Engines Detroit Diesel DD15, repair e-manual

Content

Rocker cover

• Description and operation of rocker cover and related parts
• Removal of the rocker cover
• Cleaning and inspection of the rocker cover
• Installation of the rocker cover

Camshaft and rocker shaft/engine brake assembly

• Description and operation of camshaft and rocker shaft/engine brake assembly and related parts
• Removal of camshaft and rocker shaft/engine brake assembly
• Inspection of the camshaft and rocker shaft/engine brake assembly
• Installation of the camshaft and rocker shaft/engine brake assembly
• DD13 EGR cooler cleaning procedure to remove excess fuel from cooler after engine brake solenoid failure
• DD15 EGR cooler cleaning procedure to remove excess
• Fuel from cooler after engine brake solenoid failure

Camshaft housing

• Removal of the camshaft housing
• Inspection of camshaft housing
• Installation of the camshaft housing

Camshaft timing

• Camshaft timing verification
• Timing the camshafts with the gear train installed

Gear train and engine timing

• Description and operation of gear train and related Parts
• Engine gear train installation and timing
• Checking and adjusting gear lash with camshaft Housing removed

Water manifold

• Description and operation of DD15 and DD16 water manifold and related components
• Removal of the DD15 and DD16 water manifold
• Cleaning and inspection of the DD15 and DD16 water manifold
• DD13 exhaust gas recirculation cooler water manifold assembly

Cold boost pipe (charge air pipe)

• Description and operation of cold boost pipe (charge air pipe) and related components
• Removal of the cold boost pipe (charge air pipe)
• Inspection of cold boost pipe (charge air pipe)
• Installation of the cold boost pipe (charge air pipe)

Air intake manifold

• Description and operation of air intake manifold and Related parts
• Removal of air intake manifold
• Cleaning of the air intake manifold
• Inspection of the air intake manifold
• Installation of air intake manifold

DD13 turbocharger

• Description and operation of the DD13 turbocharger and related parts
• Removal of the DD13 turbocharger
• Inspection of the DD13 turbocharger
• Installation of the DD13 turbocharger
• EGR cooler cleaning procedure to remove excess fuel from cooler after DD13 turbocharger failure

DD13 wastegate solenoid

• Description and operation of the DD13 wastegate Solenoid
• Removal of the DD13 wastegate solenoid
• Installation of the DD13 wastegate solenoid

DD15 turbocharger

• Description and operation of turbocharger and related parts
• Removal of DD15 turbocharger
• Inspection of DD15 turbocharger
• Installation of DD15 turbocharger
• EGR cooler cleaning procedure to remove excess oil from EGR cooler after DD15 turbocharger failure

DD15 axial power turbine

• Description and operation of DD15 axial power turbine And related parts
• Removal of DD15 axial power turbine
• Inspection of the DD15 axial power turbine
• Installation of DD15 axial power turbine

DD15 axial power turbine gear box

• Description and operation of DD15 axial power turbine Gear box and related parts
• Removal of the DD15 axial power turbine gear box
• Inspection of DD15 axial power turbine gear box
• Installation of the axial power turbine gear box

Cylinder head

• Description and operation of cylinder head and related Parts
• Removal of the DD13 cylinder head
• Installation of the DD13 cylinder head
• Removal of the DD15 cylinder head
• Cleaning of the cylinder head
• Assembly of cylinder head
• Installation of the DD15 cylinder head
• Removal of valve spring (cylinder head installed)
• Removal of the valve spring (cylinder head removed)
• Removal of intake and exhaust valves
• Cleaning of valves and related parts
• Inspection of valve springs
• Inspection of valve
• Installation of valve, spring, seal and valve cap
• Valve lash adjustments
• Setting the engine brake lash

Piston and connecting rod assembly

• Description and operation of piston and connecting Rod and related parts
• Removal of piston and connecting rod assembly
• Disassembly of piston and connecting rod assembly
• Inspection of piston and connecting rod assembly
• Assembly of piston and connecting rod assembly
• Installation of piston and connecting rod assembly

Cylinder liner

• Description and operation of cylinder liner and Related parts
• Removal of cylinder liner
• Inspection of cylinder liner
• Cleaning of the cylinder liner
• Installation of the cylinder liner

