Section 7.3 Water Manifold has been updated.

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1 NUMBER: 08 DD15-11 S.M. REF.: 7.3 ENGINE: DD15 DATE: September 2008 SUBJECT: WATER MANIFOLD PUBLICATION: DDC-SVC-MAN-0002 Section 7.3 Water Manifold has been updated. 7.3 WATER MANIFOLD Coolant flows from the cylinder head through an opening next to each exhaust port and into the water manifold. The water manifold is attached to the cylinder head by a total of nineteen bolts including two that are shared with the coolant outlet elbow. Two 3-port gaskets are used between the water manifold and the cylinder head.

2 1. Connecting Pipe 7. Bolt 2. Water Manifold 8. Plug 3. Screw 9. Bolt 4. Screw 10. Bolt 5. Coolant Outlet Elbow 11. Gasket 6. Gasket Figure 1 Water Manifold and Related Parts

3 1. Bolt M8 x 40 (6 qty) 4. Cylinder Head 2. Bolt M8 x 80 (5 qty) 5. Connecting Pipe 3. Bolt M8 x 100 (6 qty) 6. Water Manifold Figure 2 Water Manifold and Related Parts REMOVAL OF THE WATER MANIFOLD Remove as follows: 1. Disconnect the batteries. 2. Drain the engine coolant. 3. Remove the air cleaner. 4. Remove the heat shields. 5. Remove the exhaust gas recirculation (EGR) pipe. 6. Disconnect Doser coolant lines. 7. Disconnect EGR cooler vent line. 8. Disconnect the outlet coolant temperature sensor connector. 9. Remove EGR actuator coolant outlet line.

4 10. Remove upper radiator hose. 11. Remove four coolant outlet elbow bolts. 12. Remove EGR cooler. 13. Remove eleven upper water manifold bolts. 14. Loosen six lower water manifold bolts. 15. Remove water manifold. 16. Remove and discard gaskets. INSPECTION AND CLEANING OF THE WATER MANIFOLD Clean and inspect as follows: 1. Clean the water manifold. 2. Inspect the water manifold for damage or cracks; replace if necessary. 3. Replace the gaskets. INSTALLATION OF THE WATER MANIFOLD Install as follows: NOTICE: Ensure when installing the insert seal that the connecting pipe is lubricated with clean oil; see Figure 1; if it is not lubricated the connecting tube cannot be fully installed and the rubber can be cut. NOTICE: Do not use sealant when installing water manifold to the cylinder head. 1. Install water manifold gaskets and connecting pipe onto the water manifold. 2. Install six lower water manifold bolts and start by a few threads. 3. Install water manifold onto cylinder head. 4. Install eleven upper water manifold bolts. See Figure 3.

5 5. Torque the water manifolds bolts to 30 N m 30 (22 lb ft). See Figure 3. Figure 3 Water Manifold Torque Sequence 6. Install EGR cooler to water manifold and torque to 20 N m (15 lb ft). 7. Install coolant outlet elbow with four bolts and torque to 30 N m (22 lb ft). 8. Install upper radiator hose. 9. Install EGR actuator coolant outlet line. 10. Connect the outlet coolant temperature sensor. 11. Connect the EGR cooler vent line. 12. Connect Doser coolant lines. 13. Install the exhaust gas recirculation (EGR) pipe. 14. Install the heat shields. 15. Install the air cleaner. 16. Fill the coolant system. 17. Connect the batteries.

6 ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. 18. Start the engine and check for leaks. ADDITIONAL SERVICE INFORMATION Additional service information is available in the Detroit Diesel DD15 Workshop Manual, DDC-SVC-MAN The next revision to this manual will include the revised information. Detroit Diesel, DDC, DD15 and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. Copyright 2008 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.

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