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
File size: 44mb
Compatibility: Windows/Mac/Tablet

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:

Warnings

Rocker Cover
Description and Operation of Rocker Cover and Related Parts
Removal of the Rocker Cover
Cleaning and Inspection of the Rocker Cover
Installation of the Rocker Cover

Camshaft and Rocker Shaft/Engine Brake Assembly
Description and Operation of Camshaft and Rocker Shaft/Engine Brake Assembly and Related Parts
Description and Operation of Engine Braking
Removal of the Rocker Shaft Assembly
Removal of the Camshafts
Inspection of the Camshaft and Rocker Shaft/Engine Brake Assembly
Installation of the Camshafts
Installation of the Rocker Shafts

Camshaft Housing
Description and Operation of the Camshaft Housing
Removal of the Camshaft Housing
Inspection of the Camshaft Housing
Installation of the Camshaft Housing

Camshaft Timing
Camshaft Timing Verification
Timing the Camshafts with the Gear Train Installed

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

Coolant Crossover Pipe
Description and Operation of the Coolant Crossover Pipe
Removal of the Coolant Crossover Pipe
Installation of the Coolant Crossover Pipe

DD15 and DD16 Water Manifold Assembly
Description and Operation of DD15 and DD16 Water Manifold and Related Components
Removal of the DD15 and DD16 Water Manifold
Cleaning and Inspection of the DD15 and DD16 Water Manifold
Installation of the DD15 and DD16 Water Manifold

DD13 Exhaust Gas Recirculation Cooler – Water Manifold Assembly
Description and Operation of DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Inspection of the DD13 EGR Cooler Water Manifold Assembly
Testing and Inspection of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Installation of the DD13 EGR Cooler Water Manifold Assembly

Cold Boost Pipe (Charge Air Pipe)
Description and Operation of Cold Boost Pipe (Charge Air Pipe) and Related Components
Removal of the Cold Boost Pipe (Charge Air Pipe)
Inspection of Cold Boost Pipe (Charge Air Pipe)
Installation of the Cold Boost Pipe (Charge Air Pipe)

Composite Cold Boost Pipe
Description and Operation of the Composite Cold Boost Pipe (Charge Air Pipe) and Related Components
Inspection of Composite Cold Boost Pipe (Charge Air Pipe)
Removal of the Composite Cold Boost Pipe (Charge Air Pipe)
Installation of the Composite Cold Boost Pipe (Charge Air Pipe)

Air Intake Manifold
Description and Operation of the DD13 Air Intake Manifold and Related Parts
Description and Operation of the DD15-DD16 Air Intake Manifold and Related Parts
Removal of the Air Intake Manifold
Cleaning of the Air Intake Manifold
Inspection of the Air Intake Manifold
Installation of Air Intake Manifold

DD13 Turbocharger
Description and Operation of the DD13 Turbocharger and Related Parts
Removal of the DD13 Turbocharger
Inspection of the Turbocharger
Installation of the DD13 Turbocharger

DD13 Wastegate Solenoid
Description and Operation of the EPA10 DD13 Wastegate Solenoid
Removal of the DD13 Wastegate Solenoid
Installation of the DD13 Wastegate Solenoid
Functional Check of the DD13 Wastegate Actuator

GHG14 DD15 Wastegate Solenoid
Description and Operation of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid
Removal of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid
Installation of the GHG14 DD15 Asymmetrical Turbocharger Wastegate Solenoid

DD15 and DD16 Turbocharger
Description and Operation of the DD15 – DD16 Turbocharger and Related Parts
Removal of the DD15 and the DD16 Turbocharger
Inspection of the DD15 and DD16 Turbocharger
Installation of the DD15 and the DD16 Turbocharger
Removal of the GHG14 DD15 Asymmetrical Turbocharger
Installation of the GHG14 DD15 Asymmetrical Turbocharger

DD15 and DD16 Axial Power Turbine
Description and Operation of the DD15 and DD16 Axial Power Turbine and Related Parts
Removal of the DD15 and DD16 Axial Power Turbine
Inspection of the DD15 and DD16 Axial Power Turbine
Installation of the DD15 and DD16 Axial Power Turbine

DD15 and DD16 Axial Power Turbine Gear Box
Description and Operation of DD15 and DD16 Axial Power Turbine Gear Box and Related Parts
Removal of the DD15 and DD16 Axial Power Turbine Gear Box
Inspection of the DD15 and DD16 Axial Power Turbine Gear Box
Installation of the DD15 and DD16 Axial Power Turbine Gear Box

