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Detroit Diesel 60 Series Service Manual

Detroit Diesel 60 Series Service Manual

Diesel and natural gas-fueled engines

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6SE483 JULY 2005

~~~□~~150®

Service

Manual

Detroit Diesel®

Series 60 Diesel and

Natural Gas-Fueled

Engines

NOTE:

D_ET_R_D_I_T_~-a~-~-~-!-~-@®

Detroit Diesel Corporation

13400 Outer Drive, West / Detroit, Michigan 48239-4001

Telephone: 313-592-5000

Fax: 313-592-3878

Additional copies of this service manual may be

purchased from Detroit Diesel Corporation

Distributors. See your yellow pages- under

Engines, Diesel.

http:l/www.detroltdiesel.com

Detroit Diesel®, DDC® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation.

Series 60®is a registered trademark of Detroit Diesel Corporation.

All information subject to change without notice.

6SE483 0507 Copyright@2005 DETROIT DIESEL CORPORATION. All rights reserved.

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in

U.S.A.

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Summary of Contents for Detroit Diesel 60 Series

Page 3 SERIES 60 SERVICE MANUAL ABSTRACT This manual provides instruction for servicing on-highway applications of the Detroit Diesel Series 60 Diesel and Natural Gas-Fueled Engines. Speciﬁcally a basic overview of each major component and system along with recommendations for removal, cleaning, inspection, criteria for replacement, repair and installation and mechanical troubleshooting are contained in this manual.
Page 4: Engine Exhaust
□ 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. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 5 Revisions to this manual will be sent marked with a revision bar (see Example 2). Sections containing revisions will have a third line in the page footer (compare Examples 1 and 2). All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 6 SERIES 60 SERVICE MANUAL (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 7: Table Of Contents
CRANKSHAFT PULLEY ................1-252 1.16 FLYWHEEL ..................... 1-266 1.17 RING GEAR ..................... 1-275 1.18 FLYWHEEL HOUSING ................1-277 1.19 PISTON AND PISTON RING ..............1-285 All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 8 TURBO SPEED SENSOR (TSS) ............. 2-173 2.23 TURBO BOOST PRESSURE SENSOR ..........2-177 2.24 AIR INTAKE PRESSURE SENSOR ............2-179 2.25 OIL PRESSURE SENSOR ..............2-181 (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 9 VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS ENGINE (LOW PRESSURE SYSTEM) ..........2-255 ADDITIONAL INFORMATION ..............2-257 LUBRICATION SYSTEM OVERVIEW OF LUBRICATING SYSTEM ..........OIL PUMP ....................All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 10 THREE-PIECE EXHAUST MANIFOLD WITH FEY RINGS ..... THREE-PIECE EXHAUST MANIFOLD WITHOUT FEY RINGS ..... 7-16 THREE-PIECE EXHAUST MANIFOLD WITH HEAT SHIELD ....7-23 (Rev. 2005) All information subject to change without notice. viii 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 11 ENGINE TUNE-UP PROCEDURES FOR THE SERIES 60G ENGINE .. 13-24 13.4 VALVE LASH FOR THE SERIES 60G ENGINE ........13-26 PREVENTIVE MAINTENANCE 14.1 MAINTENANCE OVERVIEW ..............14-3 All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 12 IGNITER MODULE ................. 16-10 16.6 IGNITER MODULE BRACKET ..............16-11 16.7 IGNITION COIL HARNESS ..............16-12 16.8 SPARK PLUGS ..................16-15 INDEX ....................Index-1 (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 13: General Information
GENERAL INFORMATION Section Page SCOPE AND USE OF THIS MANUAL ............CLEARANCE OF NEW PARTS AND WEAR LIMITS ......... THE FOUR CYCLE PRINCIPLE FOR DIESEL ENGINES ......FOUR CYCLE PRINCIPLE FOR NATURAL GAS ENGINES ..... GENERAL DESCRIPTION ................. GENERAL SPECIFICATIONS ..............GENERAL SPECIFICATIONS FOR THE SERIES 60G ENGINE ....
Page 14 SERIES 60 SERVICE MANUAL (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 15: Scope And Use Of This Manual
Refer to section ADDITIONAL INFORMATION, "Table of Speciﬁcations, New Clearances, and Wear Limits" under "Speciﬁcations", for a listing of clearances of new parts and wear limits on used parts. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 16: The Four Cycle Principle For Diesel Engines
The intake charge consists of air only with no fuel mixture. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 17 ﬁrst, compression for ignition, and second, that fuel be measured and injected into the compressed air in the cylinder in the proper quantity and at the proper time. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 18: Four Cycle Principle For Natural Gas Engines
See Figure 2 for the four stroke cycle utilized on the natural gas engine. Figure 2 The Four Stroke Cycle (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 19 The burning gases are forced out of the combustion chamber through the open exhaust valve port by the upward travel of the piston. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 20: General Description
A battery charging alternator, with a suitable voltage regulator, serves to keep the battery charged. The Series 60 diesel engine was designed to be electronically controlled. The Detroit Diesel Electronic Control (DDEC) system has evolved with the product.
Page 21 (depending on option selection) in the case of damaging engine conditions, such as low oil pressure, low coolant level, or high oil temperature. Figure 3 Schematic Diagram of DDEC I All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 22 (depending on option selection) in the case of damaging engine conditions, such as low oil pressure, low coolant level, or high oil temperature. Figure 4 Schematic Diagram of DDEC II (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 23 Data Reader (DDR) requests and receives engine data and diagnostic codes. This equipment provides many unique capabilities including cylinder cutout, printer output, and data snapshot. The DDR also provides limited programming capability. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 24 Data Reader (DDR) requests and receives engine data and diagnostic codes. This equipment provides many unique capabilities including cylinder cutout, printer output, and data snapshot. The DDR also provides limited programming capability. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 25 Schematic Diagram of DDEC V Any faults that occur are stored as codes in the ECU's memory. A DDDL® can be used to read the codes. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 26: General Specifications
15.0:1 or 16.5:1 15.0:1 or 16.5:1 Number of Main Bearings Table 1 Speciﬁcations for the Series 60 Engine Figure 8 Cylinder Designation and Firing Order (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 27: General Specifications For The Series 60G Engine
Number of Main Bearings Table 2 General Speciﬁcations for the Series 60G Engine Figure 9 Cylinder Designation and Firing Order for the Series 60G Engine All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 28: Engine Model, Serial Number And Option Label (Series 60G Engine)
Table 3. Figure 10 Location of Engine Serial and Model Number on Block (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 29 All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 30 All groups or parts used on a unit are standard for the engine model unless otherwise listed on the option plate. Figure 11 Rocker Cover with Option Label (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 31: Engine Model, Serial Number And Option Label (Series 60G Engine)
DDEC III / DDEC IV DDEC V Alternate Fuel Engine 5 / 8 Customer Designation Table 4 Model Number Description for Series 60G Engine All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 32: Replacing And Repairing
Those items having machined faces, which might be easily damaged by steel or concrete, should be stored on suitable wooden racks or blocks, or a parts dolly. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 33: Cleaning
[e] Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath. [f] Wash the block in clean water or steam clean it. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 34: Steam Cleaning
Protection Agency) as possessing ozone-depleting properties. Special procedures have been developed for the handling and proper disposal of these chemicals. For environmental considerations, Detroit Diesel has replaced 1,1,1 trichloroethane with Tech Solv 340 branded solvent. (Rev. 2005) All information subject to change without notice.
Page 35 Detroit Diesel believes that a prudent environmental approach to the use of 1,1,1 trichloroethane should be taken. Therefore, Detroit Diesel recommends replacing 1,1,1 trichloroethane with Tech Solv 340 branded solvent wherever the former solvent was used.
Page 36 (with a speed of 15,000-18,000 r/min), have proven successful in removing the gasket eliminator without damaging the mating surfaces of engine parts. See Figure 13. Scotch-Brite® is a registered trademark of the 3M Corporation. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 37 A coarse pad, is suitable for steel surfaces. A medium pad is recommended for aluminum surfaces. The pads are easily interchangeable. See Figure 14. Figure 14 Scotch-Brite Surface Conditioning Disc Installation All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 38 In addition to measuring the used parts after cleaning, the parts should be carefully inspected for cracks, scoring, chipping and other detrimental conditions. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 39: Safety Precautions
Select appropriate safety glasses for the job. It is especially important to wear safety glasses when using tools such as hammers, chisels, pullers or punches. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 40 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. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 41 Use proper shielding around hydraulic lines when welding to prevent hydraulic line damage. Ensure that a metal shield separates the acetylene and oxygen that must be chained to a cart. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 42: Work Place
Check for frayed cords prior to using the tool. Be sure all electric tools are grounded. Defective electrical equipment can cause severe injury. Improper use of electrical equipment can cause severe injury. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 43: Fuel Lines
If injured by escaping ﬂuid, see a doctor at once. Serious infection or reaction can result without immediate medical treatment. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 44 This will reduce the likelihood of a dangerous spark. The following cautions should be followed when ﬁlling a fuel tank: (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 45: Personal Injury
To avoid injury from ﬁre, keep all potential ignition sources away from diesel fuel, including open ﬂames, sparks, and electrical resistance heating elements. Do not smoke when refueling. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 46 To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage. Use care when connecting battery cables to avoid electrical shock. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 47: Cleaning Agent
PERSONAL INJURY To avoid injury, use care when working around moving belts and rotating parts on the engine. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 48 (freezing). □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 49 Follow the manufacturer's instructions on proper product use. Follow the instructions on the container or by the manufacturer of the starting aid. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 50 Use of this shield does NOT preclude any other safety practices contained in this manual. Figure 15 Turbocharger Compressor Inlet Shield (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 51 SERIES 60 SERVICE MANUAL Figure 16 Turbocharger Compressor Inlet Shield, Series 60G Engine All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 52: Fluoroelastomer (Viton) Caution
This is extremely corrosive and, if touched by bare skin, may cause severe burns, sometimes with symptoms delayed for several hours. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 53: Engine Views
DDEC III/IV. See Figure 17. For Series 60G engine views, see Figure 18. For Series 60 2002 Exhaust Gas Recirculation (EGR) engine views see Figure 19. For Series 60 2004 Exhaust Gas Recirculation (EGR) engine views see Figure 20. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 54 SERIES 60 SERVICE MANUAL Figure 17 Engine Views (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 55 SERIES 60 SERVICE MANUAL Figure 18 Engine Views (60G Automotive Engine) All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 56 SERIES 60 SERVICE MANUAL Figure 19 Engine Views for 2002 Series 60 Exhaust Gas Recirculation (EGR) Engine (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 57 SERIES 60 SERVICE MANUAL Figure 20 Engine View for 2004 Series 60 Exhaust Gas Recirculation (EGR) Engine All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 58: English To Metric Conversion
To get equivalent number of: Pound-inch (lb·in.) 0.11298 Newton-meters (N·m) Pound-foot (lb·ft) 1.3558 Newton-meters (N·m) Multiply Power To get equivalent number of: Horsepower (hp) 0.746 Kilowatts (kW) (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 59: Decimal And Metric Equivalents
Kilometers/hour (km/hr) Table 5 English to Metric Conversion Table DECIMAL AND METRIC EQUIVALENTS Listed in Table 6 are the decimal and metric equivalents: All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 60: Specifications
0.500 12.70000 1.00 25.40000 Table 6 Conversion Chart-Customary and Metric Units SPECIFICATIONS This section contains fastener torque speciﬁcations and pipe plug torque speciﬁcations. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 61 M14 X 2.0 160-200 118-148 M16 X 2.0 245-306 181-226 M20 X 2.5 478-598 353-441 Table 8 Class 10.9 Torque Speciﬁcations for Metric Fasteners All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 62 *Use sealant such as Pipe Plug Sealant with Teﬂon®, PT-7271 (Loctite® 592), or equivalent on all uncoated pipe plugs. Table 9 Standard Pipe Plug Torque Speciﬁcations (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 63: Engine
ENGINE Section Page CYLINDER BLOCK AND CYLINDER LINER .......... CYLINDER HEAD ..................1-30 VALVE AND INJECTOR OPERATING MECHANISM ......1-60 VALVES, SPRINGS, GUIDES, INSERTS, SEALS AND ROTATORS ..1-79 ENGINE LIFTER BRACKETS ..............1-106 ROCKER COVER ..................1-111 CRANKSHAFT ..................1-129 CRANKSHAFT OIL SEALS ..............
