DETROIT DIESEL DD13 DD15 DD16 ENGINE EPA07/10 Repair Workshop Manual

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DETROIT DIESEL DD13 DD15 DD16 PLATFORM WORKSHOP ENGINE SERVICE MANUAL EPA07/10 DDC-SVC-MAN-0081

PDF Manual Includes the following manuals & service information:
(1) Detroit Diesel DD13 DD15 DD16 Engine Workshop Manual,
(2) Detroit Diesel DD13-DD15 Application&Installation Manual,
(3) Detroit DD15 Valve Adjustment,
(4) Detroit Diesel DD15 - EPA07 and EPA10 DD Platform, EGR Delta Pressure Sensor Update,

Engine Service Manual with detailed pictures/diagrams & information. Step by step procedures for servicing, repairing, maintaining, diagnostics & troubleshooting.

CONTENTS of:  Detroit Diesel DD13 DD15 DD16 Engine Workshop Manual
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
6.5 DD13 EXHAUST GAS RE-CIRCULATION 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 WASTE-GATE SOLENOID
10.1 DESCRIPTION AND OPERATION OF THE DD13 WASTE-GATE SOLENOID  10-3
10.2 REMOVAL OF THE DD13 WASTE GATE SOLENOID ............................. 10-4
10.3 INSTALLATION OF THE DD13 WASTE-GATE 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
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
17.1 DESCRIPTION AND OPERATION OF CRANKSHAFT AND RELATED PARTS  17-3
17.2 REMOVAL OF CRANKSHAFT ................................................................. 17-6
17.3 INSPECTION OF THE CRANKSHAFT AND RELATED PARTS ............. 17-9
17.4 INSTALLATION OF CRANKSHAFT ......................................................... 17-10
17.5 REMOVAL OF CRANKSHAFT REAR OIL SEAL ..................................... 17-14
17.6 INSTALLATION OF THE REAR OIL SEAL .............................................. 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
25.2 INSTALLATION OF THE OIL FILLER NECK ........................................... 25-4
26    OIL COOLANT MODULE
26.1 DESCRIPTION AND OPERATION OF THE OIL COOLANT MODULE .. 26-3
26.2 REMOVAL OF THE OIL COOLANT MODULE ........................................ 26-5
26.3 INSTALLATION OF THE OIL COOLANT MODULE ................................ 26-7
26.4 REMOVAL OF THE OIL THERMOSTAT .................................................. 26-9
26.5 INSTALLATION OF THE OIL THERMOSTAT .......................................... 26-11
27    PRIMING THE LUBRICATION SYSTEM
27.1 PRIMING THE ENGINE LUBRICATION SYSTEM .................................. 27-3
28    COOLING SYSTEM
28.1 DESCRIPTION AND OPERATION OF COOLING SYSTEM AND RELATED COMPONENTS  28-3
29    ENGINE WATER PUMP
29.1 DESCRIPTION AND OPERATION OF ENGINE WATER PUMP ............ 29-3
29.2 REMOVAL OF THE WATER PUMP ......................................................... 29-4
29.3 INSPECTION OF THE WATER PUMP .................................................... 29-5
29.4 INSTALLATION OF THE WATER PUMP ................................................. 29-6
30    COOLANT THERMOSTAT
30.1 DESCRIPTION AND OPERATION OF COOLANT THERMOSTAT ........ 30-3
30.2 REMOVAL OF COOLANT THERMOSTAT AND SEAL ........................... 30-5
30.3 INSPECTION OF COOLANT THERMOSTAT AND SEAL ....................... 30-6
30.4 INSTALLATION OF COOLANT THERMOSTAT AND SEAL .................... 30-7
31    COOLANT FILTER
31.1 DESCRIPTION AND OPERATION OF COOLANT FILTER ..................... 31-3
31.2 REMOVAL OF THE COOLANT FILTER .................................................. 31-4
31.3 INSTALLATION OF THE COOLANT FILTER .......................................... 31-5
32    COOLANT FILTER SERVICE MODULE
32.1 REMOVAL OF COOLANT FILTER SERVICE MODULE ......................... 32-3
32.2 INSTALLATION OF COOLANT FILTER SERVICE MODULE .................. 32-4
33    COOLANT INLET ELBOW
33.1 REMOVAL OF THE COOLANT INLET ELBOW ...................................... 33-3
33.2 INSTALLATION OF THE COOLANT INLET ELBOW .............................. 33-4
34 FLYWHEEL AND FLYWHEEL HOUSING
34.1 DESCRIPTION AND OPERATION OF FLYWHEEL, FLYWHEEL HOUSING AND RELATED PARTS  34-3
