intake Camshaft and Gear
10. Camshaft Housing

11. Gasket
12. Exhaust Camshaft Lobes
13. Exhaust Camshaft Brake Cam Lobe
14. Intake Camshaft Lobes
15. Intake Camshaft Tone Wheel

3.2 Description and Operation of Engine Braking
The engine uses an integral engine brake. Engine braking is controlled electronically by the engine
control system with an electric solenoid. When activated, the solenoid allows oil pressure to activate a
piston on the exhaust rocker arm. Engine braking is accomplished with a single exhaust valve in each
cylinder. The exhaust camshaft uses a separate engine brake-only lobe that allows for double valve
activation for high efficiency braking. The exhaust valve is first operated toward the completion of the
intake stroke, closed during the compression stroke and opened a second time when the compression
stroke is completed. The engine brake system is enabled using the following components:
EPA07 Engines
• Engine brake solenoid valve in front of engine applies low engine braking.
• Engine brake solenoid valve in rear of engine applies medium engine braking.
• For high, both front and rear solenoids are activated.
• Six exhaust rocker arms with actuator pistons.
• Six brake rocker arms which are actuated by the brake camshaft lobes.
• Exhaust camshaft has one brake cam lobe per cylinder.
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 are supplied by the front engine brake solenoid valve. Oil for cylinders 3 through 6
are supplied by the rear engine brake solenoid valve.
d 140029

2. Exhaust Rocker Arm with Actuator Piston
3. Brake Rocker Arm
4. Oil Passage for Cylinders 1 and 2
5. Oil Passage for Cylinders 3, 4, 5 and 6
6. Exhaust Rocker Arm Shaft

7. Exhaust Camshaft
8. Actuator Piston
9. Exhaust Valve
10. Brake Camshaft Lobe
11. Engine Brake Solenoid Valve, Front
12. Engine Brake Solenoid Valve, Rear
EPA10 Engines
• Engine brake solenoid valve in front of engine applies low engine braking.
• For medium engine braking, both front and rear solenoids are activated.
• For high engine braking, both front and rear solenoids are activated, along with EGR.
• Six exhaust rocker arms with actuator pistons.
• Six brake rocker arms which are actuated by the brake camshaft lobes.
• Exhaust camshaft has one brake cam lobe per cylinder.
For EPA10 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 through 3 is supplied by the front engine brake solenoid valve (11). Oil for cylinders 4
through 6 are supplied by the rear engine brake solenoid valve (12).
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2. Exhaust Rocker Arm with Actuator Piston
3. Brake Rocker Arm
4. Oil Passage for Cylinders 1, 2 and 3
5. Oil Passage for Cylinders 4, 5 and 6
7. Exhaust Camshaft
8. Actuator Piston
9. Exhaust Valve

10. Brake Camshaft Lobe

11. Engine Brake Solenoid Valve, Front
12. Engine Brake Solenoid Valve, Rear
___________________________________________________________ Printed Sat Feb 19 08:51:17 2011

3.3 Removal of Camshaft and Rocker Shaft/Engine Brake Assembly
Remove as follows:
Service Tools Used in the Procedure

Tool Num ber Tool Name Engine
W470589034000 Camshaft Timing Tool EPA07 DD13*
W470589114000 Camshaft Timing Tool EPA07/EPA10 DD13
W470589054000 Camshaft Timing Tool EPA07
W470589104000 DD15 Camshaft Timing Tool EPA07/EPA10 DD15/16
J-46392 or W904589046300 Engine Barring Tool DD Platform
W470589001500 Top Dead Center Locating Pin DD Platform
W470589044000 Intake Rocker Arm Lifter / Spacer Tool DD13
W470589074000 Exhaust Rocker Arm Lifter / Spacer Tool DD13
W470589004000 Intake / Exhaust Rocker Arm Lifter / Spacer Tool DD15
J-48883 Camshaft Bearing Cap Puller DD Platform
J-46375 Injector Unit Pump Puller DD Platform
* Can be used on EPA10 wit i modification (refer to tool letter 10 TL-9)
1. Turn engine OFF, (key OFF, engine OFF).

3. Disconnect the battery power to the engine. Refer to OEM procedures.
4. Remove the air filter and the turbocharger inlet pipe and hose. Refer to OEM procedures.
5. Remove air filter housing. Refer to OEM procedures.
6. Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
7. Remove the two 14-pin fuel injector harness connectors (1) from the camshaft housing (2).
y 2
1
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8. Using the engine barring tool (J-46392 or W904589046300), rotate the crankshaft to Top Dead
Center (TDC) on cylinder No. 1.
9. Remove the Crankshaft Position (CKP) sensor (1) from the rear of the flywheel housing. Refer to
section "Removal of the Crankshaft Position Sensor"

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Note: Top Dead Center (TDC) can be confirmed by installing the camshaft timing tool.
10. To accurately locate TDC, install the flywheel housing crankshaft TDC locating pin
(W470589001500) into the CKP sensor hole located in the rear of the flywheel housing. The
plastic tip will protrude into a cutout in the tone wheel. TDC can be verified by the proper
installation of the camshaft timing tool. See tool list below:
a. W470589034000 - EPA07 DD13
b. W470589114000 - EPA07/EPA10 DD13
c. W470589054000 - EPA07
d. W470589104000 - EPA07/EPA10 DD15 / DD16
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 the EPA07 DD13: For all EPA10 engines, Go to step 13.
a. Disconnect both 14-pin injector harness connectors (8).
b. Disconnect the 24 electrical terminals at the fuel injectors (7).
c. Disconnect two wiring terminals at each engine brake solenoid (6).
d. Loosen the Allen screws holding the intermediate frame (5) to the camshaft housing (1).
Remove the intermediate frame.

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13. F o r all E P A 10 engines:

a. Remove the fuel injector electrical harness clips (2) from the 14-pin electrical harness
connectors.
b. Remove the bolts securing the two-piece fuel injector electrical harness (1 and 3) and
remove the harness from the camshaft housing.

14. Remove the engine brake solenoids from the camshaft housing.
NOTICE:
Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts
outward, in 'A turn increments. The increment procedure needs to be followed to prevent the
rocker shaft from breaking.
15. Completely loosen all of the adjusting screws on all of the rocker arms.
16. Loosen the seven bolts securing the intake rocker shaft to the camshaft bearing caps.
NOTICE:
Make sure that the camshaft housing is not damaged during removal of the intake/exhaust
rocker shaft assemblies.
17. Using the intake rocker arm lifter / spacer tool (DD13 - W470589044000) or (DD15 / DD16 -
W470589004000), remove the intake rocker shaft assembly.
NOTICE:
Ensure when loosening the rocker shaft bolts that the bolts are loosened from the inside bolts
outward, in 'A turn increments. The increment procedure needs to be followed to prevent the
rocker shaft from breaking.
18. Loosen the seven bolts securing the exhaust rocker shaft to the camshaft caps.
NOTICE:
When removing the EPA10 exhaust rocker shaft, ensure the rockers are in the UP position.
19. Using the exhaust rocker arm lifter / spacer tool (W470589074000), remove the exhaust rocker
shaft assembly.
Note: The engine brake solenoids do not have to be removed unless they're damaged.
Note: Mark the camshaft bearing cap position for proper reassembly.

20. Remove the remaining bolts (1) from the camshaft bearing caps (2).
21. Using the camshaft bearing cap puller tool (J-48883) and injector unit pump puller tool (J-46375),
22. Using care not to damage both of the intake or exhaust camshaft tone wheels, remove the intake
Generated on 0 2 -18-2011

3.4 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.
3. Inspect the rocker shaft for scoring or scuffing; replace if necessary.
4. Inspect rocker arms for roller and bushing damage; replace if necessary.
5. Inspect adjusting screws and buttons; replace if necessary.
6. Inspect cam caps and cam journals in camshaft housing for damage; replace if necessary.
7. Inspect the tone wheel on the intake camshaft for cracks, bending or any damage. If damage is
found, replace the intake camshaft.

3.5 Installation of the Camshaft and Rocker Shaft/Engine Brake

Assembly
Install as follows:

W470589001500 TDC Locating Pin DD Platform
W470589054000 Camshaft Timing Tool EPA07 DD15
W470589044000 Intake Rocker Arm Lifter/Spacer Tool DD13
W470589074000 Exhaust Rocker Arm Lifter/Spacer Tool DD13
W470589004000 Rocker Arm Lifter/Spacer Tool DD15/DD16
* Can be used on EPA10 with modification (refer to tool letter 10 TL-9)
1. Verify that the crankshaft is at top dead center (TDC) on cylinder number one by installing TDC
Locating Pin in the crankshaft position sensor (CKP) hole located in flywheel housing.
2. Install camshaft timing tool to the rear of the camshaft housing. Tighten the two bolts.

3. Locate the etched triangle on the camshaft gear teeth and mark the teeth with a paint pen.
4. Lubricate the lower camshaft bearing surfaces and camshaft journals before installing the
camshafts. Install the exhaust and intake camshaft gear assemblies into the camshaft housing.
5. Align the marked gear teeth with the marks on the timing tool.
6. Install the camshaft timing tool to the front of the camshaft housing and into the grooves cut into
the camshafts. Secure timing tool to the camshaft housing with a bolt.
a. At this point the front timing tool should slide into the camshaft grooves easily with no
drag.
b. If there is excessive drag when installing the tool, the camshafts are out of time. If so, repeat
this procedure Go to step 3.
7. Verify that the marks on the gear teeth match the marks on the timing tool.
NOTICE:
The camshaft caps are numbered and need to be installed correctly.
8. Install the seven camshaft caps onto intake and exhaust camshafts.

NOTICE:
When installing the engine brake solenoids do not use the bolt to pull the solenoid into the
camshaft cap. Damage will occur to the O-rings on the solenoid.
9. The first and seventh camshaft caps hold the engine brake solenoids to camshaft cap. Replace the
O-rings on the solenoids prior to reinstallation and lubricate with engine oil. Seat the engine brake
solenoids into the camshaft caps by hand.
Note: EPA07 DD15 uses 28 bolts to hold the camshaft cap and housing to the cylinder head.
10. Install the 30 bolts to camshaft caps; finger tighten the bolts.
11. Using the torque sequence shown below, torque the twenty one M10 camshaft cap bolts to the
following:
a. Torque all bolts to 20 N m (15 lb ft)
b. Then torque to 50-55 N m (37-40 lb ft).
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12. Using the torque sequence shown below, torque the nine 63 mm M8 bolts to 30 N m (22 lb ft).
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13. Remove TDC locating pin from Crankshaft Position (CKP) sensor hole in the flywheel housing.
14. Install crankshaft position sensor. Refer to section "Installation of the Crankshaft Position Sensor"
15. Install a dial indicator onto gear case and zero out the dial indicator.
16. Position the stem of dial indicator to rest between the teeth on the camshaft gear.
17. Hold the number five idler gear with a screwdriver. Check the lash between the camshaft gear and
idler gear number five.
NOTICE:
The camshaft journal area is lubricated by oil that has to travel through the rocker shaft. If
the rocker shaft is installed incorrectly, oil passages will not line up. This results in
insufficient lubrication and will damage the camshaft journals. Incorrect shaft installation
can also result in the engine brakes not functioning which will cause damage to the rocker
arm bushings.
NOTICE:
The markings on the front of the rockers shafts must face the front of the engine for proper
rocker arm lubrication and engine brake operation.
Note: On EPA10 engines the intake and exhaust rocker shafts are each marked "TOP FRONT.
Top Front must face towards the front of the engine.
NOTICE:
When tightening the rocker shaft bolts, ensure that the bolts are drawn down from the inside
bolts outward, in 1/2 turn increments, before final torque. The rocker shaft can break if the
rocker shaft bolt is fully torqued without using the increment procedure.
18. The dial indicator should read 0.051 - 0.257 mm (0.002 - 0.010 in.). If the gear lash is excessive
between the exhaust or intake camshaft gear and the number five idler gear, inspect the number
five idler gear spindle, camshaft gear and camshaft housing. Repair as necessary.
19. Remove timing tools.
20. Using the Intake Rocker Arm Lifter / Spacer tool, install the intake rocker shaft assembly to the
camshaft cap and secure with seven clamping blocks and bolts.

21. Using the torque sequence shown below, torque the bolts to 50-55 N m (36-41 lb ft) +90°.
d050028a
Note: After initial torquing of each bolt, apply a paint mark to the head of the bolts to ensure
that the proper 90° turn has been achieved.
22. Using the exhaust rocker arm lifter / spacer tool, install the exhaust rocker shaft assembly to the
camshaft cap and secure with seven clamping blocks and bolts.
23. Using the torque sequence shown below, torque the bolts to 50-55 N m (36-41 lb ft) +90°.

\\
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24. Remove timing tools.

25. Install the fuel injectors, if removed. Refer to section "Installation of the Fuel Injector"
26. Lash the valves and engine brakes. Refer to section "Valve Lash Adjustments"
27. Install the fuel injector wiring harness.
Refer to section "Installation of the One-Piece Fuel Injector Wiring Harness"
Refer to section "Installation of the Two-Piece Fuel Injector Wiring Harness"
28. Install the rocker cover. Refer to section "Installation of the Rocker Cover"
29. Reconnect the battery power to the engine. Refer to OEM procedures.
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 "Priming the Engine Lubrication System"

4.1 Description and Operation 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. The camshaft housing is made of
aluminum material.

4.2 Removal of the Camshaft Housing
Remove as follows:

3. Disconnect the fuel injector harness (1) from the camshaft housing (2).
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^ ^ W A R N IN G :
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the
engine has been shut down for a minimum of 10 minutes before servicing any
component within the high pressure circuit. Residual high fuel pressure may be
present within the circuit.
4. Remove the following high pressure fuel line components:

5. Remove the rocker shaft/engine brake and camshaft assemblies. Refer to section "Removal of
Camshaft and Rocker Shaft/Engine Brake Assembly"
6. Disconnect the intake manifold temperature sensor (2).

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7. Disconnect the fuel rail pressure sensor (1).
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8. Disconnect the camshaft position sensor (1) from the camshaft housing (2).
d070060
9. Unclip all of the electrical wiring harness attaching points from the camshaft housing.
10. Remove the bolt (2) securing the doser coolant line (1) and the P-clip to the camshaft housing (3).
d070061
11. Remove the remaining two bolts (29 and 30) securing the camshaft housing to the cylinder head.

25 21 17 15 19 23 27 29
26/ 22/ 18/ 16/ 20/ 24/ 2 8 / ^ ^ ^ \jQ

d010084
^ ^ W A R N IN G :
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.
12. Attach a lifting device to the camshaft housing and lift the camshaft housing off of the cylinder
head.
___________________________________________________________ Printed Sat Feb 19 08:56:59 2011

4.3 Inspection of Camshaft Housing
Inspect the camshaft housing as follows:
1. Inspect the camshaft journals for scoring or scratches; replace if damaged.

2. Inspect the camshaft caps for cracks; replace if damaged.
3.Inspect the camshaft housing for cracks and damage to the bolt hole threads in the housing;
replace if damaged.
4. Inspect the camshaft housing sealing surfaces for damage. Inspect the following sealing surfaces
for damage:
a. The camshaft housing to rocker cover.
b. The camshaft housing to cylinder head.
c. The O-ring seal on the injector harness.
d. The O-ring seal on the engine brake solenoids.

4.4 Installation of the Camshaft Housing
Install as follows:
1. Install a new seal into the camshaft housing.
^ ^ W A R N IN G :
PERSONAL INJURY
2. Using an appropriate lifting device, install camshaft housing onto the cylinder head.
3. Ensuring that no oil gets into the bearing cap dowel pin hole, lubricate the camshaft housing
camshaft journals.
4. Install the camshaft assemblies into the camshaft housing. Refer to section "Installation of the
Camshaft and Rocker Shaft/Engine Brake Assembly"
5. Install the following high pressure fuel line components:
a. High pressure fuel line bracket (1), and high pressure fuel lines from fuel rail to high
pressure fuel pump (2). Refer to section "Installation of the High Pressure Fuel Rail Feed
Lines"
b. High pressure fuel lines from fuel rail to fuel injectors (3). Refer to section "Installation of
the High Pressure Fuel Injector Lines"
c. Fuel line from fuel rail to fuel filter module (4). Refer to section "Installation of the High
Pressure Fuel Rail Feed Lines"
2 4
7. Prime the fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel
Priming Pump"

___________________________________________________________ Printed Sat Feb 19 08:58:38 2011

5.1 Camshaft Timing Verification
Verify the camshaft timing as follows:

W470589104000 Camshaft Timing Tool EPA07/EPA10 DD15 & DD16
2. Bar the engine to Top Dead Center (TDC) with engine barring tool (J-46392 or W904589046300)
(3) on cylinder No.1 with the No. 6 valve in overlap. The dot (2) that is located inside the flywheel
tone ring is aligned with the edge of the pointer (1).
3. Locate the mark on the camshaft and mark the top of the corresponding gear tooth with a light
colored paint pen.
4. Remove the Crankshaft Position (CKP) sensor from the flywheel housing. Refer to section
"Removal of the Camshaft Position Sensor"
5. Install the flywheel TDC locating pin (W470589001500), through the crankshaft position sensor
hole in the flywheel housing and engage into the flywheel notch.

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6. Install the rear camshaft timing tool (1) onto the camshaft housing.
1
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7. Install the front camshaft timing tool (1) into the grooves cut into the cams and pin it into the
camshaft housing with a bolt.

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8. Verify that the marks on the gear teeth match the marks on the timing tool. If the marks do not
match, research the root cause of incorrect camshaft timing.

5.2 Timing the Camshafts With the Gear Train Installed
Time as follows:

Tool Num ber Tool Nam e Engine
*Can be used on EPA10 with modification (refer to tool letter 10 TL-9)
1. Bar the crankshaft over to Top Dead Center (TDC) cylinder no. 1 and lock with TDC locking pin
through the crankshaft position sensor hole.
2. Install the rear camshaft timing tool (1) onto the rear of the camshaft housing.
1
3. Locate the mark on the camshafts and mark the top of the corresponding gear tooth with a light
colored paint pin.
4. Lubricate the camshafts and camshaft housing journals with clean engine oil.
Note: The intake camshaft has the tone wheel and must be installed on the intake side of the
engine.
5. Install the camshafts into the camshaft housing in their respective locations lining up the marked
cam gear teeth with the mark on the timing plate.
6. Install the front camshaft timing tool (1) into the grooves cut into the camshafts to verify correct
cam timing. Any resistance felt while installing or removing could indicate the camshafts being
out of time. Install a bolt into the tool to hold it into place.

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___________________________________________________________ Printed Sat Feb 19 08:59:47 2011

6.1 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.
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1. Idler Gear No. 1

2. Idler Gear No. 2
3. Idler Gear No. 3
4. Idler Gear No. 4
5. Idler Gear No. 5
6. Air Compressor Gear
7. Fuel Pump Gear
8. Axial Power Turbine Gear
9. Crankshaft Gear
10. Oil Pump Gear
11. Camshaft Gear Exhaust
12. Camshaft Gear Intake
13. A. Level A

14. B. Level B
15. C. Level C
16. X. To Front of 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). The gears in the gear train are both
directly and indirectly driven by the crankshaft gear.
• Level A: The outermost gears include the crankshaft gear which drives the outer idler gear No. 1
and the oil pump gear. Idler gear No. 4 is on the crankshaft gear and the Axial Power Turbine
(APT) drives the idler gear No. 4 when the APT is creating power. The APT can add additional
torque to the crankshaft through idler gear No. 4 up to 260 N m (192 lb ft). These gears are all
helical-cut.
Note: On the DD13, there is no Axial Power Turbine (APT) and no Idler gear No. 4. The
position of the idler gear No. 4 is covered by a plate, and sealed with an O-ring.
• Level B: The middle gears include idler gear No. 1, which drives the air compressor gear and the
idler gear No. 2. Idler gear No. 2 drives the high pressure fuel pump and idler gear No. 3. These
gears are all straight-cut.
• Level C: The innermost gears include inner idler gear No. 3 which drives idler gear No. 5. Idler
gear No. 5 drives both intake and exhaust camshafts. These gears are all straight-cut.
Gear train noise is an indication of excessive gear lash, chipped or burred gear teeth. A rattling noise
usually indicates excessive gear lash. A whining noise indicates too little gear lash. Therefore, when
noise develops in a gear train, the gear train needs to be inspected.
M ultiply Crankshaft Speed by Effective Ratio to Attain Inc ividual Com ponent 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 RPM
DD15 & DD16 Idler #4 1.33 RPM
Idler #5 0.45 RPM
Water Pump 2.22 RPM
Air Compressor 1.41 RPM
Fuel Pump 1.50 RPM
Oil Pump 1.33 RPM
DD15 & DD16 Axial Power Turbine Gearbox Drive 4.00 RPM
DD15 & DD16 Axial Power Turbine Shaft 26.64 RPM
The power steering pump can be mounted in two places. If the engine is equipped with a single-cylinder
air compressor, it will be mounted to the front of the air compressor. If the engine is equipped with a
dual-cylinder air compressor, then the power steering pump will be mounted on the back of the gear case
to the fuel pump.

___________________________________________________________ Printed Sat Feb 19 09:00:36 2011

6.2 Installation and Timing of Engine Gear Train

Tool Number Tool Nam e Engine
J-48630 Crankshaft Top Dead Center Locating Tool DD Platform
J-47486 Shoulder Bolt DD Platform
J-47487 Cantilever For Idler #3 Tool DD Platform
W470589054000 Camshaft Timing Tool EPA07 DD15
W470589104000 DD15 Camshaft Timing Tool EPA07/EPA10 DD15 / DD16
* Can be used on EPA10 with modification (refer to tool letter 10 TL-9)
Install and time the gear train as follows:
Note: Coat the inside of the gears, bushings and gear train with clean oil before installation.
1. Install the crankshaft gear on the crankshaft.

2. Rotate the crankshaft to Top Dead Center (TDC) on cylinder number one. Install and lock
crankshaft TDC locating tool into place with bolt.
J-48630
3. Install spindle into idler gear No. 5.

4. Install idler gear No. 5 onto the cylinder head using shoulder bolt.
5. Install two bolts into idler gear No. 5 and hand tighten. Remove the shoulder bolt. Torque to 60-65
N m (44-48 lb ft).
6. Install the spindle into idler gear No. 3.
7. Install the cantilever tool (J-47487) onto idler gear No. 3.

J-47487
Note: When idler gear No. 3 and cantilever for idler No. 3 tool are installed to the gear case,
cantilever for idler No. 3 tool should come off of the gear with ease. If the timing tool is not
easily removed, that is an indication that the gears are not timed.
9. Check the gear lash between idler gear No. 3 and idler gear No. 5.
10. Install a dial indicator onto gear case and position the stem to rest between the teeth on large gear
of idler gear No. 3; zero out the dial indicator.
11. Hold idler gear No. 5 with a screw driver to check gear lash.
12. The lash reading on the dial indicator should be 0.079 - 0.305 mm (0.003-0.012 in.).
13. When correct gear lash is established, torque idler gear No. 3 to 60-65 N m (44-48 lb ft).
14. Install the spindle and gear plate onto the idler gear No. 2.
15. Install the spindle, idler gear No. 2, and the gear plate onto the cylinder block. Torque to 100 N m
(73 lb ft).
16. Remove the air compressor to the cylinder block (if installed). Refer to section "Removal of the
Air Compressor"
17. Install the thrust washers and spindle onto the idler gear No. 1.
Note: For ease of installation on idler gear No. 1, roll the gear into idler gear No. 2.
18. Install the spindle, thrust washers, idler gear No. 1, and gear plate onto the cylinder block by
engaging the teeth of idler gear No. 1 into the crankshaft gear teeth first, then roll upward into
idler gear No. 2. Torque to 100 N m (73 lb ft).
19. Install the air compressor. Refer to section "Installation of the Air Compressor"
Note: When installing idler gear No. 4, verify that the part number on the gear is facing the
block.
20. On the DD15 and DD16, with the cone of the idler gear No. 4 facing outward, install the thrust
washer onto the spindle then install the spindle onto the idler gear No. 4.
21. On the DD15 and DD16, install the assembled thrust washer, spindle and idler gear No. 4 onto the
cylinder block. Torque to 100 N m (73 lb ft).
Note: Tool J-47487 should remove with ease. If not, check gears for proper installation.
22. Remove the cantilever tool (J-47487) for idler No. 3.
23. For all DD Platform Engines, ensure that idler gear No. 1 is flush with the rear side of the

crankshaft gear. For DD15 & DD16, ensure that Idler gear No. 4 is flush with the front side of the
crankshaft gear.
24. Install the camshaft housing. Refer to section "Installation of the Camshaft Housing"
25. Lubricate the camshaft journals and then 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.
27. Install camshaft timing tool (1) into the holes at the rear of the camshaft housing and secure to the
camshaft housing with two bolts.
1
d000006
28. Install both of the intake and exhaust camshafts into the camshaft housing. Refer to section
"Installation of the Camshaft and Rocker Shaft/Engine Brake Assembly"
29. Rotate the camshafts until the mark on the inside of the gear aligns with the mark on camshaft
timing tool.
30. Install camshaft timing tool (1) into the holes at the slot in the front of the camshaft housing and
secure to the camshaft housing with one bolt.

