Detroit Diesel DD13 DD15 DD16 Engine Workshop Manual | EPA07/10 (EN)

EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE TABLE OF CONTENTS 1 ROCKER COVER 1.1 DESCRIPTION AND OPERATION OF ROCKER COVER AND RELATED PARTS ...................................................................................................... 1-3 1.2 REMOVAL OF THE ROCKER COVER .................................................... 1-4 1.3 CLEANING AND INSPECTION OF THE ROCKER COVER ................... 1-6 1.4 INSTALLATION OF THE ROCKER COVER ............................................ 1-7 2 CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY 2.1 DESCRIPTION AND OPERATION OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY AND RELATED PARTS ...............

2-3 2.2 REMOVAL OF CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY .............................................................................................. 2-7 2.3 INSPECTION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY ................................................................................. 2-15 2.4 INSTALLATION OF THE CAMSHAFT AND ROCKER SHAFT/ENGINE BRAKE ASSEMBLY .................................................................................

2-16 2.5 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2-26 2.6 DD15 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER ENGINE BRAKE SOLENOID FAILURE 2-31 3 CAMSHAFT HOUSING 3.1 REMOVAL OF THE CAMSHAFT HOUSING ........................................... 3-3 3.2 INSPECTION OF CAMSHAFT HOUSING ............................................... 3-8 3.3 INSTALLATION OF THE CAMSHAFT HOUSING ................................... 3-9 4 CAMSHAFT TIMING 4.1 CAMSHAFT TIMING VERIFICATION ...................................................... 4-3 4.2 TIMING THE CAMSHAFTS WITH THE GEAR TRAIN INSTALLED ........

4-6 5 GEAR TRAIN AND ENGINE TIMING 5.1 DESCRIPTION AND OPERATION OF GEAR TRAIN AND RELATED PARTS ...................................................................................................... 5-3 5.2 ENGINE GEAR TRAIN INSTALLATION AND TIMING ............................ 5-8 5.3 CHECKING AND ADJUSTING GEAR LASH WITH CAMSHAFT HOUSING REMOVED ............................................................................. 5-16 6 WATER MANIFOLD 6.1 DESCRIPTION AND OPERATION OF DD15 & DD16 WATER MANIFOLD AND RELATED COMPONENTS .......................................... 6-3 6.2 REMOVAL OF THE DD15 & DD16 WATER MANIFOLD .........................

6-5 6.3 CLEANING AND INSPECTION OF THE DD15 & DD16 WATER MANIFOLD ............................................................................................... 6-7 6.4 INSTALLATION OF THE DD15 & DD16 WATER MANIFOLD ................. 6-8 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION i

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 6.5 DD13 EXHAUST GAS RECIRCULATION COOLER WATER MANIFOLD ASSEMBLY .............................................................................................. 6-10 7 COLD BOOST PIPE (CHARGE AIR PIPE) 7.1 DESCRIPTION AND OPERATION OF COLD BOOST PIPE (CHARGE AIR PIPE) AND RELATED COMPONENTS ............................................ 7-3 7.2 REMOVAL OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ............. 7-4 7.3 INSPECTION OF COLD BOOST PIPE (CHARGE AIR PIPE) ................ 7-5 7.4 INSTALLATION OF THE COLD BOOST PIPE (CHARGE AIR PIPE) ....

7-6 8 AIR INTAKE MANIFOLD 8.1 DESCRIPTION AND OPERATION OF AIR INTAKE MANIFOLD AND RELATED PARTS .................................................................................... 8-3 8.2 REMOVAL OF AIR INTAKE MANIFOLD .................................................. 8-6 8.3 CLEANING OF THE AIR INTAKE MANIFOLD ........................................ 8-7 8.4 INSPECTION OF THE AIR INTAKE MANIFOLD ..................................... 8-8 8.5 INSTALLATION OF AIR INTAKE MANIFOLD ..........................................

8-9 9 DD13 TURBOCHARGER 9.1 DESCRIPTION AND OPERATION OF THE DD13 TURBOCHARGER AND RELATED PARTS ............................................................................ 9-3 9.2 REMOVAL OF THE DD13 TURBOCHARGER ........................................ 9-5 9.3 INSPECTION OF THE DD13 TURBOCHARGER ................................... 9-9 9.4 INSTALLATION OF THE DD13 TURBOCHARGER ................................ 9-10 9.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER DD13 TURBOCHARGER FAILURE ................