Page 64 1.34 CRANKSHAFT TIMING GEAR AND TIMING WHEEL ......1-538 1.35 ACCESSORY DRIVE ................1-557 1.36 JAKE BRAKE ................... 1-585 ADDITIONAL INFORMATION ..............1-639 (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 65: Cylinder Block And Cylinder Liner
Oil galleries are machined into the cooler side of the block. See Figure 1-1. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 66 First usage of the drilled block was on May 2, 1998, effective with engine serial number 6R408505. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 67 Refer to section 11.1.3, of this manual for information on installing the adaptorless air compressor. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 68 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-4. Figure 1-4 Flowchart for Repair or Replacement of Cylinder Block (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 69 14. Remove the charge air cooler, radiator, fan guard and other cooling system related parts as necessary to remove the engine. Refer to section 6.8.2. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 70 18. Lift the engine from its mounts using a suitable lifting device. See Figure 1-5. Figure 1-5 Lifting Engine (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 71 20. Bolt cylinder block adaptor (J–35635–2, part of tool set J–35635–A) to the cylinder block and mate it with the stand adaptor (J–35635–1, part of tool set J–35635–A). See Figure 1-7. Figure 1-7 Cylinder Block Adaptor All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 72 No. 6 x 37.92 in. (963 mm) long hose assembly (23504785) is now routed from the fuel pump discharge ﬁtting to the inlet of the secondary fuel ﬁlter. (Rev. 2005) All information subject to change without notice. 1-10 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 73 [w] Remove the oil pan, refer to section 3.11.2. [x] Remove the piston and connecting rod assembly, refer to section 1.21.2. [y] Remove the crankshaft, refer to section 1.7.2. All information subject to change without notice. (Rev. 2005) 1-11 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 74 See Figure 1-8. Figure 1-8 Cylinder Liner Removal Tool (J-45876) (Rev. 2005) All information subject to change without notice. 1-12 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 75 [e] Neutralize the acid that may cling to the casting by immersing the block in an alkaline bath. [f] Wash the block in clean water or steam clean it. All information subject to change without notice. (Rev. 2005) 1-13 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 76 7. Pressure test the cylinder block. Two methods of cylinder block pressure testing may be used depending on the test facilities available: [a] Immersion method; refer to section 1.1.3.1. [b] Leak-marker method; refer to section 1.1.3.2. (Rev. 2005) All information subject to change without notice. 1-14 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 77 4. Install the bolts through the strips and into the cylinder block. Torque the bolts on the ring strips to 230-237 N·m (170-175 lb·ft). Torque the bolts on the outside strips to 14 N·m (10 lb·ft). All information subject to change without notice. (Rev. 2005) 1-15 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 78 9. Install the cylinder block to the engine overhaul stand (J–29109). See Figure 1-6. (Rev. 2005) All information subject to change without notice. 1-16 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 79 Any coolant leakage past the upper seal is drained to the outside rather than into the crankcase, and is easily detected by a visual inspection. All information subject to change without notice. (Rev. 2005) 1-17 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 80 Drain the water jacket. Then blow out all of the passages in the cylinder block with compressed air. 10. Install the cylinder block to the engine overhaul stand (J–29109). See Figure 1-6. (Rev. 2005) All information subject to change without notice. 1-18 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 81 2. Measure the bore of each cylinder with cylinder bore gage (J–5347–B) which has a dial indicator calibrated in 0.0001 in. increments. See Figure 1-12. Figure 1-12 Gaging Cylinder Bores All information subject to change without notice. (Rev. 2005) 1-19 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 82 149.050 - 149.120 5.868 - 5.871 146.050 - 146.120 5.750 - 5.753 146.050 - 146.120 5.750 - 5.753 Table 1-1 Acceptable Cylinder Bore Diameters (Rev. 2005) All information subject to change without notice. 1-20 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 83: Feeler Gauge
ﬂatness between the liner ﬂanges. The deck must be ﬂat within 0.127 mm (0.005 in.) front-to-rear, and ﬂat within 0.0762 mm (0.003 in.) side-to-side. If not, the deck must be resurfaced. All information subject to change without notice. (Rev. 2005) 1-21 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 84 Record the amount of stock removed from the cylinder block by stamping the amount removed on the cylinder block pad. See Figure 1-15. Figure 1-15 Recording Stock Removal on Cylinder Block Pad (Rev. 2005) All information subject to change without notice. 1-22 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 85 Refer to section ADDITIONAL INFORMATION1.A, for line bore speciﬁcations which are listed in Table 1-16. NOTE: Dial bore master setting ﬁxture should be used to zero the cylinder bore gage. All information subject to change without notice. (Rev. 2005) 1-23 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 86: General Inspection
If the block is to be stored for an extended period of time, spray or dip it in a polar-type rust preventive such as "Tectyl® 502-C" from Valvoline Oil Company (or equivalent). Tectyl® is a registered trademark of Ashland Oil, Inc. (Rev. 2005) All information subject to change without notice. 1-24 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 87 ﬂange of the block. 4. Install the main bearing caps in their original positions; refer to section 1.9.3. All information subject to change without notice. (Rev. 2005) 1-25 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 88 See Figure 1-18 for location of nozzle. Torque plate nozzle retaining bolts to 30–38 N·m (22–28 lb·ft). Figure 1-18 Oil Spray Nozzle Location (Rev. 2005) All information subject to change without notice. 1-26 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 89 (J–35653). See Figure 1-19. Figure 1-19 Cup Plug Installation Tool Set All information subject to change without notice. (Rev. 2005) 1-27 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 90 [u] To install the crankshaft vibration damper, refer to section 1.14.3. [v] To install the crankshaft pulley, refer to section 1.15.3. [w] To install the engine lifter brackets, refer to section 1.5.3. (Rev. 2005) All information subject to change without notice. 1-28 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 91 Transfer the engine to a suitable engine dynamometer test stand. Operate the engine on a dynamometer following the Run-in procedure; refer to section 12.7.3.2. Install the engine in the equipment from which it was removed. All information subject to change without notice. (Rev. 2005) 1-29 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 92: Cylinder Head
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. 2005) All information subject to change without notice. 1-30 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 93: Cylinder Head Assembly
1. Roller Follower 4. Exhaust Valve Rocker Arm 2. Injector Rocker Arm 5. Camshaft 3. Intake Valve Rocker Arm Figure 1-21 Cylinder Head Assembly All information subject to change without notice. (Rev. 2005) 1-31 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 94 3. Exhaust Valve Rocker Arm 2. Intake Valve Rocker Arm 4. Camshaft 5. Spacer Figure 1-22 Cylinder Head Assembly (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 1-32 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 95 6. Valve Spring 3. Valve Seat Insert 7. Valve Rotator 4. Valve 8. Valve Keepers Figure 1-24 Valve Guides and Related Parts All information subject to change without notice. (Rev. 2005) 1-33 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 96: Mounting Flange
The fuel gallery outlet (restricted) ﬁtting is installed in the rear of the cylinder head. See Figure 1-25. Figure 1-25 Fuel Gallery Inlet and Outlet Fittings (Rev. 2005) All information subject to change without notice. 1-34 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 97 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-26. Figure 1-26 Flowchart for Repair or Replacement of Cylinder Head All information subject to change without notice. (Rev. 2005) 1-35 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 98 3. Remove the air cleaner and charge air cooler ducting from turbocharger and intake manifold. Refer to section 6.2.2and refer to section 6.3.2. (Rev. 2005) All information subject to change without notice. 1-36 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 99 17. Bracket, Oil Drain Tube Clip Mounting 8. Washer, Turbo Mounting 9. Turbocharger Assembly 18. Nut, Oil Drain Tube Clip Figure 1-27 Turbocharger Oil Lines All information subject to change without notice. (Rev. 2005) 1-37 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 100 6. Remove and inspect the exhaust manifold if necessary. Refer to section 7.2.2 and refer to section 7.2.2.1. See Figure 1-28. 1. Exhaust Manifold 2. Heat Shield Figure 1-28 Exhaust Manifold (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 1-38 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 101 8. Turbo Boost Pressure Sensor 4. Cylinder Head 9. O-ring 5. Manifold Bolt (7) 10. Intake Manifold Figure 1-29 Intake Manifold and Related Parts All information subject to change without notice. (Rev. 2005) 1-39 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 102 3. Intake Manifold Gasket 7. Air Temperature Sensor 4. Cylinder Head 8. Turbo Boost Pressure Sensor Figure 1-30 Intake Manifold and Related Parts (Natural Gas) (Rev. 2005) All information subject to change without notice. 1-40 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 103: Thermostat Housing Removal
8. Drain Cock 4. Hose, Coolant 9. Seals, Thermostat Housing (2) 5. Hose Clamps (2) 10. Cylinder Head Figure 1-31 Thermostat Housing Removal All information subject to change without notice. (Rev. 2005) 1-41 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 104 Positioning Camshaft Thrust Plate 15. Inspect the rocker arm assemblies and camshaft lobes. Refer to section 1.3.2.2, and refer to section 1.28.3.1. (Rev. 2005) All information subject to change without notice. 1-42 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 105 19. Remove the harness mounting ﬂange from the rear of the cylinder head and carefully remove the harness from the head by pulling the harness through the hole in the cylinder head. See Figure 1-25. All information subject to change without notice. (Rev. 2005) 1-43 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 106 No. 3 cam cap and two tapped Jake Brake® bolt holes. See Figure 1-34. Figure 1-34 Cylinder Head Lift Bracket Removal (Rev. 2005) All information subject to change without notice. 1-44 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 107: Cylinder Head Removal
24. Drain the engine lubricating oil, refer to section 14.6.1, to remove any coolant that may have drained into the oil pan when the water jacket was opened. Remove any coolant from the cylinder bores. All information subject to change without notice. (Rev. 2005) 1-45 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 108: Inspection Of Cylinder Head
4. Perform the following tests for cylinder head inspection. [a] Pressure test, refer to section 1.2.3.2. [b] Firedeck straightness test, refer to section 1.2.3.3. (Rev. 2005) All information subject to change without notice. 1-46 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 109 3. Install the thermostat opening cover plate, and gasket to the cylinder head using the bolts provided with the cover plate. See Figure 1-37. Figure 1-37 Thermostat Opening Cover Plate Installation All information subject to change without notice. (Rev. 2005) 1-47 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 110 2.4.6for installation of new injector tube. [b] If a cracked cylinder head is detected, replace the cylinder head. Refer to section 1.2.5. (Rev. 2005) All information subject to change without notice. 1-48 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 111 1. Use a heavy, accurate straight-edge and feeler gages to check for transverse and longitudinal warpage. See Figure 1-39. Figure 1-39 Checking Firedeck Straightness All information subject to change without notice. (Rev. 2005) 1-49 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 112 0.076 mm (0.003 in.) side-to-side. Cylinder head speciﬁcations are listed in Table 1-32. If the cylinder head ﬂatness is outside of the speciﬁcations, Detroit Diesel Corporation recommends replacing the cylinder head. (Rev. 2005) All information subject to change without notice.