34.2 REMOVAL OF FLYWHEEL HOUSING .................................................... 34-6
34.3 INSTALLATION OF FLYWHEEL HOUSING ............................................ 34-7
34.4 REMOVAL OF THE FLYWHEEL .............................................................. 34-9
34.5 INSPECTION OF FLYWHEEL ................................................................. 34-10
34.6 INSTALLATION OF FLYWHEEL .............................................................. 34-11
34.7 INSPECTION OF FLYWHEEL HOUSING AND REAR OIL SEAL AREA OF CRANKSHAFT  34-12
34.8 REMOVAL OF RING GEAR ..................................................................... 34-13
34.9 INSTALLATION OF RING GEAR ............................................................. 34-14
35    FRONT ENGINE MOUNT/RADIATOR SUPPORT
35.1 DESCRIPTION AND OPERATION OF FRONT ENGINE MOUNT/RADIATOR SUPPORT AND RELATED PARTS  35-3
35.2 REMOVAL OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT .. 35-4
35.3 INSPECTION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT  35-5
35.4 INSTALLATION OF THE FRONT ENGINE MOUNT/RADIATOR SUPPORT  35-6
36    VIBRATION DAMPER
36.1 REMOVAL OF THE VIBRATION DAMPER ............................................. 36-3
36.2 INSTALLATION OF THE VIBRATION DAMPER ..................................... 36-4
37 FRONT ENGINE COVER
37.1 DESCRIPTION AND OPERATION OF THE FRONT ENGINE COVER .. 37-3
37.2 REMOVAL OF THE FRONT ENGINE COVER ........................................ 37-4
37.3 INSPECTION OF THE FRONT ENGINE COVER ................................... 37-5
37.4 INSTALLATION OF THE FRONT ENGINE COVER ................................ 37-6
38    ENGINE LIFTER BRACKETS
38.1 DESCRIPTION AND OPERATION OF ENGINE LIFTER BRACKETS AND RELATED PARTS  38-3
38.2 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF 38-8
38.3 REMOVAL OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF  38-9
38.4 REMOVAL OF THE REAR ENGINE LIFTER BRACKETS ...................... 38-10
38.5 INSPECTION OF THE ENGINE LIFTER BRACKETS ............................ 38-11
38.6 INSTALLATION OF THE REAR ENGINE LIFTER BRACKETS .............. 38-12
38.7 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITHOUT FRONT ENGINE POWER TAKE-OFF  38-13
38.8 INSTALLATION OF THE FRONT ENGINE LIFTER BRACKET WITH FRONT ENGINE POWER TAKE-OFF
39.1 DESCRIPTION AND OPERATION OF BELT DRIVE TENSIONER AND RELATED PARTS  39-3
39.2 REMOVAL OF THE BELT TENSIONER .................................................. 39-5
39.3 INSTALLATION OF THE BELT TENSIONER .......................................... 39-6
39.4 REMOVAL OF THE IDLER PULLEY AND IDLER PULLEY BRACKET .. 39-7
39.5 INSTALLATION OF THE IDLER PULLEY AND IDLER PULLEY BRACKET  39-8
39.6 REMOVAL OF NON-BRACKETED IDLER PULLEY .............................. 39-9
39.7 INSTALLATION OF NON-BRACKETED IDLER PULLEY ........................ 39-10
39.8 REMOVAL OF THE ACCESSORY MOUNTING BRACKET .................... 39-11
39.9 INSTALLATION OF THE ACCESSORY MOUNTING BRACKET ............ 39-12
40    POLY-V-BELTS
40.1 REMOVAL OF THE POLY-V-BELTS ....................................................... 40-3
40.2 INSPECTION OF THE POLY-V-BELTS ................................................... 40-6
40.3 INSTALLATION OF THE POLY-V-BELTS ................................................ 40-9
41    AIR COMPRESSOR
41.1 DESCRIPTION AND OPERATION OF THE AIR COMPRESSOR .......... 41-3
41.2 REMOVAL OF THE AIR COMPRESSOR ................................................ 41-5
41.3 INSPECTION OF THE AIR COMPRESSOR ........................................... 41-6
41.4 INSTALLATION OF THE AIR COMPRESSOR ........................................ 41-8
42    CYLINDER BLOCK
42.1 DESCRIPTION AND OPERATION OF CYLINDER BLOCK AND RELATED PARTS  42-3
42.2 REMOVAL AND DISASSEMBLY OF ENGINE FROM THE VEHICLE .... 42-9
42.3 CLEANING THE CYLINDER BLOCK ...................................................... 42-12
42.4 REASSEMBLY AND INSTALLATION OF CYLINDER BLOCK ................ 42-16
17 CRANKSHAFT