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SUBJECT
DATE
Cylinder Head
April 2014
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0081
Platform
DD Platform
Section Title
Removal of the DD15
and DD16 Cylinder Head
Installation of the DD15
and DD16 Cylinder Head
Change
Altered instructions to remove and install the camshaft housing as
an assembly.
All information subject to change without notice.
4 03-14 Copyright © 2014 DETROIT DIESEL CORPORATION
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2 Removal of the DD15 and DD16 Cylinder Head
2
Removal of the DD15 and DD16 Cylinder Head
Because optional and accessory equipment varies with the engine application, this procedure covers only the basic engine. If
the engine is equipped with accessories that affect cylinder head removal, note the mounting details of each to assure correct
installation at reassembly.
Remove as follows:
NOTE: If the cylinder head is to be replaced, the new head must be thoroughly cleaned before installation to
remove all rust and preventive compound, especially from the fuel and oil galleries. This can be done by
immersion in a bath of fuel oil or mineral spirits-based solvent and scrubbing out all openings with a soft bristle
brush.
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.
NOTE: When clean, blow the head dry with compressed air.
WARNING: PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Remove the camshaft housing assembly. Refer to section "Removal of the Camshaft Housing Assembly".
Drain the engine oil.
Remove coolant lines from the water manifold to the fuel doser injector housing.
Remove the Exhaust Gas Recirculation (EGR) vent (de-aeration) line.
Remove the EGR actuator coolant line from the cylinder block.
Disconnect the EGR actuator connector and remove the heat shield. Refer to section "Removal of DD15 and DD16
Exhaust Gas Recirculation Valve Actuator".
Remove the turbocharger flange bolts.
Remove the EGR crossover tube. Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube".
Remove the two bolts attaching the cold boost pipe to the support bracket.
Using the flywheel and main pulley socket tool (J-45390), remove the 40 bolts securing the cylinder head to the
cylinder block.
WARNING: PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is
properly supported and securely attached to an adequate lifting device to prevent the component
from falling.
11. Using cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from the cylinder block.
12. Remove and discard the metallic gasket from the cylinder block.
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 4 03-14
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Installation of the DD15 and DD16 Cylinder Head
Install as follows:
NOTICE: Thoroughly clean oil passage holes on the cylinder block deck with a wire brush to remove any foreign
material before installation of head gasket. Failure to properly clean counter bores may result in head gasket
failure.
1. Inspect the head bolt holes in both block and head for the presence of oil, water, dirt, or damaged threads. Clean or retap as necessary. Ensure piston domes and the cylinder head and cylinder block deck surfaces are clean and free of
foreign matter.
2. Install four lift hooks onto cylinder head.
WARNING: PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is
properly supported and securely attached to an adequate lifting device to prevent the component
from falling.
3. Lift the cylinder head using tool (W470589006200) so the cylinder head can hang at a 30-45 degree angle longitude for
10 minutes. The oil and coolant will need to drain before the head can be installed on the engine.
NOTE: The area of the cylinder block between the cylinders is not a sealing surface and will not cause a coolant
leak.
4. Verify that the cylinder liner protrusion heights (J-47415A) are all within 0.0889 mm (0.0035 in.) prior to installing the
cylinder head. Minimum liner protrusion is 0.1397 mm (0.0055 in.) and maximum liner protrusion is 0.26924 mm
(0.0106 in.).
5. Alternate the cylinder head to hang in the opposite direction at the same angle for ten minutes.
NOTE: If the coolant seal on the head gasket has failed, do not proactively replace the cylinder liner seals unless
there is evidence of extensive cylinder block erosion.
6. Position a new cylinder head gasket onto engine block.
All information subject to change without notice.
4 03-14 Copyright © 2014 DETROIT DIESEL CORPORATION
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3 Installation of the DD15 and DD16 Cylinder Head
WARNING: PERSONAL INJURY
To avoid injury when removing or installing a heavy engine component, ensure the component is
properly supported and securely attached to an adequate lifting device to prevent the component
from falling.
7. Lift the cylinder head into position using cylinder head/engine lifting bar tool (W470589006200). Install the guide
studs (J-35784) through the cylinder head into the cylinder block and carefully seat the cylinder head onto the engine
block.
8. Remove the cylinder head guide studs.
9. Remove the lifting hooks from the cylinder head.
NOTICE: Do not dip the entire cylinder head mounting bolts in oil as it could provide too much oil causing
improper torque results.
10. Coat the threads and underside of bolt heads with clean engine oil before installation.
11. Install the 40 cylinder head bolts into the cylinder head.
12. Torque the 38 large bolts in four steps to:
a. 50 N·m (37 lb·ft)
b. 250 N·m (184 lb·ft)
c. 90° torque turn
d. 90° torque turn
13. Torque the small bolts (39 and 40) to 60 N·m (44 lb·ft).
14. Install the camshaft housing assembly. Refer to section "Installation of the Camshaft Housing Assembly".
15. Fill the engine with the proper amount of oil. Refer to section "Engine Oil Capacities".
16. Prime engine lubrication system. Refer to section "Priming the Engine Lubrication System".
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.
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 4 03-14
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WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
17. Start the engine and check for fuel, coolant or oil leaks.
18. Shut down the engine.
All information subject to change without notice.
4 03-14 Copyright © 2014 DETROIT DIESEL CORPORATION
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