Page 113 1-32. See Figure 1-41. If not, reduced-thickness valve seat inserts must be installed. Refer to section 1.4.6. Figure 1-41 Valve Head-to-Cylinder Head Measurement All information subject to change without notice. (Rev. 2005) 1-51 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 114 This is to eliminate surface marks. NOTE: The J–38189 tool pilot has a shoulder stop that will not allow the cutter to remove material in excess of the Detroit Diesel Corporation speciﬁcations. (Rev. 2005) All information subject to change without notice. 1-52...
Page 115: Assembly Of Cylinder Head
4. Install valve guides and seats, valves, valve stem seals, valve springs and rotators. Refer to section 1.4.8and refer to section 1.4.7. All information subject to change without notice. (Rev. 2005) 1-53 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 116: Installation Of Cylinder Head
2. Position the head gasket on the block and install cylinder head guide studs (J–35784) at front and rear of the block. See Figure 1-42. Figure 1-42 Cylinder Head Guide Studs (Rev. 2005) All information subject to change without notice. 1-54 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 117: Cylinder Head Installation
The new head bolt can be used with the former cylinder head gaskets, the former head bolts cannot be used with the new head gasket. Former and new bolts must not be mixed. All information subject to change without notice. (Rev. 2005) 1-55 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 118 7. Repeat the torque sequence to verify all of the head bolts are torqued to speciﬁcation. (Rev. 2005) All information subject to change without notice. 1-56 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 119 All information subject to change without notice. (Rev. 2005) 1-57 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 120 23. Connect the exhaust and air-to-air cooler air ducting and install the air cleaner or air separator. 24. Install any other components that were removed and ﬁll with the required ﬂuids, as recommended. Refer to OEM guidelines. (Rev. 2005) All information subject to change without notice. 1-58 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 121 25. Start the engine and check for fuel, coolant or oil leaks. Keep the engine running while you check. 26. Shut down the engine. All information subject to change without notice. (Rev. 2005) 1-59 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 122: Valve And Injector Operating Mechanism
The center rocker operates the fuel injector follower. See Figure 1-48. Figure 1-48 Rocker Arm Identiﬁcation (Rev. 2005) All information subject to change without notice. 1-60 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 123 7. Exhaust Rocker Arm Assembly 4. Fuel Injector Rocker Arm Assembly 8. Unitized Valve Adjusting Screw Assembly; Injector Figure 1-49 Rocker Arm and Related Parts All information subject to change without notice. (Rev. 2005) 1-61 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 124 3. Intake Rocker Arm Assembly 7. Exhaust Rocker Arm Assembly 4. Spacer Figure 1-50 Rocker Arm and Related Parts (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 1-62 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 125 The oil passage within one rocker arm cylinder set is shown. See Figure 1-51 and see Figure 1-52. All information subject to change without notice. (Rev. 2005) 1-63 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 126 5. Cylinder Head 3. Camshaft Cap 6. Intake Rocker Arm Assembly Figure 1-51 Rocker Arm Assembly Lubrication Schematic with Former Valve Adjusting Screw Assembly (Rev. 2005) All information subject to change without notice. 1-64 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 127 5. Cylinder Head 3. Camshaft Cap 6. Intake Rocker Arm Assembly Figure 1-52 Rocker Arm Assembly Lubrication Schematic with Unitized Valve Adjusting Screw Assemblies All information subject to change without notice. (Rev. 2005) 1-65 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 128 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-53. Figure 1-53 Flowchart for Repair or Replacement of Valve and Injector Operating Mechanism and Camshaft (Rev. 2005) All information subject to change without notice. 1-66 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 129: Removal Of Rocker Arm Assembly
Whenever nuts No. 1 or 8 are loosened or removed, the torque on the corresponding rocker shaft stud must be checked. Torque to 126–146 N·m (93–108 lb·ft). All information subject to change without notice. (Rev. 2005) 1-67 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 130 Figure 1-54 Rocker Arm Shaft Bolts and Nut Identiﬁcation Numbers Figure 1-55 Rocker Arm Shaft Bolts and Nut Identiﬁcation Numbers (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 1-68 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 131 Unitized Valve Adjusting Screws will not be serviced separately. NOTE: If removing a former valve adjusting screw with valve button and retainer clip, proceed to step 6. All information subject to change without notice. (Rev. 2005) 1-69 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 132 Front and rear rocker arm shaft sections look identical, but must not be reversed, and must be installed as removed, due to bolt hole center line distances. The DDC logo is (Rev. 2005) All information subject to change without notice. 1-70 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 133 See Figure 1-58. Figure 1-58 Rocker Arm Shaft Identiﬁcation Mark All information subject to change without notice. (Rev. 2005) 1-71 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 134 5. Run a wire brush through the oil passage to remove any foreign material or sludge. 6. Clean the exterior of the shaft and blow out the passages and oil holes; and dry with compressed air. (Rev. 2005) All information subject to change without notice. 1-72 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 135 2. Remove all of the old gasket sealer from the joint face of the Number 1 and Number 7 camshaft bearing caps and the cylinder head. Refer to "Gasket Eliminator Removal" in the "General Information" section. All information subject to change without notice. (Rev. 2005) 1-73 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 136 Former style valve adjusting screw assemblies and the unitized valve adjusting screw assemblies are interchangeable and can be mixed in the same engine. (Rev. 2005) All information subject to change without notice. 1-74 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 137 2. Check the torque on the rocker shaft studs to ensure they were not loosened when the nuts were removed. Torque the studs to 101-116 N·m (75-86 lb·ft). All information subject to change without notice. (Rev. 2005) 1-75 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 138 If the rocker arm shaft does not have ﬂats, decide on the position of the worn surfaces and rotate the rocker shaft accordingly. (Rev. 2005) All information subject to change without notice. 1-76 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 139 If new rocker arm components are installed, engine oil should be poured over the rocker arms, rocker shaft, and camshaft as a pre-lubricant. All information subject to change without notice. (Rev. 2005) 1-77 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 140: Personal Injury
□ Do not modify or tamper with the exhaust system or emission control system. 13. Start the engine and check for leaks. Shut down the engine when completed. (Rev. 2005) All information subject to change without notice. 1-78 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 141: Valves, Springs, Guides, Inserts, Seals And Rotators
Hard-alloy valve seat inserts, pressed into both intake and exhaust ports, can be replaced when worn to restore new engine performance. All information subject to change without notice. (Rev. 2005) 1-79 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 142 Replacement guides are reamed to close tolerances, and do not require reaming after installation. All valves are retained by valve rotator spring caps and two-piece tapered valve locks. (Rev. 2005) All information subject to change without notice. 1-80 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 143 When a reduced thickness valve seat insert is used, a correspondingly thicker valve spring seat must be used. See Figure 1-66, and see Figure 1-67. Figure 1-66 Standard Valve Seat Insert Thickness All information subject to change without notice. (Rev. 2005) 1-81 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 144 See Figure 1-68. The identiﬁcation ring can be seen from the right side of the engine with rocker cover removed. (Rev. 2005) All information subject to change without notice. 1-82 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 145 See Figure 1-68and see Figure 1-69. Figure 1-69 Location of Dimples on Intake Valves All information subject to change without notice. (Rev. 2005) 1-83 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 146 2. If the engine has a Jake Brake®, remove the Jake Brake® housings that cover the rocker arm and shaft assembly for the valve to be serviced refer to section 1.36.2. (Rev. 2005) All information subject to change without notice. 1-84 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 147 All valve spring or seal removal and replacement must be completed for each cylinder being serviced while the piston is at top-dead-center, before turning the crankshaft to work on another cylinder. All information subject to change without notice. (Rev. 2005) 1-85 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 148 5. Remove the cylinder head lifting hardware. 6. Turn the crank of the engine overhaul stand to position the cylinder head in an upright position. (Rev. 2005) All information subject to change without notice. 1-86 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 149 10. Remove the valve spring seat. 11. As parts are removed, mark or segregate them according to their original position for possible reuse. All information subject to change without notice. (Rev. 2005) 1-87 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 150 [b] For natural gas engines; a cloth or soft nylon brush is recommended for this procedure. NOTE: Do not use bore brush (wire) on natural gas powdered metal guides. (Rev. 2005) All information subject to change without notice. 1-88 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 151 2. Position the cylinder head, ﬁredeck side up, on a turn over stand or supported on 102 x 102 mm (4 x 4 in.) wooden blocks on a workbench. All information subject to change without notice. (Rev. 2005) 1-89 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 152: Valve Guide Removal
5. Clean the valve guide bore with bore brush (J–5437) (or equivalent), to remove all gum and carbon deposits. (Rev. 2005) All information subject to change without notice. 1-90 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 153: Inspection Of Valve
If leak paths exist, reface the valves or install new valves. If the valve heads are warped or the valve stem is bent, replace the valves. All information subject to change without notice. (Rev. 2005) 1-91 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 154 Table 1-37and listed in Table 1-39. See Figure 1-77. Figure 1-77 Intake and Exhaust Valve Face Refacing and Rim Width (Rev. 2005) All information subject to change without notice. 1-92 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 155: Inspection Of Valve Springs
Inspect valve seat inserts for wear, cracking or incorrect seat angle, which should be 31 degrees, standard valve seat insert thickness. See Figure 1-66. All information subject to change without notice. (Rev. 2005) 1-93 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 156 2. Use valve seat insert installers (J–33190) (intake) and (J–34983) (exhaust), to install new inserts. See Figure 1-79. Figure 1-79 Valve Seat Insert Installation Tools (Rev. 2005) All information subject to change without notice. 1-94 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 157: Valve Seat Insert Installation
Valve Seat Insert Insertion 4. Pilot the installer into the valve guide from the ﬁredeck surface. See Figure 1-81. Figure 1-81 Valve Seat Insert Installation All information subject to change without notice. (Rev. 2005) 1-95 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 158: Cylinder Head
