null  User manual
NUMBER: 10–12–10
2010
S.M. REF.: Listed in Table
ENGINE: EPA10 DD Platform
DATE: October
SUBJECT: EXHAUST MANIFOLD BOLTS AND SPECIFICATIONS TABLES
ADDITIONS, REVISIONS, OR UPDATES
Publication Number
Platform
Section Title
Change
DDC-SVC-MAN-0083
EPA10 DD Platform
1.3 Inspection
of Assembled
Exhaust Manifold
Additional information
Insert as stated.
on inspection for
exhaust manifold wear
and bolt wear information.
Page Number(s)
1.8 Installation of
the Exhaust Manifold
DDC-SVC-MAN-0081
EPA10 DD Platform
9.4 Installation of the
DD13 Turbocharger
Additional notes
for turbocharger
installation.
Insert as stated.
New information added.
Insert as stated.
11.4 Installation of
the DD15 and DD16
Turbocharger
DDC-SVC-MAN-0080
EPA10 DD Platform
5.1 Specifications,
New Clearances,
and Wear Limits
6.1 Specifications,
New Clearances, and
Wear Limits
NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle.
INSPECTION OF THE ASSEMBLED EXHAUST MANIFOLD
Inspect as follows:
1. Visually inspect the exhaust manifold for cracks. Replace if damaged.
2. Visually inspect the exhaust manifold for wear, distortion or warping. Replace if damaged.
3. Visually inspect bolts to see if they are stressed, stretched, or damaged as shown. If so, then
replace the bolts.
4. If bolts visually check, check maximum bolt length. Replace bolts that exceed maximum
specification.
[a]
For the DD13 only, refer to Table 12.
[b]
For the DD15 and DD16, refer to Table 24.
INSTALLATION OF THE EXHAUST MANIFOLD
Install as follows:
1. Install exhaust manifold guide studs into the cylinder head to hold the two exhaust manifold
gaskets in the correct position and facilitate manifold installation.
2. Install the exhaust manifold gaskets.
NOTE:
Ensure the guide studs and gaskets are positioned correctly for the ports and bolt holes to be
lined up properly.
NOTE:
To avoid torsional stress on the bellows, verify that the bellows clamps are not torqued and the
exhaust manifolds can twist on the bellows pipe.
3. Install the assembled exhaust manifold onto the guide studs.
NOTE:
Use high temperature anti-seize compound to ensure proper torque. Hand-tighten the exhaust bolts
to avoid bending the bellows pipe.
4. Using the proper tightening sequence shown below, install the twelve bolts and torque to 40
N·m (29 lb·ft).
NOTE:
The exhaust manifold torque sequence is the same for the three- and five-piece manifold.
NOTE:
The exhaust manifold gasket (3) between the center housing (2) and turbocharger (1) must be
installed with the part number facing up and to the rear of the engine.
5. Torque the 6mm bolt on the bellow clamps to 6-8 N·m (53-70 lb·in.) and the 1/4x28 bolt to
11-13 N·m (97-115 lb·in.).
6. Install the right and left exhaust manifold heat shields and secure with six bolts.
7. For the DD15 and DD16, install the EGR valve.
8. Install the EGR actuator pull rod.
[a]
For the DD13 only, refer to section .
[b]
For the DD15 only, refer to section .
9. Install the EGR hot pipe and gaskets to the EGR valve and EGR cooler with two new spherical
clamps. Refer to section.
10. For the DD15 only, install Axial Power Turbine and gear box. Refer to section .
11. For the DD13 only, install the turbocharger. Refer to section .
12. For the DD15 only, install the turbocharger and the interstage duct. Refer to section .
13. For the DD15 only, install the axial power turbine heat shield with eight bolts. Refer to section .
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
□ Always start and operate an engine in a well ventilated
area.
□ If operating an engine in an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper with the exhaust system or
emission control system.
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.
14. Start the engine and check for exhaust leaks.
15. If exhaust gas leaks are detected, recheck all fittings, clamps, gaskets, seals, and bolt torques.
Retest for leaks.
INSTALLATION OF THE DD13 TURBOCHARGER
Install as follows:
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.
1. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly.
2. Remove any covers that were placed over the openings of the air inlet and exhaust outlet
openings on the engine and turbocharger when the turbocharger was removed.