Cylinder Head
Description and Operation of the Cylinder Head and Related Parts
Removal of the DD13 Cylinder Head
Inspection of the Cylinder Head – DD
Cleaning of the Cylinder Head
Assembly of Cylinder Head
Installation of the DD13 Cylinder Head
Removal of the DD15 and DD16 Cylinder Head
Cleaning of the Cylinder Head
Assembly of Cylinder Head
Installation of the DD15 and DD16 Cylinder Head

Intake and Exhaust Valves and Valve Springs
Removal of the Valve Spring (Cylinder Head Installed)
Removal of the Valve Spring (Cylinder Head Removed)
Removal of Intake and Exhaust Valves
Cleaning of the Valves and Related Parts
Inspection of the Intake and Exhaust Valves
Installation of the Valve, Spring, Seal and Valve Cap
Valve Lash Adjustments
Setting the Engine Brake Lash

Piston and Connecting Rod Assembly
Description and Operation of the Piston and Connecting Rod and Related Parts
Removal of the Piston and Connecting Rod Assembly
Disassembly of Piston and Connecting Rod Assembly
Assembly of the Piston and Connecting Rod Assembly
Installation of the Piston and Connecting Rod Assembly

Cylinder Liner
Description and Operation of the Cylinder Liner and Related Parts
Removal of the Cylinder Liner
Inspection of the Cylinder Liner
Cleaning of the Cylinder Liner
Installation of the Cylinder Liner

Crankshaft
Description and Operation of the Crankshaft and Related Parts
Removal of the Crankshaft
Inspection of the Crankshaft and Related Parts
Installation of the Crankshaft
Inspection of the Main and Connecting Rod Bearing in Chassis

Crankshaft Oil Seals
Removal of the Rear Crankshaft Oil Seal
Installation of the Rear Crankshaft Oil Seal
Removal of the Front Crankshaft Oil Seal
Installation of the Front Crankshaft Oil Seal

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

Oil Pan
Description and Operation of the Oil Pan and Related Components
Removal of the Oil Pan
Cleaning of the Oil Pan
Inspection of the Oil Pan
Removal of the Threaded Insert (Plastic Oil Pan Only)
Installation of the Threaded Insert (Plastic Oil Pan Only)
Installation of the Oil Pan

Oil Level/Temperature Sensor
Description and Operation of the Oil Level/Temperature Sensor
Removal of the Oil Level/Temperature Sensor
Installation of the Oil Level/Temperature Sensor

Oil Dipstick Tube
Description and Operation of the Oil Dipstick Tube and Related Components
Removal of the Oil Dipstick Tube
Installation of the Oil Dipstick Tube

Oil Pump, Oil Suction Manifold, and Oil Lines
Description and Operation of Oil Pump and Related Components
Removal of the Oil Pump, Oil Suction Manifold, and Oil Lines
Inspection of the Oil Pump, Oil Suction Manifold, and Oil Lines
Installation of the Oil Pump, Oil Suction Manifold, and Oil Lines

Crankcase Breather
Description and Operation of the Crankcase Breather
Removal of the Crankcase Breather
Inspection of the Crankcase Breather
Installation of the Crankcase Breather

Oil Filter
Replacement of the Oil Filter

Oil Sample Valve
Replacing Oil Plug with Oil Sample Valve
Removal of Oil Sample Valve
Installation of the Oil Sample Valve

Oil Filler Neck
Removal of the Oil Filler Neck
Installation of the Oil Filler Neck

Oil Coolant Module
Description and Operation of the Oil Coolant Module
Removal of the Oil Coolant Module
Installation of the Oil Coolant Module
Removal of the Oil Coolant Module Plugs
Installation of the Oil Coolant Module Plugs

Oil Cooler
Removal of the Oil Cooler
Inspection and Pressure Testing of the Oil Cooler
Installation of the Oil Cooler

Oil Thermostat
Removal of the Oil Thermostat
Installation of the Oil Thermostat

Priming the Lubrication System
Priming the Engine Lubrication System

Cooling System
Description and Operation of the Cooling System and Related Components
Cooling System Drain Procedure
Cooling System Fill Procedure

Engine Water Pump
Description and Operation of the Engine Water Pump
Removal of the Water Pump
Inspection of the Water Pump
Installation of the Water Pump