(J–35623–A). See Figure 1-83. Figure 1-83 Check Valve Seat Concentricity [a] If the concentricity is within 0.05 mm (0.002 in.), no grinding is required. (Rev. 2005) All information subject to change without notice. 1-96 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 159 ﬁne adjustment. See Figure 1-84. Seats must be ground to a 31 degree angle. Figure 1-84 Grinding Valve Seat Insert All information subject to change without notice. (Rev. 2005) 1-97 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 160 A full 360° contact line should appear approximately centered on the valve face. (Rev. 2005) All information subject to change without notice. 1-98 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 161: Valve Guide Installation
(J–33191–A) and install this assembly over the valve guide. Drive the guide into the cylinder head until the driver bottoms in the limiting sleeve. See Figure 1-87. Figure 1-87 Valve Guide Installation All information subject to change without notice. (Rev. 2005) 1-99 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 162 2. Oil Seal Protector Cap 5. Valve 3. Valve Spring Seat 6. Valve Stem Oil Seal Figure 1-88 Valve Stem Oil Seal Installation Tools (Rev. 2005) All information subject to change without notice. 1-100 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 163 Oil Seal Protection Cap Sizing 4. Install the cap over the valve stem. See Figure 1-90. Figure 1-90 Oil Seal Protection Cap Installation All information subject to change without notice. (Rev. 2005) 1-101 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 164 6. Push the seal down on the valve stem using the seal installer (J–39109) while holding the valve head against the seal. See Figure 1-92. Figure 1-92 Valve Stem Oil Seal Installer (Rev. 2005) All information subject to change without notice. 1-102 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 165 Be sure the valve rotator is properly centered and aligned to avoid scoring the valve stem. Do not compress the spring any more than necessary to install the locks, to avoid damaging the oil seal. All information subject to change without notice. (Rev. 2005) 1-103 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 166 10. After all of the valves are installed, check the spring opening pressure on each valve using spring load gage. See Figure 1-94. Figure 1-94 Checking Valve Spring Load (Rev. 2005) All information subject to change without notice. 1-104 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 167 □ Do not modify or tamper with the exhaust system or emission control system. 20. Start the engine and check for leaks. All information subject to change without notice. (Rev. 2005) 1-105 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 168: Engine Lifter Brackets
A total of three engine lifter brackets are installed on each Series 60 engine and are utilized when removing and replacing the engine.See Figure 1-95. Figure 1-95 Lifting Engine (Rev. 2005) All information subject to change without notice. 1-106 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 169 A lifter bracket should always be reinstalled whenever removal is necessary see Figure 1-96. For engine models equipped with the compact gear train see Figure 1-97. Figure 1-96 Engine Lifter Brackets All information subject to change without notice. (Rev. 2005) 1-107 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 170 Engine Lifter Brackets Compact Gear Train Models 1. Front Lifter Bracket 3. Right Rear Lifter Bracket 2. Bolt 4. Left Rear Lifter Bracket (Rev. 2005) All information subject to change without notice. 1-108 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 171 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-99. Figure 1-99 Flowchart for Repair or Replacement of Lifter Bracket All information subject to change without notice. (Rev. 2005) 1-109 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 172 1. Install the bracket to the engine. Torque the mounting bolts to 101-126 N·m (75-93 lb·ft). 2. Install the fan support, heat exchanger support, or charge air cooler support bracket, refer to section 1.10.3. (Rev. 2005) All information subject to change without notice. 1-110 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 173: Rocker Cover
2. Rocker Cover 6. Bolt 3. Isolator 7. Element 4. Washer 8. Clip Figure 1-100 One-piece Rocker Cover - Series 60 Diesel Engine All information subject to change without notice. (Rev. 2005) 1-111 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 174 3. Washer 7. Rocker Cover Base 4. Bolt 8. Isolator Rim Seal Figure 1-101 Two-piece Rocker Cover - Series 60 Diesel Engine (Rev. 2005) All information subject to change without notice. 1-112 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 175 12. Rocker Cover Base 13. Gasket 6. Cover 7. Bolt Figure 1-102 Two Piece Rocker Cover - Series 60G Engine with Coil Over Plug Ignition All information subject to change without notice. (Rev. 2005) 1-113 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 176 2. Isolator 6. Diamond-Shaped Seal 3. Washer 7. Rocker Cover Base 4. Bolt 8. Isolator Rim Seal Figure 1-103 Two-piece Rocker Cover (Rev. 2005) All information subject to change without notice. 1-114 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 177 The three-piece design and the Series 60G cap incorporate a combination ﬁller/breather at the camshaft cover (gear case cover) position. All information subject to change without notice. (Rev. 2005) 1-115 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 178 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-105. Figure 1-105 Flowchart for Repair or Replacement of Rocker Cover (Rev. 2005) All information subject to change without notice. 1-116 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 179 5. Clean the breather recess in the rocker cover. 6. Check for damage. Replace as necessary. 7. Reinstall the breather element and retainer clip. All information subject to change without notice. (Rev. 2005) 1-117 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 180 (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 4. Blow dry with compressed air. (Rev. 2005) All information subject to change without notice. 1-118 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 181 4. Pull the six extension tubes from the cylinder head. 5. Loosen and remove the ten bolt/isolator assemblies that attach the base to the cylinder head. All information subject to change without notice. (Rev. 2005) 1-119 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 182 Reuse gaskets with manufacturing date after May 28, 1999. 4. Inspect the lower rocker cover base-to-cylinder head gasket for damage replace if gasket is damaged. (Rev. 2005) All information subject to change without notice. 1-120 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 183 Then install each section at its halfway point. Seat the seal completely around the arch. Be sure the corners are still ﬁrmly seated after the arch is completed. All information subject to change without notice. (Rev. 2005) 1-121 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 184 Make sure the seal is completely seated all the way around the valve cover. NOTE: The corners must be cleaned prior to RTV installation for best results. (Rev. 2005) All information subject to change without notice. 1-122 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 185 4. Press the two protective plugs into the two center holes until they are ﬁrmly seated. 5. Install any other components that were removed for their procedure. All information subject to change without notice. (Rev. 2005) 1-123 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 186 4. Flat Washer Figure 1-109 Rocker Cover Base Hold Down Hardware 3. Install the hold-down bolts, with washers installed, to the limiting sleeves. (Rev. 2005) All information subject to change without notice. 1-124 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 187 See Figure 1-110. Figure 1-110 Rocker Cover Base Hold-down Bolt Installation All information subject to change without notice. (Rev. 2005) 1-125 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 188 The same procedure applies to the intermediate cover diamond seal installation. (Rev. 2005) All information subject to change without notice. 1-126 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 189 2. Install the rocker cover cap to the base. Install the eight bolts that attach the cap to the base, and torque to 22-25 N·m (16-18 lb·ft) using the torque sequence. See Figure 1-113. All information subject to change without notice. (Rev. 2005) 1-127 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 190 9. Install any other parts that were removed for this procedure. 10. Refer to section1.6.8 for the exhaust caution before preceeding. Start the engine and check for leaks. Refer to section 12.7. (Rev. 2005) All information subject to change without notice. 1-128 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 191: Crankshaft
Complete static and dynamic balance of the crankshaft has been achieved by counterweights incorporated in the crankshaft. Current crankshafts may have a six-bolt or twelve-bolt mounting pattern on the front. All information subject to change without notice. (Rev. 2005) 1-129 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 192 (The iron piston pin bolts interefere with the new lightweight crankshaft design.) See Figure 1-115 and see Figure 1-116. Figure 1-115 Current and Former Crankshafts (Rev. 2005) All information subject to change without notice. 1-130 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 193 SERIES 60 SERVICE MANUAL Figure 1-116 Varied Piston Dome-Crankshaft Clearances All information subject to change without notice. (Rev. 2005) 1-131 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 194 The current design makes use of thrust washers in the upper positions only. Oversize thrust washers are available to correct for excessive end play. (Rev. 2005) All information subject to change without notice. 1-132 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 195 Former No. 6 Main Bearing Cap The current design does not use the indexing dowels. See Figure 1-119. Figure 1-119 Current No. 6 Main Bearing Cap All information subject to change without notice. (Rev. 2005) 1-133 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 196 Each standard main bearing journal is 125.000-124.968 mm (4.921-4.920 in.) in diameter and each standard connecting rod journal is 85.000-84.975 mm (3.346-3.345 in.) in diameter. (Rev. 2005) All information subject to change without notice. 1-134 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 197 The new crankshafts, bearings, and connecting rods must be used together to ensure interchangeability. Former parts cannot be mixed with new parts in the same engine. The former crankshafts will no longer be available. All information subject to change without notice. (Rev. 2005) 1-135 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 198 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-121. Figure 1-121 Flowchart for Repair or Replacement of Crankshaft (Rev. 2005) All information subject to change without notice. 1-136 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 199 180 degrees apart and install two ﬂywheel guide studs (J–36235) in their place. Then loosen and remove the remaining four pulley retaining bolts and hardened washers. Refer to section 1.15.2. All information subject to change without notice. (Rev. 2005) 1-137 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 200: Inspection Of Crankshaft
1. Clean out the oil passages thoroughly with a stiff wire brush. Clean the crankshaft with fuel oil and dry it with compressed air. (Rev. 2005) All information subject to change without notice. 1-138 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 201 No. 3 and No. 5 0.127 mm (0.005 in.) No. 1 and No. 7 No. 4 0.152 mm (0.006 in.) Table 1-3 Crankshaft Bow All information subject to change without notice. (Rev. 2005) 1-139 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 202 0.0381 mm (0.0015 in.) or the out-of-round is greater than 0.0254 mm (0.001 in.) the crankshaft must be reground. Speciﬁcations for the crankshaft are listed in Table 1-22. (Rev. 2005) All information subject to change without notice. 1-140 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 203 1.7.2.6, for magnetic particle method, refer to section 1.7.2.7, for ﬂuorescent magnetic particle method, or refer to section 1.7.2.8, for ﬂuorescent penetrant method. All information subject to change without notice. (Rev. 2005) 1-141 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 204 Unless abnormal conditions are discovered and corrected, there will be a repetition of the failure. (Rev. 2005) All information subject to change without notice. 1-142 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 205 These cracks are most likely to occur on either side of the damaged bearing. All information subject to change without notice. (Rev. 2005) 1-143 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 206 Refer to section 1.7.3. 1.7.2.12 Crankshaft Grinding The use of properly remanufactured crankshafts is very important to maximize crankshaft main and connecting rod bearing life. (Rev. 2005) All information subject to change without notice. 1-144 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 207 If one or more main or connecting rod journals require grinding, grind all of the main journals or all of the connecting rod journals to the same required size. All information subject to change without notice. (Rev. 2005) 1-145 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 208: Installation Of Crankshaft
