DD Platform Euro IV General Information / Preventive Maintenance Workshop Manual

DDC-SVC-MAN-0180
DD Platform EuroIV General

Information / Preventive Maintenance
Workshop Manual
Specifications are subject to change without notice. Detroit Diesel Corporation is registered to ISO 9001:2001.
Copyright © Detroit Diesel Corporation. All rights reserved. Detroit Diesel Corporation is a Daimler company.
Printed in U.S.A.
Table of Contents
Table of Contents
1 General Information............................................................................................................................................................... 3
2 General Specifications............................................................................................................................................................. 6
3 Safety Precautions................................................................................................................................................................... 9
4 Scope and Use of This Manual............................................................................................................................................. 15
4.1 Scope and Use of This Manual..................................................................................................................................... 15
5 Engine Model and Serial Number Designation.................................................................................................................. 16
6 Replacing and Repairing...................................................................................................................................................... 18
7 Disassembly............................................................................................................................................................................ 19
8 Cylinder Block Cleaning....................................................................................................................................................... 20
9 Additional Cleaning and Preparing..................................................................................................................................... 21
10 DD Platform Engine Views................................................................................................................................................. 24
11 Conversions Equivalents Specifications............................................................................................................................ 27
12 Fluids and Lubrication Requirements............................................................................................................................... 31
13 Coolant Requirements......................................................................................................................................................... 33
14 Preventive Maintenance Intervals..................................................................................................................................... 41
14.1 EPA07 DD Series Preventive Maintenance Tables.................................................................................................... 44
15 Monitoring the Lubricating Oil......................................................................................................................................... 47
16 How to Replace the Lubricating Oil and Oil Filter.......................................................................................................... 49
17 Engine Oil Capacities.......................................................................................................................................................... 51
17.1 Engine Oil Capacities.................................................................................................................................................. 51
18 Monitoring the Cooling System.......................................................................................................................................... 52
19 Preparing Engine for Storage............................................................................................................................................. 55
19.1 Temporary Storage (30 Days or Less)........................................................................................................................ 55
19.2 Extended Storage (More than 30 Days)...................................................................................................................... 55
20 Procedure for Restoring to Service an Engine that Has Been in Extended Storage..................................................... 58
21 Torque Specifications.......................................................................................................................................................... 59
21.1 Engine System Torque Specifications......................................................................................................................... 59
21.2 Fuel System Torque Specifications............................................................................................................................. 61
21.3 Air Intake System / Exhaust System / Exhaust Gas Recirculation System Torque Specifications............................ 62
21.4 Lubrication System / Cooling System Torque Specifications.................................................................................... 65
21.5 Electrical System Torque Specifications..................................................................................................................... 66
22 DD15 and DD16 Specifications, New Clearances, and Wear Limits.............................................................................. 67
22.1 DD15 and DD16 Specifications, New Clearances, and Wear Limits......................................................................... 67
22.2 DD15 and DD16 Oil Pressure Specifications............................................................................................................. 70
2 All information subject to change without notice.

Copyright © 2013 DETROIT DIESEL CORPORATION DDC-SVC-MAN-0180
DD Platform EuroiV General Information / Preventive Maintenance Workshop Manual
1 General Information
Scope and Use of this Manual
NOTICE: Any Aftertreatment System components that are NOT a part of the Engine System require the
technician to refer to Aftertreatment System OEM documentation for service procedure instructions. A description
of the Aftertreatment System components that ARE a part of the Engine System can be referenced in the
Aftertreatment section of the applicable Detroit™ Workshop Manual.
This manual contains complete instructions on operation, adjustment (tune-up), preventive maintenance, and repair
(including complete overhaul) for the DD Platform Engine. This manual was written primarily for persons servicing and
overhauling the engine. In addition, this manual contains all of the instructions essential to the operators and users. Basic
maintenance and overhaul procedures are common to all DD Platform Engines, and apply to all engine models.
This manual is divided into numbered sections. Section one covers the engine (less major assemblies). The following sections
cover a complete system such as the fuel system, lubrication system, or air system. Each section is divided into subsections
which contain complete maintenance and operating instructions for a specific engine subassembly. Each section begins with
a table of contents. Pages and illustrations are numbered consecutively within each section.
Information can be located by using the table of contents at the front of the manual or the table of contents at the beginning of
each section. Information on specific subassemblies or accessories within the major section is listed immediately following
the section title.
Clearance of New Parts and Wear Limits

New parts clearances apply only when all new parts are used at the point where the various specifications apply. This also
applies to references within the text of the manual. The column entitled "Limits" must be qualified by the judgement of
personnel responsible for installing new parts.
The Four-Cycle Principle for Diesel Engines

The diesel engine is an internal combustion engine, in which the energy of burning fuel is converted into energy to work the
cylinder of the engine. In the diesel engine, air alone is compressed in the cylinder, raising its temperature significantly. After
the air has been compressed, a charge of fuel is sprayed into the cylinder and ignition is accomplished by the heat of
compression. The four piston strokes of the cycle occur in the following order: intake, compression, power and exhaust.
Intake Stroke
During the intake stroke, the piston travels downward, the intake valves are open, and the exhaust valves are closed. The
down stroke of the piston facilitates air from the intake manifold to enter the cylinder through the open intake valve. The
turbocharger, by increasing the air pressure in the engine intake manifold, assures a full charge of air is available for the
cylinder. The intake charge consists of air only with no fuel mixture.
Compression Stroke
At the end of the intake stroke, the intake valves close and the piston starts upward on the compression stroke. The exhaust
valves remain closed. At the end of the compression stroke, the air in the combustion chamber has been compressed by the
piston to occupy a space about one-seventeenth as great in volume as it occupied at the beginning of the stroke. Thus, the
compression ratio is 18.1. Compressing the air into a small space causes the temperature of that air to rise. During the last
part of the compression stroke and the early part of the power stroke, a small metered charge of fuel is injected into the
combustion chamber. Almost immediately after the fuel charge is injected into the combustion chamber, the fuel is ignited by
the hot air and starts to burn, beginning the power stroke.
Power Stroke
During the power stroke, the piston travels downward and all intake and exhaust valves are closed. As the fuel is added and
burns, the gases get hotter, the pressure increases, pushing the piston downward and adding to crankshaft rotation.
All information subject to change without notice. 3

DDC-SVC-MAN-0180 Copyright © 2013 DETROIT DIESEL CORPORATION
1 General Information
Exhaust Stroke
During the exhaust stroke, the intake valves are closed; the exhaust valves are open, and the piston is on its up stroke. The
burned gases are forced out of the combustion chamber through the open exhaust valve port by the upward travel of the
piston. From the preceding description, it is apparent that the proper operation of the engine depends upon the two separate
functions: first, compression for ignition, and second, that fuel be measured and injected into the compressed air in the
cylinder in the proper quantity and at the proper time.
General Description
The DD Platform Engines described in this manual is a four-stroke cycle, high speed, diesel engine. It uses an inline cast iron
block and has a cast iron cylinder head, aluminum camshaft frame and a dual overhead camshafts. The vertically aligned gear
train, located at the rear end of the engine in a gear case, contains gears for the lubricating oil pump, crankshaft, camshafts,
air compressor drive, fuel pump drive, and axial power turbine (APT) if applicable.
Full pressure lubrication is supplied to all main, connecting, camshaft and rocker assembly bearings and to other moving
parts. The oil spray nozzles spray engine oil continuously below the piston crowns to ensure that they are cooled. A gear-type
pump draws oil from the oil pan through a screen and delivers it to the oil coolant module. The engine oil is first fed through
the oil/water heat exchanger located on the oil coolant module. During the cold start phase of the engine the oil/water heat
exchanger will rapidly warm the oil. After the warm-up phase of the engine the oil/water heat exchanger will cool the engine
oil. Once the engine oil has passed through the oil/water heat exchanger it then goes to the oil filter. Part of the clean oil goes
to the camshaft frame where it feeds the camshaft bearings and rocker assemblies. The remainder of the oil goes to the main
bearings, connecting rod bearings and gear train via the drilled oil passages in the crankshaft. The turbocharger is supplied
with engine oil by an external oil line. Oil returns to the oil pan by return ducts and return holes in the cylinder head and
cylinder block.
Coolant is circulated through the engine by a centrifugal-type water pump. The cooling system, including the radiator, is a
closed system. Heat is removed from the coolant by the radiator. Control of the engine temperature is accomplished by a
thermostat that regulates the flow of the coolant within the cooling system.
The fuel supply ensures that the fuel required for combustion is available under all operating conditions in the sufficient
quantity, at the correct time and at the required pressure. Fuel to the individual cylinders is supplied via the Amplified
Pressure Common Rail System (APCRS). The fuel system is supplied fuel via the low pressure fuel circuit, then to the high
pressure pump, then to the fuel rail where it is distributed to the individual injectors. system.
Air is supplied by the turbocharger to the intake manifold and into the engine cylinders after passing through an air-to-air
charge air cooler mounted ahead of the cooling system radiator. The charge air cooler cools the pressurized intake air charge
coming from the turbocharger before it enters the intake manifold.
Engine starting is provided by an electric starter motor energized by a battery. An alternator, with a suitable voltage regulator,
keeps the battery charged.
The DD Platform Engines were designed to be electronically controlled. The Detroit Diesel Electronic Control (DDEC)
system has evolved with the product.
Detroit Diesel Electronic Controls (DDEC) VI

The DDEC VI Motor Control Unit (MCM) receives electronic inputs from sensors on the engine and vehicle, and uses the
information to control engine operation. It computes fuel timing and fuel quantity based upon predetermined calibration
tables in its memory. DDEC VI provides an indication of engine and vehicle malfunctions. The Motor Control Unit (MCM)
continually monitors the DDEC VI system. Any faults that occur are stored as codes in the MCM's memory. A Detroit Diesel
Diagnostic Link (DDDL®) can be used to read the codes.
Detroit Diesel Electronic Controls (DDEC) 10

The DDEC10 Motor Control Unit (MCM2) receives electronic inputs from sensors on the engine and vehicle, and uses the
tables in its memory. DDEC10 provides an indication of engine and vehicle malfunctions. The Motor Control Unit (MCM2)
continually monitors the DDEC10 system. Any faults that occur are stored as codes in the MCM2’s memory. A Detroit
Diesel Diagnostic Link (DDDL®) can be used to read the codes.

Detroit Diesel Electronic Controls (DDEC) 13

The DDEC13 Motor Control Unit (MCM2.1) receives electronic inputs from sensors on the engine and vehicle, and uses the
tables in its memory. DDEC10 provides an indication of engine and vehicle malfunctions. The Motor Control Unit
(MCM2.1) continually monitors the DDEC13 system. Any faults that occur are stored as codes in the MCM2.1’s memory. A
Detroit Diesel Diagnostic Link (DDDL®) can be used to read the codes.

2 General Specifications
The general specifications for the DD Platform Engines are shown below.
Table 1.
Specifications for the DD Platform Engine
General Specifications DD13 DD15 DD16
Total Displacement (L) 12.8 14.8 15.6
Number of Cylinders 6 6 6
Valve Control DOHC DOHC DOHC
Number of Valves per Cylinder
2/2 2/2 2/2
(Intake/Exhaust)
Idle Speed 600 (rpm) 600 (rpm) 600 (rpm)
Max. Output (kW) 375 418 447
Combustion Pressure Max. (bar) 220 220 220
Compression Ratio 17.3 18:0 17.1
Stroke 156 (mm) 163 (mm) 171 (mm)
Stroke Bore Ratio 1.18 1.17 1.23
Table 2.
Filling Capacity for the EPA10/GHG14 DD Platform Engine
Truck DD13 DD15 DD16
Total Dry Engine Oil Volume 44.0 L (46.5 qt) 49.0 L (51.8 qt) 49.0 L (51.8 qt)
Oil and Filter Change 38.0 L (40.1 qt) 43.0 L (45.4 qt) 43.0 L (45.4 qt)
Remaining in Engine after Oil
6.0 L (6.3 qt) 6.0 L (6.3 qt) 6.0 L (6.3 qt)
Drain (Includes Filter Removal)
Dip Stick Min. to Max. Range 5.0 L (5.2 qt) 5.0 L (5.2 qt) 5.0 L (5.2 qt)
Sump Oil Volume 35.0 L (37.0 qt) 40.0 L (42.3 qt) 40.0 L (42.3 qt)
Table 3.
Filling Capacity for the EPA07 DD Platform Engine
Truck DD13 DD15 DD16
Total Dry Engine Oil Volume 44.0 L (46.5 qt) 49.0 L (51.8 qt) 49.0 L (51.8 qt)
Oil and Filter Change 38.0 L (40.1 qt) 43.0 L (45.4 qt) 43.0 L (45.4 qt)
6.0 L (6.3 qt) 6.0 L (6.3 qt) 6.0 L (6.3 qt)
Dip Stick Min. to Max. Range 5.0 L (5.2 qt) 5.0 L (5.2 qt) 5.0 L (5.2 qt)
Sump Oil Volume 35.0 L (37.0 qt) 40.0 L (42.3 qt) 40.0 L (42.3 qt)

Table 4.
Filling Capacity for the EPA07 DD Platform Engine (Coach)
Coach DD13 DD15 DD16
Total Dry Engine Oil Volume 51.0 L (53.8 qt) NA NA
Oil and Filter Change 45.0 L (47.6 qt) NA NA
6.0 L (6.3 qt) NA NA
Dip Stick Min. to Max. Range 5.0 L (5.2 qt) NA NA
Sump Oil Volume 42.0 L (44.4 qt) NA NA
Table 5.
Piston Specifications for the EPA10/GHG14 DD Platform Engine
Piston Specifications DD13 DD15 DD16
Diameter 132 mm (5.197 in.) 139 mm (5.472 in.) 139 mm (5.472 in.)
Total Height 113.5 mm (4.469 in.) 119.5 mm (4.705 in.) 119.5 mm (4.705 in.)
Compression Height 75 mm (2.953 in.) 81.5 mm (3.189 in.) 81.5 mm (3.189 in.)
Table 6.
Piston Specifications for the EPA07 DD Platform Engine
Piston Specifications DD13 DD15
Diameter 132 mm (5.197 in.) 139 mm (5.472 in.)
Total Height 113.5 mm (4.469 in.) 124.5 mm (4.902 in.)
Compression Height 75 mm (2.953 in.) 83.5 mm (3.287 in.)
Table 7.
Piston Pin Specifications for the DD Platform Engine
Piston Pin Specifications DD13 DD15 DD16
Outside Diameter 58 mm (2.283 in.) 62 mm (2.441 in.) 62 mm (2.441 in.)
Length 88 mm (3.465 in.) 92 mm (3.622 in.) 92 mm (3.622 in.)
Table 8.
Fuel System Specifications for the DD Platform Engine
DD13 DD15 DD15 AT DD16
Rail Pressure Max. 850 bar 900 bar 1150 bar 900 bar
Injection Pressure Max. 2000 bar 2200 bar 2500 bar 2200 bar
Table 9.
Crankshaft Bearing Specifications for the DD Platform Engine
Crankshaft Bearing
DD13 DD15 DD16
Specifications
Width 36 mm (1.417 in.) 39.5 mm (1.555 in.) 39.5 mm (1.555 in.)

