Detroit Turbotronic 638 Engine Service Repair Manual (LATEST)


Covers: Detroit / Turbotronic Series 638 Diesel Engine
Pages: 355
Format: PDF
File size: 18mb
Works with: Windows/Mac/Tablet
Notes: Bookmarked, searchable, printable, instant download

This repair manual contains complete instructions on operation, adjustment (tune-up), preventive maintenance and lubrication, and repair (including complete overhaul) for the Detroit Series 638 engine. This manual was written primarily for persons servicing and overhauling the Series 638 engine. In addition, this repair manual contains all of the instructions essential to the operators and users.‪

Latest edition, 2017.


General Information


  • Cylinder Block
  • Rocker Covers
  • Rocker Arm Assembly
  • Cylinder Head
  • Hydraulic Lifters
  • Front Cover
  • Vacuum Pump
  • Camshaft
  • Piston and Piston Ring
  • Connecting Rod
  • Crankshaft
  • Crankshaft Vibration Damper
  • Crankshaft Pulley
  • Front Oil Seal
  • Flywheel
  • Flywheel Housing
  • Cylinder Liner
  • Rear Main Bearing Carrier
  • Rear Main Seal (Flywheel Housing Installed)
  • Rear Main Seal (Flywheel Housing Removed)

Fuel System

  • Overview of Fuel System
  • Transfer Pump
  • Injector Pump
  • High Pressure Fuel Lines
  • Fuel Nozzle
  • Engine Speed Sensor
  • Coolant Temperature Sensor (ECM)
  • Coolant Temperature Switch (Dash Light)
  • Glow Plugs
  • Glow Plug Harness

Lubrication System

  • Overview of Lubrication System
  • Oil Pan
  • Oil Pump
  • Exterior Oil Line
  • Oil Filter Adaptor
  • Oil Pickup Tube
  • Oil Pressure Valve
  • Oil Dipstick Assembly

Cooling System

  • Overview of Cooling System
  • Water Pump
  • Engine Cooling Fan
  • Water Manifold
  • Thermostat

Fuel, Lubricating Oil, and Coolant

Air Intake System

  • Overview of Air Intake System
  • Intake Manifold
  • Intake Manifold Elbow
  • Air Gas Recirculator Valve
  • Turbocharger

Exhaust System Overview

Electrical Equipment

  • Overview of Electrical System
  • Battery Charging Alternator
  • Starter

Power Take-Off

  • Rear-Mounted Power Take-Off
  • Front-Mounted Power Take-Off

Special Equipment

Operation and Verification

  • Preparation for a First Time Start
  • Starting
  • Running
  • Stopping
  • Operating Conditions
  • Engine Run-in Instructions

Engine Tune-Up

Preventive Maintenance

  • Overview of Preventive Maintenance
  • Daily Maintenance
  • Maintenance of Vehicle Engines
  • Description of Maintenance Items

Engine Storage

  • Preparing Engine for Storage
  • Restoring An Extended Storage Engine

Basic Troubleshooting

  • Basic Knowledge Required
  • Testing the Electronic Control System
  • Engine Will Not Crank or Cranks Slowly
  • Low Battery Voltage
  • No Voltage to Starter Solenoid
  • Starting Circuit Connections Loose or Corroded
  • Starter Motor Operating – Engine Will Not Crank
  • Starter Motor or Starter Solenoid Inoperative

Service Tools


General Specifications
Total Displacement (L) 3.8
Total Displacement (in. ) 231
Type Four-cycle
Number of Cylinders 6
Bore mm (in.) 92 (3.62)
Stroke mm (in.) 94 (3.7)
Compression Ratio 21:1
Number of Main Bearings 7
SKU: MPM00165 Category: Tags: , , ,

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