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SUBJECT
DATE
Removal and Installation of the DD13 Cylinder Head
April 2012
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0081
Platform
EPA07/10
DD13
Section Title
Removal of the DD13
Cylinder Head
Installation of the DD13
Cylinder Head
Change
New notice that the high pressure fuel rail feed lines, vibration
dampers, mounting bracket and hardware are one time use
components.
All information subject to change without notice.
4 100-12
Copyright © 2012 DETROIT DIESEL CORPORATION
3
2 Removal of the DD13 Cylinder Head
2
Removal of the DD13 Cylinder Head
Because optional and accessory equipment varies with the engine application, these procedures covers only the basic engine. If
the engine is equipped with accessories that affect cylinder head removal, note the mounting details of each accessory to assure
correct installation at reassembly.
WARNING: PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.
Remove as follows:
1.
2.
3.
4.
5.
6.
7.
8.
Steam clean the engine.
Disconnect the batteries. Refer to OEM procedure.
Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs"
Drain the oil. Refer to OEM procedure.
Drain the coolant. Refer to OEM procedure.
Remove the turbocharger inlet pipe. Refer to OEM procedure.
Remove the rocker cover. Refer to section "Removal of the Rocker Cover"
Disconnect the following electrical harness connections:
a. Coolant outlet temperature sensor harness from the water manifold
b. Delta-P sensor
c. Intake manifold air temperature sensor
d. Intake throttle valve
e. Intake air temperature sensor
9. Remove the high pressure fuel injector lines. Refer to section "Removal of the High Pressure Fuel Injector Lines"
10. Remove high pressure fuel lines from fuel rail to high pressure fuel pump. Refer to section "Removal of the High Pressure
Fuel Rail Feed Lines"
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.
11. Remove amplifier return line, needle return line and pressure limiting valve (PLV) lines. Refer to section "Removal of
the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
12. Disconnect fuel injector harness from the fuel injectors and engine brake solenoids.
Refer to section "Removal of the One-Piece Fuel Injector Wiring Harness"
Refer to section "Removal of the Two-Piece Fuel Injector Wiring Harness"
13. Remove the camshaft and rocker shaft assemblies. Refer to section "Removal of Camshaft and Rocker Shaft/Engine Brake
Assembly"
14. Remove coolant lines from the water manifold to the fuel doser injector housing. Refer to section "Removal of the DD13
Exhaust Gas Recirculation Cooler Water Manifold Assembly"
15. Remove the Exhaust Gas Recirculation (EGR) vent (deaeration) line.
16. Remove the camshaft housing. Refer to section "Removal of the Camshaft Housing"
17. Remove the EGR crossover tube. Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube"
18. Remove the two bolts attaching the cold boost pipe to the support bracket.
19. Using the flywheel and main pulley socket tool (J-45390), remove the 40 bolts securing the cylinder head to the cylinder
block.
20. If the dipstick hose is attached to the intake throttle valve bracket, remove the clip attaching it.
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All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
4 100-12
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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.
21. Using the cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from the cylinder block.
22. Remove and discard the metallic gasket from the cylinder block.
All information subject to change without notice.
4 100-12
Copyright © 2012 DETROIT DIESEL CORPORATION
5
3 Installation of the DD13 Cylinder Head
3
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 re-tap
as necessary. Ensure piston domes, cylinder head, and cylinder block fire deck surfaces are clean and free of foreign
matter.
2. 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.
3. Install cylinder head guide studs (W471589016100).
4. Position a new cylinder head gasket onto the cylinder block.
6
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
4 100-12
4 100-12
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.
5. Install four lift hooks onto the cylinder head.
6. 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.
7. Remove the guide studs.
8. 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.
9. Coat the threads and underside of bolt heads with clean engine oil before installation.
10. Install the 40 cylinder head bolts into the cylinder head. 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.
11. Using the torque sequence shown, torque the small bolts (39 and 40) to 60 N·m (44 lb·ft).
12. Check and adjust the timing of the engine gear train, as needed. Refer to section "Installation and Timing of Engine Gear
Train" .
13. Install the turbocharger flange bolts.
14. Install the Exhaust Gas Recirculation (EGR) crossover tube. Refer to section "Installation of the EGR Crossover Tube" .
15. Install the EGR actuator harness connector, linkage and the heat shield.
16. Install the coolant lines to EGR actuator.
17. Install the camshaft housing. Refer to section "Installation of the Camshaft Housing" .
18. Install the camshaft and rocker shaft assemblies. Refer to section "Installation of the Camshaft and Rocker Shaft/Engine
Brake Assembly" .
19. Install the intake elbow.
20. Install the mixer pipe. Refer to section "Installation of the Mixer Pipe" .
21. Install the EGR venturi. Refer to section "Installation of the EGR Venturi" .
22. Install the fuel injectors. Refer to section "Installation of the Fuel Injector" .
23. Install the engine brake solenoids and injector harness.
All information subject to change without notice.
4 100-12
Copyright © 2012 DETROIT DIESEL CORPORATION
7
3 Installation of the DD13 Cylinder Head
24. Install the amplification needle and pressure limiting valve (PLV). Refer to section "Installation of the Needle, Amplifier,
and Pressure Limiting Valve Return Lines" .
25. 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" .
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.
26.
27.
28.
29.
30.
31.
32.
33.
Install the injector feed lines from fuel rail. Refer to section "Installation of the High Pressure Fuel Injector Lines" .
Connect the coolant temperature sensor harness.
Install the turbocharger inlet pipe.
Install any components that were removed and fill with required fluids as recommended. Refer to OEM guidelines.
Set the valve lash and engine brake. Refer to section "Valve Lash Adjustments" .
Install the rocker cover. Refer to section "Installation of the Rocker Cover" .
Fill the cooling system. Refer to section "Cooling System Fill Procedure" .
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.
WARNING: ENGINE EXHAUST (i)(eov34)
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
34. Start the engine and check for fuel, coolant or oil leaks.
35. Shut down the engine.
8
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
4 100-12
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