31. Ensure timing marks on the camshaft gears are at TDC and aligned to the marks on the tool.
32. Install the seven camshaft caps onto intake and exhaust camshafts.
Note: The first and seventh camshaft caps hold the engine brake solenoids to camshaft cap.
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; 14 120 mm (M10) bolts, seven 108
mm (M10) bolts and nine 63 mm (M8) bolts.
34. Install the 30 bolts to camshaft caps; finger tighten the bolts. Refer to the figure for proper bolt
placement.
35. Using torque sequence shown below, torque the 120 mm and 108 mm (M10) camshaft cap bolts
to the following:
a. Torque to 20 N m (15 lb ft).
b . Then torque to 50-55 N m (37-40 lb ft).

d010091
36. Using the torque sequence, torque the nine 63 mm (M8) bolts to 30 N m (22 lb ft).
dO10092
37. Verify correct camshaft timing by checking that the marks on the camshaft gears still align with
the timing tool.

38. Remove the timing tools from the idler gears and the camshaft housing.
39. Install the camshaft cover and the two bolts to the rear of the cylinder head. Torque the camshaft
cover bolts to 30 N m (22 lb ft).

6.3 Checking and Adjusting Gear Lash With Camshaft Housing

Removed
This is performed with camshaft housing removed. Check and adjust as follows:
1. Remove the camshaft housing if not already removed. Refer to section "Removal of the Camshaft
Housing"
2. Install a magnetic base-dial indicator gauge on engine block.
3. Set the dial indicator on the idler gear No. 5 gear tooth.
4. Turn idler gear No. 5 counterclockwise (viewed from front of engine) until "0" lash is present,
then zero the gauge on the dial indicator.
5. Check the gear lash by turning the idler gear No. 5 stop-to-stop, verify that the lash reading on the
dial indicator is 0.043 - 0.165 mm (0.0016 - 0.0065 in.).
6. If the gear lash is incorrect, continue with the following steps to adjust.
7. Remove the access cover to the idler gear No. 3 bolts.
8. Loosen the two No. 3 idler gear bolts and then snug by hand.
Note: Rotating idler gear No. 5 counterclockwise (viewed from front of engine) will result in
zero lash. Rotating idler gear No. 5 clockwise (viewed from front of engine) will result in
maximum lash.
9. Turning idler gear No. 5 by hand will change gear lash from zero lash to maximum lash.
10. Install a magnetic base-dial indicator gauge on engine block.

11. Set the dial indicator on the No. 5 idler gear tooth.
12. Turn idler gear No. 5 counterclockwise (viewed from front of engine) until "0" lash is present,
then zero the gauge on the dial indicator.
13. Push idler gear No. 5 clockwise (viewed from front of engine) till desired gear lash is present.
14. Tighten the two bolts on the No. 3 gear.
15. Check gear lash by turning idler gear No. 5 stop-to-stop; verify the lash reading on the dial
indicator should be 0.043 - 0.165 mm (0.0016 - 0.0065 in.).
16. If gear lash is OK, then final torque idler gear No. 3 bolts to 60-65 N m (44-48 lb ft).
17. Install the access cover and tighten.
18. Install the camshaft housing as needed. Refer to section "Installation of the Camshaft Housing"

7.1 Description and Operation of DD15 and DD16 W ater 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 and DD16 engines. 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. Two 3-port gaskets are
used between the water manifold and the cylinder head.
1. Connecting Pipe
2. Water Manifold
3. Bolt
4. Bolt
5. Coolant Outlet Elbow
6. Coolant Outlet Elbow Gasket
7. Bolt
8. Plug
9. Bolt
10. Bolt
11. Three-port Gasket (2 qty.)

1. Bolt M8 x 40 (6 qty.)
2. Bolt M8 x 80 (5qty.)
3. Bolt M8 x 100 (6 qty.)
4. Cylinder Head
5. Connecting Pipe
6. Water Manifold
7. Three-port Gasket (2 qty.)

7.2 Removal of the DD15 and DD16 W ater Manifold
Remove as follows:
1. Disconnect the batteries.

2. Drain the engine coolant.
3. Remove the air filter. Refer to OEM procedures.
4. Remove the exhaust manifold heat shields.
5. Remove the Exhaust Gas Recirculation (EGR) hot pipe. Refer to section "Removal of the Exhaust
Gas Recirculation Hot Pipe"
Note: When removing the HC doser coolant lines, hold the water manifold HC doser coolant
line fitting with a separate wrench.
6. Disconnect and remove the HC doser coolant lines and then remove the retaining clips.
7. Disconnect EGR cooler vent line.
8. Disconnect the outlet coolant temperature sensor electrical harness connector.
9. Remove the EGR actuator coolant outlet line.
10. Remove the upper radiator hose.
12. Remove the EGR cooler. Refer to section "Removal of the DD15 and DD16 Exhaust Gas
Recirculation Cooler"
Note: Note bolt length differences for installation.
13. Remove the eleven upper water manifold bolts.
14. Loosen the six lower water manifold bolts.
15. Remove the two bolts (1) from the retaining strap (2) for the water manifold (3) outlet to the
coolant delivery pipe (5). Remove the connector tube (4).

d200063a
16. Remove the water manifold.

17. Remove and discard the water manifold three-port gaskets.
___________________________________________________________ Printed Sat Feb 19 09:03:07 2011

7.3 Cleaning and Inspection of the DD15 and DD16 W ater 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.
___________________________________________________________ Printed Sat Feb 19 09:03:34 2011

7.4 Installation of the DD15 and DD16 W ater Manifold
Install as follows:
NOTICE:
When installing the connecting pipe, ensure that the connecting pipe is lubricated with clean
engine oil. If it is not lubricated, the connecting pipe cannot be fully installed and the rubber can
tear.
NOTICE:
Do not use sealant when installing water manifold to the cylinder head.
1.Install the water manifold gaskets and the connecting pipe onto the water manifold.
2. Install the six lower water manifold bolts and start by a few threads.
3. Install the water manifold onto cylinder head.
4. Install the eleven upper water manifold bolts.
5. Torque the water manifolds bolts to 30 N m (22 lb ft), using the torque sequence illustrated
below.
1 2 4 5 10 11 17
16 15 9 3 6 12
d200021
6. Install EGR cooler to water manifold and torque to 20 N m (15 lb ft).
7. Install coolant outlet elbow (2) with four bolts (1, 5) and gasket (4) 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).
10. Connect the outlet coolant temperature sensor.
11. Connect the EGR cooler vent line.
12. Connect doser coolant lines. Torque to 15 N m (11 lb ft).
13. Install the EGR hot pipe. Refer to section "Installation of the Exhaust Gas Recirculation Hot Pipe"
14. Install the exhaust manifold heat shields.
15. Install the air filter. Refer to OEM procedures.
16. Fill engine with coolant to the correct level.
^ ^ W A R N IN G :
ENGINE EXHAUST

8.1 Description and Operation of DD13 Exhaust Gas Recirculation

Cooler W ater Manifold Assembly
The primary purpose of the EGR cooler is to cool the engine exhaust gases prior to entering the intake
manifold. Exhaust gas cooling is accomplished by the flow of exhaust gases through the EGR cooler
tubes. The EGR cooler core then transfers the heat removed from the exhaust gases to the engine
coolant. The cooled exhaust gases are then mixed with incoming air from the Charge Air Cooler (CAC)
before being sent to the intake manifold.
1. Clamp
2. Hose
3. Coolant Delivery Pipe
4. Bolt
5. Support
6. Connecting Tube
7. Connecting Tube
8. Gasket
9. Seal Ring
10. Banjo Union
11. Banjo Bolt
12. Bolt
13. Bolt
14. Outlet Nipple
15. Gasket
16. EGR Cooler W ater Manifold Assembly

17. Clamps
18. Hot Pipe
19. EGR Crossover Tube
20. Gasket
21. Bolt
22. Venturi
23. Mixer Pipe
24. O-ring
25. Bolt
26. Bolt
27. Front Engine Lifter Bracket

8.2 Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold
Assembly
Remove as follows:
^ ^ W A R N IN G :
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
3. Drain the engine coolant.
4. Remove the front air cleaner mounting bracket from the valve cover.
Note: Note the orientation of clamps before removal.
5. Remove the two clamps from the hot pipe. Refer to section "Removal of the Exhaust Gas Recirculation
Hot Pipe"
6. Remove the hot pipe from the EGR cooler water manifold assembly and from the EGR valve and
discard spherical clamps.
7. Remove the radiator support mount.
8. Remove the two clamps from the hose connecting the coolant delivery pipe to the oil coolant module.
9. Remove the retaining strap and the two bolts from the coolant delivery pipe, then remove the coolant
delivery pipe from the engine.
10. Remove the hose clamps from the rubber connector connecting the mixer pipe to the venturi pipe.
11. Remove the mixer pipe from the cold boost pipe by removing the three bolts and one bracket bolt.
12. Disconnect the coolant outlet temperature sensor connector from the electrical wiring harness.
13. Unclip the electrical harness from the lifting eye and disconnect the Delta P harness connector.
14. Remove the EGR crossover tube and the venturi by removing the six bolts. Remove them from the
engine.
15. While holding the coolant line adapter fitting with a wrench and removing the coolant line nut with a
separate wrench, remove the EGR actuator and the doser injector housing coolant lines from the EGR
cooler water manifold assembly and the doser injector housing.
16. Remove the clamps and bolts attaching the coolant feed line to the engine and remove coolant feed line.
17. Remove the front and rear exhaust manifold heat shields.
18. Remove the coolant deaeration line from the EGR cooler water manifold assembly.
19. Remove the EGR cooler water manifold assembly by removing the nineteen bolts attaching it to the
cylinder head.
20. Remove and discard the gaskets.
Printed Sat Feb 19 09:05:43 20111

8.3 Inspection of the DD13 EGR Cooler W ater Manifold Assembly
Inspection as follows:
1. Inspect the EGR cooler water manifold assembly for damage; replace if necessary.
2. Inspect the EGR cooler water manifold assembly connecting tubes; replace if necessary.
| Printed Sat Feb 19 09:06:19 2011

8.4 Testing and Inspection of the DD13 Exhaust Gas Recirculation

Cooler W ater Manifold Assembly
Test as follows:
Note: Before performing this procedure, turn off the engine and allow it to cool, coolant should be
above 60°C (140°F).
1. Remove the Marmon clamps from the hot pipe and remove the pipe. Refer to section "Removal of
the Exhaust Gas Recirculation Hot Pipe"
2. Remove Exhaust Gas Recirculation (EGR) mixer pipe. Refer to section "Removal of the Mixer
pipe"
3. Disconnect Delta P sensor electrical harness connector.
4. Disconnect coolant inlet temperature sensor electrical harness connector.
5. Remove the venturi pipe. Refer to section "Removal of the Exhaust Gas Recirculation Venturi"
6. Unbolt and move the exhaust gas crossover tube/lifting the eye to the side, away from the EGR
cooler. Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube"
7. Install special tools W470589019100 and W470589003700 onto the EGR cooler.
a. Install the hot pipe cap (2) with the supplied Marmon clamp (3) on to the hot pipe end.
b. Install the cold pipe plug (1) into the cold pipe end and retain it with the supplied clamshell
and clamp (4).
d200036
8. Use regulator from kit J-41473 and apply 30 psi air pressure to the cooler. Close the valve and
disconnect the air supply.
9. W ait for 30 minutes and record the air gauge reading. There should be no drop in pressure.
a. There should be bubbles in the surge tank if the cooler is leaking internally.
b. If there is a pressure drop and there are no bubbles, use a soap and water solution to make
sure that there are no leaks externally from the test kit.
10. Is the cooler leaking internally?
a. If yes, replace the EGR cooler water manifold assembly . Refer to section "Removal of the
DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly"
b. If no, troubleshoot for other internal coolant system leaks. Check for coolant out exhaust
from an exhaust port and check for internal engine damage.
___________________________________________________________ Printed Sat Feb 19 09:07:08 2011

8.5 Installation of the DD13 EGR Cooler W ater Manifold Assembly
Install as follows:
NOTICE:
Ensure the connecting tubes are lubricated with clean oil; if they are not lubricated the tubes can
not be fully installed or the rubber can be cut.
1. Install two new EGR cooler water manifold assembly gaskets.

2. Install the EGR cooler water manifold assembly onto the cylinder head.
3. Install and hand tighten the 17 bolts into the EGR cooler water manifold assembly. Torque the
bolts to 30 N m (22 lb ft) in the sequence shown.
d 140069
4. Install the following:

a. EGR crossover tube. Refer to section "Installation of the Exhaust Gas Recirculation
Crossover Tube"
b. EGR venturi. Refer to section "Installation of the Exhaust Gas Recirculation Venturi"
c. Mixer pipe. Refer to section "Installation of the Mixer pipe"
5. Install the coolant delivery pipe between the EGR cooler water manifold assembly and the oil
coolant module; install two clamps onto the hose connecting the delivery pipe to the module.
Torque to 3.0-3.5 N m (26-26.5 lbin.).
6. Install the retaining plate with two bolts to connect the coolant delivery pipe to the EGR cooler
water manifold assembly.
7. Install the front and rear exhaust manifold heat shields.
8. Install the hot pipe onto the EGR cooler water manifold assembly and the EGR valve with two
new spherical clamps and tighten clamp bolts to 12 N m (9 lb ft). Refer to section "Installation of
the Exhaust Gas Recirculation Hot Pipe"
9. After installing the hot pipe from EGR cooler water manifold assembly to exhaust manifold,
sweep the EGR actuator by hand to verify it does not make contact with the clamps. If contact is
made, rotate the clamps as needed to gain clearance.
10. Install the doser injection valve coolant return line to the EGR cooler water manifold assembly.
11. Install the doser injection valve coolant supply line to the EGR cooler water manifold assembly.
12. Install the coolant outlet return to the EGR cooler water manifold assembly and to the EGR valve

actuator.
13. Install the coolant deaeration line to the EGR cooler water manifold assembly.
14. Connect the electrical wiring harness coolant outlet temperature sensor connector.
15. Install the radiator support mount.
16. Fill the engine with coolant.

9.1 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
Exhaust Gas Recirculation (EGR) System.
1. Bolt
2. Bracket
3. Bolt
4. Adaptor
5. Gasket
6. Intake Throttle Valve
7. Gasket
8. Cold Boost Pipe
9. Spacer
10. Isolators
11. Washer
12. Bracket to Oil Coolant Module
13. Bolt
14. Bolt
Printed Sat Feb 19 09:09:17 2011|


9.2 Removal of the Cold Boost Pipe (Charge Air Pipe)
Remove as follows:
1. Remove the Exhaust Gas Recirculation (EGR) mixer pipe. Refer to section "Removal of the
Mixer pipe"
2. Disconnect the sensor electrical harness connector.
3. Remove the Charge Air Cooler (CAC) hose clamp at the throttle adaptor inlet.
4. Remove the four bolts securing the cold boost pipe to the intake manifold.
5. Remove two bolts at cold boost pipe bracket on oil module.
6. Remove the cold boost pipe.
7. If the intake throttle valve is required to be removed from the cold boost pipe, refer to Section
"Removal of Intake Throttle Valve and Adaptor."

9.3 Inspection of Cold Boost Pipe (Charge Air Pipe)
Inspect as follows:
NOTICE:
If the cold boost pipe is damaged on the interior the pipe needs to be replaced.
1. Inspect the cold boost pipe for cracks, flange damage, blockage and leaks; replace if necessary.
| Printed Sat Feb 19 09:10:36 2011|

9.4 Installation of the Cold Boost Pipe (Charge Air Pipe)
Install as follows:
1. Install a new seal onto the intake manifold.

2. Loosely secure cold boost pipe to intake manifold with four bolts.
3. Attach the support bracket to the oil module with two bolts. Torque bolts to 30 N m (22 lb ft).
4. Torque the cold boost pipe to the intake manifold. Torque bolts to 30 N m (22 lb ft).
5. Install Exhaust Gas Recirculation (EGR) mixer pipe. Torque bolts to 30 N m (22 lb ft).Refer to
section "Installation of the Mixer pipe"
6. If the intake throttle valve was removed, refer to Section "Installation of Intake Throttle Valve and
Adaptor."
7. Connect the sensor electrical harness connector.

10.1 Description and Operation of the DD13 Air Intake Manifold and
Related Parts
On diesel engines, the intake charge air is routed to an air intake manifold that is bolted to the cylinder
head with thirteen bolts. Air is then routed through the air intake manifold and into the cylinders. The
mating surfaces of the air intake manifold and the cylinder head are machined. The air intake manifold is
sealed to the cylinder head with six rubber and steel gaskets. If the air intake manifold is removed, new
gaskets must be installed to maintain seal under higher boost pressure. An intake manifold air
temperature sensor is installed to the air intake manifold. The Exhaust Gas Recirculation (EGR) mixer,
intake throttle valve and adaptor are installed to the air inlet of the air intake manifold. The Charge Air
Cooler (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. For EPA10 engines, these sensors are combined to form the charge air pressure/temperature
sensor. The combination sensor is located in the cold boost pipe, and is used to measure air pressure and
air temperature combined.
1. Hex Head Bolt

2. Bracket
3. Intake Pipe Bracket
4. Air Temperature Sensor (EPA10 Engine - Plug Only)
5. Gasket
7. Cold Boost Pipe
8. Flanged Screw, Intake Manifold to Cylinder Head
10. Isolator Gasket
11. Intake Manifold
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070A01.htm 2/19/2011

12. Clamp, Outlet Pipe

13. O-ring, Elbow Turbo Outlet
14. Turbocharger Outlet Pipe
15. Gasket, Intake Manifold
16. Seal Ring
17. Intake Manifold Temperature Sensor
18. Gasket, Cold Boost Pipe
19. Bolt, Cold Boost Pipe to Intake Manifold
20. Bolt
21. Shield
23. Charge Air Pressure Sensor (EPA10 Combination Sensor)

10.2 Description and Operation of the DD15-DD16 Air Intake Manifold

and Related Parts
On diesel engines, the intake charge air is routed to an air intake manifold that is bolted to the cylinder
head with thirteen bolts. Air is then routed through the air intake manifold and into the cylinders. The
mating surfaces of the air intake manifold and the cylinder head are machined. The air intake manifold is
sealed to the cylinder head with six rubber and steel gaskets. If the air intake manifold is removed, new
gaskets must be installed to maintain seal under higher boost pressure. An intake manifold air
temperature sensor is installed to the air intake manifold. The Exhaust Gas Recirculation (EGR) mixer,
intake throttle valve and adaptor are installed to the air inlet of the air intake manifold. The Charge Air
Cooler (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. For EPA10 engines, these sensors are combined to form the charge air pressure/temperature
sensor. The combination sensor is located in the cold boost pipe, and is used to measure air pressure and
air temperature combined.
1. Bolt
2. Adaptor
3. Gasket


5. Air Temperature Sensor Guard
6. Bolt
7. Bolt, Intake Manifold to Cylinder Head
8. Isolator Gasket
10. Seal Ring, Charge Air Sensor
11. Clamp, Turbocharger Outlet Pipe
12. Turbocharger Outlet Pipe
13. Intake Manifold Air Temperature Sensor
14. Intake Manifold
15. Gasket, Intake Manifold
16. Gasket, Cold Boost Pipe
17. Bolt, Cold Boost Pipe to Intake Manifold
18. Cold Boost Pipe
19. Bolt, Combination Temperature and Pressure Sensor
20. Charge Air Pressure Sensor
22. Shield
23. Air Temperature Sensor (I-Cooler Out)

10.3 Removal of the Air Intake Manifold
Remove as follows:
1. Drain the cooling system.

2. Drain the fuel filter module. Refer to section "Draining the Fuel System Using J-48710 Prior to
Repairs"
3. Remove the poly-V-belts. Refer to section "Removal of the Poly-V-Belts"
4. Remove the Exhaust Gas Recirculation (EGR) mixer pipe and delivery pipe. Refer to section
"Removal of the Mixer pipe"
5. Remove the cold boost pipe. Refer to section "Removal of the Cold Boost Pipe (Charge Air Pipe)"
6. Remove the fuel filter module. Refer to section "Removal of the Fuel Filter Module"
7. Remove the oil coolant module. Refer to section "Removal of the Oil Coolant Module"
8. Disconnect the high pressure fuel lines connected to the common rail and output side of the high
pressure fuel pump. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting
Valve Return Lines"
9. Disconnect and remove the fuel line connected to the common rail and base of the fuel filter
housing.
10. Disconnect and remove the air intake pressure sensor electrical harness connectors from the two
air intake sensors.
11. Identify the flanged screw locations prior to removal of the flanged screws.
12. Remove the 13 flanged screws and isolator gaskets securing the air intake manifold to cylinder
head.
13. Remove the air intake manifold and the six gaskets from the cylinder head and then discard the
gaskets.

10.4 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.
^ ^ W A R N IN G ;
EYE INJURY
pressure.
3. Blow dry with compressed air.
| Printed Sat Feb 19 09:14:09 2011

10.5 Inspection of the Air Intake Manifold
Inspect as follows:
1. Visually inspect the manifold for any cracks, dents or other damage. Pay particular attention to the
bolt areas.
a. If a crack is found, replace the intake manifold.
b. If no cracks are found, reuse the intake manifold.
2. Inspect the manifold mating surface for imperfections that could affect its sealing to the cylinder
head.
a. If the manifold mating surface has imperfections, replace the intake manifold.
b. If the manifold mating surface is not damaged, reuse part.
3. Laying a 0.5 cm (20 in.) long by 6 mm (1/4 in) wide straight edge across the intake manifold,
check the mating ports surfaces for warping.
a. If all port flange area measurements are less than 0.127 mm (0.005 in.), the manifold is
reusable and can be reinstalled with new gaskets.
b. If the manifold does not meet this requirement, the manifold must be replaced.

10.6 Installation of Air Intake Manifold
Install as follows:
1. Install six gaskets to the air intake manifold.

2. Install 13 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).
3. Re-install the electrical harness connectors to appropriate sensors.
4. Install the oil coolant module. Refer to section "Installation of the Oil Coolant Module"
5. Install the fuel filter module. Refer to section "Installation of the Fuel Filter Module"
6. Install the cold boost pipe. Refer to section "Installation of the Cold Boost Pipe (Charge Air Pipe)"
7. Install Exhaust Gas Recirculation (EGR) mixer pipe and delivery pipe. Refer to section
"Installation of the Mixer pipe"
8. Install the poly-V-belts. Refer to section "Installation of the Poly-V-Belts"
9. Prime fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel Priming
Pump"
10. Fill the cooling system. Refer to OEM specifications.

11.1 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. This turning motion is transmitted to the shaft and the
compressor impeller. The intake air from the air filter is compressed by the compressor impeller and
flows over a charge air pipe to the charge air cooler. The compressed air is cooled in the charge air
cooler, permitting a more dense charge of air to be delivered to the engine, and therefore, engine output
is increased. The charge air then passes from the charge air cooler into the intake manifold. The
turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold.
d090060
1. Bolt
2. Washer
3. Turbocharger Bracket
4. Bracket
5. Stud (6 qty.)
6. Bolt
7. Heat Shield
8. Nut
9. Stud
10. Gasket
11. Turbocharger
12. Turbocharger Inlet Pipe
13. Clamp
14. Seal
15. Turbocharger Outlet Elbow Pipe
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070B01.htm 2/19/2011

16. Heat Shield

17. Air Hose
18. Electronic Proportioning Valve
___________________________________________________________ Printed Sat Feb 19 09:16:18 2011

11.2 Removal of the DD13 Turbocharger
Cleaning the turbocharger is necessary before removal.
^ ^ W A R N IN G :
PERSONAL INJURY
^ ^ W A R N IN G :
PERSONAL INJURY
To avoid injury from contact with rotating parts when an engine is operating with the air
inlet piping removed, install an air inlet screen shield over the turbocharger air inlet. The
shield prevents contact with rotating parts.
Prior to removal, visually check for:
• Missing or loose nuts and bolts

• Loose or damaged intake and exhaust ducting
• Damaged oil drain lines
• Cracked or deteriorating turbocharger housing
• External oil leakage or exhaust leaks
Replace damaged parts with new parts.
Remove as follows:
NOTICE:
Do not attempt to remove carbon or dirt buildup on the compressor or turbine wheels without
removing the turbocharger from the engine. If chunks of carbon are left on the blades, an
unbalanced condition will exist and subsequent failure of the bearings will result if the
turbocharger is operated. However, it is not necessary to disassemble the turbocharger to remove
dirt or dust buildup.
1. Remove the turbocharger heat shields.