3. Remove any covers on the oil and coolant inlet lines, oil and coolant outlet lines, and drain
openings on the turbocharger.
4. Place a new gasket, face up, with the tab towards outside on the exhaust manifold turbocharger
flange.
NOTE:
Use high temperature anti-seize compound on the studs to ensure proper torque.
5. Place the turbocharger assembly into position on the exhaust manifold flange studs. Tighten the
nuts just enough to hold the turbocharger in place.
6. Torque the turbocharger exhaust manifold nuts to 50 N·m (37 lb·ft).
7. Install a new gasket and O-ring between the opening in the bottom side of the turbocharger
center housing and the drain line that runs to the cylinder block. Torque the bolts to 30-38
N·m (22-28 lb·ft).
8. Install the turbocharger oil drain line.
9. Install the turbocharger oil supply line. Torque line to 30 N·m (22 lb·ft).
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.
10. For EPA10 DD13 engines, connect the air line supply (1) to the EPV (2).
11. Connect the turbocharger speed sensor connector to the engine wiring harness.
12. Reconnect the flange to the exhaust manifold.
13. Install the coolant inlet and outlet lines to the doser injector housing. Torque to 15 N·m (11 lb·ft).
14. Install the fuel line to the doser injection valve. Torque to 23-25 N·m (17-18 lb·ft).
15. Install the turbocharger heat shields.
16. Install the two bolts to the turbocharger support bracket and turbocharger. Torque the bolts
to 25 N·m (18 lb·ft).
17. Install the compressor elbow and the Charge Air Compressor (CAC) plumbing. Torque the
clamps to 6 N·m (4 lb·ft).
18. Connect the compressor inlet hose.
INSTALLATION OF DD15 AND DD16 TURBOCHARGER
Install as follows:
1. If removed, install the gear box. Refer to section .
2. If removed, install the axial power turbine. Refer to section .
3. If removed, loosely install the turbocharger support bracket to the cylinder block.
4. Install interstage duct onto turbocharger.
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. Attach a chain hoist and a suitable lifting sling to the turbocharger assembly.
6. Remove any covers that were placed over the openings of the air inlet and exhaust outlet
openings on the engine and turbocharger when the turbocharger was removed.
7. Remove any covers on the oil and coolant inlet and drain lines, and the oil and coolant inlet and
drain openings on the turbocharger.
8. Install new turbocharger flange gasket with the tab facing the rear of the engine.
NOTICE:
The turbocharger must be supported after it has been installed to
the exhaust manifold flange to avoid damage to the turbocharger.
NOTE:
Use high temperature anti-seize compound on the bolts to ensure proper torque.
9. Secure the turbocharger to the exhaust flange. Hand tighten bolts.
NOTE:
Do not use any type of lubricant on the inside of any air inlet hose or on the hose contact surfaces of
the turbocharger compressor housing, CAC ducting or the intake manifold.
NOTE:
When installing the turbocharger, use care when moving the turbocharger into position onto the
interstage duct.
10. Install turbocharger to turbocharger support bracket and hand tighten bolts.
11. Torque the turbocharger-to-exhaust manifold bolts to 50 N·m (37 lb·ft).
12. Tighten the interstage duct clamp to 12 N·m (9 lb·ft).
13. Torque turbine housing bracket bolts to 25 N·m (18 lb·ft).
14. Install the turbocharger oil drain line, using a new gasket and O-ring between the opening in the
bottom side of the turbocharger center housing and the drain line that runs to the cylinder block.
Torque the bolts to 30-38 N·m (22-28 lb·ft).
15. Install turbocharger oil supply line. Torque line to 30 N·m (22 lb·ft).
16. Install heat shields.
17. Install compressor elbow and charge air compressor plumbing. Torque clamps to 6 N·m (4 lb·ft).
SPECIFICATIONS, NEW CLEARANCES, AND WEAR LIMITS
Specifications, clearances and wear limits are listed below. These limits also apply to oversize and
undersize parts. It should be specifically noted that the clearances apply only when all new parts are
used at the point where the various specifications apply. This also applies to references within the
text of the manual. The column entitled "Limits" in this chart lists the amount of wear or increase
of clearance which can be tolerated in used engine parts and still ensure satisfactory performance. It
should be emphasized that the figures given as "Limits" must be qualified by the judgment of personnel
responsible for installing new parts. These wear limits are, in general, listed only for the parts more
frequently replaced in engine overhaul work. Refer to the following tables to obtain specifications, new
clearances, and wear limits for the DD13 Engine.