9-12 10 DD13 WASTEGATE SOLENOID 10.1 DESCRIPTION AND OPERATION OF THE DD13 WASTEGATE SOLENOID ............................................................................................... 10-3 10.2 REMOVAL OF THE DD13 WASTEGATE SOLENOID ............................. 10-4 10.3 INSTALLATION OF THE DD13 WASTEGATE SOLENOID ..................... 10-6 11 DD15 TURBOCHARGER 11.1 DESCRIPTION AND OPERATION OF TURBOCHARGER AND RELATED PARTS .................................................................................... 11-3 11.2 REMOVAL OF DD15 TURBOCHARGER ................................................ 11-5 11.3 INSPECTION OF DD15 TURBOCHARGER ...........................................

11-7 11.4 INSTALLATION OF DD15 TURBOCHARGER ........................................ 11-8 11.5 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS OIL FROM EGR COOLER AFTER DD15 TURBOCHARGER FAILURE ....... 11-10 12 DD15 AXIAL POWER TURBINE 12.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE AND RELATED PARTS ............................................................................ 12-3 12.2 REMOVAL OF DD15 AXIAL POWER TURBINE ..................................... 12-5 12.3 INSPECTION OF THE DD15 AXIAL POWER TURBINE ........................ 12-6 12.4 INSTALLATION OF DD15 AXIAL POWER TURBINE ............................. 12-7 All information subject to change without notice.

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

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 13 DD15 AXIAL POWER TURBINE GEAR BOX 13.1 DESCRIPTION AND OPERATION OF DD15 AXIAL POWER TURBINE GEAR BOX AND RELATED PARTS ........................................................ 13-3 13.2 REMOVAL OF THE DD15 AXIAL POWER TURBINE GEAR BOX ......... 13-5 13.3 INSPECTION OF DD15 AXIAL POWER TURBINE GEAR BOX ............. 13-6 13.4 INSTALLATION OF THE AXIAL POWER TURBINE GEAR BOX ............ 13-7 14 CYLINDER HEAD 14.1 DESCRIPTION AND OPERATION OF CYLINDER HEAD AND RELATED PARTS ......................................................................................................

14-3 14.2 REMOVAL OF THE DD13 CYLINDER HEAD ......................................... 14-10 14.3 INSTALLATION OF THE DD13 CYLINDER HEAD .................................. 14-12 14.4 REMOVAL OF THE DD15 CYLINDER HEAD ......................................... 14-15 14.5 CLEANING OF THE CYLINDER HEAD .................................................. 14-17 14.6 ASSEMBLY OF CYLINDER HEAD .......................................................... 14-18 14.7 INSTALLATION OF THE DD15 CYLINDER HEAD .................................. 14-19 14.8 REMOVAL OF VALVE SPRING (CYLINDER HEAD INSTALLED) .......... 14-22 14.9 REMOVAL OF THE VALVE SPRING (CYLINDER HEAD REMOVED) ...

14-24 14.10 REMOVAL OF INTAKE AND EXHAUST VALVES ................................... 14-25 14.11 CLEANING OF VALVES AND RELATED PARTS .................................... 14-26 14.12 INSPECTION OF VALVE SPRINGS ........................................................ 14-27 14.13 INSPECTION OF VALVE ......................................................................... 14-28 14.14 INSTALLATION OF VALVE, SPRING, SEAL AND VALVE CAP .............. 14-29 14.15 VALVE LASH ADJUSTMENTS ................................................................ 14-31 14.16 SETTING THE ENGINE BRAKE LASH ...................................................

14-33 15 PISTON AND CONNECTING ROD ASSEMBLY 15.1 DESCRIPTION AND OPERATION OF PISTON AND CONNECTING ROD AND RELATED PARTS ................................................................... 15-3 15.2 REMOVAL OF PISTON AND CONNECTING ROD ASSEMBLY ............. 15-5 15.3 DISASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY ..... 15-7 15.4 INSPECTION OF PISTON AND CONNECTING ROD ASSEMBLY ........ 15-8 15.5 ASSEMBLY OF PISTON AND CONNECTING ROD ASSEMBLY ........... 15-9 15.6 INSTALLATION OF PISTON AND CONNECTING ROD ASSEMBLY .....