2. Disconnect the turbocharger ducting.
3. Disconnect and remove the Charge Air Cooler (CAC) ducting at the compressor housing. Remove
the compressor outlet elbow and inlet elbow.

d090050
4. Remove the turbocharger oil supply and drain lines from the engine block and from the
turbocharger. Remove the O-ring from the cylinder block.
5. Remove the fuel inlet line and coolant inlet and outlet lines from the doser injection valve.
6. To prevent coolant from spilling without draining the coolant system, cap the banjo bolt inlet and
outlet coolant lines with a nut.
7. Disconnect the electrical wiring harness from the turbocharger speed sensor.
Note: Leave the air hose (1) connected to the turbocharger.
8. For EPA10 DD13 engines, remove the clamp (2) from the Electronic Proportioning Valve (EPV)
air hose (1) to the turbocharger and remove the hose (1) from the EPV.
9. Remove the right side radiator support mount from the engine block.
10. Remove flange exhaust manifold from turbocharger housing.
11. Remove the four nuts from the studs attaching turbocharger to the exhaust manifold center
section.
^ ^ W A R N IN C :
PERSONAL INJURY
12. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly.
13. Remove the two bolts from the turbocharger support bracket to the cylinder block.
14. Lower the turbocharger assembly away from the exhaust manifold and place it on a bench.
15. Discard the turbocharger gasket.
16. Cover the end of the oil supply line, the oil drain line, the air inlet and the exhaust outlet openings
on the engine and turbocharger to prevent entry of foreign material.

^ ^ W A R N IN G :
PERSONAL INJURY
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.

11.3 Inspection of the Turbocharger
Inspect as follows:
1. Remove the exhaust pipe from the turbine outlet and remove the air intake pipe from the
compressor inlet.
2. Visually inspect the turbine and compressor wheels for missing blades or blade damage.
3. Inspect the turbine and compressor wheels for heavy deposits of dirt, coke or carbon.
4. Using a flashlight, check the wheels and housings for signs of rubbing.
5. Rotate the turbine wheel to check for freedom of movement.
6. Replace the turbocharger if there is any visible damage.
a. Remove the defective turbocharger from the engine.
b. Tag the removed turbocharger for re-manufacture.
c. Install a new turbocharger to the engine.
^ ^ W A R N IN C :
ENGINE EXHAUST
7. Start the engine.

8. Run the engine speed to full load.
9. Visually inspect the exhaust for excessive smoke.
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).

11.4 Installation of the DD13 Turbocharger
Install as follows:
W A R N IN G :
PERSONAL INJURY
2. Remove any covers that were placed over the openings of the air inlet and exhaust outlet openings
on the engine and turbocharger when the turbocharger was removed.
3. Remove any covers on the oil and coolant inlet and drain lines as well as the oil and coolant inlet
and drain openings on the turbocharger.
4. Place a new gasket (1), face up, with the tab towards the outside, on the exhaust manifold
turbocharger flange (2).
©
A
d090069
NOTICE:
The turbocharger must be supported after it has been installed to the exhaust manifold flange
to avoid damage to the turbocharger.
5. Position the turbocharger to the exhaust flange. Hand tighten fasteners.

6. Torque the turbocharger-to-exhaust manifold fasteners to 50 N m (37 lb ft).
Note: Bottom bolts that mount bracket to cylinder block require washers between the bolt head
and bracket only. Do not place washers between the bracket and the turbocharger.
7. Install turbocharger support bracket to turbocharger and cylinder block and install mounting bolts.
Hand tighten bolts.

8. Torque the bolts (3) for the turbocharger support bracket (1) to cylinder block to 25 N m (18
lb ft). Then torque turbocharger bracket-to-turbine housing bolts (2) to 25 N m (18 lb ft).
9. 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.
Torque the bolts to 30-38 N m (22-28 lb ft).
^ ^ W A R N IN G :
PERSONAL INJURY
10. Install the turbocharger oil supply line. Hold the fitting on the turbocharger from rotating and
torque line to 30 N m (22 lb ft).
11. For EPA10 DD13 engines, connect the wastegate air supply line (1) to the Electronic
Proportioning Valve (EPV) (2).

12. Connect the turbocharger speed sensor connector to the engine wiring harness.
13. Reconnect the flanged manifold (turbine outlet pipe) to the turbocharger. Torque fasteners to 25
N m (18 lb ft).
14. Install the coolant inlet and outlet lines to the doser injector housing. Torque to 15 N m (11 lb ft).
15. Install the fuel line to the doser injection valve. Torque to 23-25 N m (17-18 lb ft).
Note: Do not use any type of lubricant on the inside of any air inlet hose or on the hose contact
surfaces of the turbocharger compressor housing, CAC ducting or the intake manifold.
16. Install the turbocharger heat shields.
17. Install the compressor elbow and the Charge Air Cooler (CAC) plumbing. Torque the bolts to 6
N m (4 lb ft).
18. Connect DDDL/DDRS and perform the purge hydrocarbon doser service routine to remove all the
air from the doser system.
19. If the turbocharger is being replaced due to a turbocharger shaft bearing failure, replace the engine
oil and filter.

12.1 Description and Operation of the EPA10 DD13 Wastegate Solenoid
For EPA10, the DD13 uses a wastegate solenoid to control the turbocharger wastegate. The Motor
Control Module (MCM2) uses a Pulse Width Modulation (PWM) signal to activate the wastegate
solenoid to control available air pressure to the turbocharger wastegate on the turbocharger. There are
many operating conditions that require use of the wastegate solenoid.
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070C01.htm 2/19/2011

12.2 Removal of the DD13 Wastegate Solenoid
Remove as follows:
1. Disconnect the electrical harness connector (1) from the wastegate solenoid (2).
2. Remove the hose clamp (2) and remove th e^ir line (1) from the wastegate solenoid.
3. Remove the vehicle air supply (1) to the wastegate solenoid.

d090048
4. Remove the bolt (3) and the nut (2) from the stud (1) and remove the wastegate solenoid from the
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1070C02.htm 2/19/2011
12.3 Installation of the DD13 Wastegate Solenoid
Install as follows:
1. If removed, install the stud (1) to the cylinder block boss. Torque the stud to 10 N m (7.4 lb ft).
2. Install the wastegate solenoid on the cylinder block.
3. Install the bolt (3) and the nut (2). Torque each to 30 N m (22 lb ft).
3
d090049
4. Install the vehicle air supply (1) to the wastegate solenoid. Torque to 25 N m (18 lb ft).
d090048
5. Install the air line (1) to the wastegate solenoid and tighten hose clamp (2).
6. Connect the wastegate solenoid connector (1).

13.1 Description and Operation of the DD15 - DD16 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. This turning motion is transmitted to the shaft and the
compressor impeller. The intake air from the air filter is compressed by the compressor impeller and
flows over a charge air pipe to the charge air cooler. The compressed air is cooled in the charge air
cooler, permitting a more dense charge of air to be delivered to the engine, and therefore, engine output
is increased. The charge air then passes from charge air cooler into the intake manifold. The
turbocharger is mounted on the exhaust outlet flange of the engine exhaust manifold. The turbocharger
is mounted on the exhaust outlet flange of the engine exhaust manifold.
3 \ 2 1 d090059
1. Bolt (M10 x 120 mm)

2. Bolt (M10 x 35 mm)
3. Bolt
4. Bolt (M10 x 90 mm)
5. Gear Box
6. Bolt (M10 x 65 mm)
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070D01.htm 2/19/2011

7. Gasket Seal
8. O-ring
9. Locking Dowel
10. Bolt (M10 x 20 mm)
11. Bracket
12. Bolt (M10 x 20 mm)
13. Axial Power Turbine (APT)
14. Clamp
15. Bolts
16. Air Line
17. P-clip
18. Interstage Duct
19. Clamp
20. Bolt
21. Gasket
22. Turbocharger
23. Clamp
24. Turbocharger Inlet Elbow
25. Bracket
26. Bolts (6 qty.)
27. O-ring
28. Turbocharger Speed Sensor
29. Clamp
30. Turbocharger Outlet Elbow
31. Heat Shield
32. Heat Shield Mounting Bolt

13.2 Removal of the DD15 and the DD16 Turbocharger
Cleaning the turbocharger is necessary before removal.
^ ^ W A R N IN G :
PERSONAL INJURY
^ ^ W A R N IN G :
PERSONAL INJURY
To avoid injury from contact with rotating parts when an engine is operating with the air
inlet piping removed, install an air inlet screen shield over the turbocharger air inlet. The
shield prevents contact with rotating parts.
Prior to removal, visually check for:
• Missing or loose nuts and bolts.

• Loose or damaged intake and exhaust ducting.
• Damaged oil drain lines.
• Cracked or deteriorating turbocharger housings.
• External oil leakage or exhaust leaks.
Replace damaged parts with new parts.
Remove as follows:
Note: Do not attempt to remove carbon or dirt buildup on the compressor or turbine wheels without
removing the turbocharger from the engine. If chunks of carbon are left on the blades, an unbalanced
condition will exist and subsequent failure of the bearings will result if the turbocharger is operated.
However, it is not necessary to disassemble the turbocharger to remove dirt or dust buildup.
1. Remove the turbocharger heat shield.

2. Disconnect and remove the Charge Air Cooler (CAC) ducting at the compressor housing. Remove
the compressor outlet elbow and inlet elbow.
Note: APT air feed line removal applies only to engines without an APT solenoid.
3. Remove the Axial Power Turbine (APT) air feed line from the compressor housing.
4. Remove the turbocharger oil supply and drain line from the center housing.
5. Remove and discard O-ring from the cylinder block and gasket from center section.

6. Remove large Marmon clamp connecting APT to the interstage duct.

7. Loosen the bolts attaching the turbocharger support bracket to the cylinder block.
8. Remove four bolts attaching the turbocharger to the exhaust manifold center section.
9. Remove the two bolts from turbocharger bracket to turbine housing.
W A R N IN G :
PERSONAL INJURY
Note: Turbocharger must be supported when removing the mounting bolts to avoid damage to
the turbocharger.
11. Lift the turbocharger assembly away from the engine and place it on a bench.
12. Cover turbocharger to avoid any foreign material from entering oil, air, or exhaust passages.
W A R N IN G :
PERSONAL INJURY
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.

13.3 Inspection of the DD15 and DD16 Turbocharger
Inspect as follows:
1. Remove the interstage duct from the turbine outlet and remove the air intake pipe from the
compressor inlet.
2. Using a flashlight, check the wheels and housings for signs of rubbing. Rotate the turbine wheel to
check for freedom of movement. Does the shaft rotate freely?
a. Yes; Go to step 5.
b. No; Go to step 3.
3. Visually inspect the turbine and compressor wheels for missing blades or blade damage. Is
damage visible on the compressor side only?
a. Yes; replace the turbocharger and inspect the Axial Power Turbine (APT). Refer to section
"Inspection of the DD15 and DD16 Axial Power Turbine"
b. No; Go to step 4.
4. Is the turbine side of the turbocharger damaged (i.e. missing chunks of turbine wheel, etc.)?
a. Yes; replace both the turbocharger and the APT.
Refer to section "Removal of the DD15 and the DD16 Turbocharger"
Go to step Removal of the DD15 and DD16 Axial Power Turbine
b. No; replace the turbocharger and inspect the APT.
Refer to section "Removal of the DD15 and the DD16 Turbocharger"
Refer to section "Inspection of the DD15 and DD16 Axial Power Turbine"
5. If no damage is found, do not replace turbocharger; inspect the APT for damage. Refer to section
"Inspection of the DD15 and DD16 Axial Power Turbine"

13.4 Installation of the DD15 and the DD16 Turbocharger
Install as follows:
1. If removed, install the DD15 and DD16 axial power turbine (APT) gear box. Refer to section
"Installation of the DD15 and DD16 Axial Power Turbine Gear Box"
2. If removed, install the APT. Refer to section "Installation of the DD15 and DD16 Axial Power
Turbine"
3. If removed, loosely install the turbocharger support bracket to the cylinder block.
^ ^ W A R N IN G :
PERSONAL INJURY
4. Install the interstage duct onto the APT.

6. Remove any covers that were placed over the openings of the air inlet and exhaust outlet openings
on the engine and turbocharger when the turbocharger was removed.
7. Remove any covers on the oil and coolant inlet and drain lines, and the oil and coolant inlet and
drain openings on the turbocharger.
Note: When installing the turbocharger, use care when moving the turbocharger into position
on the interstage duct.
8. Place a new gasket, face up, with the tab towards the rear, on the exhaust manifold turbocharger
flange.
NOTICE:
The turbocharger must be supported after it has been installed to the exhaust manifold flange
to avoid damage to the turbocharger.
9. Position the turbocharger to the exhaust flange. Hand tighten fasteners.

10. Torque the turbocharger-to-exhaust manifold bolts to 50 N m (37 lb ft).
11. Install turbocharger support bracket to turbocharger. Hand-tighten the mounting bolts from the
support bracket to the cylinder block.
12. Torque the turbocharger support bracket bolts to cylinder block to 25 N m (18 lb ft). Then torque
turbocharger bracket to turbine housing bolts to 25 N m (18 lb f t ).
13. Tighten the interstage duct clamp to 12 N m (9 lb ft).
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 oil drain line that runs to the cylinder
block. Torque the bolts to 30-38 N m (22-28 lb ft).
15. Install the turbocharger oil supply line. Torque the oil supply line to 30 N m (22 lb ft).
16. Connect the APT air supply line. Torque to 20 N m (15 lb ft).
Note: Do not use any type of lubricant on the inside of any air inlet hose or on the hose contact
surfaces of the turbocharger compressor housing, Charge Air Cooler (CAC) ducting or the

intake manifold.
17. Install the turbocharger heat shields.
18. Install the compressor elbow and the CAC plumbing. Torque the clamps to 6 N m (4 lb ft).
19. Connect DDDL/DDRS and perform purge hydrocarbon doser service routine to remove all the air
from the doser system.
20. If the turbocharger is being replaced due to a turbocharger shaft bearing failure, replace the engine
oil and filter.

14.1 Description and Operation of the DD15 and DD16 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. The rated speed of the turbine wheel of the APT device is about
50,000 rpm. The turbine wheel generates a torque in this range of about 10 N m (7 lb ft), which is
increased through various gear ratios up to 260 N m (192 lb ft). The exhaust gas flows to the turbine
wheel of the APT and drives the wheel. The rotational movement created is transmitted to the shaft of
the small output gear, and from there, to the large output gear of the hydrodynamic clutch. The rotational
speed is reduced because of the gear ratio between the output gear and drive gear; this gear ratio also
multiplies torque output. The hydrodynamic clutch impeller is a part of the hydrodynamic clutch
housing. The vanes on the impeller generate an oil flow in the hydrodynamic clutch which sets the
turbine wheel of the hydrodynamic clutch into rotation and the output gear is driven over a shaft. The
generated torque is transferred through the idler gear No. 4 to the crankshaft gear. It is also possible to
ensure, via the hydrodynamic clutch, that matching rotational speed takes place between the crankshaft
and the axial power turbine-drive.
The APT is connected to the engine oil circuit. The gears and the bearing are lubricated and cooled by
the engine oil. The hydrodynamic clutch is supplied with engine oil by the hollow bearing shaft. One
special aspect is the seal between the shaft and the exhaust turbine housing. The seal between these two
components is formed by using two metal sealing rings which are pressed into their seat by compressed
air. The pressure is regulated either by an air sealed pressure regulator or from the turbo charger
compressor.
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070E01.htm 2/19/2011

3 \ 2 1 d090059
1. Bolt (M10 x 120 mm)

2. Bolt (M10 x 35 mm)
3. Bolt
4. Bolt (M10 x 90 mm)
5. Gear Box
6. Bolt (M10 x 65 mm)
7. Gasket Seal
8. O-ring
9. Locking Dowel
10. Bolt (M10 x 20 mm)
11. Bracket
12. Bolt (M10 x 20 mm)
14. Clamp
15. Bolts
16. Air Line
17. P-clip
18. Interstage Duct
19. Clamp
20. Bolt

21. Gasket
22. Turbocharger
23. Clamp
25. Bracket
26. Bolts (6 qty.)
27. O-ring
29. Clamp
31. Heat Shield

14.2 Removal of the DD15 and DD16 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.
2. Drain the coolant.
3. Remove the heat shields from the turbocharger and the Axial Power Turbine (APT).
4. Disconnect the doser injector housing lines and then remove the exhaust S-pipe from APT outlet
by removing the Marmon clamp. Refer to section "Removal of the DD15 and DD16 Exhaust S-
pipe"
5. Remove the EGR hot pipe. Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe"
6. Remove the turbocharger and interstage duct. Refer to section "Removal of the DD15 and the
DD16 Turbocharger"
7. Remove the air line from the air seal pressure regulator valve or from the compressor housing of
the turbocharger.
8. Remove four bolts securing the gear box to the axial power turbine.
9. Remove four bolts from the APT support bracket.
10. Separate the turbine housing from the gear box.
11. Remove the gasket, graphite seal, oil passage tube and O-ring.

14.3 Inspection of the DD15 and DD16 Axial Power Turbine
Inspect as follows:
1. Remove the Axial Power Turbine (APT) from the gearbox and inspect the APT stator and vanes.
If any of the vanes on the stator are damaged, replace the APT assembly.
2. Clean the oil and buildup from the APT stator and vanes using mineral spirits. Replacement of the
APT for oil or carbon buildup is not necessary.
3. Rotate the APT turbine shaft. If the shaft does not turn smoothly, replace the APT assembly.
4. Remove the retaining ring from the APT stator and remove the stator from the APT housing. The
stator is removed by pulling straight away from the housing, taking care not to wedge the
assembly. A light abrasive may be used to remove buildup or corrosion inhibiting stator removal.
5. Inspect both sides of the stator (1) and the retaining ring (2); replace APT assembly if damaged.
NOTICE:
Do not use any abrasive media on the APT blades as this may cause damage or an imbalance
in the assembly.
6. With the stator removed, inspect the APT turbine blades for damage and contact with the turbine
housing. If any of the turbine blades are damaged, bent, broken, or otherwise damaged, replace the
APT assembly.
7. Visually inspect the turbine blades from the exhaust outlet. If any damage is visible, replace the
APT assembly.
8. If no physical damage was found during the inspection, thoroughly clean the assembly with
mineral spirits, reassemble the stator and retaining ring, and reuse the APT.
o Take caution not to use any abrasive materials that could damage the turbine rotor blades.
o Replace the graphite seal and O-ring seal on the APT for reuse.
o Ensure no oil or mineral spirit residue is left in the APT housing prior to reassembly.
o Using compressed air, thoroughly dry the APT housing assembly.

14.4 Installation of the DD15 and DD16 Axial Power Turbine
Install as follows:
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).
NOTICE:
DO NOT install the tube in the gear box. There is no depth stop to insure proper depth is
achieved. If the tube is too far in the gear box it will block the oil return passage and cause
damage to the APT and gear box.
3. Install the oil return tube (2) into the Axial Power Turbine (APT) (1), ensuring the tube is fully
seated into the APT housing. Be sure the oil return tube taper faces toward the gear box.
4. Position gasket seal (3) on APT snout then install graphite seal on the oil return tube (2).
5. Install O-ring on snout of APT. O-ring must be installed in the narrow groove (1) on the snout of
the APT.
Note: When installing axial power turbine to gear box, ensure that gears are aligned by viewing
through exhaust port and rotating impeller. Damage to gear box and axial power turbine will
occur if not installed correctly.
6. Install axial power turbine to gear box and bracket (the APT must be installed as straight to the
gearbox as possible; uneven installation could cause an oil leak).
7. Install the front bolt through the APT into the gear box, and hand-tighten the bolt.
8. Install two bolts through the bracket into the axial power turbine; then install two bolts through the
bracket into the cylinder block. Install the remaining three bolts into axial power turbine and hand-
tighten.
9. Torque the bolts to 55-60 N m (41-45 lb ft).
10. Install air line to axial power turbine from air seal pressure regulator valve or from the
turbocharger compressor housing. Torque the banjo bolt to 10 N m (7 lb ft).
11. Install the oil feed line from the block to the gear box (if removed). Torque to 20 N m (15 lb ft).

12. Install the turbocharger and interstage duct. Refer to section "Installation of the DD15 and the
DD16 Turbocharger"
13. Install the APT heat shields.
14. Fill the engine with coolant.

15.1 Description and Operation of DD15 and DD16 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 (APT) and
cylinder block.
3 \ 2 1 d090059
1. Bolt (M10 x 120 mm)

2. Bolt (M10 x 35 mm)
3. Bolt
4. Bolt (M10 x 90 mm)
5. Gear Box
6. Bolt (M10 x 65 mm)
7. Gasket Seal
8. O-ring
9. Locking Dowel
10. Bolt (M10 x 20 mm)
11. Bracket
12. Bolt (M10 x 20 mm)
http://extranet.detroitdiesel.com/power service/literature/Content/107/1070F01.htm 2/19/2011

14. Clamp
15. Bolts
16. Air Line
17. P-clip
18. Interstage Duct
19. Clamp
20. Bolt
21. Gasket
22. Turbocharger
23. Clamp
25. Bracket
26. Bolts (6 qty.)
27. O-ring
29. Clamp
31. Heat Shield

15.2 Removal of the DD15 and DD16 Axial Power Turbine Gear Box
Remove as follows:
1. Remove the turbocharger. Refer to section "Removal of the DD15 and the DD16 Turbocharger"
2. Remove the Axial Power Turbine (APT). Refer to section "Removal of the DD15 and DD16 Axial
Power Turbine"
3. Remove the oil line from cylinder block to APT gear box.
4. Remove four bolts from the APT gear box to the cylinder block and remove the APT gear box.

15.3 Inspection of the DD15 and DD16 Axial Power Turbine Gear Box
Inspect as follows:
1. Inspect the gear box for damage; replace if necessary.

15.4 Installation of the DD15 and DD16 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.
1. Install the Axial Power Turbine (APT) gear box to cylinder block, ensuring the gears are meshed
together when installed.
NOTICE:
Ensure the correct bolt length is used when the gear box is installed. If an incorrect bolt
length (too long) is used, the cup plugs installed in the cylinder block can be pushed out into
the gear train causing severe damage to the gear train. The correct bolt length for the bolt
installed in the upper location near the cylinder block is 35 mm (1.37 in.). The correct length
for the bolt located in the lower position of the gear box is 120 mm (4.72 in.).
2. Install four bolts into gear box and cylinder block and hand tighten.
3. Torque the four bolts to 55-60 N m (41-44 lb ft).
4. Install oil line to gear box and engine block. Torque to 35 N m (26 lb ft).

16.1 Description and Operation of the 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
• Intake and Exhaust Valves
Cylinder Head
The cylinder head has been designed with a compacted graphic iron material. There are two intake and
two exhaust valves per cylinder. To ensure the correct bolts are used when installing the cylinder head,
the bolt thread size 16 is stamped on the head of the bolt. All bolts must be tightened in the correct
sequence. The valve train assembly needs to be removed in order to access the cylinder head bolts.
The cylinder head has a split coolant jacket; the coolant flows around the cylinder to the inlet side of the
head and then to the exhaust side. The coolant flows in the lower level of the cylinder head around the
injectors and the valve seat rings. The coolant then flows around in the upper level of the cylinder head
and cools the valve guides. The advantage of this design is a very even and highly effective cooling
system.
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Intake and Exhaust Valves
There are four valves per cylinder; two intake valves and two exhaust valves. Valves are made o f heat-
treated alloys, with precision-ground heads and stems. Stem ends are hardened to minimize wear in
contact with the valve rocker buttons. All valves are retained by valve spring caps and two-piece tapered
valve locks. Valve stem oil seals are installed on both intake and exhaust valves to provide controlled
valve stem lubrication while limiting oil consumption. The exhaust valves use a nickel-based alloy and
are identified by a smaller dimple on the combustion face. The intake valves are an iron based alloy and
are identified from the exhaust valve by a larger dimple on the combustion face.

