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Detroit DD13, DD15, DD16 EPA07/10/GHG14 Engine Workshop Manual

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Covers: Detroit DD13, DD15, DD16 EPA 07/10/GHG14 Diesel Engine
Pages: 315
Format: PDF
Compatibility: Windows/Mac/Tablet
File size: 44mb

This manual contains engine-out workshop procedures, illustrations and specifications for removal, installation, inspection and rebuild/overhaul of Detroit DD13, DD15, DD16 EPA07 EPA10 GHG14 engines. Manuals for the fuel system, exhaust/aftertreatment/EGR system and troubleshooting are available separately.

Topics in the Detroit DD13 DD15 DD16 EPA07/10/GHG14 Engine Workshop Manual:

1 Warnings

2 Rocker Cover
2.1 Description and Operation of Rocker Cover and Related Parts
2.2 Removal of the Rocker Cover
2.3 Cleaning and Inspection of the Rocker Cover
2.4 Installation of the Rocker Cover

3 Camshaft and Rocker Shaft/Engine Brake Assembly
3.1 Description and Operation of Camshaft and Rocker Shaft/Engine Brake Assembly and Related Parts
3.2 Description and Operation of Engine Braking
3.3 Removal of the Rocker Shaft Assembly
3.4 Removal of the Camshafts
3.5 Inspection of the Camshaft and Rocker Shaft/Engine Brake Assembly
3.6 Installation of the Camshafts
3.7 Installation of the Rocker Shafts

4 Camshaft Housing
4.1 Description and Operation of the Camshaft Housing
4.2 Removal of the Camshaft Housing
4.3 Inspection of the Camshaft Housing
4.4 Installation of the Camshaft Housing

5 Camshaft Timing
5.1 Camshaft Timing Verification
5.2 Timing the Camshafts with the Gear Train Installed

6 Gear Train and Engine Timing
6.1 Description and Operation of Gear Train and Related Parts
6.2 Installation and Timing of Engine Gear Train
6.3 Checking and Adjusting Gear Lash with Camshaft Housing Removed

7 Coolant Crossover Pipe
7.1 Description and Operation of the Coolant Crossover Pipe
7.2 Removal of the Coolant Crossover Pipe
7.3 Installation of the Coolant Crossover Pipe

8 DD15 and DD16 Water Manifold Assembly
8.1 Description and Operation of DD15 and DD16 Water Manifold and Related Components
8.2 Removal of the DD15 and DD16 Water Manifold
8.3 Cleaning and Inspection of the DD15 and DD16 Water Manifold
8.4 Installation of the DD15 and DD16 Water Manifold

9 DD13 Exhaust Gas Recirculation Cooler – Water Manifold Assembly
9.1 Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
9.2 Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
9.3 Inspection of the DD13 EGR Cooler Water Manifold Assembly
9.4 Testing and Inspection of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
9.5 Installation of the DD13 EGR Cooler Water Manifold Assembly

10 Cold Boost Pipe (Charge Air Pipe)
10.1 Description and Operation of Cold Boost Pipe (Charge Air Pipe) and Related Components
10.2 Removal of the Cold Boost Pipe (Charge Air Pipe)
10.3 Inspection of Cold Boost Pipe (Charge Air Pipe)
10.4 Installation of the Cold Boost Pipe (Charge Air Pipe)

11 Composite Cold Boost Pipe
11.1 Description and Operation of the Composite Cold Boost Pipe (Charge Air Pipe) and Related Components
11.2 Inspection of Composite Cold Boost Pipe (Charge Air Pipe)
11.3 Removal of the Composite Cold Boost Pipe (Charge Air Pipe)
11.4 Installation of the Composite Cold Boost Pipe (Charge Air Pipe)

12 Air Intake Manifold
12.1 Description and Operation of the DD13 Air Intake Manifold and Related Parts
12.2 Description and Operation of the DD15-DD16 Air Intake Manifold and Related Parts
12.3 Removal of the Air Intake Manifold
12.4 Cleaning of the Air Intake Manifold
12.5 Inspection of the Air Intake Manifold
12.6 Installation of Air Intake Manifold

