Additions, Revisions, or Updates

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03 06-18 1 03 06-18 SUBJECT DATE Flushing the Engine Lubrication System March 2018 Additions,

EPA10/ GHG14 DD HD Flushing the Engine Lubrication System This is a new section.

1 SUBJECT DATE Flushing the Engine Lubrication System March 2018 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change EPA07/ DDC-SVC-MAN-0081 EPA10/ GHG14 DD HD Flushing the Engine Lubrication System This is a new section. DDC-SVC-MAN-0190 GHG17 HD DD All information subject to change without notice Copyright 2018 DETROIT DIESEL CORPORATION

2 Flushing the Engine Lubrication System 2 Flushing the Engine Lubrication System This procedure is used to flush the engine lubrication system and oil coolant module after an engine component

2 2 Flushing the Engine Lubrication System 2 Flushing the Engine Lubrication System This procedure is used to flush the engine lubrication system and oil coolant module after an engine component failure occurs that contaminates the system with metallic debris. Flushing the lubrication system is only necessary if there is metallic debris in the oil sump and metallic debris in the pleats of the oil filter element. Failures that create extensive debris may include connecting rod or main bearing failure, gear train failure, or turbocompound system failure (if equipped). This flushing procedure should be performed before any of the failed parts are removed, so pressure is maintained in the engine lubrication circuit. Only use this procedure when the engine will be repaired, and not replaced. Table 1. Special Service Tools Used in the Procedure Tool Numbers Tool Name Tool Graphic J Oil Priming Adaptor J or Equivalent Oil Pre-Lube Kit Flush the cylinder block and engine lubrication system as follows: 1. Is the cylinder block (including main bearing caps) damaged from a spun main bearing shell? a. Yes; replace the engine. b. No; Go to step Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 3. Disconnect the batteries. 4. Open the hood. 5. If necessary, remove the bumper for access. Refer to the Original Equipment Manufacturer (OEM) procedure. 6. Remove the oil coolant module from the engine. Refer to section "Removal of the Oil Coolant Module". NOTICE: Use a clean work bench during oil coolant module disassembly and reassembly. Organize the parts so they can be reassembled after flushing the module. 4 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

3 Remove the oil filter and oil filter cap from the oil coolant module. Discard filter and cap O-ring. Save the cap for cleaning. 8. Remove the oil filter standpipe. Save for cleaning. 9. Remove the oil thermostat and thermostat cover (if equipped). Discard seal. Save the thermostat and cover for cleaning. 10. Remove the oil cooler and oil cooler O-rings. Discard the cooler and O-rings. 11. Remove the oil filler cap. Save for cleaning. 12. Remove any oil passage plugs. Discard O-rings or sealing rings. Save plugs for cleaning. 13. Remove the coolant drain plug (below coolant thermostat cavity). Discard O-ring. Save plug for cleaning. Figure 1. Oil Coolant Module with Lubrication Components Removed All information subject to change without notice Copyright 2018 DETROIT DIESEL CORPORATION

4 2 Flushing the Engine Lubrication System Figure 2. Lubrication System Components Removed from Oil Coolant Module 14. Use a parts washer or steam cleaner to flush all of the oil passages in the oil coolant module. 15. Use appropriate brushes to remove stubborn debris. Ensure any residual oil, dirt, metal, or other contaminates have been removed from all of the oil cavities and passages in the oil coolant module. See illustrations below for examples of an oil coolant module that has been cleaned. 6 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

6 2 Flushing the Engine Lubrication System Figure 5. Clean Oil Passage 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. 16. Blow out and dry the oil passages in the oil coolant module with compressed air. 17. Clean the components removed during disassembly that will be reused. 18. Reassemble the oil coolant module using a new oil cooler, oil filter, gaskets and seals. Refer to the appropriate sections in the Workshop Manual for installation instructions. 19. Install the oil coolant module onto the engine. Refer to section "Installation of the Oil Coolant Module". NOTE: The oil pan must be thoroughly cleaned when debris has contaminated the engine lubrication system. The engine could be contaminated again if debris is allowed to remain in the sump and circulate. 20. Remove the oil pan, if not already removed. Refer to section "Removal of the Oil Pan". 21. Place a drain pan under the engine to catch oil from the flushing procedure. 22. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port (1) on the oil coolant module. 8 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

7 If equipped with an oil sample valve at the oil priming port, remove the valve and sealing washer NOTE: Tool J is used to adapt the J oil pre-lube kit for use on a DD platform heavy duty engine. 24. Install the oil priming adaptor (J-49181) into the oil priming port in the oil coolant module. Hand-tighten the adaptor. NOTICE: If chassis application prevents access, a 45-degree or 90-degree pipe fitting (1/4" NPT) can be used as an adaptor. 25. Attach the engine pre-lube kit (J-45299) to the oil priming adaptor. 26. Fill the canister with eight quarts of clean engine oil, meeting the operating requirements of the engine. 27. Open the valve on the primer and start pumping until the container is almost empty. 28. The engine lubrication system has now been flushed. 29. Close the valve on the primer and loosen the fitting; do not completely remove it from the adaptor. 30. Remove the priming adaptor from the oil coolant module with the primer line attached to keep the oil from flowing out of the module. 31. Install the Allen head plug or oil sample valve into the oil coolant module and torque to 70 to 80 N m (51 to 59 lb ft). 32. Continue with the necessary repairs to the engine. Refer to the appropriate section(s) in the applicable Workshop Manual. All information subject to change without notice Copyright 2018 DETROIT DIESEL CORPORATION