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2. Exhaust Rocker Arm with Actuator
3. Brake Rocker Arm
5. Drive Gear for Exhaust Camshaft
6. Exhaust Camshaft
7. Exhaust Valve
8. Valve Spring
9. Intake Rocker Arm
10. Intake Rocker Arm Shaft
11. Drive Gear for Intake Camshaft
12. Intake Camshaft
13. Intake Valve
14. Camshaft Housing

1. Cylinder Head Gasket

2. Exhaust Valve Seat Ring
3. Intake Valve Seat Ring
4. Exhaust Valve
5. Intake Valve
6. Cylinder Head
7. Washer
8. Valve Guide
9. Valve Stem Seal
10. Valve Keeper
11. Exhaust Valve Spring
12. Spring Retainer
13. Intake Valve Spring
14. Water Jacket Cover Plug
15. Water Jacket Seal Ring Plug
16. Water Protection Sleeve Seal Ring
17. Injector Cup
18. Cylinder Head-to-Cylinder Block Bolt

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1. Exhaust Valve
2. Valve Springs
4. Valve Clearance Adjusting Element
5. Exhaust Rocker Arm with Actuator

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1. Intake Valves
2. Valve Springs
3. Drive Gear and Timing Wheel for Intake Camshaft

1. Inlet Valves
2. Exhaust Valves

16.2 Removal of the DD13 Cylinder Head
Because optional and accessory equipment varies with the engine application, these procedures covers
only the basic engine. If the engine is equipped with accessories that affect cylinder head removal, note
the mounting details of each accessory to assure correct installation at reassembly.
Remove as follows:

2. Disconnect the batteries. Refer to OEM procedure.
3. Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs"
4. Drain the oil. Refer to OEM procedure.
5. Drain the coolant. Refer to OEM procedure.
6. Remove the turbocharger inlet pipe. Refer to OEM procedure.
8. Disconnect the following electrical harness connections:
a. Coolant outlet temperature sensor harness from the water manifold
b. Delta-P sensor
c. Intake manifold air temperature sensor
d. Intake throttle valve
e. Intake air temperature sensor
9. Remove the removal of high pressure fuel injector lines. Refer to section "Removal of the High
Pressure Fuel Injector Lines"
10. Remove high pressure fuel lines from fuel rail to high pressure fuel pump. Refer to section
"Removal of the High Pressure Fuel Rail Feed Lines"
11. Remove amplifier return line, needle return line and pressure limiting valve (PLV) lines. Refer to
section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
12. Disconnect fuel injector harness from the fuel injectors and engine brake solenoids.
Refer to section "Removal of the One-Piece Fuel Injector Wiring Harness"
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness"
13. Remove the camshaft and rocker shaft assemblies. Refer to section "Removal of Camshaft and
Rocker Shaft/Engine Brake Assembly"
14. Remove coolant lines from the water manifold to the fuel doser injector housing. Refer to section
"Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly"
15. Remove the Exhaust Gas Recirculation (EGR) vent (deaeration) line.
16. Remove the camshaft housing. Refer to section "Removal of the Camshaft Housing"
17. Remove the EGR crossover tube. Refer to section "Removal of the Exhaust Gas Recirculation
Crossover Tube"
18. Remove the two bolts attaching the cold boost pipe to the support bracket.
19. Using the flywheel and main pulley socket tool (J-45390), remove the 40 bolts securing the
cylinder head to the cylinder block.
20. If the dipstick hose is attached to the intake throttle valve bracket, remove the clip attaching it.
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21. Using the cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from
the cylinder block.
22. Remove and discard the metallic gasket from the cylinder block.

16.3 Cleaning of the Cylinder Head
Clean as follows:
1. Keep parts segregated according to original position to assure proper reassembly, if parts are to be
reused.
2. Remove all plugs.
3. Steam clean the cylinder head once it has been stripped.
4. Clean the head in a de-scaling bath.
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pressure.
5. Clean the valves, springs, and rocker shafts in fuel oil and blow dry with compressed air.
6. Clean the rocker arm assemblies.

16.4 Assembly of Cylinder Head
Assemble as follows:
1. Install all of the required cup plugs using a good grade of non-hardening sealant, such as Loctite®
620 or equivalent, on the cup plugs. Use cup plug installation set (J-35653).
2. Ensure that all cup plugs on the front face of the cylinder head are flush or below the surface.
3. Install valves, valve stem seals, valve springs and keepers.

16.5 Installation of the DD13 Cylinder Head
Install 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, cylinder head, and cylinder block fire
deck surfaces are clean and free of foreign matter.
2. Verify that the cylinder liner protrusion heights are within specification prior to installing the
cylinder head. Refer to section "Installation of the Cylinder Liner" for cylinder liner protrusion
specifications.
3. Install cylinder head guide studs (W471589016100).
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4. Position a new cylinder head gasket onto the cylinder block.
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5. Install four lift hooks onto the cylinder head.

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.
7. Remove the guide studs.
8. Remove the lifting hooks from the cylinder head.
9. Coat the threads and underside of bolt heads with clean engine oil before installation.
10. Install the 40 cylinder head bolts into the cylinder head. Torque bolts (1 through 38) in three steps
as follows:
a. 200 N m (147 lb ft)

b. 90° torque turn.

c. 90° torque turn.
11. Using the torque sequence shown, torque the small bolts (39 and 40) to 60 N m (44 lb ft).
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12. Check and adjust the timing of the engine gear train, as needed. Refer to section "Installation and
Timing of Engine Gear Train"
13. Install the turbocharger flange bolts.
14. Install the Exhaust Gas Recirculation (EGR) crossover tube. Refer to section "Installation of the
Exhaust Gas Recirculation Crossover Tube"
15. Install the EGR actuator harness connector, linkage and the heat shield.
16. Install the coolant lines to EGR actuator.
18. Install the camshaft and rocker shaft assemblies. Refer to section "Installation of the Camshaft and
19. Install the intake elbow.
20. Install the mixer pipe. Refer to section "Installation of the Mixer pipe"
21. Install the EGR venturi. Refer to section "Installation of the Exhaust Gas Recirculation Venturi"
22. Install the fuel injectors. Refer to section "Installation of the Fuel Injector"
23. Install the engine brake solenoids and injector harness.
24. Install the amplification needle and pressure limiting valve (PLV). Refer to section "Installation of
the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
25. Install the high pressure feed lines from high pressure pump to common fuel rail. Refer to section
"Installation of the High Pressure Fuel Rail Feed Lines"
26. Install the injector feed lines from fuel rail. Refer to section "Installation of the High Pressure Fuel
Injector Lines"
27. Connect the coolant temperature sensor harness.
28. Install the turbocharger inlet pipe.
29. Install any components that were removed and fill with required fluids as recommended. Refer to
OEM guidelines.
30. Set the valve lash and engine brake. Refer to section "Valve Lash Adjustments"
32. Fill the cooling system.
33. Prime engine lubrication system. Refer to section "Priming the Engine Lubrication System"

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34. Start the engine and check for fuel, coolant or oil leaks.
35. Shut down the engine.

16.6 Removal of the DD15 and DD16 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. Remove as follows:
Note: If the cylinder head is to be replaced, the new head must be thoroughly cleaned before
installation to remove all rust and preventive compound, especially from the fuel and oil galleries.
This can be done by immersion in a bath of fuel oil or mineral spirits-based solvent and scrubbing out
all openings with a soft bristle brush. When clean, blow the head dry with compressed air.

4. Drain the engine oil.
6. Remove the turbocharger inlet pipe.
8. Disconnect the following electrical harness connections:
a. Coolant outlet temperature sensor harness from the water manifold
b. Delta-P sensor
c. Intake manifold air temperature sensor
d. Intake throttle valve
e. Intake air temperature sensor
9. Remove fuel injector feed lines. Refer to section "Removal of the High Pressure Fuel Injector
Lines"
10. Remove high pressure fuel lines from fuel rail to high pressure fuel pump. Refer to section
"Removal of the Hydrocarbon Doser Block Feed Line"
11. Remove amplifier return line, needle return line and pressure limiting valve (PLV) lines. Refer to
section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
12. Disconnect fuel injector harness from the fuel injectors and engine brake solenoids.
a. For EURO 6 DD platform engines, remove one-piece fuel injector wiring harness. Refer to
section "Removal of the One-Piece Fuel Injector Wiring Harness"
b. For NAFTA DD platform engines, remove two-piece fuel injector wiring harness. Refer to
section "Removal of the Two-Piece Fuel Injector Wiring Harness"
13. Remove the camshaft and rocker shafts. Refer to section "Removal of Camshaft and Rocker
Shaft/Engine Brake Assembly"
14. Remove coolant lines from the water manifold to the fuel doser injector housing.
15. Remove the Exhaust Gas Recirculation (EGR) vent (de-aeration) line.
17. Remove the EGR actuator coolant line from the cylinder block.
18. Disconnect the EGR actuator connector and remove the heat shield. Refer to section "Removal of
the DD15 and DD16 Exhaust Gas Recirculation Valve Actuator"
19. Remove the turbocharger flange bolts.
20. Remove the EGR crossover tube. Refer to section "Removal of the Exhaust Gas Recirculation
Crossover Tube"
21. Remove the two bolts attaching the cold boost pipe to the support bracket.
22. Using the flywheel and main pulley socket tool (J-45390), remove the 40 bolts securing the
cylinder head to the cylinder block.

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23. Using cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from the
cylinder block.
24. Remove and discard the metallic gasket from the cylinder block.

16.7 Cleaning of the Cylinder Head
Clean as follows:
1. Keep parts segregated according to original position to assure proper reassembly, if parts are to be
reused.
2. Remove all plugs.
3. Steam clean the cylinder head once it has been stripped.
4. Clean the head in a de-scaling bath.
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pressure.
5. Clean the valves, springs, and rocker shafts in fuel oil and blow dry with compressed air.
6. Clean the rocker arm assemblies.

16.8 Assembly of Cylinder Head
1. Install all of the required cup plugs using a good grade of non-hardening sealant, such as Loctite®
620 or equivalent, on the cup plugs. Use cup plug installation set (J-35653).
2. Ensure that all cup plugs on the front face of the cylinder head are flush or below the surface.
3. Install valves, valve stem seals, valve springs and keepers.

16.9 Installation of the DD15 and DD16 Cylinder Head
Install 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.
2. Verify that the cylinder liner protrusion heights are all the same prior to installing the cylinder
head.
3. Install the cylinder head guide studs tool (J-35784).
4. Position a new cylinder head gasket onto engine block.
5. Install four lift hooks onto cylinder head.
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6. Lift the cylinder head into position using cylinder head/engine lifting bar tool (W470589006200).
Lower into place over the guide studs and dowel pins until it is seated on the engine block.
7. Remove the cylinder head guide studs.
8. Remove the lifting hooks from the cylinder head.
9. Coat the threads and underside of bolt heads with clean engine oil before installation.
10. Install the 40 cylinder head bolts into the cylinder head.
11. Torque the 38 large bolts in four steps to:
a. 50 N m (37 lb ft)
b. 250 N m (184 lb ft)
c. 90° torque turn

d. 90° torque turn

12. Torque the small bolts (39 and 40) to 60 N m (44 lb ft).
36 35 28 27 22 21 15 16 23 24 31 32 11 39
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14. Install the camshaft and rocker shaft assemblies. Refer to section "Installation of the Camshaft and
15. Time the camshaft assembly. Refer to section "Timing the Camshafts With the Gear Train
Installed"
16. Set the valve lash and engine brake. Refer to section "Valve Lash Adjustments"
17. Install any components that were removed and fill with required fluids as recommended. Refer to
OEM guidelines.
18. Fill the cooling system.
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20. Start the engine and check for fuel, coolant or oil leaks.
21. Shut down the engine.

17.1 Removal of the Valve Spring (Cylinder Head Installed)
Remove as follows:

4. Remove the camshaft and rocker shaft assemblies. Refer to section "Removal of Camshaft and
6. Remove the fuel injector from the appropriate cylinder. Refer to section "Removal of the Fuel
Injector"
NOTICE:
All valve spring or seal removal and replacement must be completed for each cylinder being
serviced while the piston is at Top Dead Center (TDC). After servicing a cylinder, turn the
crankshaft to TDC for the next cylinder being serviced.
7. Using the engine barring tool (J-46392), bar the engine over until the cylinder is at Top Dead
Center (TDC).
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pressure.
8. 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.
9. 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.

Note: Do not contact the valve with the compressor tool.

10. Compress the valve spring and remove the valve locks using a small magnet to prevent the locks
from falling into the cylinder head oil return galleries.
11. Release the spring and remove the valve cap and valve spring. If the valve stem oil seal is to be
replaced, remove the seal and discard it.

17.2 Removal of the Valve Spring (Cylinder Head Removed)
With the cylinder head assembly removed from the engine, remove the valve springs as follows:
1. Remove the valve locks using valve spring compressor (J-47406), compressing each valve spring.
2. Release the spring and remove the valve, valve cap and valve spring.
3. Remove the valve stem oil seal and discard the seal.
4. Remove the valve spring seat.
5. As parts are removed, mark or segregate them according to their original position for possible
reuse.
6. Mark the location of each intake and exhaust valve in accordance to its cylinder number and
whether it is an intake or an exhaust valve.
7. Flip the cylinder head over and carefully remove the valves from the cylinder head.

17.3 Removal of Intake and Exhaust Valves
Remove as follows:
1. Remove the cylinder head.

For the DD13: Refer to section "Removal of the DD13 Cylinder Head"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head"
2. Remove the valve spring(s). Refer to section "Removal of the Valve Spring (Cylinder Head
Removed)"

17.4 Cleaning of Valves and Related Parts
Clean as follows:
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pressure.
NOTICE:
If a valve is removed through a stem seal, the stem seal must be replaced.
1. Using proper eye protection, clean all of the disassembled parts with fuel oil and dry with
compressed air.
2. Clean the carbon from the valve stems and wash the valves with fuel oil.
3. Clean the valve guide bore to remove all gum and carbon deposits use bore brush (J-5437 or
equivalent) for this procedure.

17.5 Inspection of the Intake and Exhaust Valves
The valve stems must be free from scratches or scuff marks, and the valve faces must be free from
ridges or cracks. Some pitting of the valve face is normal, and is acceptable as long as no leak paths are
evident. If leak paths exist, re-face the valves or install new valves. If the valve heads are warped or the
valve stem is bent, replace the valves.

17.6 Installation of the 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. If reusing valves, install them to their original positions.
NOTICE:
Ensure all valve spring seats have been installed before the valve stem oil seal is installed.
Note: Clean valve guide of old seal material and oil before installing the new seal.
2. Install the valve spring seat over the valve guide.
3. With the valve installed into the cylinder head, clean the valve guide and valve stem with brake
cleaner.
4. Install the protective cap over the valve stem.
Note: Do not coat valve stem or seal with oil prior to installation.
5. Install the valve stem seal over the protective cap.
6. Push the seal down on the valve stem using the seal installer (J-47490). When the installer tool
contacts the cylinder head, the seal is correctly positioned. Be sure the installer is square against
the cylinder head. Remove the seal installer and protector cap.
7. Install the valve spring and retainer. If reusing parts, install them to their original positions.
NOTICE:
Be sure the valve retainer is properly centered and aligned to avoid scoring the valve stem.
Do not compress the spring any more than necessary to install the locks, to avoid damaging
the oil seal.
Note: Always install new valve stem locks when installing valves.
8. Using the valve spring compressor tool (J-47406), compress the valve spring only as much as
required to install the valve locks. After installing the valve locks, rap the end of the valve stem
sharply with a plastic mallet to seat the valve locks.
9. Remove compression test adaptor J-47411.
10. On the other three valves it may be necessary to repeat these steps for cylinders being worked on.
11. If the cylinder head is removed from engine, install the cylinder head.
For the DD13: Refer to section "Installation of the DD13 Cylinder Head"
For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head"
12. Prime the fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel
Priming Pump"
13. Close any drain cocks that were opened and fill the cooling system. Purge the air from the system
using the vent in the thermostat housing. Complete filling of the cooling system is essential for
proper engine operation.
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17.7 Valve Lash Adjustments

Accurate adjustment of clearance between intake and exhaust valves is important if maximum performance and
economy are to be obtained.
NOTICE:
Failure to measure valve clearances at the required initial period and make necessary adjustments may result
in gradual degrading of engine performance and reduced fuel combustion efficiency.
Note: Every time the valve lash is adjusted the engine brake lash will also need to be set.
Note: Adjust the valve lash before setting the engine brake lash.
1. Turn engine OFF, (key OFF, engine OFF).

3. Disconnect the starting power for the engine. Refer to OEM procedures.
4. Remove the air cleaner and the turbocharger inlet pipe and hose. Refer to OEM procedures.
5. Remove air cleaner housing. Refer to OEM procedures.
7. Using special tool (J-46392), bar the engine over until cylinder number one is at Top Dead Center (TDC)
compression stroke.
8. Using a feeler gauge (1), lash intake valves one, two and four to 0.4 mm (0.016 in.).
9. Using a feeler gauge (1), lash exhaust valves one, three and five to0.6mm (0.024 in.).
10. Using special tool (J-46392), bar the engine over 360° until cylinder number sixis at TDC compression
stroke.
11. Lash intake valves three, five, and six to 0.4 mm (0.016 in.).
12. Lash exhaust valves two, four and six to 0.6 mm (0.024 in.).
13. Torque the locknut valve adjusting screw to 50 N m (37 lb ft).
14. Remove any tools used for this procedure.
15. Set the engine brake lash. Refer to section "Setting the Engine Brake Lash"
Printed Sat Feb 19 09:44:26 2011|

17.8 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).
2. Rotate the engine until a given cylinder is at maximum intake lift. When this is reached, the brake
lash can be set on this cylinder.
3. Lash the engine brakes in the following firing order; one, five, three, six,two, then four.
4. When the engine brake rocker arm is in contact with the exhaust valve, set the lash between the
engine brake rocker arm adjusting screw and the actuator piston stem. Using Engine Brake
Adjustment tool (W470589022300), set the lash to 4.1 mm (0.1614 in.).
5. Lash the engine brakes in the following firing order; 1, 5, 3, 6, 2, and 4.
6. Torque the locknut valve adjusting screw to 50 N m (37 lb ft).
8. Reconnect the battery power to the engine. Refer to OEM procedures.

18.1 Description and Operation of the 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.
1. Connecting Rod Bolt (2 qty.)

2. Connecting Rod Bushing
3. Retaining Ring (2 qty.)
4. Piston Pin
5. Piston
6. Oil Control Ring
7. Compression Ring
8. Fire Ring
9. Connecting Rod
Each piston has an oil control ring (6), a middle compression ring (7), and a fire ring (8).

3 2
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1. Piston Skirt
2. Cover Plate (EPA07 pistons only)
3. Piston Pin
4. Retaining Clip
5. Piston Boss
6. Oil Control Ring
7. Compression Ring
8. Fire Ring
9. Cooling Galley
10. Combustion Bowl
11. Piston Dome
12. Top Land
13. Second Land

18.2 Removal of Piston and Connecting Rod Assembly
Remove as follows:
1. Drain the engine cooling system.

2. Drain the engine oil.
3. Remove the oil pan. Refer to section "Removal of the Oil Pan"
4. Remove the camshaft housing and associated parts. Refer to section "Removal of the Camshaft
Housing"
5. Remove the cylinder head and gasket.
For the DD13: Refer to section "Removal of the DD13 Cylinder Head"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head"
6. Use Scotch-Brite® pads to remove any carbon deposits from the upper inner surface (1) of the
cylinder liner.
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7. Remove the piston cooling nozzles (1) from the base of the cylinder bores and discard the nozzles.
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Position the crankshaft for each piston and connecting rod assembly to be removed at bottom dead

center.
9. Remove the connecting rod bearing cap with lower bearing shell from the connecting rod.
Note: The connecting rod assembly is a cracked rod design. Ensure when the bearing cap is
removed that it is placed on its side. Damage to the bearing cap will occur if it is placed on end;
the connecting rod assembly will need to be replaced if the cap is damaged.
10. Remove the piston and connecting rod assembly through the top of the cylinder liner.
Note: 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.
11. Assemble the connecting rod bearing cap and lower bearing shell to the connecting rod after
removal. If not already marked, match-mark the rod and cap (on the tang side) with the cylinder
number from where they were removed.

18.3 Disassembly of Piston and Connecting Rod Assembly
Disassemble as follows:
Note: Stamping cylinder numbers on the piston assembly will damage the components.
Piston assembly components should be segregated by cylinder and match-marked during disassembly to
ensure they are assembled in the same position and orientation.
1. Place the piston, dome down, on the table.

2. Using appropriate flat-nosed pliers, remove the retaining rings from the piston boss.
3. Slide out the piston wrist pin and remove the connecting rod from piston.
| Printed Sat Feb 19 09:46:14 2011

18.4 Assembly of the Piston and Connecting Rod Assembly
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.
2. Liberally lubricate the piston pin bore, the piston pin, and the connecting rod bushing in the small
end of the connecting rod with 80/90w oil (or equivalent).
3. Position the long end of the connecting rod (2) on the same side as the valve relief (1) in the top of
the piston.
4. Install piston pin into the pin bore, through the rod, until it rests against the previously installed
retaining ring.
5. Using the appropriate flat-nosed pliers, install the other retaining ring into the retaining ring recess
in the piston boss to lock the pin in place. Orient the retaining ring gap to either the 12 o'clock or 6
o'clock position.
___________________________________________________________ Printed Sat Feb 19 09:46:34 2011

18.5 Installation of the 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.
b. Install the oil ring (top label up) in the lowest groove around the oil expander ring.
c. Install the compression ring (top label up) in the middle groove.
d. Install the fire ring (top label up) in the top groove.
2. Allowable new ring end gaps for (A), (B), and C) are shown below.
Ring Ring End Gap
Fire Ring (A) 0.35 - 0.75 mm (0.024 - 0.030 in.)
Compression Ring (B) 0.7 - 0.9 mm (0.027 - 0.035 in.)
Oil Control Ring C) 0.4 - 0.6 mm (0.016 - 0.024 in.)
3. Add clean engine oil to a clean pan at least 305 mm (12 in) in diameter, until the level reaches
approximately 76 mm (3 in.).
4. Place the piston and connecting rod assembly into the pan, with the combustion dome of the
piston on the bottom of the pan.
5. Coat the upper connecting rod bearing shell with clean engine oil.
6. Coat the piston skirt liberally with the engine oil, saturating the piston rings and ring lands.
7. Coat the inside diameter of the piston ring compression tool with clean engine oil.
For the DD13: use the piston ring compressor tool (W470589005900)
For the DD15 and DD16: use the piston ring compressor tool (J-47386)
For the DD15 and DD16: the 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.
10. Lubricate the inside of the cylinder liner with clean engine oil.
11. Position the throw of the crankshaft to bottom dead center for the cylinder being installed with the
piston and connecting rod assembly.
NOTICE:
Failure to orient the piston and connecting rod assembly properly during piston installation
may result in the bearing end of the rod striking the nozzle, causing damage to the nozzle or
loosening it from the block. A damaged, bent, or loosened nozzle may cause a loss of main
gallery pressure. In these cases piston overheating or lack of adequate lubrication may result
in severe engine damage.
12. Ensure the valve relief located on the top of the piston is orientated towards the exhaust side of the
engine during installation. The piston also has an arrow that should face the front of the engine.
The connecting rod has a serial number printing that must also face towards the exhaust side of the
engine.
13. Align the ring compressor guide pins (if equipped) over the two bolt holes on the top of the
cylinder block.
NOTICE:
DO NOT force the piston into the liner. Considerable force on the piston could scratch or
otherwise damage the inside of the cylinder liner. Therefore, care must be taken during the
installation of the piston to prevent damage.
14. With care and moderate pressure, press the piston into the liner.
15. Remove the ring compressor.
16. Push or tap the piston and connecting rod within the liner until the upper rod bearing is firmly
seated on the appropriate crankshaft journal.
17. Lubricate the lower bearing shell with clean engine oil.
18. With the number on the cap and rod on the same side and the arrow facing forward, install the
bearing cap.
19. Torque the connecting rod bolts alternately to the following:
For the DD13: 190 N m (140 lb ft) + 90° torque turn
Bearing Cap to Rod Bolt Cap Bolt Maximum Length
DD13 DD15 DD16
79 mm (3.11 in.) 82.3 mm (3.240 in.) 82.3 mm (3.240 in.)
20. Check connecting rod axial clearance by moving the rod from side to side on the crank journal. If
there is no clearance, check for proper bearing cap installation.
Connecting Rod Axial Clearance
DD13 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.)
DD15 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.)
DD16 0.12 mm (0.0047 in.) 0.29 mm (0.0114 in.)
NOTICE:
Ensure when installing the piston spray nozzles that damage to the nozzle does not occur.
Damaged oil spray nozzles could result in a loss of oil pressure to cool the pistons, which
may cause engine damage.
21. Install the remaining piston and rod assemblies in the same manner.
22. Install new piston spray nozzles (1) at the base of the cylinder bores. Torque each piston spray

nozzle bolt to 30 N m (22 lb ft).
d010044
23. Using a dial gauge and holder, measure the piston protrusion relative to cylinder block top dead
center at all the pistons.
24. Allowable piston protrusion (A) is in the table below:
d030015
Engine M inimum M aximum

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.)
DD16 -0.213 mm (-0.0090 in.) 0.2075 mm (0.0081 in.)
25. If piston protrusion is not between minimum and maximum specifications, check the following:
a. Inspect piston, piston pin boss, and piston pin for wear or damage. If damaged, repair as
necessary.
b. Inspect connecting rod, checking for bent rod, piston pin bore wear or damage. If damaged,
repair as necessary.
c. Inspect connecting rod bearings for wear or damage. If damage is found replace rod
bearings.

d. Inspect crankshaft for damage to rod journal or evidence of spun bearing. If damaged, repair
as necessary.
26. Install a new cylinder head gasket and the cylinder head.
For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head"
NOTICE:
Debris from a failed bearing can damage the internal components of the oil pump. If debris
is found in the oil pan, replace the oil pump as necessary.
27. Install the lubricating oil pump inlet pipe and screen assembly, and the lubricating oil pump. Refer
to section "Installation of the Oil Pump, Oil suction Manifold, and Oil Lines"
28. Install the oil pan. Refer to section "Installation of the Oil Pan"
29. Complete any other engine assembly as necessary.
30. After the engine has been completely assembled, refill the oil pan to the proper oil level on the
dipstick.
NOTICE:
Coolant system maintenance is very important. Bleed off all the air from the system and top
off.
32. Close the drain cocks and fill the engine with the recommended coolant.
33. 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.

