4 101-12
4 101-12
1
4 101-12
SUBJECT
DATE
Removal and Installation of the Air Intake Manifold
April 2012
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
DDC-SVC-MAN-0081
DD Platform
Removal and Installation
of the Air Intake Manifold
Adding a notice to install a high pressure fuel feed line kit.
All information subject to change without notice.
4 101-12
Copyright © 2012 DETROIT DIESEL CORPORATION
3
2 Removal of the Air Intake Manifold
2
Removal of the Air Intake Manifold
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.
Drain the cooling system.
Drain the fuel filter module. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs"
Remove the poly-V-belts. Refer to section "Removal of the Poly-V-Belts"
Remove the Exhaust Gas Recirculation (EGR) mixer pipe and delivery pipe. Refer to section "Removal of the Mixer Pipe"
Remove the cold boost pipe. Refer to section "Removal of the Cold Boost Pipe (Charge Air Pipe)"
Remove the fuel filter module. Refer to section "Removal of the Fuel Filter Module"
Remove the oil coolant module. Refer to section "Removal of the Oil Coolant Module"
Disconnect the high pressure fuel rail feed lines connected to the common rail and output side of the 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. Failure to do so may result in fuel leakage and
subsequent fire.
Service kit P/N: A4720707132 contains all of the necessary parts to replace the high pressure fuel feed lines on
EPA07/10 DD13 engines and service kit P/N: 4720707032 contains all of the necessary parts to replace the high
pressure fuel feed lines on EPA07/10 DD15/16 engines.
9. Disconnect and remove the Pressure Limiting Valve (PLV) return fuel line connected to the common rail and base of the
fuel filter housing. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
10. Disconnect and remove the air intake pressure sensor electrical harness connectors from the two air intake sensors.
11. Identify the flanged screw locations prior to removal of the flanged screws.
12. Remove the 13 flanged screws and isolator gaskets securing the air intake manifold to cylinder head.
WARNING: EXPLOSION
The air intake manifold contains combustible gas. To avoid injury from explosion, do not connect the
air inlet manifold to any devices or lines external to the manifold.
13. Remove the air intake manifold and the six gaskets from the cylinder head and then discard the gaskets.
4
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
4 101-12
4 101-12
3
Installation of Air Intake Manifold
Install as follows:
1. Install six gaskets to the air intake manifold.
2. Install 13 flanged screws and isolator gaskets to the air intake manifold. Secure air intake manifold to cylinder head.
Torque the bolts to 25 N·m (18 lb·ft).
3. Re-install the electrical harness connectors to appropriate sensors.
4. Install the oil coolant module. Refer to section "Installation of the Oil Coolant Module"
5. Install the fuel filter module. Refer to section "Installation of the Fuel Filter Module"
6. Install the high pressure fuel rail feed lines connected to the common rail and output side of the high pressure fuel pump.
Refer to section "Installation of the DD13 High Pressure Fuel Rail Feed Lines"
Refer to section "Installation of the DD15 and DD16 High Pressure Fuel Rail Feed Lines"
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: A4720707132 contains all of the necessary parts to replace the high pressure fuel feed lines on
EPA07/10 DD13 engines and service kit P/N: 4720707032 contains all of the necessary parts to replace the high
pressure fuel feed lines on EPA07/10 DD15/16 engines
7. Install the Pressure Limiting Valve (PLV) return fuel line connected to the common rail and base of the fuel filter housing.
Refer to section "Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines"
8. Install the cold boost pipe. Refer to section "Installation of the Cold Boost Pipe (Charge Air Pipe)"
9. Install Exhaust Gas Recirculation (EGR) mixer pipe and delivery pipe. Refer to section "Installation of the Mixer Pipe"
10. Install the poly-V-belts. Refer to section "Installation of the Poly-V-Belts"
11. Prime fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel Priming Pump"
12. Fill the cooling system. Refer to section "Cooling System Fill Procedure"
All information subject to change without notice.
4 101-12
Copyright © 2012 DETROIT DIESEL CORPORATION
5
Was this manual useful for you? yes no
Thank you for your participation!

* Your assessment is very important for improving the work of artificial intelligence, which forms the content of this project

Download PDF

advertising