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SUBJECT
DATE
Removal and Installation of the DD15 and DD16 Cylinder Head
April 2012
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0081
Platform
EPA07/10
DD15/16
Section Title
Removal of the DD15 and
DD16 Cylinder Head
Installation of the DD15
and DD16 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.
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Copyright © 2012 DETROIT DIESEL CORPORATION
3
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.
Steam clean the engine.
Disconnect the batteries.
Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs"
Drain the engine oil.
Drain the coolant.
Remove the turbocharger inlet pipe.
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 fuel injector feed lines. Refer to section "Removal of the High Pressure Fuel Injector Lines"
10. Remove high pressure fuel rail feed lines from fuel rail to high pressure fuel pump. Refer to section "Removal of the
Hydrocarbon Doser Block Feed Line"
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.
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.
a. For EURO 6 DD platform engines, remove one-piece fuel injector wiring harness. Refer to section "Removal of the
One-Piece Fuel Injector Wiring Harness"
b. For NAFTA DD platform engines, remove two-piece fuel injector wiring harness. Refer to section "Removal of the
Two-Piece Fuel Injector Wiring Harness"
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All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
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13. Remove the camshaft and rocker shafts. 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.
15. Remove the Exhaust Gas Recirculation (EGR) vent (de-aeration) line.
16. Remove the camshaft housing. Refer to section "Removal of the Camshaft Housing"
17. Remove the EGR actuator coolant line from the cylinder block.
18. Disconnect the EGR actuator connector and remove the heat shield. Refer to section "Removal of the DD15 and DD16
Exhaust Gas Recirculation Valve Actuator"
19. Remove the turbocharger flange bolts.
20. Remove the EGR crossover tube. Refer to section "Removal of the Exhaust Gas Recirculation Crossover Tube"
21. Remove the two bolts attaching the cold boost pipe to the support bracket.
22. 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.
23. Using cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from the cylinder block.
24. Remove and discard the metallic gasket from the cylinder block.
All information subject to change without notice.
4 102-12
Copyright © 2012 DETROIT DIESEL CORPORATION
5
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 re-tap
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. 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.
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All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
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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 onetime-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.
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Copyright © 2012 DETROIT DIESEL CORPORATION
7
3 Installation of the DD15 and DD16 Cylinder Head
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.
21. Start the engine and check for fuel, coolant or oil leaks.
22. Shut down the engine.
8
All information subject to change without notice.
Copyright © 2012 DETROIT DIESEL CORPORATION
4 102-12
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