19.1 Description and Operation of the 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. Each cylinder liner has 2 sealing rings: the upper sealing
ring, sealed by the upper coolant jacket to the cylinder block bore, and the lower sealing ring, sealed by
the lower coolant jacket to the cylinder block bore.
1. Cylinder Liner
2. Compression Seal Surface
3. Upper Sealing Ring
4. Upper Coolant Jacket
5. Lower Coolant Jacket
6. Lower Collar
7. Lower Sealing Ring
8. Bottom Stop Balcony
G enerated on 0 2-18-2011

19.2 Removal of the Cylinder Liner
Remove as follows:
NOTICE:
The proper method must be followed when removing the cylinder liner. Damage to the liners and
cylinder block may occur if the proper tools and procedures are not used.
1. Remove the piston and connecting rod. Refer to section "Removal of the Piston and Connecting
Rod Assembly"
2. Install cylinder liner removal tool (J-45876) into the cylinder liner.
3. Remove cylinder liner (2).
NOTICE:
After removing the liners from the engine and prior to installation, always store them in an
upright position until ready for use. Liners left on their side for any length of time can
become egg-shaped and distorted, making installation in cylinder bores difficult or
impossible. If the cylinder liners are to be reused, they should be marked for cylinder
location and engine orientation, a paint mark can be used to indicate the front of the engine
so they may be installed to the same cylinder from which they were removed.
4. Remove the two seal rings (1, 3) from the cylinder liner (2) and discard them.

19.3 Inspection of the Cylinder Liner
Inspect as follows:
NOTICE:
Cavitation is due to poor cooling system maintenance. If uncorrected, it will eventually
make holes through the liner. This can result in combustion gases blowing water out of the
radiator, oil in the coolant, or when the engine is stopped will allow water to flow into the
cylinder and result in major engine damage due to water in the oil or hydraulic lockup.
1. Inspect the cylinder liner.

a. Check the cylinder liner for cracks or scoring. If cracks or scoring are present, replace the
liner.
b. Check the cylinder liner for cavitation. If indication of cavitation is present, replace the
liner.
c. Check for bore polishing; if detected, replace the cylinder liner.
2. Inspect the outside diameter of the liner.
a. Check the liner for fretting.
b. If any fretting is found, remove it from the surface of the liner with a course, flat stone.
3. Inspect the liner flange in two steps:
a. Inspect the top surface of compression seal for cracks, smoothness and flatness.
b. Inspect the balcony (bottom stop).
4. Inspect the block bore and cylinder liner.
a. Measure the block bore and the outside diameter of the liner.
b. If the liner does not meet specification, replace with a new part.
------------- A --------------- ►
B ----------- -
1 d010113
Location DD13 DD15 DD16
158.98 166.98 166.98

to 159 to 167 to 167
A mm mm mm
(6.2590 (6.5740 (6.5740
to to to
6.2598 6.5748 6.5748

in.) in.) in.)

141.97 148.95 148.95
to to to
141.95 148.97 148.97
mm mm mm
B
(5.589 (5.864 (5.864
to to to
5.588 5.865 5.865
in.) in.) in.)
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.

19.4 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.
1. If cleaning a new or used liner, use a clean cloth and clean engine oil.
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pressure.
2. Dry the liner with compressed air.
NOTICE:
If the liners are not to be installed at this time, oil them lightly with clean engine lubricating
oil and store them upright in a clean, dry area. Do not let the liners rest on their sides and do
not store anything on top of the liners.
3. Coat the bore of the liner with clean engine lubricating oil.
4. Allow the liner to sit for 10 minutes (to allow the oil to work into the surface finish).
5. Wipe the inside of the liner with white paper towels.
6. If a dark residue appears on the towels, repeat the oiling and wiping procedure until residue no
longer appears.

19.5 Installation of the Cylinder Liner
Install as follows:
NOTICE:
Thoroughly clean the cylinder block, liner, and counter bores to remove any foreign
material. Foreign material in the cylinder liner counter bores can cause the liner to seat
improperly. Clean with a wire brush.
1. Wipe the inside and outside of the liner clean.
NOTICE:
Ensure when installed, the seal rings are properly seated in the proper grooves (locations 1
and 3).
2. Install the two new seal rings (1, 3) onto the cylinder liner (2).
3. Lubricate the seal rings with clean engine oil.
4. Install the cylinder liner in cylinder block bore using cylinder liner installation toolJ-45876.
5. Seat the liner into the block using cylinder liner installation tool J-47407 for the DD15 and DD16,
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 lbft).
d010108
7. Install a dial indicator.

8. Measure the distance from the top of the liner flange to the top of the block. Allowable liner
protrusion is 0.18-0.27 mm (0.007-0.010 in.).
a. If the liner protrusion exceeds the maximum allowable, remove the piston and connecting
rod assembly (if installed) and then remove the liner to check for debris under the liner
flange.
b. If the liner protrusion is below the minimum specification, contact Detroit Diesel Customer
Support Center (313-592-5800).

20.1 Description and Operation of the 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. The crankshaft is mounted with seven crankshaft bearing
journals in the crankcase. There are oil holes located at the crankshaft bearing journal and the
connecting rod journal through which the crankshaft bearing and connecting rod bearing are lubricated.
Note: The DD13 engine has four counterweights, the DD15 and DD16 each have eight
counterweights.
Note: The crankshaft throws on the DD16 are longer than on the DD15 crankshaft.
d030002
1. Crankshaft Bearing Journals

2. Connecting Rod Bearing Journals
3. Counterweights (number varies by engine model)
4. Arrows show oil passage locations

d030009
1. Bolt
2. Main Bearing Caps
3. Lower Crankshaft Bearing Shells
4. Lower Connecting Rod Bearing Shells
5. Upper Connecting Rod Bearing Shells
6. Cylinder Block
7. Vibration Damper
8. Upper Crankshaft Bearing Shells
9. Thrust Washer
10. Crankshaft
11. Thrust Washer

1. Bolt
2. Vibration Damper
3. Cover Plate
4. Crankshaft Bearings
5. Connecting Rod Bearings
6. Thrust Washer
7. Bolt
8. Flywheel
9. Ring Gear
10. Crankshaft

20.2 Removal of the Crankshaft
When removal of the crankshaft becomes necessary, first remove the transmission, then proceed as
follows:

2. Drain the cooling system. Refer to OEM procedures.
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3. Drain the lubricating oil. Refer to OEM procedures.
^ ^ W A R N IN G :
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.
4. Attach the cylinder head/engine lifting bar tool (W470589006200) with hooks to the three engine
lifter brackets (one at the front and two at the rear). Remove all engine-to-base attaching bolts and
remove the engine from its chassis.
^ ^ W A R N IN G :
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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 exhaust (right) side of the cylinder block.
Mount the engine to the overhaul stand (J-29109) with adaptor (J-47389-A).

7. Remove the oil pump. Refer to section "Removal of the Oil Pump, Oil Suction Manifold, and Oil
Lines"
8. Remove the flywheel. Refer to section "Removal of the Flywheel"
9. Remove the flywheel housing. Refer to section "Removal of the Flywheel Housing"
NOTICE:
Use care when removing the crankshaft pulley and vibration assembly. If the damper is
allowed to fall, damage to the internal components of the damper may result.
10. Loosen and remove two of the crankshaft pulley retaining bolts and hardened washers 180 degrees
apart and install flywheel guide studs tool (J-36235) in their place. Then loosen and remove the
remaining six pulley retaining bolts and hardened washers.
11. Remove the vibration damper assembly. Refer to section "Removal of the Vibration Damper"
12. Remove the front engine cover. Refer to section "Removal of the Front Engine Cover"
13. Remove connecting rod caps, and/or piston assemblies (if necessary). Refer to section "Removal
of the Piston and Connecting Rod Assembly"
14. Rotate the engine so the crankshaft is facing up.
NOTICE:
Paint-mark the main bearing caps so that they can be installed to their respective, original
positions. The main bearing caps must be kept in sequence, so that they are installed to their
original positions.
15. Loosen and remove the main bearing cap bolts. Using the main bearing cap puller tool (J-48884),
remove the main bearing caps for inspection.
16. Remove the thrust washers from each side of the No. 6 main bearing cap.
17. Remove the crankshaft.

20.3 Inspection of the Crankshaft and Related Parts
Inspect as follows:
1. Inspect the crankshaft for cracks.

2. If the crankshaft shows evidence of excessive overheating, replace the crankshaft since the heat
treatment has probably been destroyed.
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pressure.
3. Clean out the oil passages thoroughly with a stiff wire brush. Clean the crankshaft with fuel oil
and dry it with compressed air.
4. Check the crankshaft journal surfaces for score marks and other imperfections. If excessively
scored, replace the crankshaft.
5. Carefully inspect the front end of the crankshaft in the area of the oil seal contact surface for
evidence of a rough or grooved condition. Any imperfections of the oil seal contact surfaces will
result in oil leakage at these points. If excessively scored, replace the crankshaft.
6. Check the crankshaft thrust surfaces for excessive wear or grooving. If excessively worn, replace
the crankshaft.
7. Inspect the crankshaft gear for damage. Replace if necessary.
8. Check the crankshaft journal run-out.
a. Set journals number 1 and number 7 on a pair of V-blocks
b. Rotate crankshaft and measure journals with a dial indicator
Journal 1 Journal 2 Journal 3 Journal 4 Journal 5 Journal 6 Journal 7
0.040 mm 0.060 mm 0.090 mm 0.060 mm 0.040 mm
On V-block On V-block
(0.0015 in.) (0.0024 in.) (0.0035 in.) (0.0024 in.) (0.0015 in.)
9. Check journals for damage.

10. Check main and rod bearings for wear or scoring. Replace as necessary.
11. Inspect the thrust washers for wear or scoring. Replace as necessary.
12. Inspect the main cap bolt length. If the length exceeds 200.5 mm (7.89 in.), replace the bolt.
13. Inspect the cylinder block journals. Refer to section "Inspection of the Main Bearing Bores"

20.4 Installation of the Crankshaft
Install as follows:
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pressure.
1. Steam clean the crankshaft to remove the rust preventive and blow out the oil passages with
compressed air.
2. Install the upper main bearing shells in the block. If the old bearing shells are to be used again,
install them in the same locations from which they were removed.
Note: When a new crankshaft is installed, ALL new main and connecting rod (upper and lower)
bearing shells and new thrust washers must also be installed.
3. Install the thrust washer upper halves in the counterbores on either side of the No. 6 bearing
saddle. Coat the backs of the thrust washers (without oil grooves) with petroleum jelly and install
with the oil-grooved sides facing away from the saddle.
4. Apply clean engine oil 360 degrees around all crankshaft bearing journals and install the
crankshaft.
Note: The main bearing caps are bored in position and stamped with position number. They
must be installed in their original positions, with the marked (numbered) side of each cap
toward the cooler side of the cylinder block.
5. Install the lower main bearing shells in the main bearing caps as follows:
a. Align the tang on the lower main bearing shell with the groove in the main bearing cap.
Install the bearing shell to the main bearing cap.
b. If the old bearing shells are to be used again, install them in the same bearing caps from
which they were removed.
6. Check main bearing cap bolt length.
DD13 175.5 mm (6.909 in.)
DD15 and DD16 200.5 mm (7.894 in.)
7. Install the main bearing caps together with lower bearing shells in place.
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).
10. Check the crankshaft end play as follows:
a. Move the crankshaft toward the gauge with a small 304 mm (less than 12 in.) pry bar. Keep
a constant pressure on the pry bar and zero the pointer on the dial indicator.
b. Remove and insert the pry bar on the other side of the bearing cap. Force the crankshaft in
the opposite direction and note the amount of end play on the dial.
c. The end play should be 0.099-0.419 mm (0.0039 -0.0165 in.). Insufficient end play can be

the result of a misaligned No. 6 main bearing, a misaligned upper thrust washer or a burr or
dirt on the inner face of one or more of the thrust washers.
Note: If the bearings have been installed properly, the crankshaft will turn freely with all of the
main bearing cap bolts drawn to the specified torque.
11. For the DD13; torque all of the main bearing cap bolts, in three steps, using the sequence shown
below. Torque the main bearing cap bolts to:
a. 150 N m (110 lb ft)
b. 300 N m (221 lb ft)
c. 90° torque turn
12. For the DD15 and DD16; torque all of the main bearing cap bolts, in four steps, using the
sequence shown below. Torque the main bearing cap bolts to:
a. 50 N m (110 lb ft)
b. 250 N m (184 lb ft)
c. 1st 90° torque turn
d. 2nd 90° torque turn
13. Install the piston and connecting rod assemblies. Refer to section "Installation of the Piston and
Connecting Rod Assembly"
14. If removed, install the cylinder head.
Refer to section "Installation of the DD13 Cylinder Head"
Refer to section "Installation of the DD15 and DD16 Cylinder Head"
15. If removed, install the camshaft housing. Refer to section "Installation of the Camshaft Housing"
16. If removed, install the gear train. Refer to section "Installation and Timing of Engine Gear Train"
17. Install the flywheel housing. Refer to section "Installation of the Flywheel Housing"
18. Replace the rear crankshaft oil seal with new seal. Refer to section "Installation of the Rear
Crankshaft Oil Seal"
19. Install the flywheel. Refer to section "Installation of the Flywheel"
20. Install the oil pump, inlet and outlet pipes. Refer to section "Installation of the Oil Pump, Oil
suction Manifold, and Oil Lines"
21. Replace the front crankshaft oil seal with new seal. Refer to section "Installation of the Front
Crankshaft Oil Seal"
22. Install the crankshaft pulley and vibration damper assembly. Refer to section "Installation of the
Vibration Damper"

^ ^ W A R N IN G :
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24. Use a cylinder head/engine lifting bar tool (W470589006200) with hooks attached to the lifting
brackets at each end of the engine and remove the engine from the overhaul stand.
25. Remove the overhaul stand adaptor plate from the engine block.
26. Install any accessories that were removed.
27. Install the engine to the equipment from which it was removed.
30. After replacing the main or connecting rod bearings or installing a new crankshaft, verify repairs.

21.1 Removal of the Rear Crankshaft Oil Seal
Remove as follows:
1. Remove the flywheel from the flywheel housing (1).
W470 589 00 4300

d010053
NOTICE:
When drilling pilot holes in the seal, ensure that the drill is straight and perpendicular to the
seal. Failure to drill the holes straight could result in damage to the seal bore, resulting in
replacement of the flywheel housing.
Note: When drilling the holes for screws, make sure to coat the drill bit with grease to catch the
shavings.
2. Drill 3.174 mm (0.125 in.) pilot holes in the seal (2); use the sheet metal screws and the rear
crankshaft seal Installer remover tool (W470589004300); remove and discard the oil seal (2).
___________________________________________________________ Printed Sat Feb 19 09:51:57 2011

21.2 Installation of the Rear Crankshaft 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.
Note: For ease of installation into the flywheel housing, apply a light coating of a soapy water
solution to the outer diameter (2) of the seal.
2. Install the new rear seal (2) onto the rear crankshaft seal installer (w470589004300).
3. Position the seal into the flywheel housing (1).
4. Install the seal by turning the forcing screw until the tool bottoms out on the end of the crankshaft.
5. Remove tool (W470589004300) and visually check the seal and sealing lip for correct installation.
6. Install the flywheel into the flywheel housing (1). Refer to section "Installation of the Flywheel"

21.3 Removal of the Front Crankshaft Oil Seal
Remove as follows:
1. Remove the poly-V-belts. Refer to section "Removal of the Poly-V-Belts"

2. Remove the vibration damper pulley. Refer to section "Removal of the Vibration Damper"
3. Install front crankshaft seal installer / remover tool (W541589023300).
NOTICE:
When drilling pilot holes for the removal of seal, ensure that the drill is straight and
perpendicular to the seal. Failure to drill the hole straight could result in damage to the seal
bore, resulting in the replacement of the front cover.
Note: When drilling the holes for screws, make sure to coat the drill bit with grease to catch the
shavings.
Note: Handle the new seal with care. Do not bend the seal lip; bending the lip will damage the
seal and cause it to leak.
4. Drill 3.174 mm (0.125 in) pilot holes in the seal, use the sheet metal screws and tool
W541589023300; remove the seal and discard the seal.

21.4 Installation of the Front Crankshaft Oil Seal
Install as follows:
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pressure.
Note: The standard size front seal has an inside diameter of 100 mm (3.937 in.).
Note: Handle the new seal with care. Do not bend the seal lip; bending the lip will damage the seal
and cause it to leak.
1. Use air to clean the sealing surfaces on the cover and crankshaft.
Note: Seal lip should face outward for proper installation.
Note: For ease of installation into the front cover, apply a light coating of a soapy water
solution to the outer diameter (1) of the seal.
2. Install a new seal onto plastic seal installation tool.
Note: The plastic seal installation tool is a one time use item; discard after using.
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 the front crankshaft seal installer/remover tool (W541589023300) to the crankshaft.
d010063a
5. Install the seal by turning the forcing screw until the tool bottoms out on the end of the crankshaft.

6. Remove the tool and visually check the seal and sealing lip for correct installation. The seal lip
should face outward when installed correctly.
7. Install the vibration damper pulley and torque the eight bolts to 200 N m (147.5 lb ft). Refer to
section "Installation of the Vibration Damper"
8. Install the poly-V belts. Refer to section "Installation of the Poly-V-Belts"

22.1 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.
1. Engine Brake
2. Turbocharger
3. Crankcase Breather
4. Oil Pump
5. Pressure Valve
6. Backflow Valve
7. Suction Pipe
8. Oil Spray Nozzle
9. Oil Cooler and Housing
10. Oil Filter
11. Oil Refill
12. Intake Rocker Arm Supply Spindle
13. Engine Brake Supply
14. Exhaust Rocker Arm Supply Spindle
15. Gear Train Oil Supply
16. Main Bearing Supply

1. Engine Brake
2. Turbocharger
3. Axial Power Turbine
5. Oil Pump
6. Pressure Valve
7. Backflow Valve
8. Suction Pipe
9. Oil Spray Nozzle
10. Oil Cooler and Housing
11. Oil Filter
12. Oil Refill
13. Intake Rocker Arm Spindle Supply
14. Engine Brake Supply
15. Exhaust Rocker Arm Spindle Supply
16. Gear Train Oil Supply
17. Main Bearing Supply

___________________________________________________________ Printed Sat Feb 19 09:54:49 2011

23.1 Description and Operation of the 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. The oil pan seal has high sealing reliability and noise reduction. In order to
determine the engine oil level, there is a conventional oil dipstick.
d010029
1. Bolt and Isolator

2. Oil Pan
3. Gasket
4. Bolt
5. Bolt
6. Nut
7. Bracket
8. Clamp
9. Bolt
10. Bolt
11. Bracket
12. Bracket
13. Dipstick and Tube
14. Clamp
15. Adapter

16. Seal
17. Threaded Insert
18. Seal Ring
19. Connecting Nut
20. Seal Ring
21. Drain Plug

23.2 Removal of the Oil Pan
Remove as follows:
1. Open the oil filter and cap.

2. Remove the drain plug and drain the engine oil.
3. Remove the dipstick.
Note: The oil pan dipstick tube adaptor cannot be removed from the oil pan or damage may
occur.
4. Loosen the dipstick tube on the oil pan. Refer to section "Removal of the Oil Dipstick Tube"
5. Remove the bolt at the harness P-clip on the front center of the oil pan.
6. Loosen the eighteen oil pan bolts. The bolts will remain installed to the pan.
7. Remove the oil pan, taking care not to damage the oil pump inlet pipe and screen.
8. Remove the oil pan seal and check for damage.

23.3 Cleaning of the Oil Pan
Clean as follows:
1. Clean the oil pan and attaching hardware with clean fuel oil or solvent.
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pressure.
2. Dry with compressed air.
NOTICE:
Do not use solvents to clean gaskets. Damage to the gasket will result.
3. Clean the surfaces the cylinder block, all four T-joints, front cover, oil pan, and flywheel housing
where they mate.
___________________________________________________________ Printed Sat Feb 19 09:56:44 2011

23.4 Inspection of the Oil Pan
Inspect as follows:
1. Check bolts and isolator assemblies for dryness, tears, or damage. Replace as necessary.
2. Check oil pan for dents, cracks or damage. Replace as necessary.
3. Inspect threaded inserts for cracks or damage. Replace as necessary.
4. Clean seals and lubricate seal grooves (if applicable) with clean fuel oil and inspect for cracks or
tears. If damage is found, replace oil pan.

23.5 Removal of the Threaded Insert (Plastic Oil Pan Only)
Remove as follows:
2. Remove threaded insert using Snap-On® tool GLD139, or equivalent. Discard O-ring.
| Printed Sat Feb 19 09:57:31 2011

23.6 Installation of the Threaded Insert (Plastic Oil Pan Only)
Install as follows:
1. Install new O-ring on threaded insert.

2. Install threaded insert into oil pan.
3. Install threaded insert connecting nut and torque to 100 N m (73 lb ft).

23.7 Installation of the Oil Pan
Install as follows:
1. When a plastic oil 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. For best results, install the seal at each corner, then at points half way
between the corners. Continue in this manner, halving the distance and seating the seal.
2. For the aluminum oil pan, place the gasket on the top of the pan.
5. Ensure the joint surfaces of the gear case, the cylinder block, and front cover are cleaned and there
is no damage that could prevent sealing.
6. Install the oil pan assembly in position on the cylinder block.
NOTICE:
Bolt grade must be determined by a marking on the bolt head. Grade 8.8 oil pan bolts cannot
be torqued above 25 N m (18 lb ft) or damage to the bolt will occur.
7. Ensure that the seal has not been disturbed. Torque the eighteen oil pan bolt assemblies to the
torque specified below, using the proper sequence.
8. Install the oil pan drain plug and torque the plug to 45 N m (33 lb ft).
9. Install bolt at harness P-clip on the front center of the oil pan.
10. Install the dipstick.
11. Install the oil filter and cap. Torque to 55 N m (40 lb ft).
12. If oil pump was removed,Refer to section "Installation of the Oil Pump, Oil suction Manifold, and
Oil Lines"
13. Prime the lubrication system. Refer to section "Priming the Engine Lubrication System"
14. Refill the oil pan with lubricating oil. Refer to section "Engine Oil Capacities"

^ ^ W A R N IN G :
ENGINE EXHAUST
15. Start the engine and inspect for leaks.