13 DD13 Turbocharger
13.1 Description and Operation of the DD13 Turbocharger and Related Parts
13.2 Removal of the DD13 Turbocharger
13.3 Inspection of the Turbocharger
13.4 Installation of the DD13 Turbocharger

14 DD13 Wastegate Solenoid
14.1 Description and Operation of the EPA10 DD13 Wastegate Solenoid
14.2 Removal of the DD13 Wastegate Solenoid
14.3 Installation of the DD13 Wastegate Solenoid
14.4 Functional Check of the DD13 Wastegate Actuator

15 GHG14 DD15 Wastegate Solenoid
15.1 Description and Operation of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid
15.2 Removal of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid
15.3 Installation of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid

16 DD15 and DD16 Turbocharger
16.1 Description and Operation of the DD15 – DD16 Turbocharger and Related Parts
16.2 Removal of the DD15 and the DD16 Turbocharger
16.3 Inspection of the DD15 and DD16 Turbocharger
16.4 Installation of the DD15 and the DD16 Turbocharger
16.5 Removal of the GHG14 DD15 Asymmetrical Turbocharger
16.6 Installation of the GHG14 DD15 Asymmetrical Turbocharger

17 DD15 and DD16 Axial Power Turbine
17.1 Description and Operation of the DD15 and DD16 Axial Power Turbine and Related Parts
17.2 Removal of the DD15 and DD16 Axial Power Turbine
17.3 Inspection of the DD15 and DD16 Axial Power Turbine
17.4 Installation of the DD15 and DD16 Axial Power Turbine

18 DD15 and DD16 Axial Power Turbine Gear Box
18.1 Description and Operation of DD15 and DD16 Axial Power Turbine Gear Box and Related Parts
18.2 Removal of the DD15 and DD16 Axial Power Turbine Gear Box
18.3 Inspection of the DD15 and DD16 Axial Power Turbine Gear Box
18.4 Installation of the DD15 and DD16 Axial Power Turbine Gear Box

19 Cylinder Head
19.1 Description and Operation of the Cylinder Head and Related Parts
19.2 Removal of the DD13 Cylinder Head
19.3 Inspection of the Cylinder Head – DD
19.4 Cleaning of the Cylinder Head
19.5 Assembly of Cylinder Head
19.6 Installation of the DD13 Cylinder Head
19.7 Removal of the DD15 and DD16 Cylinder Head
19.8 Cleaning of the Cylinder Head
19.9 Assembly of Cylinder Head
19.10 Installation of the DD15 and DD16 Cylinder Head

20 Intake and Exhaust Valves and Valve Springs
20.1 Removal of the Valve Spring (Cylinder Head Installed)
20.2 Removal of the Valve Spring (Cylinder Head Removed)
20.3 Removal of Intake and Exhaust Valves
20.4 Cleaning of the Valves and Related Parts
20.5 Inspection of the Intake and Exhaust Valves
20.6 Installation of the Valve, Spring, Seal and Valve Cap
20.7 Valve Lash Adjustments
20.8 Setting the Engine Brake Lash

21 Piston and Connecting Rod Assembly
21.1 Description and Operation of the Piston and Connecting Rod and Related Parts
21.2 Removal of the Piston and Connecting Rod Assembly
21.3 Disassembly of Piston and Connecting Rod Assembly
21.4 Assembly of the Piston and Connecting Rod Assembly
21.5 Installation of the Piston and Connecting Rod Assembly

22 Cylinder Liner
22.1 Description and Operation of the Cylinder Liner and Related Parts
22.2 Removal of the Cylinder Liner
22.3 Inspection of the Cylinder Liner
22.4 Cleaning of the Cylinder Liner
22.5 Installation of the Cylinder Liner

23 Crankshaft
23.1 Description and Operation of the Crankshaft and Related Parts
23.2 Removal of the Crankshaft
23.3 Inspection of the Crankshaft and Related Parts
23.4 Installation of the Crankshaft
23.5 Inspection of the Main and Connecting Rod Bearing in Chassis

24 Crankshaft Oil Seals
24.1 Removal of the Rear Crankshaft Oil Seal
24.2 Installation of the Rear Crankshaft Oil Seal
24.3 Removal of the Front Crankshaft Oil Seal
24.4 Installation of the Front Crankshaft Oil Seal