Refer to section 1.34.3. NOTE: It may be easier to remove the bull gear assembly and re-time the engine. (Rev. 2005) All information subject to change without notice. 1-146 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 209: Main Bearing Cap Installation
6. Install the main bearing caps together with lower bearing shells in place. Figure 1-126 Main Bearing Cap Installation All information subject to change without notice. (Rev. 2005) 1-147 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 210: Measuring Crankshaft End Play
Figure 1-127 Measuring Crankshaft End Play (Rev. 2005) All information subject to change without notice. 1-148 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 211 29. After replacing the main or connecting rod bearings or installing a new or reground crankshaft, operate the engine as outlined in the "Run-In Schedule." Refer to section 12.7.3.2. All information subject to change without notice. (Rev. 2005) 1-149 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 212: Crankshaft Oil Seals
Because of the spiral grooves on the sealing lip, a front crankshaft seal will leak if installed at the rear, and a rear crankshaft seal will leak if installed at the front. (Rev. 2005) All information subject to change without notice. 1-150 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 213: Front View
ﬂywheel housing and block to direct additional oil to the seal for cooling. See Figures 1-130 and 1-131. 1. Rib Location Figure 1-130 Cast-in-Rib Front View All information subject to change without notice. (Rev. 2005) 1-151 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 214: Rear View
This sleeve must be installed with replacement seals to prevent seal damage or oil leakage. (Rev. 2005) All information subject to change without notice. 1-152 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 215: Replacement Of Oil Seal
To determine if replacement is necessary, perform the following procedure. See Figure 1-132. To determine whether ﬂywheel housing runout is excessive, refer to section 1.18.3.1. Figure 1-132 Flowchart for Replacement of Crankshaft Oil Seal All information subject to change without notice. (Rev. 2005) 1-153 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 216 3. If the crankshaft oil seal wear sleeve remains installed on the hub of the crankshaft, reinstall the gear case cover or ﬂywheel housing. (Rev. 2005) All information subject to change without notice. 1-154 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 217 4. Remove the wear sleeve using wear sleeve remover (J–37075–A). See Figure 1-134. Refer to section 1.8.4. Figure 1-134 Crankshaft Wear Sleeve Remover Tool All information subject to change without notice. (Rev. 2005) 1-155 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 218 4. Remove any metal chips from the face of the seal, the crankshaft and the bore surface. 5. Rotate the removal tool (J–41329) clockwise until the “B” holes align with drilled holes and install sheet metal screws. (Rev. 2005) All information subject to change without notice. 1-156 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 219 Crocus cloth may be used to remove dirt, rust and to clean up the high spots from the surface of the crankshaft and gear case cover bore. Thoroughly clean the contact surfaces. All information subject to change without notice. (Rev. 2005) 1-157 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 220 Crocus cloth may be used to clean up the high spots from the surface of the crankshaft. 3. Thoroughly clean the crankshaft contact surface. Figure 1-136 Rear Oil Seal Wear Sleeve Removal (Rev. 2005) All information subject to change without notice. 1-158 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 221 Rear, Dry Housing 23519651 J–35686–20 J–35686–6 and J–35686–11 Rear, Wet Housing 23513578 J–35686–10 J–35686–6 and J–35686–11 Table 1-4 Crankshaft Seal Tool Application All information subject to change without notice. (Rev. 2005) 1-159 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 222 Failure to lubricate the outside of the seal and the inside of the bore prior to installation may damage seal causing seal to leak. (Rev. 2005) All information subject to change without notice. 1-160 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 223: Spacer Installation
3. Install the spacers to the center screw of the base. Refer to Table 1-4 and Figure 1-138. Figure 1-138 Spacer Installation All information subject to change without notice. (Rev. 2005) 1-161 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 224: Thrust Bearing
8. Tighten the hex nut until the oil seal and wear sleeve are pressed into the ﬂywheel housing or gear case cover. (Rev. 2005) All information subject to change without notice. 1-162 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 225 If the total indicator reading is more then 0.762 mm (0.030 in.) the seal must be removed and a new seal installed. All information subject to change without notice. (Rev. 2005) 1-163 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 226: Crankshaft Main Bearings
13. Upper No. 6 Thrust Bearing Shell 6. Bolt 7. No. 6 Main Cap Figure 1-141 Main Bearing Caps, Bearing Shells and Crankshaft Thrust Washers (Rev. 2005) All information subject to change without notice. 1-164 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 227 06R0762048 use the two-piece washers with locking tangs that register with locating notches in the bearing shell. See Figure 1-142. All information subject to change without notice. (Rev. 2005) 1-165 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 228 Figure 1-142 No. 6 Thrust Bearing Detail The condition of the lower bearing shells may be observed by removing the main bearing caps. (Rev. 2005) All information subject to change without notice. 1-166 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 229 3.11.2. 2. Remove the oil pump pickup and outlet pipes, and the oil pump. Refer to section 3.2.2. All information subject to change without notice. (Rev. 2005) 1-167 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 230 No. 6 and No. 7. Figure 1-144 Main Bearing Shell Remover and Installer Tool Set (Rev. 2005) All information subject to change without notice. 1-168 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 231 8. Using the main bearing cap bolts and washer removed from the engine, install the assembled main bearing cap remover and installer tool to the main bearing saddle being All information subject to change without notice. (Rev. 2005) 1-169 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 232 "Front" facing the front of the engine. If the No. 6 main bearing is being done, install the thrust washers to the bearing. Refer to step 7 in this procedure. (Rev. 2005) All information subject to change without notice. 1-170 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 233 22. After removal, clean the bearings. 1.9.2.1 Cleaning of Main Bearings Perform the following to clean the main bearing: 1. Immerse the bearing in cleaning agent. All information subject to change without notice. (Rev. 2005) 1-171 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 234 Measure the thickness of the bearing shells at a point, 90 degrees from the parting line. See Figure 1-148. Figure 1-148 Main Bearing Measurements (Rev. 2005) All information subject to change without notice. 1-172 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 235 Ensure the correct bearing to journal clearance is maintained when using these parts. NOTE: Bearing shells are NOT reworkable from one undersize to another undersize under any circumstances. All information subject to change without notice. (Rev. 2005) 1-173 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 236 6. Torque all of the main bearing cap bolts to 470-530 N·m (347-391 lb·ft). 7. Measure the main bearing bores with dial bore gage (J–5347–B). The minimum speciﬁcations are listed in Table 1-16. (Rev. 2005) All information subject to change without notice. 1-174 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 237: Gear Case Cover Pre-Exhaust Gas Recirculation (Egr)
The gear case cover also serves as a retainer for the crankshaft front oil seal. See Figure 1-150. Figure 1-150 Crankshaft Front Oil Seal All information subject to change without notice. (Rev. 2005) 1-175 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 238: Front Engine Support
The front engine support is bolted to the front of the gear case cover, directly behind the crankshaft pulley and vibration damper. See Figure 1-152 Figure 1-152 Typical Front Engine Support (Rev. 2005) All information subject to change without notice. 1-176 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 239 With the fan support bracket and the camshaft drive gear access cover removed, the gear lash between the adjustable idler gear and the camshaft drive gear can be measured and adjusted Refer to section 1.24.2.1. All information subject to change without notice. (Rev. 2005) 1-177 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 240 ﬁts in the splined hole in the center of the air compressor drive gear. The pump is installed with a gasket. (Rev. 2005) All information subject to change without notice. 1-178 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 241 2. Loosen the fan hub mounting bolts. Loosen the fan adjusting bolt. Back the adjuster off far enough to remove the drive belts. Remove the fan and fan hub assembly. Refer to section 4.6.2. All information subject to change without notice. (Rev. 2005) 1-179 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 242 7. Remove the power steering pump (if so equipped). Refer to OEM guidelines. 8. Remove the crankshaft pulley. Refer to section 1.15.2. 9. Remove the vibration damper. Refer to section 1.14.2. (Rev. 2005) All information subject to change without notice. 1-180 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 243 12. Remove the accessory drive assembly by pulling it straight out of the gear case cover to avoid damaging the rubber O-ring. See Figure 1-159. All information subject to change without notice. (Rev. 2005) 1-181 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 244 Gear Case Cover Bolt Arrangement (Front) NOTE: Bolts 21 and 22 are rear bolts on pre-1991 engines. [a] Remove the SRS. Refer to section 2.30.2. (Rev. 2005) All information subject to change without notice. 1-182 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 245 Gear Case Cover Bolt Arrangement (Right Rear) 14. Support the gear case cover with a suitable lifting device, using the front engine lift bracket. See Figure 1-163. All information subject to change without notice. (Rev. 2005) 1-183 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 246 15. Tap the gear case cover with a ﬁber mallet or plastic hammer to loosen it from the gear case. Remove the engine gear case cover. (Rev. 2005) All information subject to change without notice. 1-184 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 247: Installation Of Gear Case Cover
All information subject to change without notice. (Rev. 2005) 1-185 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 248 5. There are 34 bolts that secure the gear case cover to the gear case (including ﬁve for the fan support bracket). Install them as follows: (Rev. 2005) All information subject to change without notice. 1-186 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 249 [e] Bolts F1 through F5 are fan support bracket bolts. Install the fan support bracket and torque bolts F1, F2 and F3 to 58-73 N·m (43-54 lb·ft). Torque bolts F4 and F5 to 160-200 N·m (118-148 lb·ft). All information subject to change without notice. (Rev. 2005) 1-187 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 250 (right) side of the engine. Torque the number 2 and 3 bolts to 58-73 N·m (43-54 lb·ft) torque. See Figure 1-168. Figure 1-168 Gear Case Cover Bolt Torque Sequence (Right Rear) (Rev. 2005) All information subject to change without notice. 1-188 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 251 Refer to section 14.6.9. 18. Install the engine oil pan. Refer to section 3.11.4. Fill the crankcase with recommended lubricating oil. Refer to section 14.6.1. All information subject to change without notice. (Rev. 2005) 1-189 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 252: Gear Case Cover Exhaust Gas Recirculation (Egr) Model
