1.1.5 Reassembly of Cylinder Block

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1 SERIES 50 SERVICE MANUAL NOTICE: Castings free of grease or oil will rust when exposed to the atmosphere. Rust on machined surfaces may result in leakage. If the block is to be stored for extended period of time, spray or dip it in a polar-type rust preventative. Castings which are free of grease or oil will rust when exposed to the atmosphere Reassembly of Cylinder Block After the cylinder block has been cleaned and inspected, assemble the engine as follows: To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 40 psi (276 kpa) air pressure. 1. If a reconditioned or new service replacement cylinder block is used, steam clean it to remove the rust preventive and blow out the oil galleries with compressed air. 2. If a new service replacement block is used, stamp the engine serial number and model number on the pad provided on the left side of the block, just below the deck. See Figure Figure 1-16 Location of Engine Serial and Model Numbers All information subject to change without notice. (Rev. 10/03) 6SE Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin

2 1.1 CYLINDER BLOCK AND CYLINDER LINER 3. Also stamp the position numbers on the main bearing caps and the position of the No. 1 bearing on the cooler side of the oil pan mounting flange of the block. 4. Install the main bearing caps in their original positions; refer to Section NOTICE: Always check to make sure cooling nozzles are open and aligned after piston installation. An obstructed, misaligned, bent or damaged nozzle may not provide proper piston cooling. A loosened nozzle may cause a loss of main gallery oil pressure. In either case, piston overheating or lack of adequate lubrication may result in severe engine damage. 5. On current non-premium engines with cast iron pistons, install the bolt-on plate over the oil gallery orifice at the base of each cylinder bore. On premium engines with closed-end rods and forged steel pistons, install oil spray nozzles into these openings. See Figure 1-16a for location of nozzle. Torque plate nozzle retaining bolts to N m (22-28 lb ft). (Rev. 10/03) All information subject to change without notice From Bulletin SE Copyright 2003 DETROIT DIESEL CORPORATION

4 1.1 CYLINDER BLOCK AND CYLINDER LINER 6. Install all of the required cup plugs. Use a good grade of non-hardening sealant such as Loctite 620 (or equivalent). Apply a thin coat of sealant just inside the chamfer where the plug is to be installed and install using cup plug installation tool set, J SeeFigure1-17. Figure 1-17 Cup Plug Installation Tool Set 7. Install all of the required pipe plugs. NOTE: Whenever a pipe plug is installed, the threads must be coated with Loctite, J part of PT-7276, pipe sealant with Teflon, or equivalent, before reassembly. Certain plugs available from the parts depot already have a sealer applied to the threads. Although unnecessary, this pre-coating will not be affected if pipe sealer with Teflon is also applied. 8. Install the crankshaft main bearings, refer to Section Install the crankshaft, refer to Section Install cylinder liners if removed, refer to Section Install the piston and connecting rod assembly, refer to Section Install the oil pan, refer to Section Install the flywheel housing, refer to Section Install the flywheel, refer to Section Install the cylinder head, refer to Section (Rev. 10/03) All information subject to change without notice. 1-24b From Bulletin SE Copyright 2003 DETROIT DIESEL CORPORATION

5 SERIES 50 SERVICE MANUAL 16. Install the camshaft, refer to Section Install the gear case, refer to Section Install crankshaft timing gear and timing wheel, refer to Section Install the adjustable idler gear assembly, refer to Section Install bull gear and camshaft idler gear assembly, refer to Section Install the camshaft drive gear, refer to Section Install the gear case cover, refer to Section Install the accessory drive, refer to Section Install the vibration damper, refer to Section Install the crankshaft pulley, refer to Section Install the engine lifter brackets, refer to Section Install the valve rocker cover, refer to Section and refer to Section Install any electrical components, connectors or wiring looms that were removed during disassembly. 29. Install the SRS synchronous reference sensor, refer to Section Install the TRS timing reference sensor, refer to Section Install the ECM electronic control module and cold plate if required. Refer to Section for DDEC III ECMs; refer to Section for DDEC II ECMs. 32. Install a suitable lifting device to the engine. See Figure 1-5. To avoid injury from a falling engine, ensure the engine is securely attached to the engine overhaul stand before releasing the lifting sling. 33. Remove the engine from the engine overhaul stand. See Figure 1-6. Transfer the engine to an engine dynamometer test stand. Operate the engine following the Run-in procedure; refer to Section Reinstall the engine in the equipment from which it was removed. All information subject to change without notice. (Rev. 10/03) 6SE Copyright 2003 DETROIT DIESEL CORPORATION From Bulletin

6 1.2 CYLINDER HEAD 1.2 CYLINDER HEAD The Series 50 Engines cylinder head combines intake and exhaust valve porting and fuel injector seats with water jacketing to cool the ports, injectors and combustion chamber area. Se e Figure Figure 1-18 Cylind er Head Asse mbly and M at in g Components With the overhead camshaft design, the cylinder head assembly includes: Cylinder head Valve and injector operating mechanism Injector, valve guide and related parts Camshaft and camshaft bearings (Rev. 10/03) All information subject to change without notice F r om Bu ll eti n S E C opy rig h t D ET R O IT D I ES E L CO R P O R AT IO N

Removal and Installation of the DD15 and DD16 Cylinder Head April Removal of the DD15 and DD16 Cylinder Head

4 102-12 1 4 102-12 SUBJECT DATE Removal and Installation of the DD15 and DD16 Cylinder Head April 2012 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change DDC-SVC-MAN-0081