Table 10.
Connecting Rod Specifications for the DD Platform Engine
Connecting Rod Specifications DD13 DD15 DD16
Length 268 mm (10.55 in.) 276 mm (10.87 in.) 274 mm (10.78 in.)
Table 11.
Connecting Rod Bearing Specifications for the DD Platform Engine
Crankshaft Rod Bearing
DD13 DD15 DD16
Specifications
Width 36.4 mm (1.433 in.) 39.5 mm (1.555 in.) 39.5 mm (1.555 in.)
Table 12.
Cylinder Block Specifications for the DD Platform Engine
Cylinder Block Specifications DD13 DD15 DD16
Cylinder Diameter (mm) 132 mm (5.197 in.) 138.6 mm (5.456 in.) 138.6 mm (5.456 in.)
Cylinder Clearance (mm) 165 mm (6.496 in.) 173 mm (6.811 in.) 173 mm (6.811 in.)
Figure 1. Cylinder Designation and Firing Order

3 Safety Precautions
The following safety measures are essential when working on any Detroit™ engine.
Exhaust (Start/Run Engine)

Before starting and running an engine, adhere to the following safety precautions:
WARNING: PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.

Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
Stands
Safety stands are required in conjunction with hydraulic jacks or hoists. Do not rely on either the jack or the hoist to carry the
load. When lifting an engine, ensure the lifting device is fastened securely. Ensure the item to be lifted does not exceed the
capacity of the lifting device.
Glasses
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when using tools such as
hammers, chisels, pullers or punches.
WARNING: EYE INJURY

To avoid injury from flying debris when using compressed air, wear adequate eye protection (face
shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
Welding
Wear welding goggles and gloves when welding or using an acetylene torch.


To avoid injury from arc welding, gas welding, or cutting, wear required safety equipment such as
an arc welder's face plate or gas welder's goggles, welding gloves, protective apron, long sleeve
shirt, head protection, and safety shoes. Always perform welding or cutting operations in a well
ventilated area. The gas in oxygen/acetylene cylinders used in gas welding and cutting is under
high pressure. If a cylinder should fall due to careless handling, the gage end could strike an
obstruction and fracture, resulting in a gas leak leading to fire or an explosion. If a cylinder should
fall resulting in the gage end breaking off, the sudden release of cylinder pressure will turn the
cylinder into a dangerous projectile. Observe the following precautions when using oxygen/
acetylene gas cylinders:
• Always wear required safety shoes.
• Do not handle tanks in a careless manner or with greasy gloves or slippery hands.
• Use a chain, bracket, or other restraining device at all times to prevent gas cylinders from falling.
• Do not place gas cylinders on their sides, but stand them upright when in use.
• Do not drop, drag, roll, or strike a cylinder forcefully.
• Always close valves completely when finished welding or cutting.
WARNING: FIRE
To avoid injury from fire, check for fuel or oil leaks before welding or carrying an open flame near
the engine.
NOTICE: Use proper shielding around hydraulic lines when welding to prevent hydraulic line damage.
Ensure that a metal shield separates the acetylene and oxygen that must be chained to a cart.
Work Place
Organize your work area and keep it clean. A fall could result in a serious injury. Eliminate the possibility of a fall by:
• Wiping up oil spills
• Keeping tools and parts off the floor
After servicing or adjusting the engine:
• Reinstall all safety devices, guards or shields
• Ensure that all tools and servicing equipment are removed from the engine
Clothing
Safe work clothing fits and is in good repair. Work shoes are sturdy and rough-soled. Bare feet, sandals or sneakers are not
acceptable foot wear when adjusting and/or servicing an engine. Do not wear the following when working on an engine.

To avoid injury when working on or near an operating engine, wear protective clothing, eye
protection, and hearing protection.
Any of these items could catch on moving parts causing serious injury:
• Rings
• Wrist watches
• Loose fitting clothing

Power Tools
Do not use defective portable power tools. Check for frayed cords prior to using the tool. Be sure all electric tools are
grounded. Defective electrical equipment can cause severe injury. Improper use of electrical equipment can cause severe
injury.
WARNING: ELECTRICAL SHOCK

To avoid injury from electrical shock, follow OEM furnished operating instructions prior to usage.
Air
Recommendations regarding the use of compressed air are indicated throughout the manual.
WARNING: EYE INJURY

Fluids and Pressure

Be extremely careful when dealing with fluids under pressure. Fluids under pressure can have enough force to penetrate the
skin. These fluids can infect a minor cut or opening in the skin. If injured by escaping fluid, see a doctor at once. Serious
infection or reaction can result without immediate medical treatment.

To avoid injury from penetrating fluids, do not put your hands in front of fluid under pressure. Fluids
under pressure can penetrate skin and clothing.
Fuel
Keep the hose and nozzle or the funnel and container in contact with the metal of the fuel tank when refueling to avoid the
possibility of an electric spark igniting the fuel.
WARNING: FIRE
To avoid injury from fire caused by heated diesel-fuel vapors:
• Keep those people who are not directly involved in servicing away from the engine.
• Stop the engine immediately if a fuel leak is detected.
• Do not smoke or allow open flames when working on an operating engine.
• Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).
• To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during
operation.
WARNING: GASOLINE VAPOR IGNITION

To avoid injury from possible gasoline vapor ignition when refueling, keep the hose, nozzle, funnel,
or container in contact with the metal opening of the fuel tank. This will reduce the likelihood of a
dangerous spark.
The following cautions should be followed when filling a fuel tank:

CAUTION: PERSONAL INJURY

To avoid injury from fuel spills, do not overfill the fuel tank.
WARNING: FIRE
To avoid injury from fire, keep all potential ignition sources away from diesel fuel, including open
flames, sparks, and electrical resistance heating elements. Do not smoke when refueling.
Batteries
Electrical storage batteries emit highly flammable hydrogen gas when charging and continue to do so for some time after
receiving a steady charge.
WARNING: Battery Explosion and Acid Burn

To avoid injury from battery explosion or contact with battery acid, work in a well ventilated area,
wear protective clothing, and avoid sparks or flames near the battery. If you come in contact with
battery acid:
• Flush your skin with water.
• Apply baking soda or lime to help neutralize the acid.
• Flush your eyes with water.
• Get medical attention immediately.
Always disconnect the battery cable before working on the electrical system.

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the
starting system.
Disconnect the batteries or disable an air starter when working on the engine (except DDEC) to prevent accidental starting.
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
Use care when connecting battery cables to avoid electrical shock.
Fire
Keep a charged fire extinguisher within reach. Be sure you have the correct type of extinguisher for the situation. The correct
fire extinguisher types for specific working environments are listed in the following table.

Table 13.
Fire Extinguisher Work Environment
Type A Wood, Paper, Textile and Rubbish
Type B Flammable Liquids
Type C Electrical Equipment
Cleaning Agent
Avoid the use of carbon tetrachloride as a cleaning agent because of the harmful vapors that it releases. Ensure the work area
is adequately ventilated. Use protective gloves, goggles or face shield, and apron.

To avoid injury from harmful vapors or skin contact, do not use carbon tetrachloride as a cleaning
agent.
Exercise caution against burns when using oxalic acid to clean the cooling passages of the engine.
Working on a Running Engine

When working on an engine that is running, accidental contact with the hot exhaust manifold can cause severe burns.
CAUTION: PERSONAL INJURY

To avoid injury from unguarded rotating and moving engine components, check that all protective
devices have been reinstalled after working on the engine.

To avoid injury, use care when working around moving belts and rotating parts on the engine.
Turbocharger Compressor Inlet Shield

A turbocharger compressor inlet shield, is available and must be used anytime the engine is operated with the air inlet piping
removed. The shield helps to prevent foreign objects from entering and damaging the turbocharger and will prevent the
mechanic from accidentally touching the turbocharger impeller.

To avoid injury from contact with rotating parts when an engine is operating with the air inlet piping
removed, install an air inlet screen shield over the turbocharger air inlet. The shield prevents
contact with rotating parts.
Use of this shield does NOT preclude any other safety practices contained in this manual.
Fluoroelastomer (VITON®) Caution

Under normal design conditions, fluoroelastomer (VITON®) parts, such as O-rings and seals, are perfectly safe to handle.

WARNING: CHEMICAL BURNS

To avoid injury from chemical burns, wear a face shield and neoprene or PVC gloves when
handling fluoroelastomer O-rings or seals that have been degraded by excessive heat. Discard
gloves after handling degraded fluoroelastomer parts.
However, a potential hazard may occur if these components are raised to a temperature above 316°C (600°F), such as during
a cylinder failure or engine fire. At temperatures above 316°C (600°F) fluoroelastomer will decompose (indicated by
charring or the appearance of a black, sticky mass) and produce hydrofluoric acid. This is extremely corrosive and, if touched
by bare skin, may cause severe burns, sometimes with symptoms delayed for several hours.

4 Scope and Use of This Manual
4.1 Scope and Use of This Manual

This manual contains complete instructions on operation, adjustments (including valve lash), preventive maintenance, and
repair (including complete overhaul) for the DD Platform engine family. This manual was written primarily for persons
servicing and overhauling the engine. In addition, this manual contains all of the instructions essential to the operators and
users. Basic maintenance and overhaul procedures are common to all DD Platform engines, and apply to all engine models.
This manual is divided into numbered sections. Section One covers the engine (less major assemblies). The remaining
sections cover a complete system such as the fuel system, lubrication system, or air system. Each section is divided into
subsections which contain complete maintenance and operating instructions for a specific engine subassembly. Each section
begins with a table of contents. Pages and illustrations are numbered consecutively within each section.
Information can be located by using the table of contents at the front of the manual or the table of contents at the beginning of
each section. Information on specific subassemblies or accessories within the major section is listed immediately following
the section title.

5 Engine Model and Serial Number Designation
5 Engine Model and Serial Number Designation
The following information covers engine model number, serial number and certification label.
Engine Model and Serial Number
The fourteen-digit engine model and manufacturing serial number is etched on a pad located on the left front of the engine
cylinder block, above the date and time of manufacture. Using 472908S0005703 as an example:
• 472 = engine model (DD15 Euro IV)
• 908 = vehicle application (Freightliner)
• S = assembly plant (Detroit™)
• 0005703 = serial number
Figure 2. Engine Model and Serial Number Location

Engine Model Breakdown
• 472 - DD15
Motor Control Module and Engine Serial Number
The Motor Control Module (MCM) part number and Engine Serial Number (ESN) are located on the MCM label.

Figure 3. Motor Control Module Label

Engine Certification Exemption Label
An engine certification exemption label is attached to the engine rocker cover. This label certifies the engine conforms to
federal and state emissions regulations for its application. It gives the operating conditions under which certification was
made.
The following illustration is an EPA07 engine certification exemption label.
Figure 4. EPA07 Engine Certification Exemption Label

6 Replacing and Repairing
6 Replacing and Repairing
In many cases, a technician is justified in replacing parts with new material rather than attempting repair. However, there are
times when a slight amount of reworking or reconditioning may save a customer considerable added expense. Exchange
assemblies such as injectors, fuel pumps, water pumps and turbochargers are desirable service items.
Various factors such as the type of operation of the engine, hours in service and the next overhaul period must be considered
when determining whether new parts are installed or used parts are reconditioned to provide trouble-free operation.
For convenience and logical order in disassembly and assembly, the various subassemblies and other related parts mounted
on the cylinder block will be treated as separate items in the various sections of the manual.

7 Disassembly
A technician can be severely injured if caught in pulleys, belts or the fan of an engine that is accidentally started. To avoid
such a misfortune, take the following precautions before starting to work on an engine.

To avoid injury from accidental engine startup while servicing the engine, disconnect/disable the
starting system.

To avoid injury from the sudden release of a high-pressure hose connection, wear a face shield or
goggles. Bleed the air from the air starter system before disconnecting the air supply hose.
Before any major disassembly, the engine must be drained of lubricating oil, coolant and fuel.
To perform a major overhaul or other extensive repairs, the complete engine assembly, after removal from the engine base
and drive mechanism, should be mounted on an engine overhaul stand; then the various subassemblies should be removed
from the engine. When only a few items need replacement, it is not always necessary to mount the engine on an overhaul
stand.
Parts removed from an individual engine should be kept together so they will be available for inspection and assembly. Those
items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable wooden racks
or blocks, or a parts dolly.

8 Cylinder Block Cleaning
8 Cylinder Block Cleaning
Before removing any of the subassemblies from the engine (but after removal of the electrical equipment), the exterior of the
engine should be thoroughly cleaned.
NOTICE:
This cleaning procedure may be used on all ordinary cast iron and steel parts for the engine. Aluminum parts,
such as the flywheel housing, air intake manifold, oil filter adaptor and the camshaft gear access cover should
NOT be cleaned in this manner. Mention will be made of special procedures when necessary.
NOTICE:
The DD Platform Engine is equipped with various sensors and other electronic components which may be
damaged if subjected to the high temperatures in a solvent tank. Do not immerse any electrical components in a
solvent tank. Care should be taken to ensure that all electronic components are removed from the various engine
assemblies before they are immersed in a solvent tank.
Then, after each subassembly is removed and disassembled, the individual parts should be cleaned. Thorough cleaning of
each part is absolutely necessary before it can be satisfactorily inspected. Various items of equipment needed for general
cleaning are listed below.
The cleaning procedure used for all ordinary cast iron parts is the same as the following cylinder block cleaning procedure.
Any special cleaning procedures will be mentioned when required.
Remove cylinder liners before putting the block in cleaning or descaling baths, to avoid trapping cleaning agents in block
liner seating bores.
After stripping and before removing the cylinder block from the overhaul stand for cleaning and inspection, install the two
metric eye bolts into head bolt holes at each end of the cylinder block.
Remove all oil and water gallery and weep hole plugs to allow the cleaning solution to enter the inside of the oil and water
passages.
1. Using two metric eye bolts installed in the head bolt holes at opposite ends of the block, and with a suitable lifting
device and spreader bar, immerse and agitate the block in a hot bath of a commercial, heavy-duty alkaline solution.
2. Wash the block in hot water or steam clean it to remove the alkaline solution.
3. If the water jackets are heavily scaled, proceed as follows:
a. Agitate the block in a bath of inhibited phosphoric acid.
b. Allow the block to remain in the acid bath until the bubbling action stops (approximately 30 minutes).
c. Lift the block, drain it and immerse it again in the same acid solution for 10 more minutes. Repeat until all scale
is removed from the water jacket area.
d. Rinse the block in clear, hot water to remove the acid solution.
e. Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath.
f. Wash the block in clean water or steam clean it.
WARNING: EYE INJURY

4. Dry the cylinder block with compressed air.

5. Blow out all of the bolt holes and passages with compressed air.
6. Be certain that all water passages and oil galleries have been thoroughly cleaned. After the cylinder block has been
thoroughly cleaned and dried, install weep hole plugs and precoated pipe plugs. Install new cup plugs using a coating
of good grade non-hardening sealant such as Loctite® 620 or equivalent.