24.1 Description and Operation of the 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. The oil dipstick tube and oil pan adaptor allow the dipstick to extend into the oil. The oil
level is observed by removing the dipstick and reading the oil level.
d010102
1. Upper Dipstick Stabilizing Bracket (DD15/DD16 only)

2. Dipstick
3. Lower Dipstick Bracket
4. Oil Dipstick Tube
5. Hose Clamp
6. Oil Pan Adaptor
Printed Sat Feb 19 09:58:43 2011|


24.2 Removal of the Oil Dipstick Tube
Remove as follows:
1. Loosen the hose clamp (6) attaching oil dipstick tube (2) to the oil pan adaptor.
2. Remove all P-clips (4) attaching oil dipstick tube to bracket (1) and upper bracket on the DD15
and DD16.
___________________________________________________________ Printed Sat Feb 19 09:59:25 2011

24.3 Installation of the Oil Dipstick Tube
Install as follows:
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.
3. Tighten the hose clamp (6) attaching the oil dipstick tube to the adaptor.

25.1 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.
A crankshaft drive gear drives the oil pump drive gear. The oil pump drive gear drives the two impellers
within the oil pump housing. The rotational movement of the impellers and the design of the pump
chamber suctions the engine oil from the oil pan, through oil strainer to the oil pump inlet. The engine
oil is delivered under pressure to the oil pump outlet, to the oil pump pressure line and then through the
return flow check valve to the main oil duct, into the engine oil circuit. The pressure regulator valve
regulates engine oil pressure. The pressure regulator valve has the oil pressure applied to it from the
engine oil in the main oil duct. Excess engine oil is fed by the pressure regulator valve to the suction
side according to the oil pressure in the main oil duct. This regulates the engine oil pressure and reduces
the operating energy input of the oil pump. High pressures in the oil circuit are avoided using the safety
valve. High pressure can occur in the cold start phase o f the engine if the engine oil is not yet of
sufficient viscosity. The safety valve opens at a pressure >10 bar and directs part of the engine oil back
into oil pan.

25.2 Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines
Remove as follows:
1. Remove oil drain plug from the oil pan and drain the oil.
3. Remove the four bolts (2) securing the oil suction manifold (1) to the engine block (3).
d180008
4. Remove the oil suction manifold (1), oil lines (6 and 11) and O-rings (5 and 10). Discard the O-
rings.
5. Remove the three bolts (7) securing the oil pump (9) to the engine block (3) and remove the oil
pump assembly (8 and 9) from the engine block.

25.3 Inspection of the Oil Pump, Oil Suction Manifold, and Oil Lines
Inspect as follows:
^ ^ C A U T IO N :
protection (face shield or safety goggles) and do not exceed 40 psi (276 kPa) air
pressure.
1. Wash all parts in clean fuel oil and dry them with compressed air.
2. Clean the suction and pressure pipe and screen in clean fuel oil and blow dry with compressed air.
___________________________________________________________ Printed Sat Feb 19 10:01:10 2011

25.4 Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines
Install as follows:
1. Check the oil pump part number to be sure it is correct for this application.
2. Position the oil pump on the cylinder block so that the drive gear of the oil pump meshes with the
crankshaft gear.
3. Install oil pump with three bolts. Torque the bolts to 30 N m (22 lb ft).
4. Install oil lines with new O-rings on each end.
5. Install four bolts and secure the oil intake manifold to the cylinder block. Torque the bolts to 60
N m (44 lb ft).

26.1 Description and Operation of the 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. The gases from the crankcase
contain engine oil that can lead to adverse effects on engine emission levels.
The blow-by gas produced by the engine passes into the blow-by gas inlet in the crankcase breather
housing. In the housing, the blow-by gas flows to the centrifuge. The centrifuge drive gear is driven by
pressurized engine oil, causing the centrifuge to turn. The centrifugal force that is created causes the
blow-by gas to be pushed against the inside wall of the housing. The engine oil contained in the blow-by
gas runs along the inside wall downwards and flows to the outlet for the engine oil that has been
separated back into the oil pan. The cleaned blow-by gas flows to the outlet for blow-by gas to the
atmosphere. The crankcase breather is maintenance free for the working life of the component.

1. Bolt
2. Gasket
3. Outlet Tube
4. Bolt
5. Gasket
6. Gasket
7. Inlet Tube
8. Bolt
9. Bolt
10. Seal
1 ^
d010043a
1. Bolt
2. Crankcase Breather Housing

3. Gasket
4. Threaded Fitting
5. Breather Pipe
6. Screw
7. Bracket
8. O-ring
9. Screw
10. Speed Sensor
11. O-ring

26.2 Removal of the Crankcase Breather
Remove as follows:
1. Disconnect speed sensor electrical harness connection, on EPA10 engines, from the crankcase
breather and unclip the electrical harness from the crankcase breather assembly.
Note: Note orientation of bracket located on top bolt.
2. On EPA07 engines, remove the two bolts and gasket from the breather pipe. Discard gasket.
3. On EPA10 engines, disconnect the quick-connect fitting at the cylinder block.
4. Remove the four bolts and gasket from the crankcase breather and remove crankcase breather
from the cylinder block. Discard the gasket.
| Printed Sat Feb 19 10:02:29 2011

26.3 Inspection of the Crankcase Breather
Inspect as follows:
1. Clean the gasket surface of the engine block prior to installation of crankcase breather.
2. Inspect the tubes, clamps and hoses for wear or damage; replace if necessary.
3. Inspect the crankcase breather for cracks or damage; replace if necessary.
4. Inspect the sensor and replace, if necessary.

26.4 Installation of the Crankcase Breather
Install as follows:
1. Install the crankcase breather to the engine block with a new gasket and four bolts. Torque the
bolts to 60 N m (44 lb ft).
2. On EPA07 engines, install the breather pipe and new gasket to the engine block. Torque the two
3. On EPA10 engines, snap the breather pipe to the fitting on the cylinder block.
^ ^ W A R N IN G :
ENGINE EXHAUST
^ ^ W A R N IN G :
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of
California to cause cancer, birth defects, and other reproductive harm.
o Always start and operate an engine in a well ventilated area.

o If operating an engine in an enclosed area, vent the exhaust to the outside.
o Do not modify or tamper with the exhaust system or emission control
system.
4. Connect electrical harness, if equipped.


27.1 Replacement of the Oil Filter
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. After draining is complete, remove the assembly from the housing (4).
Note: For EVO Bus, when removing the filter, separate the cap from the filter before pulling
out of the module. Remove as two separate components.
Note: Use care to prevent foreign objects from entering the filter housing.
2. Remove the filter element by pressing and twisting the side and detaching it from the cap. Discard
the filter element.
3. Remove the oil filter O-ring and discard. Lightly coat a new O-ring with clean engine oil and
install it on the filter cap.
4. Check the filter housing for any debris and remove if necessary.
5. Insert a new filter element into the oil filter cap.
6. Insert the filter element and cap assembly into the housing. Torque the capto 40-50 N m (30-37
lbft).
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1071B01.htm 2/19/2011
28.1 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.
___________________________________________________________Printed Sat Feb 19 10:04:39 2011

28.2 Removal of Oil Sample Valve
Remove as follows:
___________________________________________________________ Printed Sat Feb 19 10:05:05 2011
28.3 Installation of the Oil Sample Valve
Install as follows:
1. Install the oil sample valve and washer onto the oil coolant module and torque to 80 N m (59
lbft).
___________________________________________________________ Printed Sat Feb 19 10:05:30 2011
29.1 Removal of the Oil Filler Neck
2. Remove oil filler neck (2) from the oil coolant module (6).
3. Discard O-ring (1).
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1071D01.htm 2/19/2011
29.2 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).
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1071D02.htm 2/19/2011
30.1 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.
Engine oil flows through the oil water heat exchanger and then to the main oil stream feed into the oil
filter unit. Oil flows into the oil filter unit from outside of the oil coolant module through the oil filter
element to the support dome where it is cleaned. The cleaned engine oil flows to the support dome and
main oil flow drain back into the oil circuit.
d180002a
1. Coolant Pump
2. Oil Coolant Module
3. Oil W ater Heat Exchanger
4. Oil Filter Unit
5. Oil Fill

d200008
1. Bolt
2. Pulley
3. Bolt
4. W ater Pump
5. W ater Pump Seal
6. Oil Cooler Module
7. Thermostat Seal
8. Thermostat
9. Bolt

30.2 Removal of the Oil Coolant Module
Remove as follows:
1. Drain the coolant from radiator. Refer to OEM procedures.

2. Open the drain plug (1) on the cylinder block located next to the oil coolant module and drain the
coolant.
3. Remove engine harness connectors from the coolant temperature sensor, intake air temperature
sensor, and throttle valve. Unclip the harness from the oil coolant module.
4. Remove the coolant delivery pipe, mixer pipe, cold boost pipe and throttle valve assembly. Refer
to section "Removal of the Cold Boost Pipe (Charge Air Pipe)"
5. Remove the heater, coolant recovery, and Exhaust Gas Recirculation (EGR) coolant supply hoses
from oil coolant module. Inspect the coolant coupler hose for damage. Discard if damage is found.
6. Disconnect the coolant line from the fuel module to the oil coolant module.
7. Remove the poly-V-belt from the water pump pulley. Refer to section "Removal of the Poly-V-
Belts"
8. Remove the radiator hose from the thermostat housing.
Note: Ensure any remaining coolant is drained from the oil coolant module and from the
cylinder block to prevent coolant from contaminating the engine oil.
9. Remove the radiator support rod and bracket.
10. Remove the oil dipstick tube by removing the two bolts and bracket attaching it to the cylinder
block.
11. Remove eleven bolts securing oil coolant module to engine block and remove oil coolant module.
12. Remove and discard the gasket.

30.3 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.
3. Install new gasket.
4. Install the oil coolant module onto the guide studs and cylinder block.
5. Install eleven bolts and torque to the following:
o 10 N m (7 lb ft)
o Final torque the bolts to 60-65 N m (44-47 lb ft)
6. Remove tool (J-36107). Install the remaining two bolts into the oil cooler module. Torque the
bolts to the following:
o 10 N m (7 lb ft)
o Final torque the bolts to 60-65 N m (44-47 lb ft)
7. Install the dipstick tube and two bolts and torque to 15 N m (11 lb ft).
8. Install the radiator support strut bracket. Torque to 100 N m (74 lb ft).
9. Install the water pump if removed. Refer to section "Installation of the W ater Pump"
10. Install the poly-V-belt to the water pump pulley. Refer to section "Installation of the Poly-V-
Belts"
11. Install electrical engine harness to the sensor.
12. Connect coolant line to fuel module and oil coolant module.
13. Install heater hose to oil coolant module.
14. If open, close the drain plug on the cylinder block located next to the oil coolant module.
Note: Before installing coolant crossover pipe, check the coupler hose for damage. Replace as
necessary.
15. Install Exhaust Gas Recirculation (EGR) coolant delivery pipe and hose to oil coolant module and
tighten the two hose clamps.
16. Install the two EGR coolant delivery pipe bolts to the oil coolant module and torque to 30 N m
(22 lb ft).
17. Install cold boost pipe and four bolts to intake manifold. Torque bolts to 12 N m (9 lb ft).
18. If removed, install mixer tube to cold boost pipe with three bolts. Torque 30 N m (22 lb ft).
19. If removed, install the intake throttle valve to cold boost pipe. Torque bolts to 30 N m (22 lb ft).
20. Fill the coolant system.

31.1 Removal of the Oil Cooler
Remove as follows:
1. Remove the oil coolant module. Refer to section "Removal of the Oil Coolant Module"
2. Remove eight bolts securing the oil cooler to the oil coolant module. Discard O-rings.
| Printed Sat Feb 19 10:07:54 2011

31.2 Inspection and Pressure Testing of the Oil Cooler
Inspect as follows:
1. Inspect the oil cooler sealing surfaces and old gaskets for imperfections.
Note: Damaged gaskets or sealing imperfections may produce symptoms similar to a leaking
oil cooler. Do NOT replace the oil cooler unless it has been confirmed as leaking with this test.
2. Install the pressure test adaptors (W060589009100) over each of the oil passages of the oil cooler
(5), as the DD13, DD15, and DD16 oil cooler leak test setup illustrates, using the supplied
fasteners. Evenly torque fasteners to 10 N m (8 lb ft).
^ ^ W A R N IN G :
EYE INJURY
pressure.
NOTICE:
The pressure regulator and gauge (J-45982-7) are not included in the oil cooler leak test
adaptor kit. This gauge and regulator can be found in the cylinder head and block leak tester
kit (J-45987). If test kit J-45987 was not shipped to your facility as an essential tool, a
suitable air pressure regulator and gauge capable of 275 kPa (40 PSI) is adequate.
3. Connect the pressure hose (4) to the pressure regulator (3) (J-45982-7 or equivalent).
4. Check and ensure that the shutoff valve (2) is in the OFF position. Connect shop air to the
pressure regulator.
5. Set the regulator to zero pressure by pulling up on the adjusting knob and turning counter
clockwise until it stops.
6. Turn shutoff valve to the ON position.
7. Adjust system pressure by pulling up on the adjusting knob and turn clockwise until pressure
reading on gauge is 275 kPa (40 PSI).
NOTICE:
DO NOT connect pressure hose (J-47313-2) to air supply fitting on the oil cooler until the
pressure regulator has been adjusted to 275 kPa (40 PSI) in order to avoid exceeding the
required pressure.
8. Once the pressure regulator has been adjusted, connect the pressure hose to the air supply fitting
on the adaptor plate.
^ ^ W A R N IN G

BURNS
To avoid injury from burning, use lifting tools and heat-resistant gloves when
handling heated components.
9. Submerge the oil cooler completely in a hot water tank for five minutes.
10. In the event of a failed oil cooler, a steady stream of air bubbles will appear from the oil cooler.
Note: Some leakage may occur from the adaptor fittings. Do NOT mistake this for a leaking oil
cooler.
11. Reduce the air pressure and remove the oil cooler test kit components from the oil cooler.
___________________________________________________________ Printed Sat Feb 19 10:08:22 2011

31.3 Installation of the Oil Cooler Oil Cooler
Install as follows:
1. Using new O-rings, install the oil cooler to the oil coolant module.
2. Torque the eight securing bolts to 25-30 N m (18-22 lb ft).
3. Install the oil coolant module. Refer to section "Installation of the Oil Coolant Module"
___________________________________________________________ Printed Sat Feb 19 10:08:39 2011

32.1 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).
4. Using tool W470589030900, remove the thermostat from the oil coolant module housing.
d200053
5. Discard the seal (3) and the O-ring (4).
___________________________________________________________ Printed Sat Feb 19 10:09:01 2011
32.2 Installation of the Oil Thermostat
Install as follows:
1. Install a new O-ring (4) on the oil thermostat (5).
^ d200054
2. Using tool W470589030900, install the thermostat to the oil coolant module housing. Torque to
50 N m (37 lb ft).
d200053
3. Install new seal, install the oil thermostat cover (1) to the oil coolant module (3) using four bolts
(2). Torque the bolts to 30 N m (22 lb ft).
4. Connect the electrical harness to the sensor.

5. Clip the electrical harness to the oil thermostat cover.
33.1 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.
2. If equipped with an oil sample valve, remove the valve and washer.
Note: Tool J-49181 is used to adapt the J-45299 priming pump.
3. Install oil system priming adaptor tool (J-49181) into the oil priming port (1) in the oil coolant
module.
NOTICE:
If chassis application prevents access, a 90-degree or a 45-degree pipe fitting (1/4" NPT) can
be used (if needed) for access.
4. Install the engine pre-lube kit (J-45299) to the fitting adaptor (1).
5. Fill the canister with eight quarts of oil.
6. Open the valve on the primer and start pumping until the container is empty.
7. Fill the container with an additional eight quarts of oil and pump until the canister is empty.
8. The oil system is now primed with sixteen quarts of oil. Pour the remaining oil into the oil filler
until the correct full level is obtained. For quantities, Refer to section "Monitoring the Lubricating
Oil"
9. Close the valve and loosen the fitting; do not completely remove it from the adaptor.
10. Remove the priming adaptor from the oil coolant module with the line attached to keep the oil
from flowing out of the module.

d 180025
11. Install the alien head plug or oil sample valve to the module and torque to 70-80 N m (51-59
lb ft).
^ ^ W A R N IN G :
ENGINE EXHAUST
12. Start the engine and monitor the oil pressure.

13. After the engine oil pressure stabilizes, shut the engine down and check the oil per the oil check
guidelines.

34.1 Description and Operation of the 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
2. Oil Cooler
3. Crankcase
4. Cylinder Head
5. Water Manifold
6. Compressor
7. Exhaust Gas Recirculation Cooler
8. Fuel Cooler
9. Thermostat
10. Fan
11. Radiator
12. Reservoir
13. Coolant Filter
14. Heat Exchanger
15. Filling Valve
16. Pressure Control Valve


18. Trans Cooler
19. Heat Exchanger
20. Doser
21. A97. EGR Actuator
22. B65. 1 Inlet Temp Sensor
23. B65. 2 Outlet Temp Sensor
24. B. Coolant Fill Line
25. E. De-aeration
26. KK. Radiator Circuit
27. KS. Bypass Line
28. M. Engine
29. R. Auto Trans Cooler Flow
30. V. Coolant Feed
31. VA.Clt EGR to Clr Actuator
32. VH. Clt Heat Exchanger
33. VM. Clt to Doser
d200002
1. Water Pump
2. Coolant Filter
3. Short Circuit Line
4. Coolant Return Flow

5. Coolant Outlet to Cooler Circuit

7. Coolant Return Flow
8. Water Manifold
9. Cylinder Head
10. Cylinder Block
11. Air Compressor
12. Fuel Cooler
13. Oil/Water Heat Exchanger
14. Thermostat

35.1 Description and Operation of the Engine W ater 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. The water pump pulley is mounted to the
water pump with five bolts. The water pump is driven by the poly-V-belt that is installed onto the water
pump pulley. The rotary motion of the pulley is transmitted by the hub to the shaft. The shaft drives the
impeller which causes the coolant to circulate in the coolant circuit.
1. Bolt
2. Water Pump Pulley
3. Bolt
4. Water Pump
5. Water Pump Seal

35.2 Removal of the W ater Pump
Remove as follows:

3. Loosen the five bolts securing the water pump pulley to the water pump.
^ ^ W A R N IN G :
PERSONAL INJURY
To avoid injury to hands and fingers from the spring-loaded auto belt tensioner
violently snapping back, do not cut the belt to remove it.
4. Remove the poly-V belt. Refer to section "Removal of the Poly-V-Belts"

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).

35.3 Inspection of the W ater 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. Inspect as follows:
NOTICE:
Before replacing the water pump for a belt noise there are some basic checks that need to be done.
Refer to section "Inspection of the Belt Drive Tensioner System" to correctly determine the cause
of the belt noise.
1. Clean the water pump and surrounding area.

3. Remove the water pump. Refer to section "Removal of the Water Pump"
6. Inspect the bearings in the pump for slop, tight, or a choppy feeling; replace the pump if damaged.
7. Inspect the water pump seal (2) for damage. Replace the seal if damaged.
35.4 Installation of the W ater Pump
Install as follows:
1. Install the water pump seal (5) to the water pump (4).
6
d200057
2. Install the water pump (4) to the oil coolant module (6) with nine bolts (3) and torque to 30 N m
(22 lb ft).
3. Install the water pump pulley (2) to the water pump with five bolts (1) and finger tighten and
install belt.
4. Install the poly-V-belt. Refer to section "Installation of the Poly-V-Belts"
5. Torque the water pump pulley bolts to 25 N m (18 lb ft).
6. Fill the coolant system.
7. Reconnect the batteries.
^ ^ W A R N IN G :
ENGINE EXHAUST
8. Start the engine and inspect for leaks.

36.1 Description and Operation of the 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).

2. Seal
3. Thermostat
The coolant thermostat regulates coolant flow from the engine to the radiator. The thermostat regulates
coolant flow to control the temperature of the coolant within the coolant circuit. The following benefits
result from regulating the coolant at the inlet temperature of the engine:
• Reduced thermal cycling of the engine

• Operating temperature is reached faster
• Emissions are reduced
• Improved vehicle heating
Thermostat Operating Modes
The coolant from the radiator and the radiator bypass mix in the thermostat housing. The thermostat
regulates the temperature of this mixed flow circuit. Three different operating conditions occur due to
the coolant mixed flow temperature:
• Bypass mode: When the coolant mixed flow temperature is below 87°C (188°F), the circulating
thermostat is closed. The coolant circulates through the radiator bypass to the coolant thermostat.
None of the flow passes through the radiator.
• Mixed mode: For a coolant mixed flow temperature above 87°C (188°F) to and less than 95°C
(203°F), the circulating thermostat opens partially and the coolant flows at the same time through
the engine radiator and the radiator bypass to the coolant thermostat.
• Radiator operation: When the coolant inlet temperature is above 95°C (203°F) the circulating
thermostat is completely open. The coolant flows through the radiator to the coolant thermostat.

None of the flow passes through the radiator bypass.
Other minor coolant loops exist in addition to those described above. The flow through these loops are
unaffected by the position of the coolant thermostat. These loops include the flow through the vehicle
cab heater, vehicle bunk heater, the EGR actuator, and the doser.
___________________________________________________________ Printed Sat Feb 19 10:13:19 2011

36.2 Removal of the Engine Coolant Thermostat and Seal
Remove as follows:
^ ^ W A R N IN G :
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. Wear adequate protective
clothing (face shield, rubber gloves, apron, and boots). Remove the cap slowly to relieve
pressure.

2. Remove the plug on the cylinder block below the oil coolant module to drain the remaining
coolant.
3. Loosen hose clamp at the thermostat.
4. Remove the four thermostat housing-to-oil cooler module attaching bolts.
5. Remove the thermostat housing assembly from the oil coolant module and hose.
6. Remove the thermostat housing seal._________

36.3 Inspection of the Coolant Thermostat and Seal
Inspect as follows:
1. Visually inspect all parts for wear or damage.

a. If wear or damage is found, replace parts.
b. If wear or damage is not found, reuse parts.
2. Visually inspect thermostat body seal for damage, cracks or nicks.
a. If any damage is noted, replace seal.
b. If no damage is found, reuse parts.
3. Visually inspect the tip of the thermostat for wear or damage.
a. If wear or damage is found, replace parts.
b. If wear or damage is not found, reuse parts.

36.4 Installation of the Coolant Thermostat and Seal
Install as follows:
1. Install seal (2) onto thermostat housing (3).
d200048
2. Install thermostat into hose and onto oil cooler module (1).
3. Torque four bolts to 30 N m (22 lb ft).
4. Tighten clamp at the hose.
5. Fill engine with coolant to the correct level.
^ ^ W A R N IN G :
ENGINE EXHAUST

37.1 Description and Operation of the Coolant Filter
DD Platform engine cooling systems are protected by a coolant filter element that may contain
supplemental corrosion inhibitors.
| Printed Sat Feb 19 10:14:47 2011

37.2 Removal of the Coolant Filter
Remove as follows:
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.

37.3 Installation of the Coolant Filter
Install as follows:
1. Install a new O-ring (2) onto the cap.
-1
-2
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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).
___________________________________________________________ Printed Sat Feb 19 10:15:35 2011

38.1 Removal of the Coolant Filter Service Module
Remove as follows:

2. Remove the hose clamps and then remove the hoses.
3. Remove the 10 bolts from the coolant filter service module and then remove the coolant filter
service module from the engine.
4. Discard the O-rings (3 and 4) and the seals (5).
G enerated on 0 2 -18-2011
38.2 Installation of the Coolant Filter Service Module
Install as follows:
1. Install new O-rings (3 and 4) and seals (5). Lubricate with clean coolant.
2. Install the coolant filter service module on the oil cooler module.
3. Install the 10 bolts and torque to 37 N m (27 lb ft).
4. Install hoses and hose clamps.
5. Fill coolant to appropriate level.
^ ^ W A R N IN G :
ENGINE EXHAUST
6. Start engine and check for leaks.

39.1 Removal of the Coolant Inlet Elbow
Remove as follows:

2. Remove two bolts (1) from the coolant inlet elbow (2).
3. Remove the coolant inlet elbow (2) from the coolant service filter module (4).
4. Remove and discard the O-ring (3).
39.2 Installation of the Coolant Inlet Elbow
Install as follows:
1. Install a new O-ring (3).

2. Install the coolant inlet elbow (2) to the coolant filter service module (4) with two bolts (1).
3. Torque bolts to 30 N m (22 lb ft).