8 3 Flushing the Engine Lubrication System 3 Flushing the Engine Lubrication System This procedure is used to flush the engine lubrication system and oil coolant module after an engine component failure occurs that contaminates the system with metallic debris. Flushing the lubrication system is only necessary if there is metallic debris in the oil sump and metallic debris in the pleats of the oil filter element. Failures that create extensive debris may include connecting rod or main bearing failure, gear train failure, or turbocompound system failure (if equipped). This flushing procedure should be performed before any of the failed parts are removed, so pressure is maintained in the engine lubrication circuit. Only use this procedure when the engine will be repaired, and not replaced. Table 2. Special Service Tools Used in the Procedure Tool Numbers Tool Name Tool Graphic J Oil Priming Adaptor J or Equivalent Oil Pre-Lube Kit Flush the cylinder block and engine lubrication system as follows: 1. Is the cylinder block (including main bearing caps) damaged from a spun main bearing shell? a. Yes; replace the engine. b. No; Go to step Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps. CAUTION: ELECTRICAL SHOCK To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. 3. Disconnect the batteries. 4. Open the hood. 5. If necessary, remove the bumper for access. Refer to the Original Equipment Manufacturer (OEM) procedure. 6. Remove the oil coolant module from the engine. Refer to section "Removal of the Oil Coolant Module". NOTICE: Use a clean work bench during oil coolant module disassembly and reassembly. Organize the parts so they can be reassembled after flushing the module. 10 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

9 Remove the oil filter and oil filter cap from the oil coolant module. Discard filter and cap O-ring. Save the cap for cleaning. 8. Remove the oil filter standpipe. Save for cleaning. 9. Remove the oil thermostat and thermostat cover (if equipped). Discard seal. Save the thermostat and cover for cleaning. 10. Remove the oil cooler and oil cooler O-rings. Discard the cooler and O-rings. 11. Remove the oil filler cap. Save for cleaning. 12. Remove any oil passage plugs. Discard O-rings or sealing rings. Save plugs for cleaning. 13. Remove the coolant drain plug (below coolant thermostat cavity). Discard O-ring. Save plug for cleaning. Figure 6. Oil Coolant Module with Lubrication Components Removed All information subject to change without notice Copyright 2018 DETROIT DIESEL CORPORATION

10 3 Flushing the Engine Lubrication System Figure 7. Lubrication System Components Removed from Oil Coolant Module 14. Use a parts washer or steam cleaner to flush all of the oil passages in the oil coolant module. 15. Use appropriate brushes to remove stubborn debris. Ensure any residual oil, dirt, metal, or other contaminates have been removed from all of the oil cavities and passages in the oil coolant module. See illustrations below for examples of an oil coolant module that has been cleaned. 12 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

03 06-18 Figure 8. Clean Oil Filter Housing Figure 9.

12 3 Flushing the Engine Lubrication System Figure 10. Clean Oil Passage 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. 16. Blow out and dry the oil passages in the oil coolant module with compressed air. 17. Clean the components removed during disassembly that will be reused. 18. Reassemble the oil coolant module using a new oil cooler, oil filter, gaskets and seals. Refer to the appropriate sections in the Workshop Manual for installation instructions. 19. Install the oil coolant module onto the engine. Refer to section "Installation of the Oil Coolant Module". NOTE: The oil pan must be thoroughly cleaned when debris has contaminated the engine lubrication system. The engine could be contaminated again if debris is allowed to remain in the sump and circulate. 20. Remove the oil pan, if not already removed. Refer to section "Removal of the Oil Pan". 21. Place a drain pan under the engine to catch oil from the flushing procedure. 22. Using a 17 mm Allen tool, remove the Allen head plug from the oil priming port (1) on the oil coolant module. 14 All information subject to change without notice. Copyright 2018 DETROIT DIESEL CORPORATION

13 If equipped with an oil sample valve at the oil priming port, remove the valve and sealing washer NOTE: Tool J is used to adapt the J oil pre-lube kit for use on a DD platform heavy duty engine. 24. Install the oil priming adaptor (J-49181) into the oil priming port in the oil coolant module. Hand-tighten the adaptor. NOTICE: If chassis application prevents access, a 45-degree or 90-degree pipe fitting (1/4" NPT) can be used as an adaptor. 25. Attach the engine pre-lube kit (J-45299) to the oil priming adaptor. 26. Fill the canister with eight quarts of clean engine oil, meeting the operating requirements of the engine. 27. Open the valve on the primer and start pumping until the container is almost empty. 28. The engine lubrication system has now been flushed. 29. Close the valve on the primer and loosen the fitting; do not completely remove it from the adaptor. 30. Remove the priming adaptor from the oil coolant module with the primer line attached to keep the oil from flowing out of the module. 31. Install the Allen head plug or oil sample valve into the oil coolant module and torque to 70 to 80 N m (51 to 59 lb ft). 32. Continue with the necessary repairs to the engine. Refer to the appropriate section(s) in the applicable Workshop Manual. All information subject to change without notice Copyright 2018 DETROIT DIESEL CORPORATION

Additions, Revisions, or Updates

11 01-14 1 11 01-14 SUBJECT DATE DD15 and DD16 Cylinder Head November 2014 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change DDC-SVC-MAN-0081 DDC-SVC-MAN-0181 DDC-SVC-MAN-S181