9 Additional Cleaning and Preparing
Steam Cleaning
A steam cleaner is a necessary item in a large shop and is useful for removing heavy accumulations of grease and dirt from
the exterior of the engine and its subassemblies.
Solvent Tank Cleaning

Aluminum or plastic parts such as the flywheel housing, fuel pump drive, air intake manifold, oil filter adaptor, camshaft gear
access cover, oil pan or rocker covers, should not be cleaned in this manner.
A tank of sufficient size to accommodate the largest part that will require cleaning (usually the cylinder block) should be
provided and provisions made for heating the cleaning solution.

To avoid injury while performing the test or procedure, wear adequate eye, face protection, and
heat-resistant gloves.
Fill the tank with a commercial heavy-duty solvent, that is heated to 52°C (125°F). Lower large parts directly into the tank
with a hoist. Place small parts in a wire mesh basket and lower them into the tank. Immerse the parts long enough to loosen
all of the grease and dirt.
Rinsing Bath
Provide another tank of similar size containing hot water for rinsing the parts.
Drying
WARNING: EYE INJURY

Parts may be dried with compressed air. In some cases the heat from the hot tanks will quite frequently complete drying of
the parts without the use of compressed air.
Rust Preventive
If parts are not to be used immediately after cleaning, dip them in a suitable rust preventive compound. The rust preventive
compound should be removed before installing the parts in an engine.
Gasket Removal
The gasket used on numerous mating surface joints results in a very thin film that must be removed from both surfaces prior
to reassembly. As many of the surfaces are aluminum and/or dimensionally critical, conventional scraping methods, or the
use of emery cloth for removing the gasket is not recommended. Four-inch, 3M Scotch-Brite® Surface Conditioning Discs,
used with an electric or air powered hand drill (with a speed of 15,000-18,000 r/min), have proven successful in removing the
gasket without damaging the mating surfaces of engine parts.

9 Additional Cleaning and Preparing
Figure 5. Conditioning Disc Gasket Removal

A coarse pad, is suitable for steel surfaces. A medium pad is recommended or aluminum surfaces. The pads are easily
interchangeable.
Figure 6. Scotch-Brite Surface Conditioning Disc Installation

Inspection
The purpose of parts inspection is to determine which parts can be used and which must be replaced. Although the engine
specifications given throughout the text will aid in determining which parts should be replaced, considerable judgment must
be exercised by the inspector. The guiding factors in determining the usability of worn parts, that are otherwise in good
condition, is the clearance between the mating parts and the rate of wear on each of the parts. If it is determined that the rate
of wear will maintain the clearances within the specified maximum allowable until the next overhaul period, the reinstallation
of used parts may be justified. Rate of wear of a part is determined by dividing the amount the part has worn by the hours it
has operated.

Many service replacement parts are available in various undersize or oversize as well as standard sizes. Also, service kits for
reconditioning certain parts and service sets that include all of the parts necessary to complete a particular repair job are
available.
A complete discussion of the proper methods of precision measuring and inspection are outside the scope of this manual.
However, every shop should be equipped with standard gages, such as dial bore gages, dial indicators, and inside and outside
micrometers.
In addition to measuring the used parts after cleaning, the parts should be carefully inspected for cracks, scoring, chipping
and other detrimental conditions.

10 DD Platform Engine Views
Engine views for the EPA10 DD13 engine is shown below.
1. Exhaust Gas Recirculation Actuator 5. Turbocharger

2. Exhaust Manifold 6. Fuel Doser Valve
3. Exhaust Gas Recirculation Cooler 7. Crankcase Breather
4. Coolant Elbow
Figure 7. DD13 Right Side Engine View

1. Water Pump 8. Doser Block Assembly

2. Oil Coolant Module 9. Single Air Compressor
3. Delta P Sensor 10. Fuel Filter Module
4. Engine Oil Filter 11. Motor Control Module (MCM)
5. Rocker Cover 12. Thermostat
6. Air Intake Manifold 13. Cylinder Block / Engine Serial Number Location
7. High Pressure Fuel Pump
Figure 8. DD13 Left Side Engine View
Engine views for the EPA10 DD15 engine is shown below.
1. Fuel Doser Valve 6. Alternator

2. Turbocharger Compound 7. Turbocharger
3. Exhaust Gas Recirculation Valve/Actuator 8. Crankcase Breather
4. Exhaust Gas Recirculation Cooler 9. Starter
5. Coolant Elbow
Figure 9. DD15 Engine Right Side View

1. Water Pump 5. Single Air Compressor

2. Delta P Sensor 6. Fuel Filter Module
3. Oil Coolant Module 7. Motor Control Module (MCM)
4. Fuel System 8. Thermostat
Figure 10. DD15 Engine Left Side View

11 Conversions Equivalents Specifications
Torque Specifications, Decimal and Metric equivalents, and English to metric conversions are located below.
ENGLISH TO METRIC CONVERSION

Shown below are the English to metric conversions.
Table 14.
Multiply Length By To get equivalent number of:
Inch (in.) 25.4 Millimeters (mm)
Foot (ft) 0.3048 Meters (m)
Yard (yd) 0.9144 Meters (m)
Mile (mile) 1.609 Kilometers (km)
Multiply Area By To get equivalent number of:
Inch² (in.²) 645.2 Millimeters² (mm²)
Inch² (in.²) 6.45 Centimeters² (cm²)
Foot² (ft²) 0.0929 Meters² (m²)
Yard² (yd²) 0.8361 Meters² (m²)
Multiply Volume By To get equivalent number of:
Inch³ (in.³) 16387 Millimeters³ (mm³ )
Inch³ (in.³ ) 16.387 Centimeters³ (cm³
Inch³ (in.³ ) 0.0164 Liters (L)
Quart (qt) 0.9464 Liters (L)
Gallon (gal) 3.785 Liters (L)
Yard³ (yd³ ) 0.7646 Meters³ (m³ )
Multiply Mass By To get equivalent number of:
Pound (lb) 0.4536 Kilograms (kg)
Ton (ton) 907.18 Kilograms (kg)
Ton (ton) 0.907 Tonne (t)
Multiply Force By To get equivalent number of:
Kilogram (kg) 9.807 Newtons (N)
Ounce (oz) 0.2780 Newtons (N)
Pound (lb) 4.448 Newtons (N)
Multiply Temperature By To get equivalent number of:
Degree Fahrenheit (°F) (°F-32) ÷ 1.8 Degree Celsius (°C)
Multiply Acceleration By To get equivalent number of:
Foot/second² (ft/sec² ) 0.3048 Meter/second² (m/s² )
Inch/second² (in./sec² ) 0.0254 Meter/second² (m/s² )
Multiply Torque By To get equivalent number of:
Pound-inch (lb·in.) 0.11298 Newton-meters (N·m)

Multiply Length By To get equivalent number of:
Pound-foot (lb·ft) 1.3558 Newton-meters (N·m)
Multiply Power By To get equivalent number of:
Horsepower (hp) 0.746 Kilowatts (kW)
Multiply Pressure By To get equivalent number of:
Inches of water (in. H 2O) 0.2491 Kilopascals (kPa)
Pounds/square in. (lb/in.²) 6.895 Kilopascals (kPa)
Multiply Energy or Work By To get equivalent number of:
British Thermal Unit (BTU) 1055 Joules (J)
Foot-pound (ft·lb) 1.3558 Joules (J)
kilowatt-hour (kW·hr) 3,600,000. or 3.6 x 106 Joules (J = one W/s)
Multiply Light By To get equivalent number of:
Foot candle (fc) 10.764 Lumens/meter² (lm/m² )
Multiply Fuel Performance By To get equivalent number of:
Miles/gal (mile/gal) 0.4251 Kilometers/liter (km/L)
Gallons/mile (gal/mile) 2.3527 Liter/kilometer (L/km)
Multiply Velocity By To get equivalent number of:
Miles/hour (mile/hr) 1.6093 Kilometers/hour (km/hr)
DECIMAL AND METRIC EQUIVALENTS

Shown below are the decimal and metric equivalents:
Table 15.
Fractions of an inch Decimal (in.) Metric (mm) Fractions of an inch Decimal (in.) Metric (mm)
1/64 0.015625 0.39688 33/64 0.515625 13.09687
1/32 0.03125 0.79375 17/32 0.53125 13.49375
3/64 0.046875 1.19062 35/64 0.546875 13.89062
1/16 0.0625 1.58750 9/16 0.5625 14.28750
5/64 0.078125 1.98437 37/64 0.578125 14.68437
3/32 0.09375 2.38125 19/32 0.59375 15.08125
7/64 0.109375 2.77812 39/64 0.609375 15.47812
1/8 0.125 3.175 5/8 0.625 15.87500
9/64 0.140625 3.57187 41/64 0.640625 16.27187
5/32 0.15625 3.96875 21/32 0.65625 16.66875
11/64 0.171875 4.36562 43/64 0.671875 17.06562
3/16 0.1875 4.76250 11/16 0.6875 17.46250
13/64 0.203125 5.15937 45/64 0.703125 17.85937
7/32 0.21875 5.55625 23/32 0.71875 18.25625
15/64 0.234375 5.95312 47/64 0.734375 18.65312
1/4 0.250 6.35000 3/4 0.750 19.05000

Fractions of an inch Decimal (in.) Metric (mm) Fractions of an inch Decimal (in.) Metric (mm)
17/64 0.265625 6.74687 49/64 0.765625 19.44687
9/32 0.28125 7.14375 25/32 0.78125 19.84375
19/64 0.296875 7.54062 51/64 0.796875 20.24062
5/16 0.3125 7.93750 13/16 0.8125 20.63750
21/64 0.328125 8.33437 53/64 0.828125 21.03437
11/32 0.34375 8.73125 27/32 0.84375 21.43125
23/64 0.359375 9.12812 55/64 0.859375 21.82812
3/8 0.375 9.52500 7/8 0.875 22.22500
25/64 0.390625 9.92187 57/64 0.890625 22.62187
13/32 0.40625 10.31875 29/32 0.90625 23.01875
27/64 0.421875 10.71562 59/64 0.921875 23.41562
7/16 0.4375 11.11250 15/16 0.9375 23.81250
29/64 0.453125 11.50937 61/64 0.953125 24.20937
15/32 0.46875 11.90625 31/32 0.96875 24.60625
31/64 0.484375 12.30312 63/64 0.984375 25.00312
½ 0.500 12.70000 1 1.00 25.40000
Torque Specifications - Fasteners

The proper bolt and nut torque is dependent on its size. Standard (non-metric) nut and bolt torque specifications are shown
below.
Table 16. Standard (Non-metric) Fastener Torque Specifications

Nut and Bolt Size, mm 280M or Better Torque, N·m 280M or Better Torque, lb·ft
No.10-24 5-7 4-5
1/4 in.-20 9-12 7-9
1/4 in.-28 11-14 8-10
5/16 in.-18 18-23 13-17
5/16 in.-24 20-26 15-19
3/8 in.-16 41-47 30-35
3/8 in.-24 47-53 35-39
7/16 in.-14 62-68 46-50
7/16 in.-20 77-83 57-61
½ in.-13 96-102 71-75
½ in.-20 112-126 83-93
9/16 in.-12 122-136 90-100
9/16 in.-18 145-159 107-117
5/8 in.-11 186-199 137-147
5/8 in.-18 228-241 168-178
3/4 in.-10 325-339 240-250

Nut and Bolt Size, mm 280M or Better Torque, N·m 280M or Better Torque, lb·ft
3/4 in.-16 393-407 290-300
7/8 in.-9 556-569 410-420
7/8 in.-14 644-657 475-485
1 in.-8 789-799 580-590
1 in.-14 928-942 685-695
The proper torque specifications for metric nuts and bolts are shown below.
Table 17. Class 10.9 Torque Specifications for Metric Fasteners

Nut and Bolt Size, mm Property Class 10.9 Torque, N·m Property Class 10.9 Torque, lb·ft
M6 X 1.0 13-16 10-12
M8 X 1.25 30-38 22-28
M10 X 1.5 58-73 43-54
M12 X 1.75 101-126 75-93
M14 X 2.0 160-200 118-148
M16 X 2.0 245-306 181-226
M20 X 2.5 478-598 353-441
Torque Specification - Pipe Plugs

Standard pipe plug torque specifications are shown below.
Table 18. Standard Pipe Plug Torque Specifications

*Pipe Plug Size, NPTF Torque Specifications, N·m Torque Specifications, lb·ft
1/8 in. 14-18 10-13
1/4 in. 19-24 14-18
3/8 in. 24-31 18-23
½ in. 31-39 23-29
3/4 in. 45-56 33-41
1 in. 101-126 75-93
1-1/4 in. 129-161 95-119
1-1/2 in. 149-187 110-138
*Use sealant such as Pipe Plug Sealant with Teflon®, PT-7271 (Loctite® 592), or equivalent on all uncoated pipe plugs.

12 Fluids and Lubrication Requirements
Oxidation of the particulate matter in the fuel is the key to filter performance. This requires that the catalyzing agent
(platinum-coated passages) are providing optimum enhancement to the oxidation process. The following fuel requirements
must be met, otherwise the Aftertreatment warranty may be compromised:
• Use Ultra-Low Sulfur Diesel (ULSD) fuel (15 ppm sulfur content maximum), based on ASTM D2622 test procedure.
• Lube oil must have a sulfated ash level less than 1.4 wt %; currently referred to as CJ-4, CI-4/SM CI-4 Plus.
Figure 11. Oil and Fuel Labels

Biodiesel Fuels
Biodiesel fuels meeting ASTM D 6751 specification, prior to blending can be mixed up to 5% maximum by volume in
petroleum diesel fuel. Detroit highly recommends biodiesel fuels made from soybean or rapeseed oil through the proper
transesterification reaction process. Other feedstock source of biodiesel fuels such as animal fat and used cooking oils are not
recommended by Detroit. The resulting mixture must meet ASTM D 975 specification. More information is available on
http://www.demanddetroit.com.
Failures attributed to the use of biodiesel fuel will not be covered by Detroit™ product warranty. Also, any engine
performance problem related to the use of biodiesel fuel would not be recognized nor considered Detroit's responsibility.
Diesel Exhaust Fluid

Diesel Exhaust Fluid (DEF) contains urea and purified water which meets the stringent purity requirements of ISO 22241.
DEF can maintain a safe shelf life of 12 months when stored between 15-85°F and begins to freeze around 12°F. Diesel
Exhaust Fluid is a key component of Selective Catalytic Reduction (SCR) systems when mixed with the engine’s exhaust to
convert smog-forming nitrogen oxides (NOx) into harmless nitrogen and water vapor. Diesel Exhaust Fluid is colorless,
odorless and is classified as a nonhazardous material by the EPA. It is less toxic than most other automotive fluids and is
biodegradable. Despite its classification, it still requires special handling since it can cause skin and eye irritation.
Contaminated or otherwise unusable amounts must be properly disposed of or preferably recycled. DO NOT dispose of DEF
in sewer drains or into the environment. Refer to the product MSDS or dispose of in accordance with all applicable local,
state, and federal regulations.