15-11 16 CYLINDER LINER 16.1 DESCRIPTION AND OPERATION OF CYLINDER LINER AND RELATED PARTS .................................................................................... 16-3 16.2 REMOVAL OF CYLINDER LINER ........................................................... 16-4 16.3 INSPECTION OF CYLINDER LINER ...................................................... 16-5 16.4 CLEANING OF THE CYLINDER LINER .................................................. 16-7 16.5 INSTALLATION OF THE CYLINDER LINER ...........................................

16-8 17 CRANKSHAFT 17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS ...................................................................................................... 17-3 17.2 REMOVAL OF CRANKSHAFT ................................................................. 17-6 17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS ............. 17-9 17.4 INSTALLATION OF CRANKSHAFT ......................................................... 17-10 All information subject to change without notice. DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION iii

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - ENGINE 17.5 REMOVAL OF CRANKSHAFT REAR OIL SEAL ..................................... 17-14 17.6 INSTALLATION OF THE REAR OIL SEAL .............................................. 17-15 17.7 REMOVAL OF THE CRANKSHAFT FRONT OIL SEAL .......................... 17-17 17.8 INSTALLATION OF THE CRANKSHAFT FRONT OIL SEAL .................. 17-18 18 LUBRICATION SYSTEM 18.1 DESCRIPTION AND OPERATION OF THE LUBRICATION SYSTEM AND RELATED COMPONENTS ..............................................................

18-3 19 OIL PAN 19.1 DESCRIPTION AND OPERATION OF OIL PAN AND RELATED COMPONENTS ....................................................................................... 19-3 19.2 REMOVAL OF OIL PAN ........................................................................... 19-4 19.3 CLEANING OF OIL PAN .......................................................................... 19-5 19.4 INSPECTION OF OIL PAN ...................................................................... 19-6 19.5 REMOVAL OF THREADED INSERT — PLASTIC OIL PAN ONLY ......... 19-7 19.6 INSTALLATION OF THREADED INSERT — PLASTIC OIL PAN ONLY .

19-8 19.7 INSTALLATION OF OIL PAN ................................................................... 19-9 20 OIL DIPSTICK TUBE 20.1 DESCRIPTION AND OPERATION OF OIL DIPSTICK TUBE AND RELATED COMPONENTS ...................................................................... 20-3 20.2 REMOVAL OF THE OIL DIPSTICK TUBE ............................................... 20-4 20.3 INSTALLATION OF THE OIL DIPSTICK TUBE ....................................... 20-5 21 OIL PUMP 21.1 DESCRIPTION AND OPERATION OF OIL PUMP AND RELATED COMPONENTS .......................................................................................

21-3 21.2 REMOVAL OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES ....................................................................................................... 21-4 21.3 INSPECTION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES ....................................................................................................... 21-5 21.4 INSTALLATION OF THE OIL PUMP, OIL SUCTION MANIFOLD, AND OIL LINES ................................................................................................ 21-6 22 CRANKCASE BREATHER 22.1 DESCRIPTION AND OPERATION OF CRANKCASE BREATHER ........ 22-3 22.2 REMOVAL OF THE CRANKCASE BREATHER ......................................

22-5 22.3 INSPECTION OF THE CRANKCASE BREATHER ................................. 22-6 22.4 INSTALLATION OF THE CRANKCASE BREATHER .............................. 22-7 23 OIL FILTER 23.1 REPLACEMENT OF THE OIL FILTER .................................................... 23-3 24 OIL SAMPLE VALVE 24.1 REPLACING OIL PLUG WITH OIL SAMPLE VALVE .............................. 24-3 24.2 REMOVAL OF OIL SAMPLE VALVE ....................................................... 24-4 24.3 INSTALLATION OF OIL SAMPLE VALVE ................................................ 24-5 25 OIL FILLER NECK 25.1 REMOVAL OF THE OIL FILLER NECK ...................................................

25-3 All information subject to change without notice. iv DDC-SVC-MAN-0081 2010 Copyright © 2010 DETROIT DIESEL CORPORATION

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