4. Fill coolant to appropriate level.
^ ^ W A R N IN G :
ENGINE EXHAUST
5. Start engine and check for leaks.

40.1 Description and Operation of the Flywheel, Flywheel Housing and

Related Parts
This section explains the description(s) and operation(s) of the following components:
• Flywheel
• Ring Gear
• Flywheel Housing
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.
Ring Gear
The steel ring gear and flywheel is a two-piece assembly. Prior to assembly, the ring gear is heated to
expand its diameter. It is then installed onto the flywheel and allowed to cool. After the ring gear cools,
it contracts onto the flywheel, locking it in place.

1. Steel Ring Gear

2. Flywheel
Flywheel Housing
The flywheel housing is a one-piece aluminum casting mounted against the rear of the engine. It
provides a cover for the gear drive and houses the flywheel. The crankshaft rear oil seal, which is
pressed into the housing, may be removed or installed without removing the housing.
The power steering pump on some applications may be mounted on the flywheel housing. An engine
barring or locking device can be attached at the opening on the bottom of the flywheel housing. This
allows the engine to be barred or locked for maintenance or repair work.

1. Gasket
2. Seal
3. Stud
4. Stud
5. Access Hole Cover
6. Nut
7. Flywheel Housing
8. Cover
9. Bolt (2)

1. Bolt M10 x 90 (3 qty.)

2. Bolt M14 x 1.5 x 70 (1 qty.)
3. Bolt M14 x 1.5 x 90 (6 qty.)
4. Bolt M10 x 45 (6 qty.)
5. Gasket (1 qty.)
6. Cover (1 qty.)
7. Bolt M8 x 30 (2 qty.)
8. Bolt M14 x 1.5 x 180 (1 qty.)
9. Bolt M8 x 45 (2 qty.)
10. Flywheel Housing
11. Gasket
12. Stud (1 qty.)
13. Nut M12-10 (1 qty.)
14. Cover
15. Bolt (2 qty.)

40.2 Removal of the Flywheel Housing
Remove as follows:
1. Drain engine oil and remove the oil pan.

2. Remove the doser injector feed line.
3. Remove the Crankshaft Position (CKP) sensor. Refer to section "Removal of the Crankshaft
Position Sensor"
5. Remove two bolts securing exhaust pipe bracket to flywheel housing.
6. For the DD15 and DD16; remove the clamp from the exhaust pipe and the axial power turbine and
then remove exhaust pipe.
A
BODILY INJURY
To avoid injury from a falling component, ensure a proper lifting device is used.
Never stand beneath a suspended load.
7. Support the engine by placing suitable jack stands under the cylinder block pan rails. Make sure
not to damage the sealing surfaces of the oil pan rails.
8. Remove the rear engine mounts from the flywheel housing. Refer to the applicable vehicle service
manual.
9. Thread two guide stud tools (J-43431) for the 14 mm bolts, into the cylinder block.
10. Remove the remainder of the bolts that secure the flywheel housing to the cylinder block.
11. Strike the front face of the housing alternately on each side with a soft hammer to loosen and work
it off the dowel pins.
12. Remove and discard the flywheel housing gasket.
13. Remove all sealing material from the flywheel housing.

40.3 Inspection of the Flywheel Housing and Rear Oil Seal Area of
Crankshaft
Inspect as follows:
1. Inspect flywheel housing for cracks and any other damage.

a. Check sealing surface for damage.
b. Check flywheel housing for cracks.
c. If damaged or cracked, repair is not possible; replace the part.
2. Inspect the flywheel where the rear oil seal makes contact. Check for groove in flywheel; if
grooved, replace flywheel.

40.4 Installation of the 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.
3. Install all of the housing bolts in their proper location; finger-tighten them.
1 ^
d030006
1. Bolt, M8 x 16 (2 qty.) 30 N m (22 lb ft)

2. Bolt, M14 x 1.5 x 90 (6 qty.) 120 N m (88 lb ft)
3. Bolt, M10 x 45 (6 qty.) 60 N- m (44 lbft)
5. Bolt, M14 x 1.5 x 180 (1 qty.) 120 N- m (88 lbft)
7. Bolt, M8 x 30 (2
qty.) 30 N- m (22 lbft)
8. Bolt, M14 x 1.5 x 70 (1 qty.) 120 N- m (88 lbft)
9. Stud, (1 qty.)
10. Nut, M12-10 (1 qty.) 100 N- m (74 lbft)
4. Remove the guide studs.
5. Torque the flywheel housing bolts using the sequence and torque shown.

6. Install the rear engine mounts to the flywheel housing.

7. Remove the jack stands and any other supports used to support the engine.
8. Inspect the crankshaft rear main oil seal. If any damage is found, replace as necessary.
9. Install the flywheel. Refer to section "Installation of the Flywheel"
10. For the DD15 and DD16; install the exhaust pipe and bracket to the flywheel housing and axial
power turbine. Install two bolts into the bracket and flywheel housing. Install a clamp onto the
exhaust pipe and axial power turbine.
11. Install the crankshaft position sensor. Refer to section "Installation of the Crankshaft Position
Sensor"
12. Install the oil pan and fill the engine with new oil.
13. Prime the lubrication system. Refer to section "Priming the Engine Lubrication System"

40.5 Removal of the Flywheel
Remove as follows:
1. Remove the Crankshaft Position Sensor (CKP). Refer to section "Removal of the Camshaft
Position Sensor"
2. Remove eleven of the twelve flywheel attaching bolts, leaving one bolt at the 12 o'clock position.
3. Install two flywheel guide studs (J-41672) through the flywheel and into the crankshaft at the 3
and 9 o'clock positions.
4. Attach the flywheel lifting tool (J-25026) or some other suitable lifting device, to the flywheel.
^ ^ C A U T IO N :
FALLING FLYWHEEL
To avoid injury from a falling flywheel when removing the last bolt, hold the
flywheel against the crankshaft by hand to prevent it from slipping off the
crankshaft. The flywheel is not doweled to the crankshaft.
5. Attach a chain hoist to the lifting tool.

6. Loosen, but do not remove the last flywheel attaching bolt.
7. Lift lightly on flywheel using lifting device and remove last bolt.
A
BODILY INJURY
To avoid injury from a falling component, ensure a proper lifting device is used.
Never stand beneath a suspended load.
8. Remove flywheel.

40.6 Inspection of the Flywheel
Inspect as follows:
1. Inspect the clutch contact base of the flywheel.

a. Check clutch contact base for scoring, wear, or cracks.
b. The flywheel may be re-faced if the clutch contact face is scored or worn.
c. The flywheel must be replaced if the clutch contact face shows cracks.
2. Inspect the ring gear.
a. Check ring gear for excessively worn or damaged gear teeth.
b. If damaged gear teeth are detected, replace the ring gear.
3. Inspect crankshaft and flywheel contact surface.
a. Check the butt end of the crankshaft and flywheel contact surface for damage.
b. Lightly stone the contact surface to remove any fretting, brinelling, or burrs.

40.7 Installation of the 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.
2. Properly attach the flywheel lifting tool to the flywheel. Using a chain hoist, position the flywheel
in the flywheel housing.
Note: Be sure to line up the locating pin hole with the pin on the crankshaft.
3. Align the flywheel bolt holes with the crankshaft bolt holes.
4. Remove the flywheel lifting tool and guide studs.
Note: Clean engine oil must never be used between two surfaces where maximum friction is
desired, as between the crankshaft and the flywheel.
5. Apply clean engine oil to the threads and to the bolt head contact area (underside) of the
remaining bolts. Any excess must be wiped off.
6. Install the flywheel lock J-46392 or W470589046300.
Note: Maximum flywheel bolt length for reuse is 88mm, if bolt length exceeds this, replace the
used bolts with new bolts.
7. Install the bolts and torque them to 200-220 N m (147-162 lb ft) and then an additional 90° to
100° torque turn.

40.8 Removal of the Ring Gear
Remove the ring gear as follows:
safety steps.
2. Remove the transmission.
4. Using an acetylene torch, cut the ring gear U to % of the way through, without allowing the flame
to touch the flywheel.
5. The uncut portion will now yield. Tap the ring gear to remove it from the flywheel.

40.9 Installation of the Ring Gear
Install as follows:
1. Support the flywheel, ring gear side up, on a solid flat surface.
^ ^ W A R N IN G :
BURNS
To avoid injury from burning, use lifting tools and heat-resistant gloves when
handling heated components.
NOTICE:
Do not, under any circumstances, heat the gear over 204°C (399°F). Excessive heat may
destroy the original heat treatment. Heat treating crayons which are placed on the ring gear
and melt at a predetermined temperature, may be obtained from most tool vendors. Use of
these crayons will ensure against overheating the gear.
2. Rest the gear on a flat metal surface. Heat the gear uniformly with an acetylene torch, keeping the
torch moving around the gear to avoid hot spots.
3. Use a pair of tongs to place the gear on the flywheel with the chamfer, if any, facing the same
direction as on the gear just removed.
4. Tap the gear in place against the shoulder of the flywheel. If the gear cannot be tapped into place
readily so that it is seated all the way around, remove it, and apply additional heat.
5. Once the ring gear is installed, install the flywheel. Refer to section "Installation of the Flywheel"
6. Install the transmission.

41.1 Description and Operation of the Front Engine Mount/Radiator

Support and Related Parts
The front engine mount/radiator support is mounted to the cylinder block with four bolts.
d 2 20 00 0
1. Front Engine Mount/Radiator Support

2. Bolts
3. Engine Block
Printed Sat Feb 19 10:22:48 20~TT1

41.2 Removal of the Front Engine Mount/Radiator Support
Remove as follows:

2. Remove the Charge Air Cooler (CAC) hoses.
3. Remove the air cooling components. Refer to OEM guidelines.
4. Remove the four bolts securing the front engine mount/radiator support and remove front engine
mount/radiator support.

41.3 Inspection of the Front Engine Mount/Radiator Support
Inspect as follows:
1. Inspect the front engine mount/radiator support for damage; replace as necessary.

41.4 Installation of the Front Engine Mount/Radiator Support
Install as follows:
1. Install the front engine mount/radiator support to the cylinder block with four bolts. Torque bolts
to 250 N m (184 lb ft).
2. Install Charge Air Cooler (CAC) hoses.
3. Install air cooling components refer to OEM guidelines.
4. Fill with coolant to the appropriate levels.

42.1 Removal of the Vibration Damper
Remove as follows:
1. Remove the poly-V-belt. Refer to section "Removal of the Poly-V-Belts"

2. Remove the eight bolts (1) attaching the vibration damper (2) to the crankshaft (4).
3. Using guide studs tool J-43431, remove the vibration damper.

4. Remove the splash ring (3).

42.2 Installation of the Vibration Damper
Install as follows:
1. Install the splash ring (1) with cup-side (2) toward end of crankshaft.
d010112
2. Using guide studs tool (J-43431), install the vibration damper onto the crankshaft.
3. Install the eight bolts attaching the vibration damper to the crankshaft. Torque to 200 N m (147.5
lb ft).
___________________________________________________________ Printed Sat Feb 19 10:25:15 2011

43.1 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.
1. Front Mounting Bracket Bolt (4 qty.)

2. Front Mounting Bracket
3. Vibration Damper Mounting Bolts (8 qty.)
4. Vibration Damper
5. Splash Ring
6. Front Radial Seal
7. Front Cover Mounting Bolts (10 qty.)
8. Front Cover
9. Front Cover Gasket
10. Oil Pan Gasket
11. Oil Pan
12. Oil Pan Mounting Bolts (18 qty.)

43.2 Removal of the Front Engine Cover
Remove as follows:
1. Shut off engine, apply the parking brake, chock the wheels, and perform any other applicable
safety steps.
2. Remove the poly-V-belt. Refer to section "Removal of the Poly-V-Belts"
3. Remove the eight bolts attaching the vibration damper to the crankshaft. Refer to section
"Removal of the Vibration Damper"
4. Remove the splash ring.
Note: The oil pan must be completely removed to clean the gasket and groove to prevent
potential oil leaks.
6. Remove the ten mounting bolts attaching the front engine cover to the cylinder block and remove
the front engine cover.

43.3 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.

43.4 Installation of the Front Engine Cover
Install as follows:
1. Install a new front cover housing gasket on the cylinder block.

2. Install the front cover housing to the cylinder block. Torque the front cover mounting bolts to 60
N m (44 lb ft) in the sequence shown.
d010094
3. Install the oil pan to cylinder block. Refer to section "Installation of the Oil Pan"
4. Install the splash ring on the front of the crankshaft.
5. If the front crankshaft seal is damaged and requires replacement, replace as necessary. Refer to
section "Installation of the Front Crankshaft Oil Seal"
6. Install the vibration damper and pulley to the crankshaft. Refer to section "Installation of the
Vibration Damper"

44.1 Description and Operation of the 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. A third engine lifter bracket is located on the front which is part of the
Exhaust Gas Recirculation (EGR) system crossover tube.
EPA07 DD13 Lifting Bracket Locations
Below shows the lifting bracket locations for the EPA07 DD13.
18
d000037
1. Venturi
2. Bolt
3. Gasket
4. Mounting Bolt
5. Bolt (6 qty.)
6. Bolt
7. Exhaust Gas Crossover Tube/Lifting Eye
8. Exhaust Gas Connecting Tube
9. Bolt
10. Plate

11. EGR Cooler / W ater Manifold Assembly

12. Coolant Crossover Tube
13. Cylinder Head
14. Bolt
15. Rear Lifting Bracket - Left Side
16. Rear Lifting Bracket - Right Side
17. Mixer Pipe
18. Clamp
19. Connector Hose
EPA10 DD13 Lifting Bracket Locations
1. Venturi
2. Bolt
3. Gasket
4. Mounting Bolt
5. Bolt
6. Bolt (6 qty.)
7. Exhaust Gas Crossover Tube
8. Exhaust Gas Connecting Tube

9. Bolt
10. Plate
11. EGR Cooler / Water Manifold Assembly
13. Cylinder Head
14. Bolt
15. Rear Lifting Bracket - Left Side
16. Rear Lifting Bracket - Right Side
17. Mixer Pipe
18. Clamp
19. Connector Hose
20. Lifting Bracket
EPA07 DD15 Lifting Bracket Location
d000036
1. Venturi
2. Bolt
3. Gasket
4. Bolt
5. Bolt (6 qty.)

6. Bolt
7. Exhaust Gas Crossover Tube/Lifting Eye
8. Exhaust Gas Connector Tube
9. Bolt
10. Plate
12. Water Manifold
14. Cylinder Head
15. Bolt
16. Rear Lifter Bracket - Left Side
17. Rear Lifter Bracket - Right Side
18. Mixer Pipe
19. Clamp
20. Connector Hose
EPA10 DD15 and DD16 Lifting Bracket Location
Below shows the lifting bracket locations for the EPA10 DD15 and DD16.
1. Venturi
2. Bolt

3. Gasket
4. Bolt
5. Bolt
6. Bolt (6 qty.)
7. Exhaust Gas Crossover Tube
8. Exhaust Gas Connector Tube
9. Bolt
10. Plate
12. Water Manifold
14. Cylinder Head
15. Bolt
16. Rear Lifter Bracket - Left Side
17. Rear Lifter Bracket - Right Side
18. Mixer Pipe
19. Clamp
20. Connector Hose
21. Lifter Bracket

44.2 Removal of the Front Engine Lifter Bracket Without Front Engine
Power Take-Off
2. Remove the front engine lifter bracket.
44.3 Installation of the Front Engine Lifter Bracket W ithout 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).
| Printed Sat Feb 19 10:28:20 2011

44.4 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.
3. Remove the two bolts attaching the venturi to the exhaust gas crossover tube/lifting eye.
4. Remove the six bolts attaching the exhaust gas crossover tube/lifting eye to the cylinder head.
5. Remove the bolt attaching the exhaust gas crossover tube/lifting eye to the coolant crossover tube.
6. Remove the bolt attaching the coolant crossover tube to the exhaust gas crossover tube/lifting eye.
7. Slide the exhaust gas crossover tube/lifting eye off the exhaust gas connector tube and remove
from engine.
8. Remove the exhaust gas connector tube from the Exhaust Gas Recirculation (EGR) cooler.

44.5 Installation of the Front Engine Lifter Bracket With Front Engine
Power Take-Off
For EPA07 engines, install as follows:
1. Install a new Exhaust Gas Recirculation (EGR) connector tube, if needed, onto EGR cooler and
install EGR exhaust gas crossover tube/lifting eye to cylinder head.
2. Loosely install six bolts to exhaust gas crossover tube/lifting eye.
3. Install bolt attaching the exhaust gas crossover tube/lifting eye to the coolant crossover tube.
Torque to 30 N m (22 lb ft).
4. Install bolt attaching the coolant crossover tube to the exhaust gas crossover tube/lifting eye.
Torque to 30 N m (22 lb ft).
5. Tighten six exhaust gas crossover tube/lifting eye bolts to cylinder head. Torque to 60 N m (44
lb ft).
6. Slide mixer pipe onto hose with soap and water for ease of installation.
7. Install venturi to exhaust gas crossover tube/lifting eye with a new gasket and two bolts; torque
8. Slide hose onto venturi using soap and water for ease of installation.
9. Install two clamps onto hose and tighten.

44.6 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.
| Printed Sat Feb 19 10:29:23 2011

44.7 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.
| Printed Sat Feb 19 10:29:40 2011

44.8 Installation of the Rear Engine Lifter Brackets
Install 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).
| Printed Sat Feb 19 10:29:57 2011

45.1 Description and Operation of the 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. The fan clutch and the engine fan are driven by one ten-ribbed poly-V-
belt.
The belt tensioners are firmly bolted onto the accessory bracket. The tensioning arms with tensioner
pulleys are turned counterclockwise by the force of the springs to provide the required tension in the
belts. There is a square hole in each tensioning arm to install a L> in socket tool for removal and
installation of the poly-V-belts. The outer poly-V-belt must be removed before removing the inner poly-
V-belt.
1. Crankcase Damper
2. Poly-V-Belt for the Fan

3. Alternator
4. Pulley
5. Poly-V-Belt for Alternator, Refrigerant Compressor and Coolant Pump
6. Tensioner Pulley
7. Refrigerant Compressor
8. Accessory Mounting Bracket
9. Belt Tensioner
10. Fan Clutch
11. Pulley and Spacer
12. Water Pump
13. Idler Pulley Bracket
14. Idler Pulley

45.2 Removal of the Belt Tensioner
Remove as follows:
1. Remove the two poly-V-belts. Refer to section "Removal of the Poly-V-Belts"

2. Remove the three bolts from the tensioner.
3. Remove the tensioner from the bracket.
___________________________________________________________ Printed Sat Feb 19 10:30:53 2011

45.3 Installation of the Belt Tensioner
Install as follows:
1. Install the tensioner to the bracket.

2. Install the three bolts attaching the tensioner to the bracket. Torque to 60 N m (44 lb ft).
3. Install the two poly-V-belts. Refer to section "Installation of the Poly-V-Belts"
___________________________________________________________ Printed Sat Feb 19 10:31:10 2011

45.4 Removal of the Idler Pulley and Idler Pulley Bracket
Remove as follows:

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.

45.5 Installation of the Idler Pulley and Idler Pulley Bracket
Install as follows:
1. Install the idler pulley bracket to the engine.

2. Install the two bolts to the idler pulley bracket. Torque to 60 N m (44 lb ft).
3. Install the idler pulley to the idler pulley bracket. Torque to 60 N m (44 lb ft).

45.6 Removal of the Non-Bracketed Idler Pulley
Remove as follows:

2. Remove the bolt from the idler pulley. Remove the idler pulley and spacer from the engine block.
| Printed Sat Feb 19 10:31:57 2011

45.7 Installation of the Non-Bracketed Idler Pulley
Install as follows:
1. Insert bolt through idler pulley and spacer.

2. Install bolt to engine block. Torque to 60 N m (44 lb ft).
___________________________________________________________ Printed Sat Feb 19 10:32:14 2011

45.8 Removal of the Accessory Mounting Bracket
Remove as follows:

2. Remove the three bolts from the belt tensioner.
3. Remove the belt tensioner from the accessory mounting bracket.
4. Remove the air conditioner compressor. Refer to OEM procedures.
5. Remove the alternator. Refer to OEM procedures.
6. Remove the six bolts attaching the accessory mounting bracket to the engine.
7. Remove the accessory mounting bracket.

45.9 Installation of the Accessory Mounting Bracket
Install as follows:
1. Install the accessory mounting bracket to the engine.

2. Install the six bolts attaching the accessory mounting bracket to the engine. Torque to 60 N m (44
lb ft).
3. Install the alternator. Refer to OEM procedures.
4. Install the air conditioner compressor. Refer to OEM procedures.
5. Install the accessory mounting to the belt tensioner bracket.
6.Install the three bolts to the belt tensioner. Torque to 60 N m (44 lb ft).
7.Install the two poly-V-belts. Refer to section "Installation of the Poly-V-Belts"

46.1 Description and Operation of the Poly-V Belts
The Poly-V belts are used to transmit power or torque from the crankshaft to each of the accessory
components.
These belts are currently constructed of a compound known as EPDM (Ethylene Propylene Diene
Monomer) instead of the typical Neoprene used in the past. The compound is much more elastic by
design, making it very resistant to cracking throughout its lifespan. Because the compound wears much
like a tire does on the road, a visual check of the belt is not a good indicator of belt wear. The proper
method is to measure how much each of the ribs is worn using a calibrated gauge, available from Gates.

46.2 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 six inch extension on
the socket tool to reduce the danger of cracking the tensioner. Apply smooth pressure to tensioner.
Jerking or sudden pressure could cause damage to tensioner.
NOTICE:
Never pre-tension the non-grooved pulley idler arm before the grooved idler pulley arm is pre-
tensioned.
NOTICE:
Never turn the pulley idler arms clockwise.
NOTICE:
When removing the poly-V-belts always remove the belt driving the fan first and then remove the
belt driving the alternator, refrigerant compressor and coolant pump.
NOTICE:
Do not use any type of cleaning solvent to the rubber parts on the tensioner.
1. Install a half-inch extension tool into the square hole (2) on the grooved pulley idler arm (1).
d130029a
2. Turn the grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100 N m
(66-73 lb ft).

d130008
3. Insert an M10x80 bolt (or equivalent pin), into the bracket hole (2) in the idler arm.
4. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position.
5. Remove the poly-V belt.
6. Install a half-inch extension into the square hole (V) on the non-grooved pulley idler arm (1).
7. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100
N m (66-73 lb ft).
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.
10. Remove the belt from the pulleys, then remove the alternator and refrigerant compressor.

46.3 Inspection of the Poly-V-Belts
Unlike neoprene belts, EPDM belts are inspected using the wear of the belt ribs as an indicator of
remaining life in addition to a visual inspection. A precision wear gauge, available from Gates®, is the
preferred method of determining belt wear.
Inspect as follows:
Poly-V-Belt Inspection Concerns

ABRASION CHUNK-OUT
IMPROPER INSTALL CRACKING
PILLING UNEVEN RIB WEAR
MISALIGNMENT GRAVEL PENETRATION
1. Inspect the belt contact surfaces for chips, flaking, cracks and discoloration.
a. If any of the above conditions are present, correct the problem and replace the belt.
b. If the belt is visually OK, Go to step 2.

2. Using the appropriate Gates® belt wear gauge, measure the amount of wear on the belt.
3. Inspect the belt (2) for wear using the gauge (1) as follows:
a. Shut the engine off (key OFF, engine OFF).
b. Place the long end of the tool between the ribs of the worn belt.
d050041
o If the wear gauge (2) is visible above the ribs of the belt, the belt may be reused (1).
o If the wear gauge (2) does not protrude above the ribs (4) of the belt, replace the belt.
d050042
4. Inspect the bearings in the idler pulleys and accessories by rotating the pulleys to look for bearing
slop or choppy feeling bearings.
5. Inspect the tensioner assembly. Is the spring damper damaged or leaking? Is there wear on the
bushing of the alternator side arm? Belt tracking toward the forward side of the pulley (A) may be
evidence of worn bushings.
a. If damage is present, replace the tensioner assembly.
b. If no damage is evident, the tensioner may be reused.

