5 02-12
5 02-12Rev
1
5 02-12Rev
SUBJECT
DATE
Installation of the DD13,DD15, and DD16 Cylinder Head
February 2013
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0081
Platform
DD Platform
Section Title
Change
Installation of the DD13
Cylinder Head
Added tilting instructions to drain the oil and coolant out of the
cylinder head just like the DD15 installation.
Installation of the DD15
and DD16 Cylinder Head
Added tilting instructions to drain the oil and coolant out of the
cylinder head just like the DD15 installation. Added Notice: Do not
dip the entire cylinder head mounting bolts in oil as it could provide
too much oil causing improper torque results.
All information subject to change without notice.
5 02-12Rev Copyright © 2013 DETROIT DIESEL CORPORATION
3
2 Installation of the DD13 Cylinder Head
2
Installation of the DD13 Cylinder Head
Install as follows:
NOTICE: Thoroughly clean counter bores 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, cylinder head, and cylinder block fire deck surfaces are clean and free of foreign
matter.
2. Install four lift hooks onto the 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.
WARNING: PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.
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.
4. Verify that the cylinder liner protrusion heights are within specification prior to installing the cylinder head. Refer to
section "Installation of the Cylinder Liner" for cylinder liner protrusion specifications.
5. Alternate the cylinder head to hang in the opposite direction at the same angle for ten minutes.
6. Install cylinder head guide studs (W471589016100).
4
All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-12Rev
5 02-12Rev
NOTE: Be sure both fire decks on the block and head surfaces are clean and dry, especially in the grommet
areas.
7. Position a new cylinder head gasket onto the cylinder block.
8. Lift the cylinder head into position using cylinder head/engine lifting bar tool (W470589006200). Lower cylinder head
into place over the guide studs and dowel pins until it is seated on the engine block.
9. Remove the guide studs.
10. 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.
11. Coat the threads and underside of bolt heads with clean engine oil before installation.
12. Install the 40 cylinder head bolts into the cylinder head using the torque sequence shown below. Torque bolts (1
through 38) in three steps as follows:
a. 200 N·m (147 lb·ft).
b. 90° torque turn.
c. 90° torque turn.
13. Using the torque sequence shown, torque the small bolts (39 and 40) to 60 N·m (44 lb·ft).
All information subject to change without notice.
5 02-12Rev Copyright © 2013 DETROIT DIESEL CORPORATION
5
2 Installation of the DD13 Cylinder Head
14. Check and adjust the timing of the engine gear train, as needed. Refer to section "Installation and Timing of Engine
Gear Train".
15. Install the turbocharger flange bolts.
16. Install the Exhaust Gas Recirculation (EGR) crossover tube. Refer to section "Installation of the Exhaust Gas
Recirculation Crossover Tube".
17. Install the EGR actuator harness connector, linkage and the heat shield.
18. Install the coolant lines to EGR actuator.
19. Install the camshaft housing. Refer to section "Installation of the Camshaft Housing".
20. Install the camshaft and rocker shaft assemblies. Refer to section "Installation of the Camshaft and Rocker Shaft/
Engine Brake Assembly".
21. Install the intake elbow.
22. Install the mixer pipe. Refer to section "Installation of the Mixer Pipe".
23. Install the EGR venturi. Refer to section "Installation of the Exhaust Gas Recirculation Venturi".
24. Install the fuel injectors. Refer to section "Installation of the Fuel Injector - Three-Filter System".
25. Install the engine brake solenoids and injector harness.
26. Install the amplification needle and pressure limiting valve (PLV). Refer to section "Installation of the Needle,
Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter System".
27. Install the high pressure feed lines from high pressure pump to common fuel rail.
Refer to section "Installation of the DD13 High Pressure Fuel Rail Feed Lines - Three-Filter System".
NOTICE: The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware are one-timeuse components and MUST be replaced any time they are removed. Service kit P/N: A4720707132 contains all of
the necessary parts to replace the high pressure fuel feed lines on EPA07/10 DD13 engines.
28. Install the injector feed lines from fuel rail. Refer to section "Installation of the High Pressure Fuel Injector Lines Three-Filter System".
29. Connect the coolant temperature sensor harness.
30. Install the turbocharger inlet pipe.
31. Install any components that were removed and fill with required fluids as recommended. Refer to OEM guidelines.
32. Set the valve lash and engine brake. Refer to section "Valve Lash Adjustments".
33. Install the rocker cover. Refer to section "Installation of the Rocker Cover".
34. Fill the cooling system. Refer to section "Cooling System Fill Procedure".
35. Prime engine lubrication system. Refer to section "Priming the Engine Lubrication System".
6
All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-12Rev
5 02-12Rev
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.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
36. Start the engine and check for fuel, coolant or oil leaks.
37. Shut down the engine.
All information subject to change without notice.
5 02-12Rev Copyright © 2013 DETROIT DIESEL CORPORATION
7
3 Installation of the DD15 and DD16 Cylinder Head
3
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.
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.
6. Install the cylinder head guide studs tool (J-35784).
7. Position a new cylinder head gasket onto engine 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.
8
All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-12Rev
5 02-12Rev
8. Lift the cylinder head into position using cylinder head/engine lifting bar tool (W470589006200). Lower into place
over the guide studs and dowel pins until it is seated on the engine block.
9. Remove the cylinder head guide studs.
10. 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.
11. Coat the threads and underside of bolt heads with clean engine oil before installation.
12. Install the 40 cylinder head bolts into the cylinder head.
13. 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
14. Torque the small bolts (39 and 40) to 60 N·m (44 lb·ft).
15. Install the camshaft housing. Refer to section "Installation of the Camshaft Housing".
16. Install the camshaft and rocker shaft assemblies. Refer to section "Installation of the Camshaft and Rocker Shaft/
Engine Brake Assembly".
17. Set the valve lash and engine brake. Refer to section "Valve Lash Adjustments".
NOTICE: Notice: The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware are
one-time-use components and MUST be replaced any time they are removed. Failure to do so may result in fuel
leakage and subsequent fire. Service kit P/N: A4720707032 contains all of the necessary parts to replace the high
pressure fuel feed lines on EPA07/10 DD15/16 engines.
18. Install any components that were removed and fill with required fluids as recommended. Refer to OEM guidelines.
19. Fill the cooling system. Refer to section "Cooling System Fill Procedure"
20. 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.
All information subject to change without notice.
5 02-12Rev Copyright © 2013 DETROIT DIESEL CORPORATION
9
3 Installation of the DD15 and DD16 Cylinder Head
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
21. Start the engine and check for fuel, coolant or oil leaks.
22. Shut down the engine.
10
All information subject to change without notice.
Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-12Rev
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