9 03-15 1 9 03-15 SUBJECT DATE Water Manifold - DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly September 2015 Additions, Revisions, or Updates Publication Number / Title DDC-SVC-MAN-0083 DDC-SVC-MAN-0183 Platform EPA07 EPA10 GHG14 DD Platform Section Title Change Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly Common safety steps added. Procedure change - Removal of Exhaust Manifold added for access to torque manifold bolts correctly Installation of the DD13 EGR Cooler Water Manifold Assembly Common safety steps added. Procedure change - Installation of Exhaust Manifold added for access to torque manifold bolts correctly. All information subject to change without notice. 9 03-15 Copyright © 2016 DETROIT DIESEL CORPORATION 3 2 Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly 2 Removal of the DD13 Exhaust Gas Recirculation Cooler Water Manifold Assembly Remove as follows: WARNING: PERSONAL INJURY To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component. 1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. 2. Open the hood. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 3. Disconnect batteries. Refer to Original Equipment Manufacturer (OEM) procedures. 4. If needed, remove the bumper. Refer to OEM procedures. 5. If needed remove the splash shield. Refer to OEM procedures. WARNING: FIRE HAZARD Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage. 6. Steam clean the engine. 7. Drain the engine coolant. Refer to section "Cooling System Drain Procedure". 8. Remove the front air cleaner mounting bracket from the valve cover. NOTE: Note the orientation of clamps before removal. 9. Remove the two clamps from the hot pipe. Refer to section "Removal of the Exhaust Gas Recirculation Hot Pipe". 10. Remove the hot pipe from the EGR cooler water manifold assembly and from the EGR valve and discard spherical clamps. 11. Remove the radiator support mount. 12. Remove the two clamps from the hose connecting the coolant delivery pipe to the oil coolant module. 13. Remove the retaining strap and the two bolts from the coolant delivery pipe, then remove the coolant delivery pipe from the engine. 14. Remove the hose clamps from the rubber connector connecting the mixer pipe to the venturi pipe. 15. Remove the mixer pipe from the cold boost pipe by removing the three bolts and one bracket bolt. 16. Disconnect the coolant outlet temperature sensor connector from the electrical wiring harness. 17. Unclip the electrical harness from the lifting eye and disconnect the Delta P harness connector. 18. Remove the EGR crossover tube and the venturi by removing the six bolts. Remove them from the engine. 19. While holding the coolant line adapter fitting with a wrench and removing the coolant line nut with a separate wrench, remove the EGR actuator and the doser injector housing coolant lines from the EGR cooler water manifold assembly and the doser injector housing. 20. Remove the clamps and bolts attaching the coolant feed line to the engine and remove coolant feed line. 21. Remove the exhaust manifold. Refer to section "Removal of the Exhaust Manifold". 22. Remove the coolant deaeration line from the EGR cooler water manifold assembly. 23. Remove the EGR cooler water manifold assembly by removing the nineteen bolts attaching it to the cylinder head. 4 All information subject to change without notice. Copyright © 2016 DETROIT DIESEL CORPORATION 9 03-15 9 03-15 24. Remove and discard the gaskets. All information subject to change without notice. 9 03-15 Copyright © 2016 DETROIT DIESEL CORPORATION 5 3 Installation of the DD13 EGR Cooler Water Manifold Assembly 3 Installation of the DD13 EGR Cooler Water Manifold Assembly Install as follows: NOTICE: Ensure the connecting tubes are lubricated with clean oil; if they are not lubricated, the tubes cannot be fully installed or the rubber can be cut. 1. Install two new Exhaust Gas Recirculation (EGR) cooler water manifold assembly gaskets on to the EGR cooler water manifold assembly. 2. Install the EGR cooler water manifold assembly onto the cylinder head. 3. Install and hand tighten the 17 bolts into the EGR cooler water manifold assembly. Torque the bolts to 30 N·m (22 lb·ft) in the sequence shown. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 6 Install the EGR crossover tube. Refer to section "Installation of the Exhaust Gas Recirculation Crossover Tube". Install the EGR venturi. Refer to section "Installation of the Exhaust Gas Recirculation Venturi". Install the mixer pipe. Refer to section "Installation of the Mixer Pipe". Install the exhaust manifold. Refer to section "Installation of the Exhaust Manifold". Install the coolant delivery pipe between the EGR cooler water manifold assembly and the oil coolant module; install two clamps onto the hose connecting the delivery pipe to the module. Torque to 3.0 to 3.5 N·m (26 to 26.5 lb·in.). Install the retaining plate with two bolts to connect the coolant delivery pipe to the EGR cooler water manifold assembly. Torque bolts to 20 N·m (15 lb·in.). Install the hot pipe onto the EGR cooler water manifold assembly and the EGR valve with two new spherical clamps and tighten clamp bolts to 12 N·m (9 lb·ft). Refer to section "Installation of the Exhaust Gas Recirculation Hot Pipe". After installing the hot pipe from EGR cooler water manifold assembly to exhaust manifold, sweep the EGR actuator by hand to verify it does not make contact with the clamps. If contact is made, rotate the clamps as needed to gain clearance. Install the doser injection valve coolant return line to the EGR cooler water manifold assembly. • For the 5mm long thread fitting, torque to 15 N·m (11 lb·ft). • For the 15mm long thread fitting, torque to 22 N·m (16 lb·ft). Install the doser injection valve coolant supply line to the EGR cooler water manifold assembly. • For the 5mm long thread fitting, torque to 15 N·m (11 lb·ft). • For the 15mm long thread fitting, torque to 22 N·m (16 lb·ft). Install the coolant outlet return to the EGR cooler water manifold assembly and to the EGR valve actuator. Install the coolant deaeration line to the EGR cooler water manifold assembly. Connect the electrical wiring harness coolant outlet temperature sensor connector. Install the radiator support mount. All information subject to change without notice. Copyright © 2016 DETROIT DIESEL CORPORATION 9 03-15 9 03-15 18. Fill the engine with coolant. 19. If removed, install the bumper. Refer to OEM procedures. 20. If removed, install the splash shield. Refer to OEM procedures. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 21. Connect the batteries. Refer to OEM procedures. 22. Close the hood. All information subject to change without notice. 9 03-15 Copyright © 2016 DETROIT DIESEL CORPORATION 7
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