Table 1
Component
Reference
12.8L Piston and Piston Rings
Listed in Table 2
12.8L Piston Pin
Listed in Table 3
Piston Protrusion
Listed in Table 4
Idler Gear Specifications
Listed in Table 5
Idler Gear Axial Play
Listed in Table 6
Intake Valves
Listed in Table 7
Exhaust Valves
Listed in Table 8
Cylinder Block
Listed in Table 9
Cylinder Liner
Listed in Table 10
Cylinder Head
Listed in Table 11
Maximum Bolt Length
Listed in Table 12
Engine Component Reference Table
Engine Part (Standard Size, New)
Minimum
Maximum
Limits
Piston Diameter
131.92 mm
(5.194 in.)
-
–
Compression Rings
–
–
–
Gap; Top Compression (Fire Ring)
0.45 mm
(0.018 in.)
0.55 mm
(0.022 in.)
–
Gap; (No. 2 Middle Compression Ring)
0.90 mm
0.035 (in.)
1.10 mm
(0.043 in.)
–
Oil Control Rings
–
–
–
Gap (Oil Control Ring)
0.30 mm
(0.012 in.)
0.50 mm
(0.020 in.)
–
Table 2
12.8L Piston and Piston Rings
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Piston Pin Outside Diameter
58 mm
(2.28 in.)
–
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Piston Protrusion
-0.201 mm
(-0.007913 in.)
0.2215 mm
(0.00872 in.)
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limit
Backlash (crank gear idler 1)
0.039 mm
(0.0015 in.)
0.039 mm
(0.0015 in.)
–
Backlash (idler 1- idler 2)
0.042 mm
(0.0016 in.)
0.166 mm
(0.0065 in.)
–
Backlash (idler 2 - idler 3)
0.042 mm
(0.0016 in.)
0.166 mm
(0.0065 in.)
–
Backlash (idler 3 - 5) hold
#5 and measure #3.
0.079 mm
0.003 in.)
0.305 mm
0.012 in.)
–
Backlash (idler 3 - 5) hold
#3 and measure #5.
0.043 mm
0.0016 in.)
0.165 mm
0.0065 in.)
–
Backlash ( idler 5 to camgear)
0.051 mm
(0.002 in.)
0.257 mm
(0.0101 in.)
–
Backlash (crank gear- oil
pump gear)
0.032 mm
(0.0012 in.)
0.388 mm
(0.0152 in.)
–
Backlash (crank gear- idler 4)
0.039 mm
(0.0015 in.)
0.197 mm
(0.0077 in.)
–
Backlash (idler 4 turbocompound gear)
0.037 mm
(0.0015 in.)
0.143 mm
(0.0056 in.)
–
Backlash (crank gear oil
pump gear)
0.032 mm
(0.0012 in.)
0.388 mm
(0.0152 in.)
–
Backlash (idler 2- High
Pressure Fuel Pump gear)
0.041 mm
(0.0016 in.)
0.167 mm
(0.0065 in.)
–
Table 3
Table 4
Table 5
Piston Pin
Piston Protrusion
Idler Gear Specifications
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Idler 1 axial play
0.100 mm
(0.003937 in.)
0.330 mm
(0.01299 in.)
–
Idler 2 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Idler 3 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Idler 4 axial play
0.100 mm
(0.003937 in.)
0.330 mm
(0.01299 in.)
–
Idler 5 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Table 6
Idler Gear Axial Play
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Stem Diameter
9.46 mm
(0.3724 in.)
–
–
Valve Height
240.0 mm
(9.449 in.)
–
–
Table 7
Intake Valves
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Stem Diameter
9.442 mm
(0.3717 in.)
–
–
Valve Height
246.5 mm
( 9.70 in.)
–
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Block Bore: Diameter
159 mm
(6.259 in.)
159.15 mm
(6.27 in.)
–
Maximum
Limits
Table 8
Table 9
Exhaust Valves
Cylinder Block
Engine Part (Standard
Size, New)
Minimum
Outside Diameter Top of Liner
158.98 mm
(6.26 in.)