12 Fluids and Lubrication Requirements
Figure 12. API Label

13 Coolant Requirements
The coolant provides a medium for heat transfer and controls the internal temperature of the engine during operation. In an
engine having proper coolant flow, some of the heat of combustion is conveyed through the cylinder walls and the cylinder
head into the coolant. Without adequate coolant, normal heat transfer cannot take place within the engine, and engine
temperature rapidly rises. Therefore, coolant must be carefully selected and properly maintained.
The following terms are used throughout this section and must be understood.
• Coolant - The fluid mixture circulating in the engine cooling system.
• IEG - Full strength (non-diluted) Inhibited Ethylene Glycol meeting applicable heavy-duty formulation specifications.
• IPG - Full strength (non-diluted) Inhibited Propylene Glycol meeting applicable heavy-duty formulation specifications.
• SCA - Supplemental Coolant Additives. Used to prevent corrosion, cavitation, and the formation of deposits.
• Initial fill - Any time the cooling system is empty, then filled with new coolant.
• Precharged IEG - Also referred to as a fully formulated IEG. Contains the proper amount of SCA. Additional SCA must
not be used with a precharged IEG at initial fill.
• Precharged IPG - Also referred to as a fully formulated IPG. Contains the proper amount of SCA. Additional SCA must
not be used with a precharged IPG at initial fill.
• Dropout - Sludge or deposit formation in or on cooling system components.
Using a coolant with the appropriate concentrations of SCA is one of the most important aspects of quality engine
maintenance. To achieve the chemical balance needed to protect a cooling system, certain coolant basics must be understood.
This section provides the directions and information required to ensure cooling system protection for DD Series engines.
These recommendations are general rules and reflect the current technology. Specific concerns not covered should be
addressed to your local Detroit™ representative.
The coolant used in DD Series engines must meet the following basic requirements:
• Provide an adequate heat transfer medium.
• Protect against cavitation damage.
• Provide a corrosion/erosion-resistant environment.
• Prevent formation of scale or sludge deposits.
• Be compatible with cooling system components.
• Provide adequate freeze and boil protection.
A properly maintained coolant can be used up to the intervals listed in Table 3-12. At this time the cooling system must be
drained, thoroughly cleaned and filled with approved coolant.
To achieve these requirements, coolants are mixtures of good quality water, SCA and often an IEG or IPG for freeze
protection. The rest of this bulletin will describe the requirements and usage of the water, SCA, IEG, and IPG.
Water
Water is the best practical medium for heat transfer. However, water alone can cause corrosion and inherently contains
minerals that can produce scale deposits on internal cooling system surfaces. Chlorides, sulfates, magnesium, and calcium
dissolved in the water can cause scale deposits, and/or corrosion.
Distilled or deionized water is preferred to minimize the adverse effects of minerals in water.

Figure 13. Water Evaluation Procedure

The maximum allowable limits for minerals in water are seen below.
Table 19. Maximum Allowable Limits for Minerals in Water

Mineral Limit - ppm Limit - grains per gallon
Chlorides 40 2.5
Sulfates 100 5.8
Total dissolved solids 340 20
Total Hardness: Magnesium & Calcium 170 10
Antifreeze, Inhibited Ethylene Glycol

Ethylene glycol is used for freeze and boil protection of the coolant. IEG, commonly referred to as antifreeze, also contains
chemicals that provide a limited protection against corrosion. The use of an IEG product with a low silicate formulation that
meets either the ASTM D6210–A, ASTM D 4985 and TMC RP329 Type A requirements is recommended.
Table 20. Power Cool Fully Formulated/Precharged IEG

Power Cool - DDC Part Number Size
23512138 1 gallon
23512139 55 gallons
23512140 bulk

Table 21. Coolant Freezing and Boiling Temperatures vs. Inhibited Ethylene Glycol (IEG) Concentration
(Sea Level)
Ethylene Glycol Volume Freezing Point Boiling Point
%
0 32ºF 0ºC 212.0ºF 100.0ºC
10 24.2ºF 4.3ºC 212.6ºF 100.2ºC
20 14.9ºF -9.5ºC 215.1ºF 101.7ºC
25 9.3ºF -12.6ºC 216.7ºF 102.5ºC
30 3.0ºF -16.1ºC 218.2ºF 103.4ºC
35 -4.3ºF -20.2ºC 219.8ºF 104.3ºC
40 -13.1ºF -25.0ºC 221.4ºF 105.2ºC
45 -23.5ºF -30.9ºC 223.1ºF 106.1ºC
50 -36.2ºF -37.9ºC 225.1ºF 107.2ºC
55 -51.6ºF -46.5ºC 227.4ºF 108.4ºC
60 -70.3ºF -56.8ºC 230.5ºF 110.1ºC
65 < – 70ºF < – 60ºC 234.5ºF 112.2ºC
70 N/A N/A 239.9ºF 115.2ºC
80 N/A N/A 256.4ºF 124.2ºC
90 N/A N/A 284.0ºF 139.6ºC
100 N/A N/A 327.7ºF 164.0ºC
Coolants not Recommended

Methyl alcohol-based antifreeze should not be used in DD Series engines because of its effect on the non-metallic
components of the cooling system and its low boiling point. Similarly, methoxy propanol-based antifreeze should not be used
in DD Series engines because it is not compatible with fluoroelastomer seals found in the cooling system. Glycol-based
coolants formulated for heating/ventilation/air conditioning (HVAC) should not be used in DD Series engines. These
coolants generally contain high levels of phosphates, that can deposit on hot internal engine surfaces and reduce heat transfer.
Supplemental Coolant Additive

SCAs provide protection for the cooling system components. The coolant must have the proper concentration of SCAs.
Detroit™ Maintenance products are recommended for use in DD Series engines.
NOTICE: Excessive amounts of chemicals in the engine coolant can cause a gel-type or crystalline deposit that
reduces heat transfer and coolant flow. The deposit, called dropout takes the color of the coolant when wet, but
appears as a white powder when dry. It can pick up solid particles in the coolant and become gritty, causing
excessive wear of water pump seals and other cooling system components. The wet gel can be removed by non-
acid (alkali) type heavy-duty cleaner, Detroit Maintenance Product cleaner DD-2001 (sodium nitrite/sodium
tetraborate). If the gel is allowed to dry, it is necessary to disassemble the engine and clean with a caustic
solution or mechanically clean individual components.
The proper application of SCA will provide:

• pH control to prevent corrosion.
• Water-softening to deter formation of mineral deposits.
• Cavitation protection to reduce the effects of cavitation.
The proper dosage for initial cooling system fill is listed in the "Initial Fill SCA Dosage" Table. Maintenance cooling system
fill is listed in the "Maintenance Fill SCA Dosage" Table, initial coolant inhibitor element size requirements for IPG and IEG

plus water coolant mixtures are listed in the "Coolant Inhibitor Element Size Requirements-Initial Fill Dosage for IEG or IPG
plus Water Coolant Mixtures" Table. Coolant inhibitor element size requirements, initial dosage for water-only systems, are
listed in the "Coolant Inhibitor Element Size Requirements-Initial Dosage for Water-Only System" Table. The proper
maintenance dosages are listed in the "Coolant Inhibitor Element Size Requirements-Maintenance Dosage for IEG, IPG,
Precharged, and Water-Only Coolant Mixture" Table.
Table 22. Initial Fill SCA Dosage

Coolant Coolant Element Liquid *
Precharged IEG and Water NONE NONE
IEG and Water Select Element listed in the Coolant Inhibitor 3% by volume, or 1 pint per 4 gallons
Element Size Requirements-Initial Fill
Dosage for IEG or IPG plus Water Coolant
Mixtures Table.
Water only Select Element listed in the Coolant Inhibitor 6% by volume, or 1 quart per 4 gallons
Element Size Requirements-Initial Dosage
for Water-Only System Table.
*1 gallon = 3.785 L; 2 pints = 1 quart; 4 quarts = 1 gallon
Table 23. Maintenance Fill SCA Dosage

Coolant Element Liquid *
Select element listed in Table 3-8. 0.6% by volume or 1 pint per 20 gallons
*1 gallon = 3.785 L; 8 pints = gallon
Table 24. Coolant Inhibitor Element Size Requirements-Initial Fill Dosage for IEG or IPG plus Water
Coolant Mixtures
Cooling System Capacity, L (Gallons) Quantity
34-45 (9-12) 1
49-61 (13-16) 1
Table 25. Coolant Inhibitor Element Size Requirements-Initial Dosage for Water-Only System
Cooling System Capacity L (Gallons) SCA Element Quantity Additional SCA Liquid Required
26 (7) 1 None
38 (10) 1 None
57 (15) 2 None
Table 26. Coolant Inhibitor Element Size Requirements-Maintenance Dosage for IEG, IPG, Precharged,
and Water-Only Coolant Mixture
Cooling System Capacity, L (Gallons) Filter Quantity Liquid Only Number of Pints
34-45 (9-12) 1 ½ - 3/4
49-61 (13-16) 1 3/4 - 1
The concentration of SCA will gradually deplete during normal engine operation. Check the SCA concentration at the regular
intervals listed in the "Required Coolant Inhibitor Test Intervals" Table. Additional SCA must be added to the coolant when
it becomes depleted below a specified level (listed in the "SCA Limits with ASTM D6210–A, ASTM-D 4985 and TMC

RP329 TYPE A (50/50 Coolant/Water Mixture)" Table). Maintenance dosage of SCA must only be added if nitrite
concentration is less than 900 ppm. If nitrite concentration is greater than 900 ppm, do not add additional SCA.
Table 27. Required Coolant Inhibitor Test Intervals

Service Application Inhibitor Test Interval
On-highway Trucks and Motor Coaches 330,000 km (205,000 miles)
City Transit Coaches, Pick-up and Delivery, Short Trip, and 9,600 km (6,000 miles) or three months, whichever comes first.
Emergency Vehicles
Table 28. SCA Limits with ASTM D6210–A, ASTM-D 4985 and TMC RP329 TYPE A (50/50 Coolant/Water
Mixture)
SCA Minimum SCA ppm Maximum SCA ppm
Boron (B) 1,000 1,500
Nitrite (NO2) 900 3,200
Nitrates (NO3) 0 1,000
Silicon (Si) 50 250
Phosphorus (P) 0 500
pH 8.0 11.0
Soluble Oils
Soluble oil additives are not approved for use in the DD Series engine cooling systems. A small amount of oil adversely
affects heat transfer. A 1.25% concentration of soluble oil increases the fire deck temperature 6%. A 2.50% concentration
increases the fire deck temperature 15%.
Chromate
Chromate additives are not approved for use in the DD Series engine cooling systems. Chromate additives can form
chromium hydroxide, commonly called green slime. This, in turn, can result in engine damage due to poor heat transfer.
Cooling systems operated with chromate-inhibited coolant must be chemically cleaned with Power Cool 2015 cooling system
cleaner and conditioner (or equivalent sulfamic acid/sodium carbonate cleaner) and flushed.
Some coolant filter elements with magnesium internal support plates have caused engine damage. The coolant dissolves the
magnesium and deposits it on the hot zones of the engine where heat transfer is most critical. The use of elements with these
plates is not approved.
Detroit Cooling System Maintenance Products

Detroit Maintenance Products with SCA are water-soluble chemical compounds. These products are available in coolant
filter elements, liquid packages, and a fully formulated IEG.
Coolant Inhibitor Elements

Replaceable coolant inhibitor elements (spin-on canisters) are available in various sizes suitable for cooling systems of
varying capacity. If a fully formulated IEG coolant is not used, a pre-charge element must be installed. Selection of the
proper element size is vital when precharging the coolant system at initial fill. If a coolant inhibitor element is used, it is
important to make sure that the coolant inlet/outlet valves on the element adaptor head are fully opened prior to filling the
cooling system with coolant.
NOTE: A fully formulated IEG must NOT have SCA added at initial fill.
The need for maintenance elements is determined by the results of the SCA concentration test performed at each cooling
system service interval.

Supplemental Coolant Additive Test Procedures

Nitrite concentration is an indication of the SCA concentration in the coolant. Nitrite test kits and test strips are commercially
available. The coolant must be tested for required inhibitor levels at the intervals listed in the Required Coolant Inhibitor Test
Intervals table. SCA levels must be within the ranges listed in the SCA Limits with ASTM D6210–A, ASTM-D 4985 and
TMC RP329 TYPE A (50/50 Coolant/Water Mixture) table.
Liquid Supplemental Coolant Additive

Detroit Cooling System Maintenance Procedures SCA and Cleaners are available in liquid form and are listed in the table
below.
Table 29. Liquid SCA and Additional Coolant Treatment Products

Product Size*
Power Cool® 2000 - Liquid SCA 1 pint (12 per case)
Power Cool 2000 - Liquid SCA half gallon (6 per case)
Power Cool 2000 - Liquid SCA 5 gallons
Power Cool 2000 - Liquid SCA 55 gallons
Power Cool 3000 † - Liquid SCA 1 pint (12 per case)
Power Cool 3000 † - Liquid SCA half gallon (6 per case)
Power Cool 3000 † - Liquid SCA 5 gallons
Power Cool 3000 † - Liquid SCA 55 gallons
Power Cool 2001 ON-LINE CLEANER half gallon (6 per case)
Power Cool 2001 ON-LINE CLEANER 5 gallons
Power Cool 2001 ON-LINE CLEANER 55 gallons
Power Cool 2015, Twin Pac, Dry Chemical Cleaner/Conditioner 2 per case
* 1 gallon = 3.785 L; 8 pints = gallon
† Power Cool 3000 is more compatible with hard water than Power Cool 2000. Use Power Cool on-line cleaner for light deposits. Use Power
Cool dry chemical cleaner conditioner for heavy deposits or scale.
Test Kit Procedures

Use Detroit Powertrac® 3-Way Coolant Test Strips (part number 23515917) to measure nitrite and glycol concentrations.
Cavitation/corrosion protection is indicated on the strip by the level of nitrite concentration.
NOTICE: Do not use Detroit Power Cool® test strips to determine the inhibitor levels of coolant with non-DDC
approved additive packages. Incompatible chemicals and variance in inhibitor levels in the additive packages may
cause inaccurate interpretation of test strip readings. This can lead to under-inhibiting the coolant, which may
result in cavitation erosion.
Freeze and boil over protection is determined by glycol concentration. Use test strips as follows:
1. Dip the strip into coolant for one second. Remove and shake briskly to eliminate excess fluid.
2. Immediately compare end pad (% glycol) to the color chart.
3. Sixty seconds (one minute) after dipping, compare the nitrite pad to the chart contained within the kit.
For best results make the tests while the coolant is between 10 - 60°C (50 - 140°F). Wait at least 60 seconds, but not longer
than 75 seconds, before reading the nitrite level. Promptly replace and tighten the container cap after each use. Discard
unused strips if they have turned light pink or tan.
A factory coolant analysis program is available through authorized Detroit™ service outlets.