The gear case cover and gear case bolt together at the front of the engine to form a sealed compartment for the engine gear train. See Figure 1-170. Figure 1-170 Engine Gear Case and Cover Series 60 EGR Model (Rev. 2005) All information subject to change without notice. 1-190 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 253 The gear case cover also serves as a retainer for the crankshaft front oil seal. See Figure 1-171. 1. Oil Seal Figure 1-171 Crankshaft Front Oil Seal All information subject to change without notice. (Rev. 2005) 1-191 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 254 The front engine support is bolted to the front of the gear case cover, directly behind the crankshaft pulley and the vibration damper. See Figure 1-172. 1. Front Engine Mount 2. Bolt Figure 1-172 Front Engine Support (Rev. 2005) All information subject to change without notice. 1-192 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 255 1. Accessory Drive Assembly 3. (Optional) Power Steering Pump Location 2. Fan Support Bracket Figure 1-173 Gear Case Cover Mounted Components EGR Model All information subject to change without notice. (Rev. 2005) 1-193 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 256 Refer to section 1.25.2.2. See Figure 1-174. Figure 1-174 Gear Case Cover Fan Bracket and Camshaft Access Cover (Rev. 2005) All information subject to change without notice. 1-194 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 257 3. Loosen the fan hub mounting bolts. Loosen the fan adjusting bolt. Back the adjuster off far enough to remove the drive belts. Remove the fan and fan hub assembly. Refer to section 4.6.2. All information subject to change without notice. (Rev. 2005) 1-195 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 258 4. For engines equipped with a fan support bracket, remove nine fan support bolts and remove fan support. See Figure 1-176. Figure 1-176 Fan Support Bolt Locations (Rev. 2005) All information subject to change without notice. 1-196 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 259 6. Rotate engine until cylinder No.1 is at TDC; install timing pin (J–45947) into the slot in crankshaft. 1. Timing Pin Figure 1-178 Timing Pin Location All information subject to change without notice. (Rev. 2005) 1-197 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 260 See Figure 1-179. 1. Front Engine Support 2. Bolt Figure 1-179 Front Engine Support 18. Remove timing pin bracket. (Rev. 2005) All information subject to change without notice. 1-198 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 261 20. Remove accessory drive by pulling it straight out of the gear case cover to avoid damaging the rubber O-ring. 21. Remove fuel pump. Refer to section 2.8. All information subject to change without notice. (Rev. 2005) 1-199 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 262 Ensure water pump bolt at the six O”clock position is removed for gear case cover removal. 1. Bolt 3. Air Compressor 2. Gear Case Figure 1-181 Air Compressor Bolt Location (Rev. 2005) All information subject to change without notice. 1-200 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 263 2. Clean the gasket sealer from the mating surfaces of any components or access covers that were removed from the gear case cover, and the gear case cover itself. All information subject to change without notice. (Rev. 2005) 1-201 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 264 NOTE: Ensure seal is installed in the rear of thr gear case cover (Rev. 2005) All information subject to change without notice. 1-202 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 265 3. Position the gear case cover onto the guide studs and slide gear case cover to the mating surface of gear case. Index the two dowels in the gear case. See Figure 1-183. All information subject to change without notice. (Rev. 2005) 1-203 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 266 6. Install accessory drive. Refer to section 1.35.5. 7. Install air compressor. Refer to section 11.1. 8. Install fuel pump. Refer to section 2.8. (Rev. 2005) All information subject to change without notice. 1-204 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 267 9. Install timing pin bracket to gear case cover with two bolts and torque bolts to 30-38 N·m (22-28 lb·ft). See Figure 1-185. 1. Bolt 2. Timing Pin Bracket Figure 1-185 Timing Pin Bracket and Related Parts All information subject to change without notice. (Rev. 2005) 1-205 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 268 10. Install engine front mount to gear case cover. Torque four bolts to 160-200 N·m (118-148 lb·ft). See Figure 1-186. 1. Front Mount 2. Bolts Figure 1-186 Engine Front Mount (Rev. 2005) All information subject to change without notice. 1-206 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 269 20. Adjust Jake Brake assemblies. Refer to section 1.36. 21. Install rocker covers; for one-piece refer to section 1.6.8; for two-and three-piece refer to section 1.6.9. All information subject to change without notice. (Rev. 2005) 1-207 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 270 If engine is not equipped with a fan hub install cover plate and gasket, torque four bolts to 30-38 N·m (22-28 lb·ft). See Figure 1-188. 1.Bolt 3. Gasket 2. Cover Plate Figure 1-188 Cover Plate and Related Parts (Rev. 2005) All information subject to change without notice. 1-208 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 271 Fan Bracket Bolt Locations 24. Install engine oil pan. Refer to section 3.11.4. Fill the crankcase with recommended lubricating oil. Refer to section 14.6.1. All information subject to change without notice. (Rev. 2005) 1-209 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 272: Gear Case Pre-Exhaust Gas Recirculation (Egr)
See Figure 1-191 and see Figure 1-192. (Rev. 2005) All information subject to change without notice. 1-210 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 273: Right Side
SERIES 60 SERVICE MANUAL Figure 1-191 Gear Case Stiffening Bracket (Left Side) Figure 1-192 Gear Case Stiffening Bracket (Right Side) All information subject to change without notice. (Rev. 2005) 1-211 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 274 3. O-ring 7. Fuel Pump Drive Coupling 4. Fuel Pump Drive Housing 8. Fuel Pump Assembly Figure 1-194 Fuel Pump Drive Assembly (Rev. 2005) All information subject to change without notice. 1-212 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 275 6. Spacer 13. Drive Housing Gasket 7. Drive Hub 14. Gear Case Housing Figure 1-195 Air Compressor or Raw Water Pump Drive Assembly All information subject to change without notice. (Rev. 2005) 1-213 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 276: Water Pump Assembly
Figure 1-196 Water Pump Assembly To eliminate the possibility of oil leakage at the adjustable idler gear stud location, Detroit Diesel recommends the following: When rebuilding a Series 60 engine, or if the gear case is removed for any reason, the three original adjustable idler gear studs should be removed and replaced with new studs.
Page 277 The Synchronous Reference Sensor (SRS) is an electronic component that is bolted to the gear case at the lower, intake (left) side of the engine. See Figure 1-198. Figure 1-198 Synchronous Reference Sensor All information subject to change without notice. (Rev. 2005) 1-215 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 278 Accessory Drive Gear Access Cover (Pre-1991 Engines) For gear lash measurement and adjustment procedures for the gears in the engine gear train, Refer to section 1.24.2.1. (Rev. 2005) All information subject to change without notice. 1-216 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 279 Do not use the oil plug location for an oil supply or for checking oil pressure. Figure 1-201 Adjustable Idler Gear Lubrication Gallery All information subject to change without notice. (Rev. 2005) 1-217 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 280: Removal Of Gear Case
3. Remove the rocker arm assemblies. Refer to section 1.3.2. 4. Perform all of the steps for camshaft removal. Refer to section 1.28.2. (Rev. 2005) All information subject to change without notice. 1-218 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 281 9. Remove the fuel pump from the fuel pump drive assembly (or air compressor). Refer to section 2.8.2. 10. Remove the air compressor. Refer to section 11.1.5. All information subject to change without notice. (Rev. 2005) 1-219 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 282 14. Using a plastic hammer or ﬁber mallet, tap the rear face of the camshaft thrust plate to remove the thrust plate, camshaft drive gear hub and camshaft drive gear from the gear case. (Rev. 2005) All information subject to change without notice. 1-220 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 283: Gear Case Removal
Figure 1-207 Gear Case Removal 17. Use a rubber hammer or plastic mallet to loosen the gear case from the cylinder block dowels. All information subject to change without notice. (Rev. 2005) 1-221 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 284: Inspection Of Gear Case
Excess gasket eliminator material can extrude into the oil passage between the block and gear case, causing early failure of components. In addition, the (Rev. 2005) All information subject to change without notice. 1-222 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 285 3. Using a suitable lifting sling made of cloth or leather, position the bull gear and camshaft idler gear opening of the gear case over the gear case alignment plug. Index the hole in the All information subject to change without notice. (Rev. 2005) 1-223 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 286 See Figure 1-210. Figure 1-210 Cylinder Block Locating Diamond Dowel (Rev. 2005) All information subject to change without notice. 1-224 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 287 5. Install the 12 gear case-to-cylinder block retaining bolts, ﬁnger-tight. All information subject to change without notice. (Rev. 2005) 1-225 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 288 11. Lubricate the rubber O-ring on the camshaft thrust plate with clean engine oil. Install the camshaft thrust plate assembly, with the camshaft drive gear and hub in place to the gear (Rev. 2005) All information subject to change without notice. 1-226 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 289 4. Bull Gear 2. Adjustable Idler Gear 5. Crankshaft Timing Gear 3. Camshaft Drive Gear Figure 1-214 Engine Gear Train Timing Marks All information subject to change without notice. (Rev. 2005) 1-227 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 290 19. Check the timing marks on the gears to ensure the gear train is properly timed. See Figure 1-214. 20. Perform the following: [a] For crankshaft timing gear-to-oil pump gear lash measurement. Perform step 2, refer to section 1.24.2.1. (Rev. 2005) All information subject to change without notice. 1-228 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 291 [g] Install the two bolts securing the former right side gear case stiffening bracket to the cylinder head or one bolt securing the current right side bracket. Torque the former All information subject to change without notice. (Rev. 2005) 1-229 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 292 21. Refer to section 1.28.5, "Installation of Camshaft Bearing" and perform the necessary steps. 22. For bull gear-to-accessory drive gear lash measurement, perform step 10. Refer to section 1.24.2.1. 23. Continue engine assembly. (Rev. 2005) All information subject to change without notice. 1-230 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 293: Gear Case Exhaust Gas Recirculation (Egr) Model
The components that are mounted to the gear case include the water pump assembly, (see Figure 1-219), air compressor drive assembly (see Figure 1-220) and the adjustable idler gear assembly. (See Figure 1-221). All information subject to change without notice. (Rev. 2005) 1-231 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 294 1. Water Pump Assembly 3. Seal 2. Bolt Figure 1-219 Water Pump Assembly and Related Parts 1. Air Compressor Figure 1-220 Air Compressor (Rev. 2005) All information subject to change without notice. 1-232 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 295 Figure 1-221 Adjustable Idler Gear and Related Parts To eliminate the possibility of oil leakage at the adjustable idler gear stud location, Detroit Diesel recommends the following: □ When rebuilding a Series 60 engine, or if the gear case is removed for any reason, the three original adjustable idler gear studs should be removed and replaced with new studs.