6. Inspect the pulleys for damage and excessive wear. If pulleys or the belts are damaged, change the
damaged pulley and the belt.________________
d 130027
7. Check wear pattern on all idler pulleys.

a. If wear pattern location is incorrect (A), change the pulley and bracket.
b. If wear pattern location is correct (B), idler and bracket can be reused.
http://extranet.detroitdiesel.com/power_service/literature/Content/107/1072E03.htm 2/19/2011

46.4 Installation of the Poly-V-Belts
Install as follows:
Note: If tensioners are pre-tensioned, Go to 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).
3. Insert an M10x80 bolt (or equivalent pin), into the bracket hole in the grooved pulley idler arm.
4. Release the idler arm. The grooved pulley idler arm is now locked in a pre-tensioned position.
5. Install a half-inch extension into the square hole in the non-grooved pulley idler arm bracket.
6. Turn the non-grooved pulley idler arm counterclockwise. Maximum allowable torque is 90-100
N m (66-73 lb ft).
7. Insert an M10x80 bolt (or equivalent pin), into the bracket hole on the non-grooved pulley idler
arm.
8. Release the idler arm. The non-grooved pulley idler arm is now locked in a pre-tensioned position.
9. Install the poly-V-belts onto the pulleys.
10. Ensure the belts are properly installed on the pulleys.
11. Install a half-inch extension into the square hole (V) on the non-grooved idler arm.
12. Turn the non-grooved pulley idler arm counterclockwise until the pin holding the idler arm can be
removed. Remove the pin.
13. Install a half-inch extension into the square hole in the grooved pulley idler arm.
14. Turn the grooved pulley idler arm counterclockwise until the pin holding the grooved pulley idler
arm can be removed. Remove the pin.

47.1 Description and Operation of the Air Compressor
The function of the air compressor is to provide and maintain air under pressure to operate devices in air
brake systems. Detroit Diesel offers two sizes of air compressors. The single cylinder has a displacement
360 cm3 and the two cylinder has a displacement 650 cm3. Both compressors are installed with an
Energy Saving System (ESS) to save fuel.
The air compressor is mounted to the rear of the cylinder block on the left side of the engine.
The engine provides a continuous supply of oil to the compressor. Oil is routed from the oil passage in
the gear case to the compressor oil inlet. The air compressor is designed to permit direct installation of
the compressor onto the gear case. The compressor consists of a water-cooled cylinder head assembly
and an integral air-cooled crankcase assembly. The cylinder head assembly is made up of the cylinder
head, cooling plate and valve plate assembly and uses two sealing gaskets. The cylinder head contains
air and water ports as well as an unloader assembly. A cooling plate is located between the cylinder head
and valve plate assemblies and assists in cooling. The valve plate assembly consists of brazed steel
plates which have valve openings and passages for air and engine coolant to flow into and out of the
cylinder head.
Description and Operation of the Single Cylinder Air Compressor and Related
Parts
1. Bolt
2. Cover
3. O-ring
4. Coolant Return Line Assembly
5. Coolant Inlet Line Assembly
6. Single Cylinder Air Compressor
7. O-ring
8. Gear
9. Nut
10. Clamp (OEM provided)

11. Bolt (OEM provided)

12. Intake Line (OEM provided)
13. Bolt
Description and Operation of the Two Cylinder Air Compressor and Related
Parts
1. Bolt
2. Bolt
3. Bracket
4. Bolt
5. Cover
6. O-ring
7. Coolant Return Line Assembly
8. Coolant Inlet Line Assembly
9. Two Cylinder Air Compressor
10. O-ring
11. Gear
12. Nut
13. Clamp (OEM provided)
14. Bolt (OEM provided)
15. Intake Line (OEM provided)
16. Bolt
Description and Operation of the Unloader Valve
The air compressor is driven by the engine and functions continuously when the engine is in operation.
The function of the unloader valve allows the air compressor to operate in an unloaded state, where the
compressor piston continues to reciprocate, but does not build additional air pressure in the vehicles
compressed air system. Located within the cylinder head, the unloader valve assembly (in conjunction
with the governor) controls whether the air compressor operates in a loaded or unloaded state.

When the vehicle air pressure system is above the minimum threshold, air pressure from the governor
acts on the unloader piston, lifting it off its seat. With the unloader valve unseated, air from the cylinder
flows into a small chamber in the head instead of into the vehicles compressed air system. Air then
cycles between the cylinder and chamber in the head until the unloader valve is seated once again.
Note: Air in piston shuttles back and forth from the piston to the closed room during unloaded
operation.
d 130035
1. Air from Governor Unloader Port

2. Closed Room
3. Unloader Piston Up and Unseated
When the vehicle air pressure system is below the minimum threshold, no air pressure is sent to the
unloader valve. With the unloader valve seated, the air compressor will build air pressure in the vehicle
compressed air system.

5 6 7
d 130036
1. Inlet Valve Closed

2. Valve Plate
3. Cooling Plate
4. Air Discharge Port
5. Air Inlet Port
6. Discharge Valve Open
7. Unloader Port
8. Piston Down and Sealed
Note: The two-cylinder compressor requires two Unloader Valve Service Kits, one for each cylinder.
1. Unloader Cap
2. Gasket
3. Balance Piston
4. Spring

5. Splash Shield
6. O-ring
7. Unloader Piston
8. O-ring
9. O-ring

47.2 Removal of the Air Compressor
Remove as follows:

NOTICE:
Ensure the air pressure has been released from the air lines before removing the lines from
the air compressor.
3. Relieve air pressure from tanks.

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

8. Discard air compressor gasket.

47.3 Inspection of the Air Compressor
Advanced troubleshooting information for the Bendix® air compressor can be found on the Bendix web
site at http:Wwww.bendix.com or call the Bendix Technical Assistance Center at 1-800-AIR-BRAKE,
(1-800-247-2725).
1. Inspect the intake hose adapters for physical damage; make certain to check the adapters at both
ends of the intake hose or tubing.
2. Inspect the intake hose clamps and tighten them if needed.
3. Inspect the intake hose or line for signs of drying, cracking, chafing and ruptures; replace if
necessary.
4. Ensure all metal tubes are tight to the mating fitting.
5. Inspect the metal tubes for any cracks or breaks; replace as necessary.
6. Check the exterior of the compressor for signs of oil seepage. Refer to the troubleshooting for
appropriate tests and corrective action. Check for cylinder head gasket air leakage. Refer to the
Bendix web site for procedure and repair components.

47.4 Installation of the Air Compressor
Install as follows:
1. If removed, install the air compressor gear to the air compressor shaft and secure with nut. Thread
is left-handed; torque nut to 210-250 N m (155-185 lb ft).
2. Clean all foreign material from the mating surfaces of the air compressor and the cylinder block.
NOTICE:
Ensure the correct bolt length is used when the air compressor is installed. If an incorrect
bolt length (too long) is used, the cup plugs installed in the cylinder block can be pushed out
into the gear train causing severe damage to the gear train. The correct bolt length is 35 mm
(1.37 in.).
NOTICE:
Ensure when the air compressor coolant lines are installed that there is an O-ring and an O-
ring retainer installed on both ends of the coolant lines. Ensure that the air compressor
retainer is installed on the coolant line and is pushed down to lock the lines onto the inlet
and outlet ports to the cylinder block, fuel filter module and air compressor. A leak will
occur if the lines are incorrectly installed and the coolant line retainer is not engaged in the
locked position. If the O-ring or the coolant line retainers are missing or removed, replace
the coolant line.
3. Install a new O-ring on the air compressor hub and a new O-ring on the oil supply, and then install
the air compressor on the cylinder block. Torque the four bolts to 60 N m (44 lb ft).
4. Install the coolant supply and return lines to the air compressor.
5. Install the air lines to and from the air compressor. Refer to OEM specifications.

48.1 Removal of the Air Compressor Unloader Valve
Remove as follows:
1. Clean the area surrounding the unloader valve assembly.

Note: For LK-862 two cylinder compressors, retain the original caps for re-assembly. For BA-
921 single-cylinder compressors, discard cap, but retain the splash shield.
2. Hold the unloader cap (1) in place to restrain the spring pressure and remove the two unloader cap
screws. Remove and discard the unloader cap (1) and gasket (2).
3. Remove and discard the balance piston (3) and spring (4) from the cylinder head. Then remove
and discard the unloader piston (7) along with its three O-rings (6, 8, 9).
4. Inspect the cylinder head bore for any scoring or damage. If damage is found, replace the
compressor.

48.2 Inspect of the Air Compressor Unloader Valve
Inspect as follows:
1. Check for leaks at the unloader port. Replace leaking or worn O-rings.
2. Make certain that the unloader system lines are connected properly.
3. Cycle the compressor through the loaded and unloaded cycle several times. Make certain that the
governor cuts-in (compressor resumes compressing air) at a minimum of 105 psi (cut-out should
be approximately 15-20 psi greater than cut-in pressure. Adjust or replace the governor as
required.
4. Note that the compressor cycles to the loaded and unloaded conditions promptly. If prompt action
is not noted, repair or replace the governor and/or repair the compressor unloader.

48.3 Installation of the Air Compressor Unloader Valve
Install as follows:
1. Clean the unloader piston bore in the cylinder head.

Note: Install the largest and smallest O-rings to the outside of the piston.
2. Using the lubricant provided, thoroughly lubricate and install the O-rings on the unloader piston
and lubricate the unloader piston bore in the cylinder head. It is recommended to utilize the entire
grease cartridge for each unloader valve assembly being installed.
3. Insert the spring into the unloader piston.
4. Lubricate the balance piston and insert the piston (smaller diameter first) into the spring
previously installed in the unloader piston.
Note: For the LK-862 two cylinder compressor, install the original unloader caps and discard
the caps supplied with the service kit. For the BA-921 single cylinder compressor, install the
cap supplied in the kit, and re-use the splash shield.
5. Position the unloader cap gasket on the cylinder head. Position the unloader cap (and splash shield
for the BA-921 single cylinder compressor) on top of the balance piston, making certain the cap is
oriented properly.
6. Using manual pressure, gently push the balance piston into the unloader piston until the unloader
cap rests against the cylinder head.
7. Install and torque the unloader cap screws to 7-8 N m (62-71 lb in.).

49.1 Description and Operation of the Cylinder Block and Related Parts
The cylinder block is the basic engine structure, establishing and maintaining the alignment o f 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. The cylinder block lower collar design allows for a shorter distance between
cylinders and a more compact design for the cylinder block. Each cylinder bore is sealed to a cylinder
liner with two sealing rings: the upper sealing ring seals the upper coolant jacket to the cylinder block
bore, and the lower sealing ring seals the lower coolant jacket to the cylinder block bore.
1. Cylinder Liner
2. Top of Cylinder Liner
3. Upper Sealing Ring
4. Upper Coolant Jacket
5. Lower Coolant Jacket
6. Lower Collar
7. Lower Sealing Ring
8. Bottom of Cylinder Liner
The cylinder liners are designed as "bottom stop" cylinder liners 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.

1. Bolt, Front Cover to Cylinder Block

2. Front Crankshaft Seal
3. Front Cover
4. Gasket, Front Cover to Cylinder Block
5. Expansion Plug, Front Oil Duct Intake
6. Expansion Plug, Front Oil Duct Outlet
7. Expansion Plug, Connector Front Oil Duct Outlet
8. Bottom Cylinder Liner Seal Ring
9. Cylinder Liner
10. Top Cylinder Liner Seal Ring
11. Expansion Plug, Connector Crankcase Ventilation
12. Plug
13. Dowel Pin
14. Expansion Plug, Cooling W ater Duct
15. Pin
16. Expansion Plug
17. Coolant Drain Plug
18. Dowel Pin
19. Dowel Pin, Crankshaft Bearing Cap
20. Piston Oil Spray Nozzle
21. Bolt, Oil Spray Nozzle
22. Main Bearing Cap
23. Bolt, Crankshaft Bearing Cap to Cylinder Block
The cylinder block has 1.5 mm counterbores machined on top for the cylinder head to cylinder block
sealing surface. The lubrication and coolant holes in the cylinder block supply the cylinder head with oil
and coolant. This allows for a superior sealing pressure between the gasket, cylinder head and cylinder
block. The cylinder block uses replaceable, wet-type cylinder liners.

1. Coolant Return for Cylinder Head Coolant Manifold

2. Coolant Feed for Oil Water Heat Exchanger
3. Coolant Connection for Fuel Heat Exchanger
4. Coolant Connection for Air Compressor
5. Coolant Connection for EGR Cooler
6. Coolant Transfer Hole to Cylinder Head
7. Coolant Return from Cylinder Head

1. Oil Holes
2. Connection for Oil Pressure Sensor
3. Connection for Engine Oil Temperature Sensor
4. Oil Return for Oil Filter Change
5. Oil Return Connection from Oil W ater Heat Exchanger
6. Oil Feed Connection to Oil Water Heat Exchanger
7. Oil Hole
8. Holes for Feed Gear Drive
9. Connection for Oil Feed to Axial Power Turbine
10. Oil Feed Connection for Cylinder Block Ventilation
11. Oil Feed Connection Turbocharger
12. Oil Hole
13. Oil Transfer Holes to the Cylinder Head
14. Oil Return from Cylinder Head

1. Oil Return to Oil Pan

2. Oil Feed Bore

1. Oil Feed Hole for Main Bearing and Connecting Rod Bearing
2. Oil Feed Hole for Oil Spray Nozzles
___________________________________________________________ Printed Sat Feb 19 10:37:48 2011

49.2 Removal and Disassembly of the Engine From 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:

2. Disconnect the battery cable(s) from the battery(s).
3. Drain the cooling system. Refer to OEM procedures.
4. Drain the lubricating oil.
5. Disconnect the lines on the fuel filter module from the fuel tank.
6. Remove the air cleaner ducting as necessary for engine removal. Refer to OEM guidelines.
7. Remove the charge air cooler ducting from the turbocharger and intake manifold.
8. Disconnect the exhaust piping from the engine.
9. Remove the 21-pin connector from the MCM.
10. Disconnect wiring from the starter and remove.
11. Disconnect the alternator and other electrical equipment, as necessary.
12. Disconnect the air compressor air lines, as necessary.
13. Disconnect and remove the coolant hoses.
14. Remove the charge air cooler, radiator, fan guard and other cooling system-related parts as
necessary to remove the engine.
A
FALLING ENGINE
To avoid injury from a falling engine, an adequate lifting device with a spreader
bar and sling should be used to lift the engine. The sling and spreader bar should be
adjusted so the lifting hooks are vertical to prevent bending the lifter brackets. To
ensure proper weight distribution, all provided lifter brackets must be used.
15. Connect cylinder head/engine lifting bar tool (W470589006200) to the engine using all three
lifting brackets (two at the rear and one at the front).
16. Remove the engine mounting bolts.
17. Lift the engine from its mounts using W470589006200.
18. Separate the engine from the transmission.
19. Remove the fuel filter module. Refer to section "Removal of the Fuel Filter Module"
20. Remove the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump"
^ ^ W A R N IN G :
FALLING ENGINE

21. Use engine overhaul stand (J-29109) for support when stripping an engine cylinder block.
22. Rotate engine in either direction and lock it into position.
23. Remove the inlet and outlet fuel lines connected to the Motor Control Module (MCM), if
equipped.
24. Remove any electrical components, accessories, connectors or wiring looms from the engine.
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 "Removal of the Rocker Cover"
b. Remove the engine lifter brackets.
Refer to section "Removal of the Front Engine Lifter Bracket without Front Engine Power
Take-off"
Refer to section "Removal of the Front Engine Lifter Bracket with Front Engine Power
Take-off"
Refer to section "Removal of the Rear Engine Lifter Brackets"
c. Remove the vibration damper. Refer to section "Removal of the Vibration Damper"
d. Remove the flywheel. Refer to section "Removal of the Flywheel"
e. Remove the flywheel housing. Refer to section "Removal of the Flywheel Housing"
f. Remove the idler gears.
g. Remove the camshaft housing. Refer to section "Removal of the Camshaft Housing"
h. Remove the cylinder head.
For DD13: Refer to section "Removal of the DD13 Cylinder Head"
For DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head"
i. Remove the oil pan. Refer to section "Removal of the Oil Pan"
j. Remove the piston and connecting rod assembly. Refer to section "Removal of the Piston
and Connecting Rod Assembly"
k. Remove the cylinder liners. Refer to section "Removal of the Cylinder Liner"
l. Remove the crankshaft. Refer to section "Removal of the Crankshaft"
NOTICE:
Before removing main bearing caps, be sure each is stamped or punch-marked in
numerical order, beginning with No. 1 at the front, to ensure installation in their
original position. Mark all caps on the oil cooler side (left side) of the engine to
prevent reversal at assembly. Failure to mark numerical order may result in the caps
being put back in incorrect order, improper crankshaft support and severe crankshaft
or bearing damage or both.
m. Remove the crankshaft main bearings.

49.3 Cleaning the Cylinder Block
NOTICE:
This cleaning procedure may be used on all ordinary cast iron and steel parts for the engine.
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.
Before removing cylinder liners for block cleaning, the liner bores should be gauged to determine
whether liner replacement is necessary. Remove cylinder liners with the cylinder liner removal tool (J-
45876) before putting the block in cleaning or de-scaling baths, to avoid trapping cleaning agents in
block liner seating bores. Clean the cylinder block as follows:
1. Remove all oil and water gallery plugs to allow the cleaning solution to enter the inside of the oil
and water passages. Remove piston oil spray nozzles at the base of each cylinder bore.
2. Immerse and agitate the block in a hot bath of a commercial, heavy-duty alkaline solution.
3. Wash the block in hot water or steam clean it to remove the alkaline solution.
4. If the water jackets are heavily scaled, proceed as follows:
a. Immerse and agitate the block in a bath of inhibited phosphoric acid.
b. Allow the block to remain in the acid bath until the bubbling action stops (approximately 30
minutes).
c. Lift the block, drain it and immerse it again in the same acid solution for 10 more minutes.
Repeat until all scale is removed from the water jacket area.
d. Rinse the block in clear, hot water to remove the acid solution.
e. Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath.
f. Wash the block in clean water and dry it.
^ ^ W A R N IN G :
EYE INJURY
pressure.
5. Dry the cylinder block with compressed air. Blow out all of the bolt holes and passages with
compressed air.
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).

49.4 Inspection of the Cylinder Block
Inspect as follows:
1. Remove the cylinder liners and check to determine whether liner replacement is necessary.
NOTICE:
The measurements are average gauge readings at each position. Also, the out-of-round must
not exceed 0.0254 mm (0.001 in.).
2. Measure the bore of each cylinder with cylinder bore gauge (J-5347-B ) which has a dial indicator
calibrated in 0.0001 in increments.
3. Measure cylinder block bore, at the positions on axis 90 degrees apart. If the diameter does not
exceed the dimensions, the block may be reused.
| Printed Sat Feb 19 10:39:59 2 0 l1

49.5 Inspection of the Main Bearing Bores
Inspect as follows:
1. Install the main bearing caps in their original positions. Lubricate the cap bolt threads and head
contact surfaces with a small quantity of clean engine oil.
2. Install the main cap bolts and torque bolts to 50 N m (37 lb ft).
DD13 DD15 DD16
Main Bearing Cap Bolt 175.5 mm (6.909 in.) 200.5 mm (7.894 in.) 200.5 mm (7.894 in.)
3. Torque the main cap bolts again to 150 N m (103 lb ft).

For the DD13, final torque the main cap bolts to 300 N m (221 lb ft). Then, torque turn the bolts
an additional 90°.
For the DD15 and DD16, final torque the main cap bolts to 250 N m (184 lb ft). Then, torque turn
the bolts an additional 90°; and again torque turn the bolts an additional 90°.
Note: Dial bore master setting fixture should be used to zero the cylinder bore gauge.
4. Measure the main bearing bores using dial bore gauge which has a dial indicator calibrated in
0.0001 in increments. Set the cylinder bore gauge on zero in master setting fixture.

49.6 General Inspection and Rust Prevention of the Cylinder Block
Inspect as follows:
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. Replace any loose or damaged dowel pins.
NOTICE:
Castings free of grease or oil will rust when exposed to the atmosphere. Rust on machined surfaces
may result in leakage.
After inspection, if the cylinder block is not to be used immediately, spray the machined surfaces with
engine oil.
If the block is to be stored for an extended period of time, spray or dip it in a polar-type rust preventive
such as "Tectyl® 502-C" from Valvoline Oil Company (or equivalent).
Tectyl® is a registered trademark o f Ashland Oil, Inc.
| Printed Sat Feb 19 10:40:45 2011

49.7 Reassembly and Installation of the Cylinder Block
After the cylinder block has been cleaned and inspected, assemble the engine as follows:
^ ^ W A R N IN G :
EYE INJURY
pressure.
1. Before a reconditioned or new service replacement cylinder block is used, steam clean it to
remove the rust preventive. Blow out the oil galleries with compressed air.
2. If a new service replacement block is used, stamp the engine serial number and model number on
the pad provided on the front left side of the block.
3. Also stamp the position numbers on the main bearing caps and the position of the No. 1 bearing
on the cooler side of the oil pan mounting flange of the block.
4. Install the main bearing caps in their original positions.
5. Install all of the required cup plugs. Use a good grade of non-hardening sealant such as Loctite®
620 (or equivalent). Apply a thin coat of sealant just inside the chamfer where the plug is to be
installed and install using cup plug installation tool set (J-35653).
6. With the engine mounted on the overhaul stand, install all of any remaining subassemblies and
parts on the cylinder block.
a. Install the crankshaft main bearings. Refer to section "Installation of the Crankshaft"
b. Install the crankshaft. Refer to section "Installation of the Crankshaft"
c. Install the cylinder liners. Refer to section "Installation of the Cylinder Liner"
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. A loosened nozzle may cause a loss of main gallery oil
pressure. In either case, piston overheating or lack of adequate lubrication may result
in severe engine damage.
NOTICE:
When installed, ensure the spray nozzles are aligned.
d. Install the piston and connecting rod assembly. Refer to section "Installation of the Piston
and Connecting Rod Assembly"
e. Install the gear train. Refer to section "Installation and Timing of Engine Gear Train"
f. Install the flywheel housing. Refer to section "Installation of the Flywheel Housing"
g. Install the oil pan. Refer to section "Installation of the Oil Pan"
h. Install the flywheel. Refer to section "Installation of the Flywheel"
i. Install the cylinder head.

For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder
Head"
j. Install the camshaft housing. Refer to section "Installation of the Camshaft Housing"
k. Install the vibration damper. Refer to section "Installation of the Vibration Damper"
l. Install the crankshaft pulley.
m. Install the engine lifter brackets.
Refer to section "Installation of the Rear Engine Lifter Brackets"
Refer to section "Installation of the Front Engine Lifter Bracket without Front Engine
Power Take-Off"
Refer to section "Installation of the Front Engine Lifter Bracket with Front Engine Power
Take-Off"
n. Install the rocker cover. Refer to section "Installation of the Rocker Cover"
o. Install any electrical components, accessories, connectors or wiring looms that were
removed during disassembly.
p. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor
Control Module"
q. Install the cylinder head/engine lifting bar tool (W470589006200) to the engine.
A
FALLING ENGINE
To avoid injury from a falling engine, an adequate lifting device with a

spreader bar and sling should be used to lift the engine. The sling and
spreader bar should be adjusted so the lifting hooks are vertical to prevent
bending the lifter brackets. To ensure proper weight distribution, all provided
lifter brackets must be used.
r. Remove the engine from the overhaul stand.

s. Prime engine lubrication system. Refer to section "Priming the Engine Lubrication System"
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.

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What are the main components of the rocker cover assembly?

What are the main components of the rocker cover assembly?

What are the steps to remove the rocker cover?

What are the steps to remove the rocker cover?

Power Service Literature Page 1 of 1

1 California Proposition 65 Warning and Engine Idle Notice

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Copyright © 2011 by Detroit D iesel Corporation. All rights reserved.

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2.1 Description and Operation of Rocker Cover and Related Parts

1. Elastomer Seal (Gasket)

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2.2 Removal of the Rocker Cover

1. Steam clean the engine.

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2.3 Cleaning and Inspection of the Rocker Cover

Clean and inspect as follows:

1. Remove the sealing gasket from the rocker cover.

3. Blow dry with compressed air.

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2.4 Installation of the Rocker Cover

3. Install the rocker cover onto the camshaft housing.

6. Start the engine and check for leaks.

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3.1 Description and Operation of Camshaft and Rocker Shaft/Engine

1. Camshaft Bearing Cap

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3.2 Description and Operation of Engine Braking

1. Exhaust Rocker Arm

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1. Exhaust Rocker Arm

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10. Brake Camshaft Lobe

___________________________________________________________ Printed Sat Feb 19 08:51:17 2011

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3.3 Removal of Camshaft and Rocker Shaft/Engine Brake Assembly

Service Tools Used in the Procedure

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

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13. F o r all E P A 10 engines:

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Printed Sat Feb 19 08:51:48 2011

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