Summary of Coolant Recommendations

Coolant recommendations may be summarized as follows:
WARNING: HOT COOLANT

To avoid scalding from the expulsion of hot coolant, never remove the cooling system pressure cap
while the engine is at operating temperature. Wear adequate protective clothing (face shield,
rubber gloves, apron, and boots). Remove the cap slowly to relieve pressure.
• Always maintain the engine coolant to meet Detroit™ specifications.

• Only use water that meets Detroit™ specifications. Distilled or deionized water is preferred.
• The proper dosage of SCA must be included in the coolant at initial fill for all DD Platform engines. This dosage can be
either included in part or entirely in the IEG used, or it may need to be added. Dosage is also dependent on whether water
or IEG is used. The user is urged to refer to the full text of this bulletin to determine the proper dosage. Mixing of different
manufacturers' inhibitors (SCAs) could cause cooling system problems.
• Maintain the SCA to the prescribed concentration. Test the nitrite concentration by using a titration kit or Detroit™ 3-Way
Coolant Test Strips. Add SCA only if the nitrite concentration is below 900 ppm.
• Do not use another manufacturer's test kit to measure the SCA concentration of Detroit Maintenance Products.
• Pre-mix coolant makeup solutions at proper concentration before adding to coolant system.
• Where antifreeze/boil over protection is required, use only ethylene glycol coolant (low silicate formulation) meeting
ASTM D6210–A, ASTM D 4985 and TMC RP329 Type A.
• Always maintain proper coolant level.
• A properly maintained cooling system can be operated for up to intervals listed in the Cooling System Cleaning Intervals
table below. The cooling system must be thoroughly cleaned. Replace coolant at these intervals.
Table 30. Cooling System Cleaning Intervals

Coolant Interval - Whichever comes first Action
Conventional Detroit POWER COOL 32,000 km (20,000 miles) 3 Months, or 500 Test nitrite concentration with test strip. Add
Antifreeze/Water Hours SCA or dilute coolant as needed.
Drain and clean system. Refill with new

480,000 km (300,000 miles) or 2 Years
coolant.
EG Antifreeze/Water + Conventional 32,000 km (20,000 miles) 3 Months, or 500 Test nitrite concentration with test strip. Add
Corrosion Inhibitor Hours SCA or dilute coolant as needed.

480,000 km (300,000 miles) or 2 Years
coolant.
PG Antifreeze/Water + Conventional 32,000 km (20,000 miles) 3 Months, or 500 Test nitrite concentration with test strip. Add
Corrosion Inhibitor Hours SCA or dilute coolant as needed.

Engine Overhaul
coolant.
EG Antifreeze/Water + OAT Inhibitor 480,000 km (300,000 miles) 2 years or

Add Power Cool Plus Extender
10,000 Hours
960,000 km (600,000 miles) 4 Years, or Drain and clean system. Refill with new
Engine Overhaul coolant.

Coolant Interval - Whichever comes first Action
PG Antifreeze/Water + OAT Inhibitor 480,000 km (300,000 miles) 2 Years, or

10,000 Hours
960,000 km (600,000 miles) 4 Years, or Drain and clean system. Refill with new
Water Only + Conventional Corrosion 32,000 km (20,000 miles) 3 Months, or 500 Test nitrite concentration with test strip. Add
Inhibitor Hours SCA or dilute coolant as needed.

Engine Overhaul
coolant.
Water Only + OAT Inhibitor 480,000 km (300,000 miles) 2 Years, or

10,000 Hours
960,000 km (600,000 miles), 4 Years, or Drain and clean system. Refill with new
Do not use the following in Detroit™ engine cooling systems:

• Soluble oil
• Chromate SCA
• Methoxy propanol-base coolant
• Methyl alcohol-base coolant
• Sealer additives or coolant containing sealer additives
• HVAC coolant

14 Preventive Maintenance Intervals
The following guide establishes preventive maintenance intervals. These recommendations should be followed as closely as
possible to obtain long life and optimum performance from your engine. When performed on a regular basis, changing the
engine oil, coolant, and filters is the least costly way of obtaining safe and reliable vehicle operation. Added benefits and
savings occur when you check that the valves, fuel injectors, oil and cooling circuits are in good working order during oil
changes.
The intervals shown apply only to the maintenance functions described. These functions should be coordinated with other
regularly scheduled maintenance.
Scheduled Maintenance Intervals

Before placing your new vehicle in service, determine the correct maintenance schedule application for your intended use of
the vehicle.
Maintenance Schedule Applications

There are three types of maintenance schedules for the On-Highway Vehicle applications; Severe Service, Short-Haul
Service, and Long-Haul Service.
• Severe Service:Severe service applies to vehicles that annually travel up to 30,000 miles (48,000 kilometers) and average
less than 5 miles per gallon or that operate under severe conditions.
• Short Haul:Short Haul service applies to vehicles that annually travel up to 30,000-60,000 miles (48,000-96,000
kilometers) and average between 5.1 and 5.9 miles per gallon.
• Long Haul:Long Haul service (over-the-road transport) applies to vehicles that annually travel more than 60,000 miles
(96,000 kilometers) and average greater than 6 miles per gallon with minimal city stop-and-go operation.
Schedule Use
Complete each maintenance operation at the required interval. The intervals are based on a collaboration of field and fleet
data. For a more accurate analysis of when fluids should be changed, such as engine oil, refer to publication Engine
Requirements; Lubricating Oil, Fuel and Filters and publication Coolant Selections for Detroit™ Engines, available from
authorized Detroit™ distributors.
Each maintenance table shows which maintenance operation must be performed at the recommended interval (in miles,
kilometers, and hours).
NOTE: Failure to check and maintain Supplemental Coolant Additive levels at required concentrations will result
in severe damage (corrosion) to the engine cooling system and related components. Coolant must be inhibited
with the recommended Supplemental Coolant Additives listed in this manual.
Cooling System Flush and Fill

Coolant Flush and Fill - Proper maintenance of the cooling system is vital to its performance and longevity. The cooling
system must, on a constant basis, deal with cavitation, temperature / pressure swings, and continuous threats on the additive
package. Once the additives have been depleted from the coolant, it will only be a matter of time until the engine components
suffer. Refer to section "Cooling System Fill Procedure"
Cooling System Inspection - Inspect the cooling system as follows:

1. Inspect the radiator, condenser, coolant pump, engine oil cooler, freeze plugs, and heat exchanger for damage and leaks.

2. Check all cooling system pipes and hoses for damage and leaks; ensure they are positioned to avoid chafing, and are
securely fastened.
3. Check the outside of the radiator and condenser for blockage. Check fins for damage; straighten them if necessary.
Valve Lash Checking and Adjustment

Valve lash checking and adjustment should be performed per the maintenance intervals prescribed under the proper service
category for the engine. All three service categories (Severe, Short Haul, and Long Haul) require a 'first time' valve lash
adjustment at a shorter interval. After the initial adjustment, all others are based on the same mileage intervals. Proper valve
lash clearance allows the engine to produce the best possible performance with the lowest emissions. Valve lash adjustments
should be performed by an authorized Detroit™ maintenance or repair facility.
Drive Belt
Belts should be neither too tight nor too loose. Belts that are too tight impose extra loads on the crankshaft, fan and/or
alternator bearings, shortening both belt and bearing life. Excessively overtightened belts can result in crankshaft breakage. A
loose belt will slip and generate excessive heat that may cause damage to the belt and accessory drive components.

To avoid injury from rotating belts and fans, do not remove and discard safety guards.
Belt Replacement - Drive belts (V and poly-V) should be replaced every 2,000 hours or 100,000 miles (160,000 km).
After an extended time in service, minor rib cracks may appear, usually one or two cracks per inch is considered normal. A
concern occurs when the belt ribs exhibit severe multiple cracking or 'chunking'. At this point, the belt should be replaced.
Poly-V Belt
Auto Tensioner - Auto tensioners are usually maintenance free for the life of the engine. However, routine inspections should
be performed. Uneven belt wear can indicate a loose, wore out, or bad bearing on the auto tensioner. A build up of dirt or
grime around the front bearing surface of the wheel can indicate a future bearing failure due to inadequate lubrication.
Fuel / Water Separator

Incorporated into the fuel filter module is a fuel/water separator. The separator removes emulsified water as well as droplets
and is located in the lower compartment of the fuel filter module. A water-in-fuel (WIF) sensor indicates when trapped water
needs to be drained.

NOTICE: Do not over-tighten the water drain valve. Failure to properly tighten the water drain valve may cause
damage to the water drain valve and housing.
1. Water in Fuel Separator Cap 3. Final Filter Cap

2. Water Drain Valve 4. Pre Filter Cap
Figure 14. Three-Filter Fuel System Fuel Filter Module
1. Water in Fuel Separator(Coalescer/Final Filter) Cap 3. Water Drain Valve

2. Pre Filter Cap
Figure 15. Two-Filter Fuel System Fuel Filter Module
Three-Filter Fuel Filters
The prefilter is housed within the fuel filter module. The prefilter element filters particles down to 100 microns and is
snapped into the prefilter cap. The water separator/coalescer filter is housed within the fuel filter module. The water
separator/coalescer has the task of separating out the water contained in the fuel and also filtering out particles down to 10
microns. The water separator/coalescer filter snappes into the water separator/coalescer cap. The final filter is housed within
the fuel filter module. The final filter element filters particles down 3 to 5 microns and snaps into the final filter cap.

Two-Filter Fuel Filters

The prefilter is housed within the fuel filter module. The prefilter element filters particles down to 100 microns and is
snapped into the prefilter cap. The coalescer/final filter is housed within the fuel filter module. The coalescer/final filter has
the task of separating out the water contained in the fuel and also filtering out particles down to 3 to 5 microns. The
coalescer/final filter snaps into the coalescer/final filter cap.
Air System
Air Cleaner - The air cleaner element should be inspected per the maintenance intervals or more often if the engine is
operated under severe dust conditions.
Replace the element, if necessary. Check the gaskets for deterioration and replace, if necessary. If the dry type air cleaner is
equipped with an aspirator, check for aspirator damage or clogging. Clean, repair or replace, as necessary.
NOTICE: Do not allow the air inlet restriction to exceed 5.5 kPa (22 in. H2O) under any engine operating
conditions. A clogged air cleaner element will cause excessive intake restriction and reduced air supply to the
engine resulting in increased fuel consumption, inefficient engine operation and reduced engine life.
Inspect the entire air system for leaks daily. Look especially for torn air inlet piping or boots and loose or damaged clamps.
Have worn or damaged parts repaired or replaced, as required. Retighten loose connections
Air Cleaner Replacement - Dry type air cleaner elements should be replaced after one year of service or when the maximum
allowable air intake restriction has been reached, whichever comes first.
Air-to-Air Charge Cooler - Periodically inspect the air-to-air charge cooler for buildup of dirt, mud, etc. and wash off using a
mild soap solution. Check the charge cooler, ductwork, and flexible connections for leaks and have repaired or replaced, as
required.
Exhaust System
The exhaust manifold retaining bolts and other connections should be inspected for leaks. The exhaust pipe rain cap should
be checked for proper operation, if so equipped. With the introduction of an Aftertreatment system, the sealing of the exhaust
system is critical and should be inspected regularly.
Air Compressor
The air compressor incorporates three of the major systems of a diesel engine (air, lubrication, and coolant). Proper
inspection of air compressor would include inspecting for air, oil, and coolant leaks. Due to inadequate internal sealing air
compressors, when failed, can produce excessive crankcase pressure or allow an engine to ingest oil.
Aftertreatment System (ATS)

There is a need to periodically remove accumulated ash, derived from engine lube oil, from the filter. This ash does not
oxidize in the filter during the regeneration process and must be removed through a cleaning procedure. All Detroit™ ATS-
equipped engines will illuminate a dashboard warning lamp indicating the need for ash cleaning.
Vibration Damper
The viscous vibration damper should be inspected periodically and replaced if dented or leaking. Heat from normal engine
operation may, over a period of time, cause the fluid within the damper to break down and lose its dampening properties. For
this reason the viscous vibration damper must be replaced at time of normal major engine overhaul, regardless of apparent
condition.
14.1 EPA07 DD Series Preventive Maintenance Tables

Table 31.
Severe Service Maintenance Intervals (EPA07)
Miles X 1000/ 25 50 75 100 125 150 175 200
Km X 1000/ 40 80 120 160 200 240 280 320
Hours* 640 1280 1925 2565 3205 3850 4490 5130
Lubricating Oil R R R R R R R R
Lubricating Oil Filter R R R R R R R R
Coolant Refer to section “How to Select Coolant” for the listing of required intervals using the recommended
coolants.
Cooling System Filter R
Fuel Filters
Prefilter R R R R R R R R
Coalescer (Water Separator) R R R R R R R R
Final Filter R R R R R R R R
Initial Valve Lash Adjustment Adjust at 60,000 mi (100,000 km), at 180,000 mi (300,000 km), and then at every 180,000 mi. (300,000
km) or nearest maintenance interval.
Belts I I I I I I I R
Air System I I I I I I I I
Air Cleaner I I I I I I I I
Exhaust System I I I I I I I I
Aftertreatment Device Inspect external hardware and connections at every oil change. Remove ash at 300,000 miles (480,000
km) or 9,000 hours.*
Air Compressor I I I I I I I I
• *Whichever comes first.
• All items are described in "Routine Preventive Maintenance."
• R = Replace
• I = Inspect
Table 32.
Short Haul Service Maintenance Intervals (EPA07)
Miles X 1000/ 35 70 105 140 175 210 245 280
Km X 1000/ 55 110 165 220 275 330 385 440
Hours 895 1795 2690 3590 4485 5380 6280 7180
Lubricating Oil R R R R R R R R
Lubricating Oil Filter R R R R R R R R
coolants.
Fuel Filters
Prefilter R R R R R R R R
Coalescer (Water Separator) R R R R R R R R
Final Filter R R R R R R R R
Initial Valve Lash Adjustment Adjust at 60,000 mi (100,000 km), at 180,000 mi (300,000 km), and then at every 180,000 mi. (300,000
Belts I I I I I I I R
Air System I I I I I I I I