Page 296 An opening is provided in the center of the gear case for the installation of the spindle and bull gear. See Figure 1-222. 1. Bull Gear 2. Spindle Figure 1-222 Bull Gear and Spindle Location (Rev. 2005) All information subject to change without notice. 1-234 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 297 Do not use the oil plug location for an oil supply or for checking oil pressure. Figure 1-224 Air Compressor Lubrication Gallery (EGR Model) All information subject to change without notice. (Rev. 2005) 1-235 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 298 3. Remove fuel pump. Refer to section2.6. 4. Remove air compressor. Refer to section 11.1.2. 5. Remove water pump from gear case. Refer to section 4.2.2. (Rev. 2005) All information subject to change without notice. 1-236 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 299 7. Remove fourteen bolts that secure gear case to engine block. See Figure 1-226. Figure 1-226 Gear Case Mounting Bolt Locations EGR Model 8. Using a leather or cloth-wrapped strap, to support the gear case. All information subject to change without notice. (Rev. 2005) 1-237 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 300 Clean all of the parts with clean fuel oil and dry with compressed air. 3. Remove the oil gallery plug at the top of the gear case. (Rev. 2005) All information subject to change without notice. 1-238 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 301 Gear Case O-ring Installation Location and Loctite Application 2. Install two guide studs into the front of the cylinder block. See Figure 1-229. All information subject to change without notice. (Rev. 2005) 1-239 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 302 See Figure 1-229. 1. Diamond Dowel Location 3. Diamond Dowel Location 2. Guide Studs Figure 1-229 Cylinder Block Diamond Dowel and Guide Stud Location (Rev. 2005) All information subject to change without notice. 1-240 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 303 9. Install adjustable idler gear. Refer to section 1.31.3. 10. Install bull gear. Refer to section 1.32.3. 11. Install the gear case cover. Refer to section.1.11.3 All information subject to change without notice. (Rev. 2005) 1-241 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 304: Crankshaft Vibration Damper
342.9 mm (13.5 in.) damper, and all 12.7 liter engines, were equipped with a 342.9 mm (13.5 in.) damper. Beginning in April 1993, all Series 60 engines are built with a 342.9 mm (13.5 in.) damper. (Rev. 2005) All information subject to change without notice. 1-242 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 305 ﬂuid. See Figure 1-232. 1. Crankshaft 3. Damper Shell 2. Viscous Fluid 4. Internal Flywheel Figure 1-232 Viscous Vibration Damper Detail All information subject to change without notice. (Rev. 2005) 1-243 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 306 Detroit Diesel Corporation does not manufacture, sell or install vibration damper safety shields due to the wide variety of installations in which Detroit Diesel engines are applied. Space restrictions in these numerous applications make it necessary to design an appropriate type of shield for each installation.
Page 307 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-233. Figure 1-233 Flowchart for Repair or Replacement of Crankshaft Damper All information subject to change without notice. (Rev. 2005) 1-245 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 308 2. Remove the inspection plug in the bottom of the ﬂywheel housing and install the ﬂywheel lock (J–36375)–A. See Figure 1-234. Figure 1-234 Flywheel Lock (Rev. 2005) All information subject to change without notice. 1-246 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 309 CANNOT be repaired. 9. Remove the vibration damper by sliding it off the guide studs. 10. Remove the ﬂywheel lock and guide studs. All information subject to change without notice. (Rev. 2005) 1-247 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 310 [b] Slight scratches or burrs may be removed with an emery cloth. [c] If deep scratches are detected, replace with new damper. Figure 1-235 Damper and Crankshaft Contact Surfaces (Rev. 2005) All information subject to change without notice. 1-248 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 311 4. If the vibration damper has been damaged, inspect the crankshaft. Refer to section 1.7.2.1. Crankshaft damage may have resulted. All information subject to change without notice. (Rev. 2005) 1-249 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 312 Finger-tighten the bolts. 7. Remove the two guide studs. 8. Install the remaining two new special bolts with hardened washers installed. (Rev. 2005) All information subject to change without notice. 1-250 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 313 14. Install any other components that were removed for this operation. 15. Refer to section 12.7 for veriﬁcation of proper crankshaft vibration damper installation. All information subject to change without notice. (Rev. 2005) 1-251 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 314: Crankshaft Pulley
Do not substitute any other bolts or washers. The crankshaft pulley bolts and washers are special parts. These bolts are not reusable. Figure 1-236 Crankshaft Pulley Mounted Directly to the Crankshaft (Rev. 2005) All information subject to change without notice. 1-252 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 315 A 3/4 in. square drive hole in the center of the crankshaft pulley allows the use of a 3/4 in. drive breaker bar or ratchet for barring the engine over. See Figure 1-238. Figure 1-238 Barring Engine Over All information subject to change without notice. (Rev. 2005) 1-253 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 316 The crankshaft pulley assembly is secured to the spindle with two woodruff keys, a crankshaft pulley bolt and hardened washer. The crankshaft pulley bolt is also used to bar the engine over. See Figure 1-239. (Rev. 2005) All information subject to change without notice. 1-254 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 317 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-241. Figure 1-241 Flowchart for Repair or Replacement of Crankshaft Pulley All information subject to change without notice. (Rev. 2005) 1-255 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 318 Figure 1-242 Crankshaft Pulley Mounted Directly to the Crankshaft 7. Install two guide studs (J–36235) to the holes where the bolts were removed. (Rev. 2005) All information subject to change without notice. 1-256 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 319 2. Remove the inspection plug in the bottom of the ﬂywheel housing. 3. Install the ﬂywheel lock (J–36375–A). See Figure 1-243. Figure 1-243 Flywheel Lock All information subject to change without notice. (Rev. 2005) 1-257 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 320 180 degrees apart. Discard the bolts. These bolts are not reusable. 9. Install two guide studs (J–36325) to the holes from which the bolts were removed. (Rev. 2005) All information subject to change without notice. 1-258 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 321 3. Inspect the retaining bolt seat relief areas. [a] Check relief area for stress cracks. [b] If stress cracks are discovered, replace the pulley or spindle. All information subject to change without notice. (Rev. 2005) 1-259 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 322 [c] If galls or burrs are major, the pulley or spindle will need to be replaced. Figure 1-245 Crankshaft Pulley and Vibration Damper Inspection (Rev. 2005) All information subject to change without notice. 1-260 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 323 6. Install the crankshaft pulley over the guide studs and onto the crankshaft. The crankshaft pulley may be installed in any position. All information subject to change without notice. (Rev. 2005) 1-261 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 324 Refer to section 14.6.9. 14. Install any other components that were removed for this operation. Install the spindle mounted pulley and hub assembly as follows: (Rev. 2005) All information subject to change without notice. 1-262 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 325 4. Install two guide studs to two of the holes in the crankshaft that are 180 degrees apart. 5. Install the vibration damper over the guide studs and onto the crankshaft. Refer to section 1.14.3. All information subject to change without notice. (Rev. 2005) 1-263 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 326 The crankshaft pulley spindle may be installed in any position. See Figure 1-248. Figure 1-248 Crankshaft Pulley and Hub Assembly Installation with Spindle (Rev. 2005) All information subject to change without notice. 1-264 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 327 16. Install any other components that were removed for this operation. 17. Refer to section 12.3 for veriﬁcation of proper crankshaft pulley installation. All information subject to change without notice. (Rev. 2005) 1-265 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 328: Flywheel
2. Scuff Plate 6. Flywheel Housing Spacer 3. Flywheel 7. Ring Gear 4. Flywheel Housing Figure 1-249 Typical Flywheel Assembly (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 1-266 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 329 The ﬂywheel must be removed for service operations such as replacing the starter ring gear, crankshaft oil seal, crankshaft or the ﬂywheel housing. All information subject to change without notice. (Rev. 2005) 1-267 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 330 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-251. Figure 1-251 Flowchart for Repair or Replacement of Flywheel (Rev. 2005) All information subject to change without notice. 1-268 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 331 6. Install two ﬂywheel guide studs (J–36235) through the ﬂywheel and into the crankshaft at the 3 and 9 o'clock positions. See Figure 1-252. Figure 1-252 Flywheel Guide Studs All information subject to change without notice. (Rev. 2005) 1-269 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 332 11. Remove the last ﬂywheel attaching bolt and scuff plate. (Discard scuff plate.) 12. Remove ﬂywheel. (Rev. 2005) All information subject to change without notice. 1-270 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 333 See Figure 1-254. [b] Lightly stone the contact surface to remove any fretting, brinelling, or burrs. Figure 1-254 Crankshaft and Flywheel Mating Surfaces All information subject to change without notice. (Rev. 2005) 1-271 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 334 ﬂywheel. 7. Install the bolts and torque them to 75 N·m (55 lb·ft). (Rev. 2005) All information subject to change without notice. 1-272 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 335 Torque Turn Limits 9. Remove the ﬂywheel lock tool (J–36375–A). 10. Install the pipe plug and torque to 45-56 N·m (33-41 lb·ft). All information subject to change without notice. (Rev. 2005) 1-273 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 336 14. If maximum total indicator reading exceeds, 0.0254 mm per millimeter of radius (0.001 in. per inch of radius), it may be necessary to repeat the assembly procedure until the cause can be detected and eliminated. (Rev. 2005) All information subject to change without notice. 1-274 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 337: Ring Gear
ﬂame to touch the ﬂywheel. 2. The uncut portion will now yield. Tap the ring gear to remove it from the ﬂywheel. All information subject to change without notice. (Rev. 2005) 1-275 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 338 4. Tap the gear in place against the shoulder on the ﬂywheel. If the gear cannot be tapped into place readily so that it is seated all the way around, remove it, and apply additional heat. (Rev. 2005) All information subject to change without notice. 1-276 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 339: Flywheel Housing
The crankshaft rear oil seal, which is pressed into the housing, may be removed or installed without removing the housing. Refer to section 1.8.2. All information subject to change without notice. (Rev. 2005) 1-277 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 340 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-260. Figure 1-260 Flowchart for Repair or Replacement of Flywheel Housing (Rev. 2005) All information subject to change without notice. 1-278 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 341 See Figure 1-261. Figure 1-261 Pilot Stud Installation NOTE: The illustration is shown with the ﬂywheel housing already removed for clarity. All information subject to change without notice. (Rev. 2005) 1-279 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 342 [b] If crankshaft is grooved, install a wear sleeve over the crankshaft end. An oversized I.D. rear oil seal must be used with the rear sleeve. Refer to section 1.8.5. (Rev. 2005) All information subject to change without notice. 1-280 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 343 3. Support the housing and position it over the crankshaft and against the cylinder block. NOTE: Whenever crankshaft rear seal is put over the crankshaft, use crankshaft oil seal expander. Refer to section 1.8.5. All information subject to change without notice. (Rev. 2005) 1-281 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 344 8. Install the ﬂywheel. Refer to section 1.16.3. 9. Install oil pan; refer to section 3.11.4, and reﬁll the engine with new oil; refer to section 14.6.1. (Rev. 2005) All information subject to change without notice. 1-282 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 345 5. Adjust each dial indicator to read zero at the twelve o'clock position. All information subject to change without notice. (Rev. 2005) 1-283 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 346 10. Install the ﬂywheel. Refer to section 1.16.3. 11. Check the run-out again. If desired run-out cannot be accomplished, replace the ﬂywheel housing. (Rev. 2005) All information subject to change without notice. 1-284 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 347: Piston And Piston Ring