159.04 mm
(6.27 in.)
–
Outside Diameter Bottom
of Liner
141.97 mm
(5.59 in.)
142.05 mm
(5.60 in.)
–
Table 10
Cylinder Liner
Engine Part (Standard
Size, New)
Fire Deck Flatness
Table 11
Cylinder Head
0.02 mm over 150 mm distance and a maximum 0.05 mm
(0.0007874 in. over 5.906 in. and a maximum 0.001969 in.)
Bolt Length
Maximum
Cylinder Head Bolt
194 mm
(7.638 in.)
Main Bearing Cap Bolt
175.5 mm
(6.909 in.)
Bearing Cap to Rod Bolt Cap Bolt
79 mm
(3.11 in.)
Flywheel with Crankshaft gear to Crankshaft Bolt
88 mm
(3.465 in.)
Rocker Shaft Bolt
80.3 mm
(3.161 in.)
Damper Bolts
29.3 mm
(1.153 in)
#1 Idler Gear
84.0 mm
(3.307 in)
#2 Idler Gear
55.5 mm
(2.185 in)
#3 Idler Gear
60.5 mm
(2.381 in)
#5 Idler Gear
45.5 mm
(1.791 in)
Turbocharger Mounting Bolts
40.0 mm
(1.574 in)
Exhaust Bolts (Three-Piece Manifold Bolts)
Bolt: 80.5 mm (3.169 in.)
Spacer: 9.0 mm (0.354 in.)
Table 12
Maximum Bolt Length
SPECIFICATIONS, NEW CLEARANCES, AND WEAR LIMITS
Specifications, clearances and wear limits are listed below. These limits also apply to oversize and
undersize parts. It should be specifically noted that the clearances apply only when all new parts are
used at the point where the various specifications apply. This also applies to references within the
text of the manual. The column entitled "Limits" in this chart lists the amount of wear or increase
of clearance which can be tolerated in used engine parts and still ensure satisfactory performance. It
should be emphasized that the figures given as "Limits" must be qualified by the judgment of personnel
responsible for installing new parts. These wear limits are, in general, listed only for the parts more
frequently replaced in engine overhaul work. Refer to the following tables to obtain specifications, new
clearances, and wear limits for the DD15 and DD16 engines.
Table 13
Component
Reference
Piston and Piston Rings
Listed in Table 14
Piston Pin
Listed in Table 15
Piston Protrusion
Listed in Table 16
Idler Gear Specifications
Listed in Table 17
Idler Gear Axial Play
Listed in Table 18
Intake Valves
Listed in Table 19
Exhaust Valves
Listed in Table 20
Cylinder Block
Listed in Table 21
Cylinder Liner
Listed in Table 22
Cylinder Head
Listed in Table 23
Maximum Bolt Length
Listed in Table 24
Engine Component Reference Table
Engine Part (Standard Size, New)
Minimum
Maximum
Limits
Piston Diameter
139 mm
(5.194 in.)
–
–
Compression Rings
–
–
–
Gap Top Compression (Fire Ring)
0.60 mm
(0.024 in.)
0.75 mm
(0.030 in.)
–
Gap (No. 2 Middle Compression Ring)
0.70 mm
(0.028 in.)
0.90 mm
(0.035 in.)
–
Gap (Oil Control Ring)
0.40 mm
(0.016 in.)
0.60 mm
(0.024 in.)
–
Table 14
Piston and Piston Rings
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Piston Pin Outside Diameter
62 mm
(2.44 in.)
–
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Piston Protrusion
-0.213 mm
(-0.009094 in.)
0.2075 mm
(0.008169 in.)
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Backlash (crank gear idler 1)
0.039 mm
(0.0015 in.)
0.197 mm
(0.0078 in.)
–
Backlash (idler 1- idler 2)
0.042 mm
(0.0016 in.)
0.166 mm
(0.0065 in.)
–
Backlash (idler 2 - idler 3)
0.042 mm
(0.0016 in.)
0.166 mm
(0.0065 in.)
–
Backlash (idler 3 - 5) hold
#5 and measure #3.
0.079 mm
0.003 in.)
0.305 mm
0.012 in.)