Short Haul Service Maintenance Intervals (EPA07)

Air Cleaner I I I I I I I I
Exhaust System I I I I I I I I
Air Compressor I I I I I I I I
• R = Replace
• I = Inspect
Table 33.
Long Haul Service Maintenance Intervals (EPA07)
Miles X 1000/ 50 100 150 200 250 300
Km X 1000/ 80 160 240 320 400 480
Hours 1280 2565 3845 5125 6410 7690
Lubricating Oil R R R R R R
Lubricating Oil Filter R R R R R R
coolants.
Fuel Filters
Prefilter R R R R R R
Coalescer (Water Separator) R R R R R R
Final Filter R R R R R R
Initial Valve Lash Adjustment Adjust at 60,000 mi (100,000 km), at 180,000 mi. (300,000 km), and then at every 180,000 mi. (300,000
Belts I I I I I R
Air System I I I I I I
Air Cleaner I I I I I I
Exhaust System I I I I I I
Air Compressor I I I I I I
• R = Replace
• I = Inspect

15 Monitoring the Lubricating Oil
Perform the following maintenance on the lubricating oil:

1. Check the oil level daily with the engine stopped and on a level surface. If the engine has just been stopped and is
warm, wait approximately 20 minutes to allow the oil to drain back into the oil pan before checking.
NOTE: the dipstick has a positive locking device such as a lever or twist-lock design that must be disengaged
before pulling the dipstick out of the guide tube. Use a shop rag to wipe off the end of the dipstick. Wait 15
seconds to allow any crankcase pressure to dissipate through the guide tube and let the oil level settle in the oil
pan.
2. Add the proper grade of oil to maintain the correct level on the dipstick. Remove the dipstick from the guide tube.
Before adding lubricating oil, refer to "How to Select Lubricating Oil."
NOTICE: Do NOT fill beyond the maximum fill level on the dipstick, since overfilling may result in high oil
consumption and possible severe engine damage.
NOTE: If the engine operating temperature is below 60° C (140° F), the engine must be on a level surface and
then shut down for 60 minutes for an accurate oil level reading. Otherwise, the engine must be brought up to an
operating temperature of 60° C (140° F), parked on a level surface and then shut down for five minutes for an
accurate oil level reading.
3. Reinstall the dipstick and make sure it is fully inserted into the guide tube. Remove the dipstick and read the oil level
dipstick.
NOTICE: Do not add oil if the oil reading is in the crosshatch area on the dipstick. There are approximately 5.0 L
(5.2 qts) from the minimum mark to the maximum mark on the dipstick. Overfilling the oil pan can cause engine
damage.
NOTICE: If the oil level is constantly above normal and excess oil has not been added to the crankcase, consult
with an authorized Detroit service outlet for the cause. Fuel or coolant dilution of lubricating oil can result in
serious engine damage.
4. Check the oil level daily. With the engine stopped, use the oil dipstick and measure the oil level on crosshatch area on
the dipstick. Figure below shows Maximum oil level (1) and Minimum oil level (2). If the oil reading is in the
crosshatch area or between the bends of the dipstick, then the oil is at the proper level for engine operation.

15 Monitoring the Lubricating Oil
5. Add the proper grade of oil to maintain the satisfactory range on the dipstick. All diesel engines are designed to use
some oil, so the periodic addition of oil is normal. Before adding lubricating oil, refer to "How to Select Lubricating
Oil."

16 How to Replace the Lubricating Oil and Oil Filter
The oil filter is an integral part of the lubrication system. Proper filter selection and maintenance are important to satisfactory
engine performance and service life. The filter should be used to maintain a clean system, not to clean up a contaminated
system. The maintenance intervals for the appropriate duty cycle are listed in tables in this manual.
Change the oil and replace the lubricating oil filter as follows:
NOTE: If the used oil was contaminated by fuel or coolant, it may be necessary to take the vehicle to a certified
Detroit Service Center. The Service Center may drain the oil and then remove the oil pan, oil pump, and oil pump
intake manifold to drain the remaining oil held back by the backflow valve. It is important to remove all
contaminated oil from the engine.
NOTE: Change the engine oil only when the engine oil temperature is approximately 60°C (140°F). Changing cold
oil will result in extended drain times.

To avoid injury, never remove any engine component while the engine is running.
1. Place the transmission in neutral, and set the parking brake.
NOTICE: Use care to prevent foreign objects from entering the filter housing.
2. Clean outside of the oil filter housing.

3. Using a 36-mm socket, unscrew the oil filter cap and filter and allow the oil to drain into the housing. After draining is
complete, remove the assembly from the housing.
4. Remove the filter element by pressing and twisting the side and detaching it from the cap.
5. Remove the oil filter O-ring and discard. Lightly coat a new O-ring with clean engine oil and install it on the filter cap.
6. Check the filter housing for any debris and remove if necessary.
7. Insert a new filter element into the oil filter cap.
8. Insert the filter element and cap assembly into the housing. Torque the cap to 40 to 50 N·m (30 to 37 lb·ft).
9. Drain oil from the oil pan as follows:
a. Place a suitable receptacle, 55 L (58 qt) or more, beneath the oil drain plug on the underside of the oil pan.
b. Carefully unscrew the oil drain plug, and allow the oil to drain out.
c. Discard the plug seal ring.
10. Install the oil pan drain plug with a new O-ring and torque the plug:
a. On a plastic oil pan, torque plug to 45 N·m +/- 7 N·m (33 lb·ft +/- 5 lb·ft).
b. On an aluminum oil pan, torque plug to 60 N·m +/- 9 N·m (44 lb·ft +/- 6 lb·ft ).
NOTICE: Do not add oil if the oil reading is between the crosshatch area on the dipstick. There are approximately
5.0 L (5.2 qt) from the fill mark to the full mark. Overfilling the oil pan can cause engine damage.
11. Add new engine oil through the oil fill tube in the following amount; Refer to section "Engine Oil Capacities". Verify
the oil level reading is between the full and fill marks on the dipstick.


16 How to Replace the Lubricating Oil and Oil Filter
WARNING: ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
NOTICE: If no oil pressure is shown after approximately 10 seconds, stop the engine and determine the cause.
Running the engine with no oil pressure could result in engine damage.
12. Start the engine with the accelerator pedal in the idle position (600 rpm). Monitor the oil pressure gauge or indicator
lamp. Keep the engine running at idling speed (600 rpm) until the oil pressure reading is 10.2 psi (70 kPa) or more for
the DD15.
NOTICE: Do not add oil if the oil reading is between the crosshatch area on the dipstick. There are approximately
5.0 L (5.2 qt) from the fill mark to the full mark. Overfilling the oil pan can cause engine damage.
NOTE: If the engine operating temperature is below 60°C (140°F), the engine must be on a level surface and then
shut down for 60 minutes for an accurate oil level reading. Otherwise, the engine must be brought up to an
operating temperature of 60°C (140°F), parked on a level surface and then shut down for five minutes for an
accurate oil level reading.
13. Check the filter housing for signs of leakage.

14. Stop the engine. Check the oil level again per the following guidelines. If necessary, add oil no more than 5.0 L (5.2 qt)
at a time up to the maximum fill level on the oil dipstick.

17 Engine Oil Capacities
17.1 Engine Oil Capacities

Consult with a Detroit distributor to obtain the proper engine oil filters.
The engine oil capacities for the DD Platform Engine On-Highway Vehicle application are listed in the following tables.
Contact your local Detroit service center if you need more specific information.
NOTE: There are approximately 5.0 L (5.2 qts) of oil represented from the fill mark to the full mark.
NOTICE: Overfilling the oil pan can cause engine damage.
Table 34.
Engine Oil Capacities
Truck DD15
Total Dry Engine Oil Volume 49.0 L (51.8 qt)
Oil and Filter Change 43.0 L (45.4 qt)
Remaining in Engine after Oil Drain (Includes Filter Removal) 6.0 L (6.3 qt)
Dip Stick Min. to Max. Range 5.0 L (5.2 qt)
Sump Oil Volume 40.0 L (42.3 qt)

18 Monitoring the Cooling System
The cooling system must be full for proper operation of the engine.

Check the coolant level daily and maintain it between the full and low marks on the surge tank. Add coolant as required, but
do not overfill.
Make a daily visual check for cooling system leaks. Look for an accumulation of coolant when the engine is running and
when it is stopped. Coolant leaks may be more apparent on an engine when it is cold.
The inhibitors in antifreeze solutions must be replenished with an approved corrosion inhibitor supplement when indicated by
testing the coolant.
NOTICE: Coolant must be inhibited with the recommended Supplemental Coolant Additives (SCAs) listed in this
guide. Failure to check and maintain SCA levels at required concentrations will result in severe damage
(corrosion) to the engine cooling system and related components.
The cooling system is protected by an SCA element. In addition, the engine can be equipped with a coolant filter/inhibitor
system as an installed option or as an after-sale item.
A coolant system properly maintained and protected with supplemental coolant inhibitors can be operated up to the intervals
listed. At these intervals the coolant must be drained and disposed of in an environmentally responsible manner according to
state and/or federal (EPA) recommendations.
Install a new cooling system filter at intervals defined in the Maintenance Intervals.
The DD Platform engine is equipped with a coolant filter. The coolant filter contains supplemental corrosion inhibitors.
Service the cooling system as follows:
NOTE: Change the coolant filter only after the vehicle has cooled and no residual pressure is present.
1. Place the transmission in neutral, and set the parking brake.

2. Clean the outside of the coolant filter housing.
NOTE: Ensure when servicing the oil coolant module that coolant from module does not contaminate the
lubrication system.
NOTE: Use care to prevent foreign objects from entering the filter housing.
3. Using a 36-mm socket, unscrew cap and filter and allow the coolant to drain into the housing.
4. Remove the drain plug from the bottom of the oil coolant module and drain any remaining coolant from the oil coolant
module into a suitable container.
NOTICE: Coolant is a hazardous material and needs to be disposed in an environmentally responsible manner.
5. Open the coolant drain plug (1) located on the left side of the engine block and attach a hose to the plug.

6. Collect the used antifreeze in a suitable container, and dispose of the solution in an environmentally responsible
manner, according to state and federal (EPA) recommendations.
7. Remove the filter from the plastic cap by placing the filter on a solid surface and apply pressure on the plastic cap at an
angle.
8. Remove oil coolant filter O-ring and discard it. Lightly lubricate a new O-ring with clean engine oil and install it on the
filter cap.
9. Check filter housing for any debris and remove if necessary.
10. Insert a new filter element into the cap.
11. Insert element and cap assembly into the housing. Torque the cap to 55-60 N·m (41-44 lb·ft).
12. Replace all drain plugs and close all drain valves.
13. Add coolant to the correct levels. Refer to section "Cooling System Fill Procedure"



14. Start engine with the accelerator pedal in the idle position. Monitor all gauges or indicator lamps.
15. Check the filter housings for signs of leakage.
16. If the cooling system is contaminated, flush the cooling system as follows:
17. With the engine cool, drain the coolant from the engine and radiator. Refer to section "Cooling System Drain
Procedure". Dispose of the coolant in an environmentally safe manner, according to state and federal Environmental
Protection Agency (EPA) recommendations.
18. Refill with soft, clean water and a cleaning system compound.
Table 35.
Coolant Type Part Number Description
200164 One Half Gallon Jug -6 Per Case
On-Line Cleaner 200105 5 Gallon Pail
200155 55 Gallon Drum


19. Start the engine and operate it for 15 minutes after the thermostat has opened, to thoroughly circulate the water.
20. Stop the engine and allow to cool. Drain the unit completely.
NOTICE: If the engine is hot, fill slowly to prevent rapid cooling and distortion of the engine castings.
21. If the engine is hot, refill slowly with clean water and start the engine and operate for 15 minutes after the thermostats
have opened.
22. Stop the engine and allow it to cool.
23. With engine cool, drain the cleaner residue from the cooling system.
24. Refill the cooling system.
25. Purge entrapped air by allowing the engine to warm-up without the pressure cap installed. With the transmission in
neutral, increase engine speed above 1000 rpm. Add coolant as required. Refer to section "Cooling System Fill
Procedure"
26. Allow engine to cool.
27. Install the pressure cap after filling the coolant system to the required coolant level.

19 Preparing Engine for Storage
It will be necessary to remove all rust or corrosion completely from any exposed part before applying rust preventive
compound. Therefore, it is recommended that the engine be processed for storage as soon as possible after removal from
operation.
The engine should be stored in a building that is dry and can be heated during the winter months. Moisture-absorbing
chemicals are available commercially for use when excessive dampness prevails in the storage area.
19.1 Temporary Storage (30 Days or Less)

An engine prepared in this manner can be returned to service in a short time by removing the seals at the engine openings and
by checking the engine coolant, fuel oil, lubricating oil and transmission oil levels.
To protect the engine for a temporary period of time (30 days or less), follow this procedure:
1. With the engine at ambient temperature and cool to the touch, drain engine crankcase oil into a suitable container.
Dispose of the oil in an environmentally friendly manner, according to state and/or federal (EPA) recommendations.
2. Fill the crankcase to the proper level with the recommended viscosity and grade of oil.
3. Fill the fuel tank with the recommended grade of fuel oil. Operate the engine for two (2) minutes at 1200 rpm and no
load. Do not drain the fuel system or the crankcase after this run.
4. Check the air cleaner and service it, if necessary.
NOTE: If an antifreeze solution is not required during storage, flush the cooling system with a good soluble oil
(3% – 5% by volume) rust inhibitor to prevent rusting of the outside diameter of the cylinder liners.
5. If freezing weather is expected during the storage period, check the antifreeze/coolant for required freeze and inhibitor
protection. Add antifreeze solution to the cooling system in accordance with Detroit's recommendations. Refer to
section "How to Select Coolant"
WARNING: EYE INJURY

6. Clean the exterior of the engine (except electrical parts) with fuel oil and dry with compressed air.
7. Seal all engine openings. The material used must be waterproof, vapor-proof and possess sufficient physical strength to
resist puncture and damage from the expansion of entrapped air.
19.2 Extended Storage (More than 30 Days)

Outdoor storage of the engine is not recommended. If units must be kept out of doors, follow the preparation and storage
instructions already given. Protect units with quality, weather-resistant tarpaulins (or other suitable covers) arranged to
provide for air circulation.
NOTICE: Do not use plastic sheeting for outdoor storage. Enough moisture can condense on the inside of the
plastic to rust ferrous metal surfaces and pit aluminum surfaces. If a unit is stored outside for any extended period
of time, severe corrosion damage can result.
NOTE: Plastic is fine for indoor storage.
The stored engine should be inspected periodically. If there are any indications of rust or corrosion, corrective steps must be
taken to prevent damage to the engine parts. Perform a complete inspection at the end of one year and apply additional
treatment as required.