Crankshaft

• Description and operation of crankshaft and related Parts
• Removal of crankshaft
• Inspection of the crankshaft and related parts
• Installation of crankshaft
• Removal of crankshaft rear oil seal
• Installation of the rear oil seal
• Removal of the crankshaft front oil seal
• Installation of the crankshaft front oil seal

Lubrication system

• Description and operation of the lubrication system and related components

Oil pan

• Description and operation of oil pan and related components
• Removal of oil pan
• Cleaning of oil pan
• Inspection of oil pan
• Removal of threaded insert — plastic oil pan only
• Installation of threaded insert — plastic oil pan only
• Installation of oil pan

Oil dipstick tube

• Description and operation of oil dipstick tube and Related components
• Removal of the oil dipstick tube
• Installation of the oil dipstick tube

Oil pump

• Description and operation of oil pump and related Components
• Removal of the oil pump, oil suction manifold, and oil lines
• Inspection of the oil pump, oil suction manifold, and oil lines
• Installation of the oil pump, oil suction manifold, and oil lines

Crankcase breather

• Description and operation of crankcase breather
• Removal of the crankcase breather
• Inspection of the crankcase breather
• Installation of the crankcase breather

Oil filter

• Replacement of the oil filter
• Oil sample valve
• Replacing oil plug with oil sample valve
• Removal of oil sample valve
• Installation of oil sample valve

Oil filler neck

• Removal of the oil filler neck
• Installation of the oil filler neck

Oil coolant module

• Description and operation of the oil coolant module
• Removal of the oil coolant module
• Installation of the oil coolant module
• Removal of the oil thermostat
• Installation of the oil thermostat

Priming the lubrication system

• Priming the engine lubrication system

Cooling system

• Description and operation of cooling system and related components

Engine water pump

• Description and operation of engine water pump
• Removal of the water pump
• Inspection of the water pump
• Installation of the water pump

Coolant thermostat

• Description and operation of coolant thermostat
• Removal of coolant thermostat and seal
• Inspection of coolant thermostat and seal
• Installation of coolant thermostat and seal

Coolant filter

• Description and operation of coolant filter
• Removal of the coolant filter
• Installation of the coolant filter

Coolant filter service module

• Removal of coolant filter service module
• Installation of coolant filter service module

Coolant inlet elbow

• Removal of the coolant inlet elbow
• Installation of the coolant inlet elbow

Flywheel and flywheel housing

• Description and operation of flywheel, flywheel housing and related parts
• Removal of flywheel housing
• Installation of flywheel housing
• Removal of the flywheel
• Inspection of flywheel
• Installation of flywheel
• Inspection of flywheel housing and rear oil seal area of crankshaft
• Removal of ring gear
• Installation of ring gear

Front engine mount/radiator support

• Description and operation of front engine mount/radiator support and related parts
• Removal of the front engine mount/radiator support
• Inspection of the front engine mount/radiator support
• Installation of the front engine mount/radiator support

Vibration damper

• Removal of the vibration damper
• Installation of the vibration damper

Front engine cover

• Description and operation of the front engine cover
• Removal of the front engine cover
• Inspection of the front engine cover
• Installation of the front engine cover

Engine lifter brackets

• Description and operation of engine lifter brackets and related parts
• Removal of the front engine lifter bracket without front engine power take-off
• Removal of the front engine lifter bracket with front engine power take-off
• Removal of the rear engine lifter brackets
• Inspection of the engine lifter brackets
• Installation of the rear engine lifter brackets
• Installation of the front engine lifter bracket without front engine power take-off
• Installation of the front engine lifter bracket with front engine power take-off

Belt drive tensioner system

• Description and operation of belt drive tensioner and related parts
• Removal of the belt tensioner
• Installation of the belt tensioner
• Removal of the idler pulley and idler pulley bracket
• Installation of the idler pulley and idler pulley bracket
• Removal of non-bracketed idler pulley
• Installation of non-bracketed idler pulley
• Removal of the accessory mounting bracket
• Installation of the accessory mounting bracket

Poly-v-belts

• Removal of the poly-v-belts
• Inspection of the poly-v-belts
• Installation of the poly-v-belts

Air compressor

• Description and operation of the air compressor
• Removal of the air compressor
• Inspection of the air compressor
• Installation of the air compressor

Cylinder block

• Description and operation of cylinder block and related parts
• Removal and disassembly of engine from the vehicle
• Cleaning the cylinder block
• Reassembly and installation of cylinder block

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