–
Backlash (idler 3 - 5) hold
#3 and measure #5.
0.043 mm
0.0016 in.)
0.165 mm
0.0065 in.)
–
Backlash ( idler 5 to camgear)
0.051 mm
(0.002 in.)
0.257 mm
(0.0101 in.)
–
Backlash (crank gear- oil
pump gear)
0.032 mm
(0.0012 in.)
0.388 mm
(0.0152 in.)
–
Backlash (crank gear- idler 4)
0.039 mm (0.0015 in.)
0.197 mm(0.0077 in.)
–
Backlash (idler 4 turbocompound gear)
0.037 mm
(0.0015 in.)
0.143 mm
(0.0056 in.)
–
Backlash (crank gear oil
pump gear)
0.032 mm
(0.0012 in.)
0.388 mm
(0.0152 in.)
–
Backlash (idler 2- High
Pressure Fuel Pump gear)
0.041 mm
(0.0016 in.)
0.167 mm
(0.0065 in.)
–
Table 15
Table 16
Table 17
Piston Pin
Piston Protrusion
Idler Gear Specifications
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Idler 1 axial play
0.100 mm
(0.003937 in.)
0.330 mm
(0.01299 in.)
–
Idler 2 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Idler 3 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Idler 4 axial play
0.100 mm
(0.003937 in.)
0.330 mm
(0.01299 in.)
–
Idler 5 axial play
0.100 mm
(0.003937 in.)
0.180 mm
(0.007087 in.)
–
Table 18
Idler Gear Axial Play
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Stem Diameter
9.46 mm
(0.3724 in.)
–
–
Valve Height
240.0 mm
(9.449 in.)
–
–
Table 19
Intake Valves
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Stem Diameter
9.442 mm
(0.3717 in.)
–
–
Valve Height
246.5 mm
(9.70 in.)
–
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Block Bore: Diameter
164.4 mm
(6.47 in.)
167 mm
6.57 in.
–
Engine Part (Standard
Size, New)
Minimum
Maximum
Limits
Outside Diameter (Top
of Liner)
166.98 mm
(6.579 in.)
167 mm
(6.58 in.)
–
Outside Diameter (Bottom
of Liner)
148.07 mm
(5.869)
149.04 mm
(5.873 in.)
–
Table 20
Table 21
Table 22
Exhaust Valves
Cylinder Block
Cylinder Liner
Engine Part (Standard
Size, New)
Fire Deck Flatness
Table 23
Cylinder Head
0.02 mm over 150 mm distance and a maximum 0.05 mm
(0.0007874 in over 5.906 in. and a maximum 0.001969 in.)
Bolt Length
Maximum
Cylinder Head Bolt
194 mm
(7.638 in.)
Main Cap Bolt
200.5 mm
(7.894 in.)
Bearing Cap to Rod Bolt Cap Bolt
82.3 mm
(3.240 in.)
Flywheel with Crankshaft Gear to Crankshaft Bolt
88 mm
(3.465 in.)
Rocker Shaft Bolts
80.3 mm
(3.161 in.)
Damper Bolts
29.3 mm
(1.153 in.)
#1 Idler Gear
84.0 mm
(3.307 in.)
#2 Idler Gear
55.5 mm
(2.185 in.)
#3 Idler Gear
60.5 mm
(2.381 in.)
#4 Idler Gear
84.0 mm
(3.307 in.)
#5 Idler Gear
45.5 mm
(1.791 in.)
Turbocharger Mounting Bolts
40.0 mm
(1.574 in.)
Exhaust Bolts (Three-Piece Manifold Bolts)
Bolt: 80.5 mm (3.169 in.)
Spacer: 9.0 mm (0.354 in.)
Exhaust Bolts (Five-Piece Manifold Bolts)
Center Bolts
Bolt: 80.5 mm (3.169 in.)
Spacer: 9.0 mm (0.354 in.)
Outer Bolts
Bolt: 60.5 mm (2.381 in.)
Spacer: 5.0 mm (0.196 in.)
Maximum bolt shaft length to be measured during repair. If the bolts are out of specification they must be replaced.
Table 24
Maximum Bolt Length
ADDITIONAL SERVICE INFORMATION
Additional service information is available in Power Service Literature.
Detroit Diesel®, DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.
© Copyright 2010 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.
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