19 Preparing Engine for Storage
To prepare an engine for extended storage (more than 30 days), follow this procedure:
1. Drain the cooling system. Refer to section "Cooling System Drain Procedure", and flush with clean, soft water. Refill
with clean, soft water and add a rust inhibitor to the cooling system.
2. Circulate the coolant by operating the engine until normal operating temperature is reached. Refer to section "Cooling
System Fill Procedure".
3. Stop the engine.
4. With the engine at ambient temperature and cool to the touch, drain the engine crankcase oil into a suitable container.
Remove the oil filters. Dispose of the oil and filters in an environmentally friendly manner, according to state and/or
federal (EPA) recommendations. Replace the drain plug and torque to 45-50 N·m (33-77 lb·ft).
5. Install new lubricating oil filters. Fill the crankcase to the proper level with Tectyl® 930A preservative lubricating oil
or an equivalent 30-weight preservative lubricating oil meeting Mil-L-21260C, Grade 2 Specification.
NOTE: If engines are stored where condensation of water in the fuel tank may be a problem, additives containing
methyl carbitol or butyl cellusolve may be added to the fuel. Follow manufacturer's instructions for treatment.
Where biological contamination of fuel may be a problem, add a biocide such as Biobor® JF (or equivalent) to the
fuel. When using a biocide, follow the manufacturer's concentration recommendations and observe all cautions
and warnings.
6. Drain the fuel tank. Refill with enough clean No. 1 diesel fuel to permit the engine to operate for about ten (10)
minutes. If draining the fuel tank is not convenient, use a separate, portable supply of recommended fuel.
7. Drain the fuel system and remove the fuel filters. Dispose of used filters in an environmentally responsible manner,
according to state and/or federal (EPA) recommendations. Fill the new filters with No. 1 diesel fuel or pure kerosene
and install on the engine.
8. Operate the engine for five (5) minutes to circulate the clean fuel throughout the engine. Be sure the engine fuel system
is full.
9. Stop the engine and allow to cool. Then disconnect the fuel return line and the inlet line at the primary filter and
securely plug both to retain the fuel in the engine.
10. Transmission: Follow the manufacturer's recommendations for prolonged storage.
11. Power Take-Off: If equipped, follow manufacturer's recommendations for prolonged storage.
NOTE: Failure to properly seal off the turbocharger air inlet and exhaust outlet openings before engine storage
may permit air drafts to circulate through the turbocharger and rotate the turbine/compressor shaft without an
adequate flow of lubricating oil to the center housing bearings resulting in severe bearing damage.
12. Turbocharger: Since turbocharger bearings are pressure lubricated through the external oil line leading from the oil
filter adaptor while the engine is operating, no further attention is required. However, the turbocharger air inlet and
turbine exhaust outlet connection should be sealed off with moisture-resistant tape.
NOTE: Do not apply oil, grease or any wax-base compound to the flywheel. The cast iron will absorb these
substances, which can sweat out during operation and cause the clutch to slip.
13. Apply a non-friction rust preventive compound to all exposed engine parts. If convenient, apply the rust preventive
compound to the engine flywheel. If not, disengage the clutch mechanism to prevent the clutch disc from sticking to the
flywheel.
14. Drain the engine cooling system. If the engine will be exposed to freezing temperatures, install genuine Detroit Power
Cool antifreeze or an equivalent ethylene glycol-base or propylene glycol-base antifreeze solution that provides the
required freeze, boil over and inhibitor protection. Refer to section "Coolant Requirements"
15. Drain the preservative oil from the engine crankcase. Reinstall and torque the 3/4" – 14 square, magnetic drain plug to
45-50 N·m (33-77 lb·ft).
16. Remove and clean the battery and battery cables with a baking soda-water solution and rinse with fresh water. Do not
allow the soda solution to enter the battery. Add distilled water to the electrolyte (if necessary) and fully charge the
battery. Store the battery in a cool (never below 0° C or 32° F) dry place. Keep the battery fully charged and check the
level and specific gravity of the electrolyte regularly.
17. Insert heavy paper strips between the pulleys and drive belts to prevent sticking.
18. Seal all engine openings, including the exhaust outlet, with moisture-resistant tape. Use cardboard, plywood or metal
covers where practical.

19. Clean and dry the exterior painted surfaces of the engine and spray with a suitable liquid automobile body wax, a
synthetic resin varnish, or a rust preventive compound.
20. Protect the engine with a good weather-resistant tarpaulin and store it under cover, preferably in a dry building which
can be heated during the winter months.

20 Procedure for Restoring to Service an Engine that Has Been in Extended Storage
20 Procedure for Restoring to Service an Engine that Has Been in

Extended Storage
If an engine has been in extended storage, prepare it for service as follows:

1. Remove the covers and tape from all the openings of the engine, fuel tank and electrical equipment. Do not overlook
the exhaust outlet.
2. Remove the plugs from the inlet and outlet fuel lines and reconnect the lines to their proper positions.
3. Wash the exterior of the engine with fuel oil to remove the rust preventive. Do not wash electrical components.
4. Remove the rust preventive from the flywheel. Flush any soluble oil rust inhibitor (if used) in the cooling system.
5. Remove the paper strips from between the pulleys and drive belts.
6. Fill the crankcase to the proper level with the required grade of lubricating oil. Use a pressure lubricator to insure all
bearings and rocker shafts are lubricated.
7. Fill the fuel tank with the required fuel.
8. Close all drain cocks and fill the engine cooling system with clean, soft water and required inhibitors. If the engine is to
be exposed to freezing temperatures, install genuine Detroit Power Cool antifreeze or an equivalent ethylene glycol-
base or propylene glycol-base antifreeze solution which provides required freeze, boil over, and inhibitor protection.
Refer to section "How to Select Coolant"
9. Install and connect the battery. Make sure the average specific gravity of the battery is 1.260 or higher. Charge the
battery, if necessary.
10. Service the air cleaner, if required.
11. Transmission: Follow the manufacturer's recommendations covering the return of the transmission to service.
12. Power Take-Off: If equipped, follow the manufacturer's recommendations covering the return of the power take-off to
service.
13. Turbocharger: Remove the covers from the turbocharger air inlet and turbine outlet connections. Reconnect piping as
required. Pre-lube the turbocharger center bearing housing. Refer to section "Lubrication System Checks"
14. Fill the cooling system. Refer to section "Cooling System Fill Procedure"

15. After all preparations are completed, start the engine.
NOTE: The small amount of rust preventive which remains in the fuel system will cause smoky exhaust for a few
minutes.
NOTE: Before subjecting the engine to a load or high speed, allow it to reach normal operating temperature.
16. Check for trouble codes.

a. If there are no codes, perform a parked regeneration.
b. If there are codes, repair what is necessary then perform a parked regeneration.

21 Torque Specifications
21.1 Engine System Torque Specifications

These tables contain the torque specifications for the engine system components.
Table 36.
Rocker Cover
Component Metric Unit English Unit
Rocker Cover to Camshaft Housing 20 N·m 14 lb·ft
Air filter Bracket(s) to Rocker Cover 20 N·m 14 lb·ft
Table 37.
Camshaft Housing and related components
Injector Harness Mounting Screws 10 N·m 7 lb·ft
Injector Harness Electrical Contacts to
1.5 N·m 13 lb·in.
Injector
Jake® Brake Solenoid Terminals 1.5 N·m 13 lb·in.
Rocker Shaft Bolts (intake and exhaust) 50–55 N·m +90° torque turn 36–41 lb·ft +90° torque turn
Jake® Brake Solenoid Hold-Down Screws 10 N·m 88 lb·in.
Camshaft Housing Mounting Bolts
(14) 120 mm length (M10) Primary 20 N·m Primary 15 lb·ft
Final 50-55 N·m Final 37-40 lb·ft
Final 50-55 N·m Final 37-40 lb·ft
Final 30 N·m Final 22 lb·ft
Camshaft Position Sensor 10 N·m 88 lb·in.
Table 38.
Cylinder Head
DD13 Large Cylinder Head Bolts 200 N·m+ 180° torque turn 147 lb·ft + 180° torque turn
DD13 Small Cylinder Head Bolts 60 N·m 44 lb·ft
DD15 & DD16 Large Cylinder Head Bolts First 50 N·m First 37 lb·ft
Second 250 N·m Second 184 lb·ft
Third 180° torque turn Third 180° torque turn
DD15 & DD16 Small Cylinder Head Bolts 60 N·m 44 lb·ft
Valve Adjusting Screw 50 N·m 37 lb·ft

Table 39.
Piston and Connecting Rod Assembly
DD13 Connecting Rod Bolts 190 N·m + 90° torque turn 140 lb·ft + 90° torque turn
DD15 & DD16 Connecting Rod Bolts 115 N·m + 180° torque turn 85 lb·ft + 180° torque turn
Piston Spray Nozzle 30 N·m 22 lb·ft
Table 40.
Crankshaft
DD13 Main Bearing Cap Bolts First 50 N·m First 36 lb·ft
Third 300 N·m Third 221 lb·ft
Fourth 90° torque turn Fourth 90° torque turn
DD15 Main Bearing Cap Bolts First 50 N·m First 36 lb·ft
Third 250 N·m Third 184 lb·ft
Fourth 90° torque turn Fourth 90° torque turn
Fifth 90° torque turn Fifth 90° torque turn
Vibration Damper Pulley 200 N·m 147.5 lb·ft
Table 41.
Flywheel and Flywheel Housing
Flywheel Bolts 200-220 N·m + 90° to 100° torque turn 147-162 lb·ft + 90° to 100° torque turn
Flywheel Housing Bolts
M8 x 16 (2 Qty) 30 N·m 22 lb·ft
M14 x 1.5 x 90 120 N·m 88 lb·ft
M10 x 45 (6 Qty) 60 N·m 44 lb·ft
M10 x 90 (3 Qty) 60 N·m 44 lb·ft
M14 x 1.5 x 180 (1 Qty) 120 N·m 88 lb·ft
M8 x 45 (2 Qty) 30 N·m 22 lb·ft
M8 x 30 (2 Qty) 30 N·m 22 lb·ft
M14 x 1.5 x 70 (1 Qty) 120 N·m 88 lb·ft
M12-10 (1 Qty) 100 N·m 74 lb·ft
Table 42.
Engine Mounted Radiator Support
Engine Mounted Radiator Support Bolts 250 N·m 184 lb·ft

Table 43.
Engine Lifter Brackets
Rear Lifter Bracket 180 N·m 132 lb·ft
Venturi Pipe to Front Crossover Tube Lifter
30 N·m 22 lb·ft
Bracket
Coolant Delivery Pipe to Front Crossover
30 N·m 22 lb·ft
Tube Lifter Bracket
Table 44.
Belt Drive Tensioner
Maximum Allowable Torque 60 N·m 44 lb·ft
Table 45.
Air Compressor Drive Gear Nut
Drive Gear Nut (left-hand thread) 210-250 N·m 155-185 lb·ft
21.2 Fuel System Torque Specifications

These table contains the torque specifications for the fuel system.
Table 46.
Prefilter Cap 15-20 N·m 11-15 lb·ft
Water Separator/Coalescer Cap 55-60 N·m 40-44 lb·ft
Water-In-Fuel Sensor 9-13 N·m 6.5-9.5 lb·ft
Final Filter Cap 55-60 N·m 40-44 lb·ft
Fuel Filter Module Mounting Bolts 60 N·m 44 lb·ft
Air Compressor Coolant Line to Fuel Filter
25 N·m 18 lb·ft
Module
Fuel Lines to Fuel Filter Module 25 N·m 18 lb·ft
Low Pressure Pump to High Pressure Pump 8 N·m 6 lb·ft
Fuel Inlet For Low Pressure Pump 45 N·m 33 lb·ft
Fuel Return For Low Pressure Pump 45 N·m 33 lb·ft
Fuel Pump Eyebrow Mounting Bolts 30 N·m 22 lb·ft
High Pressure Pump to Flywheel Housing 60 N·m 44 lb·ft
High Pressure Fuel Pump to Bracket 30 N·m 22 lb·ft
High Pressure Fuel Pump Bracket to Block 100 N·m 74 lb·ft
High Pressure Fuel Pump Upper Fuel
30 N·m 22 lb·ft
Manifold Bolts
High Pressure Fuel Pump Lower Fuel
30 N·m 22 lb·ft
Manifold Bolts
High Pressure Fuel Pump Emergency
35 N·m 26 lb·ft
Lubrication Line


Fuel Inlet For High Pressure Pump 45 N·m 33 lb·ft
Fuel Return For High Pressure Pump 45 N·m 33 lb·ft
Version Seven Banjo Bolts 35 N·m 26 lb·ft
Amplifier Return Fitting At Fuel Inlet For Low
35 N·m 26 lb·ft
Pressure Pump
Needle Return Fitting At Fuel Inlet For High
35 N·m 26 lb·ft
Pressure Pump
Fuel Supply Line to Doser Block Assembly 40 N·m 30 lb·ft
High Pressure Lines From High Pressure
40 N·m 30 lb·ft
Pump to Fuel Rail
Two Stage Valve 26 N·m 20 lb·ft
Pressure Relief Valve 32 N·m 25 lb·ft
Quantity Control Valve 8 N·m 6 lb·ft
High Pressure Line Nuts at Fuel Rail and
Camshaft Frame and/or at Fuel Rail and 40 N·m 30 lb·ft
Pump
Low Pressure Fuel Pump Inlet Or Outlet
30 N·m 22 lb·ft
Lines to Filter Module
Fuel Rail to Camshaft Frame 10 N·m 7 lb·ft
Injector Feed Tubes to Fuel Rail 40 N·m 29 lb·ft
Pressure Limiting Valve Fuel Return Line to
35 N·m 25 lb·ft
Fuel Filter Module
Fuel Rail Pressure Sensor 65-70 N·m 48-52 lb·ft
Pressure Limiting Valve 95-105 N·m 70-77 lb·ft
Injector Hold-Down Bolt 20 N·m + 90° 15 lb·ft + 90°
High Pressure Lines to Injector 40 N·m 29 lb·ft
Injector Feed Line Seal 15 N·m 11 lb·ft
Injector Connections 1.5 N·m 12 lb·in
Allen Head Injector Harness Hold-Down
10 N·m 7 lb·ft
Bolts
Injector Tube 45 N·m ±5 33 lb·ft ±3
Fuel Doser Injector Valve 20 N·m 14 lb·ft
Fuel Line to Fuel Doser Injector Valve 18 N·m 12 lb·ft
Fuel Doser Housing to Exhaust Pipe 34 N·m 25 lb·ft
Coolant Feed and Return Lines 15 N·m 11 lb·ft
Fuel Line to Fuel Doser Injector Valve 16-20 N·m 11.8-14 lb·ft
Doser Block Bracket 25 N·m 18 lb·ft
Doser Block Assembly 32-36 N·m 24-27 lb·ft
Fuel Compensation Pressure Sensor 11 N·m 8 lb·ft
21.3 Air Intake System / Exhaust System / Exhaust Gas Recirculation System Torque
Specifications
This table contains the Torque Specifications for the Air Intake System / Exhaust System / Exhaust Gas Recirculation
System.