25 Lubrication System
25.1 Description and Operation of the Lubrication System and Related Components

26 Oil Pan
26.1 Description and Operation of the Oil Pan and Related Components
26.2 Removal of the Oil Pan
26.3 Cleaning of the Oil Pan
26.4 Inspection of the Oil Pan
26.5 Removal of the Threaded Insert (Plastic Oil Pan Only)
26.6 Installation of the Threaded Insert (Plastic Oil Pan Only)
26.7 Installation of the Oil Pan

27 Oil Level/Temperature Sensor
27.1 Description and Operation of the Oil Level/Temperature Sensor
27.2 Removal of the Oil Level/Temperature Sensor
27.3 Installation of the Oil Level/Temperature Sensor

28 Oil Dipstick Tube
28.1 Description and Operation of the Oil Dipstick Tube and Related Components
28.2 Removal of the Oil Dipstick Tube
28.3 Installation of the Oil Dipstick Tube

29 Oil Pump, Oil Suction Manifold, and Oil Lines
29.1 Description and Operation of Oil Pump and Related Components
29.2 Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines
29.3 Inspection of the Oil Pump, Oil Suction Manifold, and Oil Lines
29.4 Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines

30 Crankcase Breather
30.1 Description and Operation of the Crankcase Breather
30.2 Removal of the Crankcase Breather
30.3 Inspection of the Crankcase Breather
30.4 Installation of the Crankcase Breather

31 Oil Filter
31.1 Replacement of the Oil Filter

32 Oil Sample Valve
32.1 Replacing Oil Plug with Oil Sample Valve
32.2 Removal of Oil Sample Valve
32.3 Installation of the Oil Sample Valve

33 Oil Filler Neck
33.1 Removal of the Oil Filler Neck
33.2 Installation of the Oil Filler Neck

34 Oil Coolant Module
34.1 Description and Operation of the Oil Coolant Module
34.2 Removal of the Oil Coolant Module
34.3 Installation of the Oil Coolant Module
34.4 Removal of the Oil Coolant Module Plugs
34.5 Installation of the Oil Coolant Module Plugs

35 Oil Cooler
35.1 Removal of the Oil Cooler
35.2 Inspection and Pressure Testing of the Oil Cooler
35.3 Installation of the Oil Cooler

36 Oil Thermostat
36.1 Removal of the Oil Thermostat
36.2 Installation of the Oil Thermostat

37 Priming the Lubrication System
37.1 Priming the Engine Lubrication System

38 Cooling System
38.1 Description and Operation of the Cooling System and Related Components
38.2 Cooling System Drain Procedure
38.3 Cooling System Fill Procedure

39 Engine Water Pump
39.1 Description and Operation of the Engine Water Pump
39.2 Removal of the Water Pump
39.3 Inspection of the Water Pump
39.4 Installation of the Water Pump

40 Variable Speed Engine Water Pump
40.1 Description and Operation of the Variable Speed Engine Water Pump
40.2 Removal of the Variable Speed Water Pump
40.3 Inspection of the Variable Speed Water Pump
40.4 Installation of the Variable Speed Water Pump
40.5 Removal of the Variable Speed Water Pump Pulley
40.6 Installation of the Variable Speed Water Pump Pulley

41 Coolant Thermostat
41.1 Description and Operation of the Coolant Thermostat
41.2 Removal of the Engine Coolant Thermostat and Seal
41.3 Inspection of the Coolant Thermostat and Seal
41.4 Installation of the Coolant Thermostat and Seal

42 Coolant Filter
42.1 Description and Operation of the Coolant Filter
42.2 Removal of the Coolant Filter
42.3 Installation of the Coolant Filter

43 Coolant Filter Service Module
43.1 Removal of the Coolant Filter Service Module
43.2 Installation of the Coolant Filter Service Module