Variable Speed Engine Water Pump
Description and Operation of the Variable Speed Engine Water Pump
Removal of the Variable Speed Water Pump
Inspection of the Variable Speed Water Pump
Installation of the Variable Speed Water Pump
Removal of the Variable Speed Water Pump Pulley
Installation of the Variable Speed Water Pump Pulley

Coolant Thermostat
Description and Operation of the Coolant Thermostat
Removal of the Engine Coolant Thermostat and Seal
Inspection of the Coolant Thermostat and Seal
Installation of the Coolant Thermostat and Seal

Coolant Filter
Description and Operation of the Coolant Filter
Removal of the Coolant Filter
Installation of the Coolant Filter

Coolant Filter Service Module
Removal of the Coolant Filter Service Module
Installation of the Coolant Filter Service Module

Coolant Inlet Elbow
Removal of the Coolant Inlet Elbow
Installation of the Coolant Inlet Elbow

Flywheel, Ring Gear and Flywheel Housing
Description and Operation of the Flywheel, Flywheel Housing and Related Parts
Removal of the Flywheel Housing
Inspection of the Flywheel Housing and Rear Oil Seal Area of Crankshaft
Installation of the Flywheel Housing
Removal of the Flywheel
Inspection of the Flywheel
Machining of the Flywheel
Installation of the Flywheel
Removal of the Ring Gear
Installation of the Ring Gear

Front Engine Mount/Radiator Support
Description and Operation of the Front Engine Mount/Radiator Support and Related Parts
Removal of the Front Engine Mount/Radiator Support
Inspection of the Front Engine Mount/Radiator Support
Installation of the Front Engine Mount/Radiator Support

Vibration Damper
Removal of the Vibration Damper
Installation of the Vibration Damper

Front Engine Cover
Description and Operation of the Front Engine Cover
Removal of the Front Engine Cover
Inspection of the Front Engine Cover
Installation of the Front Engine Cover

Engine Lifter Brackets
Description and Operation of the Engine Lifter Brackets and Related Parts
Removal of the Front Engine Lifter Bracket without Front Engine Power Take-off
Installation of the Front Engine Lifter Bracket without Front Engine Power Take-Off
Removal of the Front Engine Lifter Bracket with Front Engine Power Take-off
Installation of the Front Engine Lifter Bracket with Front Engine Power Take-Off
Removal of the Rear Engine Lifter Brackets
Inspection of the Engine Lifter Brackets
Installation of the Rear Engine Lifter Brackets

Belt Drive Tensioner System
Description and Operation of the Belt Drive Tensioner and Related Parts
Removal of the Belt Tensioner
Installation of the Belt Tensioner
Removal of the Idler Pulley and Idler Pulley Bracket
Inspection of the Idler Pulley Bracket
Installation of the Idler Pulley and Idler Pulley Bracket
Removal of the Non-Bracketed Idler Pulley
Installation of the Non-Bracketed Idler Pulley
Removal of the Accessory Mounting Bracket
Installation of the Accessory Mounting Bracket

Poly-V-Belts
Description and Operation of the Poly-V Belts
Removal of the Poly-V-Belts
Inspection of the Poly-V-Belts
Installation of the Poly-V-Belts

Air Compressor
Description and Operation of the Air Compressor
Removal of the Air Compressor
Inspection of the Air Compressor
Inspection of the Diesel Exhaust Fluid Compressed Air Flow System after Air Compressor Failure
Installation of the Air Compressor

Air Compressor Unloader Valve
Removal of the Air Compressor Unloader Valve
Inspection of the Air Compressor Unloader Valve
Installation of the Air Compressor Unloader Valve

Cylinder Block
Description and Operation of the Cylinder Block and Related Parts
Removal and Disassembly of the Engine from Vehicle
Cleaning the Cylinder Block
Inspection of the Cylinder Block
Inspection of the Main Bearing Bores
General Inspection and Rust Prevention of the Cylinder Block
Reassembly and Installation of the Cylinder Block
Removal of the Gear Case Front Cover
Installation of the Gear Case Front Cover

Engine Wiring Harness
Removal of the Engine Wiring Harness #NAME? Fuel System
Installation of the Engine Wiring Harness #NAME? Fuel System
Removal of the Engine Wiring Harness – Two-Filter Fuel System
Installation of the Engine Wiring Harness – Two-Filter Fuel System

Clutch
Removal of the Clutch
Installation of the Clutch

Pilot Bearing
Removal of the Pilot Bearing
Installation of the Pilot Bearing

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