Table 47.
Intake Manifold
Intake Manifold Bolts 25 N·m 18 lb·ft
Cold Boost Pipe 30 N·m 22 lb·ft
Charge Air Cooler Outlet Air Temperature
35 N·m 26 lb·ft
Sensor
Intake Manifold Air Temperature Sensor 35 N·m 26 lb·ft
Table 48.
DD13 Turbocharger
Turbocharger Exhaust Manifold Bolts 50 N·m 37 lb·ft
Turbocharger Oil Drain Line 30-38 N·m 22-28 lb·ft
Turbocharger Oil Supply Line 30 N·m 22 lb·ft
Doser Injection Valve Coolant Inlet And
15 N·m 11 lb·ft
Outlet Lines
Fuel Line to Doser Injection Valve 23-25 N·m 17-18 lb·ft
Turbocharger Support Bracket 25 N·m 18 lb·ft
Compressor Elbow and Charge Air
6 N·m 4 lb·ft
Compressor Plumbing Clamps
Table 49.
DD15 Turbocharger
Turbocharger Exhaust Manifold Bolts 50 N·m 37 lb·ft
Bracket Bolts 25 N·m 18 lb·ft
6 N·m 4 lb·ft
Compressor Plumbing Clamps
Compressor
Table 50.
DD15 Axial Power Turbine
Gear Box to Cylinder Block 55-60 N·m 41-45 lb·ft
Bracket into Axial Power Turbine 55-60 N·m 41-45 lb·ft
Bracket into Cylinder Block 55-60 N·m 41-45 lb·ft
Airline to Axial Power Turbine 10 N·m 7 lb·ft
Oil Feed Line from Block to Axial Power
20 N·m 15 lb·ft
Turbine

Table 51.
DD15 Gear Box
Gear Box to Cylinder Block 55-60 N·m 41-44 lb·ft
Table 52.
Exhaust Manifold
Exhaust Manifold Bolts 40 N·m 29 lb·ft
S-Pipe Marmon Clamps at Axial Power
12 N·m 9 lb·ft
Turbine
S-Pipe Bracket 60 N·m 44 lb·ft
Table 53.
DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly
Exhaust Gas Recirculation Cooler Water
30 N·m 22 lb·ft
Manifold Bolts
Center Housing Clamps 12 N·m 9 lb·ft
Table 54.
DD15 Exhaust Gas Recirculation Cooler
Exhaust Gas Recirculation Cooler Straps 20 N·m 14 lb·ft
Exhaust Pipe on Exhaust Gas Recirculation
12 N·m 9 lb·ft
Cooler Clamps
Table 55.
DD13 Exhaust Gas Recirculation Valve Actuator
Exhaust Gas Recirculation Valve Actuator to
30 N·m 22 lb·ft
Cylinder Block Bolts
Coolant Line to Exhaust Gas Recirculation
25 N·m 18 lb·ft
Valve Actuator
Coolant Line to Exhaust Gas Recirculation
Valve Actuator and Exhaust Gas 35 N·m 26 lb·ft
Recirculation Water Manifold
Table 56.
DD13 Mixer Tube
Mixer Tube onto Cold Boost Pipe 30 N·m 22 lb·ft

Table 57.
DD15 Mixer Tube
Mixer Tube onto Cold Boost Pipe 30 N·m 22 lb·ft
Table 58.
Intake Throttle Valve
Intake Throttle Valve to Cold Boost Pipe 30-38 N·m 22-28 lb·ft
21.4 Lubrication System / Cooling System Torque Specifications

This table contains the torque specifications for the lubrication system / cooling system.
Table 59.
LUBRICATION SYSTEM
Component Metric Unit (N·m) English Unit (lb·ft)
Threaded Insert
100 N·m 73 lb·ft
Connecting Nut
Oil Pan Drain Plug 45 N·m 33 lb·ft
Oil Pan Bolts Grade 8.8 20-25 N·m Grade 8.8 15-18 lb·ft
Grade 10.9 30-35 N·m Grade 10.9 22-26 lb·ft
Dipstick Tube Fitting
60 N·m 44 lb·ft
M20X1.5
70 N·m 51 lb·ft
M22X1.5
90 N·m 66 lb·ft
M27X1.5
100 N·m 73 lb·ft
M30X1.5
Oil Filter and Cap 55 N·m ±5 40 lb·ft ±5
Oil Pump Bolts 30 N·m 22 lb·ft
Oil Manifold to
Cylinder Block M10 60 N·m 44 lb·ft
Bolts
Oil Manifold to
30 N·m 22 lb·ft
Cylinder Block M8 Bolt
Crankcase Breather to
60 N·m 44 lb·ft
Engine Block
Breather Pipe 30 N·m 22 lb·ft
Filter Cover 55 N·m 40 lb·ft
Thermostat to Oil
20-25 N·m 15-19 lb·ft
Coolant Module

LUBRICATION SYSTEM
Component Metric Unit (N·m) English Unit (lb·ft)
Oil Coolant Module
10 N·m 7 lb·ft
Guide Studs
Oil Coolant Module 10 N·m 7 lb·ft
Bolts
Final torque 60-65 N·m Final torque 44-47 lb·ft
Allen Head Plug to
70-80 N·m 51-59 lb·ft
Module
Oil Sample Valve 80 N·m 59 lb·ft
Table 60.
COOLING SYSTEM
Thermostat 30 N·m 22 lb·ft
Water Manifolds Bolts 30 N·m 22 lb·ft
Exhaust Gas Recirculation Cooler to Water
20 N·m 15 lb·ft
Manifold
Coolant Outlet Elbow 30 N·m 22 lb·ft
Water Pump Pulley 25 N·m 18 lb·ft
21.5 Electrical System Torque Specifications

This table contains the torque specifications for the electrical system.
Table 61.
Electrical System
Motor Control Module 2 to Engine Bolts 34 N·m 25 lb·ft
Fuel Line to Motor Control Module 2 55 N·m 40 lb·ft
Fuel Line to Fuel Filter Module 55 N·m 40 lb·ft

22 DD15 and DD16 Specifications, New Clearances, and Wear Limits
22.1 DD15 and DD16 Specifications, New Clearances, and Wear Limits
Specifications, clearances and wear limits are listed below. These limits also apply to oversize and undersize parts. It should
be specifically noted that the clearances apply only when all new parts are used at the point where the various specifications
apply. This also applies to references within the text of the manual. The column entitled "Limits" in this chart lists the amount
of wear or increase of clearance which can be tolerated in used engine parts and still ensure satisfactory performance. It
should be emphasized that the figures given as "Limits" must be qualified by the judgment of personnel responsible for
installing new parts. These wear limits are, in general, listed only for the parts more frequently replaced in engine overhaul
work. Refer to the following tables to obtain specifications, new clearances, and wear limits for the DD15 and DD16 engines.
Table 62.
Piston and Piston Rings
Engine Part (Standard Size, New) Minimum Maximum Limits
Piston Diameter 139 mm
— —
5.194 in.
Compression Rings
Gap Top Compression (Fire Ring) 0.60 mm 0.75 mm
—
0.024 in. 0.030 in.
Gap (No. 2 Middle Compression 0.70 mm 0.90 mm
Ring) —
0.028 in. 0.035 in.
Oil Control Ring
Gap (Oil Control Ring) 0.40 mm 0.60 mm
—
0.016 in. 0.024 in.
Table 63.
Piston Pin
Piston Pin Outside Diameter 62 mm
— —
2.44 in.
Table 64.
Piston Protrusion
Piston Protrusion -0.213 mm 0.2075 mm
—
-0.009094 in. 0.008169 in.

Table 65.
Idler Gear Specifications
Backlash (Crank Gear Idler 1) 0.039 mm 0.197 mm
—
0.0015 in. 0.0078 in.
Backlash (Idler 1- Idler 2) 0.042 mm 0.166 mm
—
0.0016 in. 0.0065 in.
Backlash (Idler 2 - Idler 3) 0.042 mm 0.166 mm
—
0.0016 in. 0.0065 in.
Backlash (Idler 3 - 5) Hold #5 and 0.079 mm 0.305 mm
Measure #3 —
0.003 in. 0.012 in.
Backlash (Idler 3 - 5) Hold #3 and 0.043 mm 0.165 mm
Measure #5 —
0.0016 in. 0.0065 in.
Backlash ( Idler 5 to Camshaft 0.051 mm 0.257 mm
Gear) —
0.002 in. 0.0101 in.
Backlash (Crankshaft Gear- Oil 0.032 mm 0.388 mm
Pump Gear) —
0.0012 in. 0.0152 in.
Backlash (Crankshaft Gear- Idler 4) 0.039 mm 0.197 mm
—
0.0015 in. 0.0077 in.
Backlash (Idler 4 - Turbocharger 0.037 mm 0.143 mm
Compound Gear) —
0.0015 in. 0.0056 in.
Backlash (Crank Gear Oil Pump 0.032 mm 0.388 mm
Gear) —
0.0012 in. 0.0152 in.
Backlash (Idler 2- High Pressure 0.041 mm 0.167 mm
Fuel Pump gear) —
0.0016 in. 0.0065 in.
Table 66.
Idler Gear Axial Play
Idler 1 Axial Play 0.100 mm 0.330 mm
—
0.003937 in. 0.01299 in.
—
0.003937 in. 0.007087 in.
—
0.003937 in. 0.007087 in.
—
0.003937 in. 0.01299 in.
—
0.003937 in. 0.007087 in.

Table 67.
Intake Valves
Stem Diameter 9.46 mm
— —
0.3724 in.
Valve Height 240.0 mm
— —
9.449 in.
Table 68.
Exhaust Valves
Engine Part (Standard Size,
Minimum Maximum Limits
New)
Stem Diameter 9.442 mm
— —
0.3717 in.
Valve Height 246.5 mm
— —
9.70 in.
Table 69.
Cylinder Block
Block Bore: Diameter 164.4 mm 167 mm
—
6.47 in. 6.57 in.
Table 70.
Cylinder Liner
Outside Diameter (Top of Liner) 166.98 mm 167 mm
—
6.579 in. 6.58 in.
Outside Diameter (Bottom of Liner) 148.07 mm 149.04 mm
—
5.869 in. 5.873 in.
Table 71.
Cylinder Head
Engine Part (Standard Size, New)
Fire Deck Flatness 0.02 mm over 150 mm distance and a maximum 0.05 mm
0.0007874 in over 5.906 in and a maximum 0.001969 in

Table 72.
Maximum Bolt Length
Bolt Maximum
Cylinder Head Bolt 194 mm
7.638 in.
Main Cap Bolt 200.5 mm
7.894 in.
Bearing Cap to Rod Bolt Cap Bolt 82.3 mm
3.240 in.
Flywheel with Crankshaft Gear to 88 mm
Crankshaft Bolt
3.465 in.
Rocker Shaft Bolts 80.3 mm
3.161 in.
Damper Bolts 29.3 mm
1.153 in.
#1 Idler Gear 84.0 mm
3.307 in.
2.185 in.
2.381 in.
3.307 in.
1.791 in.
Turbocharger Mount Bolts 40.0 mm
1.574 in.
Exhaust Bolts (3-Piece Manifold Bolts)
Exhaust Bolts 80.5 mm
Bolt:
3.169 in.
9.0 mm
Spacer:
0.354 in.
Exhaust Bolts (5-Piece Manifold Bolts)
Center Bolts 80.5 mm
Bolt:
3.169 in.
9.0 mm
Spacer:
0.354 in.
Outer Bolts 60.5 mm
Bolt:
2.381 in.
5.0 mm
Spacer:
0.196 in.
Note: Maximum bolt shaft length to be measured during repair. If the bolts are out of specification they must be replaced.
22.2 DD15 and DD16 Oil Pressure Specifications

The minimum oil pressure specifications at operating temperature for a DD15 or DD16 engine are as follows:

Table 73.
RPM BAR PSI
600 .7 10.0
1200 1.6 23.2
1800 2.5 36.3


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DD Platform EuroIV General

2 All information subject to change without notice.

Scope and Use of this Manual

Clearance of New Parts and Wear Limits

The Four-Cycle Principle for Diesel Engines

All information subject to change without notice. 3

Detroit Diesel Electronic Controls (DDEC) VI

Detroit Diesel Electronic Controls (DDEC) 10

4 All information subject to change without notice.

Detroit Diesel Electronic Controls (DDEC) 13

All information subject to change without notice. 5

6 All information subject to change without notice.

All information subject to change without notice. 7

Figure 1. Cylinder Designation and Firing Order

8 All information subject to change without notice.

Exhaust (Start/Run Engine)

WARNING: PERSONAL INJURY

WARNING: PERSONAL INJURY

WARNING: EYE INJURY

All information subject to change without notice. 9

WARNING: PERSONAL INJURY

WARNING: PERSONAL INJURY

10 All information subject to change without notice.

WARNING: ELECTRICAL SHOCK

WARNING: EYE INJURY

Fluids and Pressure

WARNING: PERSONAL INJURY

WARNING: GASOLINE VAPOR IGNITION

The following cautions should be followed when filling a fuel tank:

All information subject to change without notice. 11

CAUTION: PERSONAL INJURY

WARNING: Battery Explosion and Acid Burn

WARNING: PERSONAL INJURY

Use care when connecting battery cables to avoid electrical shock.

12 All information subject to change without notice.

Type A Wood, Paper, Textile and Rubbish

Type B Flammable Liquids

Type C Electrical Equipment

WARNING: PERSONAL INJURY

Working on a Running Engine

CAUTION: PERSONAL INJURY

WARNING: PERSONAL INJURY

Turbocharger Compressor Inlet Shield

WARNING: PERSONAL INJURY

Fluoroelastomer (VITON®) Caution

All information subject to change without notice. 13

WARNING: CHEMICAL BURNS

14 All information subject to change without notice.

4 Scope and Use of This Manual

4.1 Scope and Use of This Manual

All information subject to change without notice. 15

5 Engine Model and Serial Number Designation

Figure 2. Engine Model and Serial Number Location

16 All information subject to change without notice.

Figure 3. Motor Control Module Label

Figure 4. EPA07 Engine Certification Exemption Label

All information subject to change without notice. 17

6 Replacing and Repairing

18 All information subject to change without notice.

WARNING: PERSONAL INJURY

WARNING: PERSONAL INJURY

All information subject to change without notice. 19