44 Coolant Inlet Elbow
44.1 Removal of the Coolant Inlet Elbow
44.2 Installation of the Coolant Inlet Elbow

45 Flywheel, Ring Gear and Flywheel Housing
45.1 Description and Operation of the Flywheel, Flywheel Housing and Related Parts
45.2 Removal of the Flywheel Housing
45.3 Inspection of the Flywheel Housing and Rear Oil Seal Area of Crankshaft
45.4 Installation of the Flywheel Housing
45.5 Removal of the Flywheel
45.6 Inspection of the Flywheel
45.7 Machining of the Flywheel
45.8 Installation of the Flywheel
45.9 Removal of the Ring Gear
45.10 Installation of the Ring Gear

46 Front Engine Mount/Radiator Support
46.1 Description and Operation of the Front Engine Mount/Radiator Support and Related Parts
46.2 Removal of the Front Engine Mount/Radiator Support
46.3 Inspection of the Front Engine Mount/Radiator Support
46.4 Installation of the Front Engine Mount/Radiator Support

47 Vibration Damper
47.1 Removal of the Vibration Damper
47.2 Installation of the Vibration Damper

48 Front Engine Cover
48.1 Description and Operation of the Front Engine Cover
48.2 Removal of the Front Engine Cover
48.3 Inspection of the Front Engine Cover
48.4 Installation of the Front Engine Cover

49 Engine Lifter Brackets
49.1 Description and Operation of the Engine Lifter Brackets and Related Parts
49.2 Removal of the Front Engine Lifter Bracket without Front Engine Power Take-off
49.3 Installation of the Front Engine Lifter Bracket without Front Engine Power Take-Off
49.4 Removal of the Front Engine Lifter Bracket with Front Engine Power Take-off
49.5 Installation of the Front Engine Lifter Bracket with Front Engine Power Take-Off
49.6 Removal of the Rear Engine Lifter Brackets
49.7 Inspection of the Engine Lifter Brackets
49.8 Installation of the Rear Engine Lifter Brackets

50 Belt Drive Tensioner System
50.1 Description and Operation of the Belt Drive Tensioner and Related Parts
50.2 Removal of the Belt Tensioner
50.3 Installation of the Belt Tensioner
50.4 Removal of the Idler Pulley and Idler Pulley Bracket
50.5 Inspection of the Idler Pulley Bracket
50.6 Installation of the Idler Pulley and Idler Pulley Bracket
50.7 Removal of the Non-Bracketed Idler Pulley
50.8 Installation of the Non-Bracketed Idler Pulley
50.9 Removal of the Accessory Mounting Bracket
50.10 Installation of the Accessory Mounting Bracket

51 Poly-V-Belts
51.1 Description and Operation of the Poly-V Belts
51.2 Removal of the Poly-V-Belts
51.3 Inspection of the Poly-V-Belts
51.4 Installation of the Poly-V-Belts

52 Air Compressor
52.1 Description and Operation of the Air Compressor
52.2 Removal of the Air Compressor
52.3 Inspection of the Air Compressor
52.4 Inspection of the Diesel Exhaust Fluid Compressed Air Flow System after Air Compressor Failure
52.5 Installation of the Air Compressor

53 Air Compressor Unloader Valve
53.1 Removal of the Air Compressor Unloader Valve
53.2 Inspection of the Air Compressor Unloader Valve
53.3 Installation of the Air Compressor Unloader Valve

54 Cylinder Block
54.1 Description and Operation of the Cylinder Block and Related Parts
54.2 Removal and Disassembly of the Engine from Vehicle
54.3 Cleaning the Cylinder Block
54.4 Inspection of the Cylinder Block
54.5 Inspection of the Main Bearing Bores
54.6 General Inspection and Rust Prevention of the Cylinder Block
54.7 Reassembly and Installation of the Cylinder Block
54.8 Removal of the Gear Case Front Cover
54.9 Installation of the Gear Case Front Cover

55 Engine Wiring Harness
55.1 Removal of the Engine Wiring Harness -Three-Filter Fuel System
55.2 Installation of the Engine Wiring Harness -Three-Filter Fuel System
55.3 Removal of the Engine Wiring Harness – Two-Filter Fuel System
55.4 Installation of the Engine Wiring Harness – Two-Filter Fuel System

56 Clutch
56.1 Removal of the Clutch
56.2 Installation of the Clutch

57 Pilot Bearing
57.1 Removal of the Pilot Bearing
57.2 Installation of the Pilot Bearing

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