Series 60G engine incorporates a 3.5 mm ﬁre ring, a rectangular cut compression ring and a three-piece oil ring. See Figure 1-267. The compression ring is identiﬁed with a purple stripe. All information subject to change without notice. (Rev. 2005) 1-285 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 348 1.19 PISTON AND PISTON RING Figure 1-267 Three–piece Gas Oil Ring (Rev. 2005) All information subject to change without notice. 1-286 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 349 7. Compression Ring* 4. Piston Dome 8. Fire Ring* * Identiﬁcation Mark to Face Top of Dome Figure 1-268 Piston Ring Location All information subject to change without notice. (Rev. 2005) 1-287 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 350: Diesel Only
1.19 PISTON AND PISTON RING Figure 1-269 Comparison of Piston Ring Packs (Rev. 2005) All information subject to change without notice. 1-288 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 351 3. Snap Ring 8. Compression Ring 4. Piston Pin Bushing 9. Fire Ring 5. Piston Dome Figure 1-270 Forged Steel Piston and Related Parts All information subject to change without notice. (Rev. 2005) 1-289 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 352 (Rev. 2005) All information subject to change without notice. 1-290 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 353 A threaded hole on each side of the oil hole receives the connecting rod attaching bolts. See Figure 1-273. Figure 1-273 Piston Pin Cross Section All information subject to change without notice. (Rev. 2005) 1-291 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 354 (Rev. 2005) All information subject to change without notice. 1-292 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 355 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-274. Figure 1-274 Flowchart for Repair or Replacement of Piston and Piston Rings All information subject to change without notice. (Rev. 2005) 1-293 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 356 2. Withdraw the piston pin and mark the front of the piston with a paint pencil, so it can be returned to the correct cylinder location. NOTE: Steel pistons will require the removal of the circlip before withdrawing the piston pin. (Rev. 2005) All information subject to change without notice. 1-294 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 357 DDC recommends that compressed air be directed between the dome pin bore and back of the bearing at one end until the bearing pops up out of the bearing retaining hole. All information subject to change without notice. (Rev. 2005) 1-295 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 358 6. Clean the inside surfaces of the piston dome and skirt and the oil relief channels in the oil ring grooves. (Rev. 2005) All information subject to change without notice. 1-296 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 359 [a] Using piston ring land step gage, check the groove as in the compression ring groove. [b] If the compression ring groove is worn beyond usable limits, replace piston dome. All information subject to change without notice. (Rev. 2005) 1-297 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 360 7. On steel piston engines, inspect the connecting rod bushing. [a] Check the bushing for excessive fretting. [b] If excessive fretting is evident, replace the connecting rod assembly. (Rev. 2005) All information subject to change without notice. 1-298 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 361 This will ensure that the rings are parallel with the top of the liner, and that they are positioned in the liner within the normal area of ring travel. All information subject to change without notice. (Rev. 2005) 1-299 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 362 Allowable Ring End Gap On-Highway Engines 5. Refer to section 1.19.5 for assembly of rings for diesel engines or refer to section 1.19.6 for Series 60G engines. (Rev. 2005) All information subject to change without notice. 1-300 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 363 1. Oil Control Ring 3. Piston 2. Oil Control Ring Groove 4. Oil Control Ring Expander Figure 1-278 Piston Ring Installation (Diesel) All information subject to change without notice. (Rev. 2005) 1-301 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 364 The oil control ring expander has a white paint stripe. Make sure the paint mark can be seen after the oil control ring is installed at ring gap. (Rev. 2005) All information subject to change without notice. 1-302 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 365 2. Stagger the ring gaps around the piston. See Figure 1-280. Figure 1-280 Piston Ring Positioning (Diesel) 3. Refer to section 1.21.4 for piston and connecting rod assembly procedure. All information subject to change without notice. (Rev. 2005) 1-303 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 366 Installation of Compression Ring 2. Install the ﬁre ring in the top groove of the piston, using a piston ring expander tool. (Rev. 2005) All information subject to change without notice. 1-304 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 367 3. Stagger the ring gaps around the piston. See Figure 1-282. Figure 1-282 Top View of Piston Dome 4. Refer to section 1.21.4 for piston and connecting rod assembly procedure. All information subject to change without notice. (Rev. 2005) 1-305 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 368: One-Piece Piston Assembly And Piston Ring
4. Retainer 2. Compression Ring 5. Piston Assembly 3. Oil Control Ring with Expander 6. Piston Pin Figure 1-283 One-Piece Piston Assembly (Rev. 2005) All information subject to change without notice. 1-306 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 369 * Identiﬁcation Mark to Face Top of Dome Figure 1-284 One-Piece Piston Assembly Ring Location Figure 1-285 Comparision of Piston Ring Packs All information subject to change without notice. (Rev. 2005) 1-307 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 370 For model year 2000 engines, an oil passage was incorporated into the connecting rod design to improve lubrication to the piston pin. (Rev. 2005) All information subject to change without notice. 1-308 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 371 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-288. Figure 1-288 Flowchart for Repair or Replacement of Piston and Piston Rings All information subject to change without notice. (Rev. 2005) 1-309 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 372 NOTE: The one-piece piston assembly require the removal of the retainer before withdrawing the piston pin. (Rev. 2005) All information subject to change without notice. 1-310 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 373 [b] If any of these indications are present, replace the piston assembly. NOTE: Burn spots may indicate an obstruction in the connecting rod oil passage. All information subject to change without notice. (Rev. 2005) 1-311 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 374 8. Check the block bore for excessive out-of-round, taper, and high spots that could cause failure of the piston. Speciﬁcations are listed in Table 1-16. (Rev. 2005) All information subject to change without notice. 1-312 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 375 See Figure 1-290. Remove the ring from the liner after the measurement is complete. Figure 1-290 Piston Ring Gap Measurement All information subject to change without notice. (Rev. 2005) 1-313 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 376 0.21 - 0.51 mm (0.008 - 0.020 in.) Table 1-6 Allowable Ring End Gap On-Highway Engines 5. Refer to section 1.19.5 for assembly of rings for diesel engines. (Rev. 2005) All information subject to change without notice. 1-314 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 377 1. Oil Control Ring 3. Piston Assembly 2. Oil Control Ring Groove 4. Oil Control Ring Expander Figure 1-291 One-Piece Piston Assembly Installation All information subject to change without notice. (Rev. 2005) 1-315 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 378 The oil control ring expander has a identifying paint stripe. Make sure the paint mark can be seen after the oil control ring is installed at ring gap. (Rev. 2005) All information subject to change without notice. 1-316 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 379 2. Stagger the ring gaps around the piston. see Figure 1-293. Figure 1-293 One-Piece Piston Ring Positioning (Diesel) 3. Refer to section 1.21.4 for piston and connecting rod assembly procedure. All information subject to change without notice. (Rev. 2005) 1-317 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 380: Piston And Connecting Rod Assembly
Some 14L and steel piston cylinder kit procedures differ from the cast iron piston procedures. Information regarding 14L and steel cylinder kits will follow cast iron procedures when different. (Rev. 2005) All information subject to change without notice. 1-318 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 381 Remove the piston and connecting rod assembly as follows (except 14L and 12.7 EGR On-Highway engines): 1. Drain the engine cooling system. Refer to section 14.6.4. 2. Drain the engine oil. Refer to section 14.6.1. All information subject to change without notice. (Rev. 2005) 1-319 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 382 9. Push the piston and rod assembly out through the top of the cylinder block. NOTE: The piston cannot be removed from the bottom of the cylinder block. (Rev. 2005) All information subject to change without notice. 1-320 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 383 5. Position the crankshaft journal for the cylinder kit assembly to be removed at bottom dead center. 6. Remove the bearing cap. All information subject to change without notice. (Rev. 2005) 1-321 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 384 9. Rotate the engine by hand until the entire cylinder kit assembly is pushed up where the liner can be removed by grabbing the tool to pull the kit completely out of the engine block. (Rev. 2005) All information subject to change without notice. 1-322 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 385 For forged steel pistons, mark the pin, skirt, and dome. For one-piece piston assemblies mark the pin and the dome/skirt assembly. All information subject to change without notice. (Rev. 2005) 1-323 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 386 3. Loosen the two bolts that secure the connecting rod to the piston pin and remove the two bolts and spacers. Discard bolts. 4. Remove the connecting rod. 5. Remove the piston, pin and skirt from the holding ﬁxture. (Rev. 2005) All information subject to change without notice. 1-324 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 387 4. Disassemble the piston dome from the skirt. 5. Slide out the piston pin and remove the connecting rod from piston assembly. All information subject to change without notice. (Rev. 2005) 1-325 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 388 The lower bearing can then be pushed full into the bore. 7. Lubricate the piston pin bearings with clean engine oil. (Straight 30 weight oil is recommended). (Rev. 2005) All information subject to change without notice. 1-326 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 389 95-122 N·m (70-90 lb·ft). See Figure 1-299. 15. Complete the process by tightening the bolts to 150.2–163.8 N·m (110–120 lb·ft) ﬁnal torque. All information subject to change without notice. (Rev. 2005) 1-327 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 390 Orient the snap ring gap to either the 12 o'clock or 6 o'clock position. (Rev. 2005) All information subject to change without notice. 1-328 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 391 4. Coat the piston liberally with the engine oil, saturating the piston rings and lands. Figure 1-302 Piston and Connecting Rod Assembly Lubrication All information subject to change without notice. (Rev. 2005) 1-329 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 392 7. Coat the inside diameter of the ring compression tool (J–35598–A) liberally with clean engine oil from the pan. (Rev. 2005) All information subject to change without notice. 1-330 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 393: Piston Ri Ng Compressor
(on the tang side of the rod and cap) as on the connecting rod that was replaced. All information subject to change without notice. (Rev. 2005) 1-331 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 394 Connecting Rod Guide and Oil Nozzle Protector Installation NOTE: The oil nozzle protectors (J-43661) are threaded at the upper end and attach to the rod bolts. (Rev. 2005) All information subject to change without notice. 1-332 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 395 Lift the assembly out of the pan, and allow excess oil to drain back into the pan. NOTE: Do not allow the piston to slide out of the bottom of the ring compressor. All information subject to change without notice. (Rev. 2005) 1-333 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 396 There are orientation lugs cast into one side of the upper and lower sections of the connecting rod. These orientation lugs face the front of the engine. See Figure 1-308. Figure 1-308 Orientation Lugs (Rev. 2005) All information subject to change without notice. 1-334 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 397 15. Position the ring compressor, with piston and connecting rod inside, into the proper cylinder until the ring compressor is resting squarely on the cylinder liner. See Figure 1-309. Figure 1-309 Use of Ring Compressor All information subject to change without notice. (Rev. 2005) 1-335 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 398 22. Install the bearing cap. The number on the cap and rod should be on the same (oil cooler) side. See Figure 1-310. Figure 1-310 Connecting Rod and Cap Identiﬁcation (Rev. 2005) All information subject to change without notice. 1-336 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 399 3. Place the piston and connecting rod assembly into pan, with the dome of the piston on the bottom of the pan. See Figure 1-311. All information subject to change without notice. (Rev. 2005) 1-337 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 400 8. Clamp the ring compressor, with groove (pilot bore) of the compressor facing away from the connecting rod, around the dome and rings. (Rev. 2005) All information subject to change without notice. 1-338 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 401 See Figure 1-313. Figure 1-313 Installation of Ring Compressor for One piece Piston Assembly All information subject to change without notice. (Rev. 2005) 1-339 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 402 18. Position the throw of the crankshaft journal to bottom dead center for the cylinder being installed with the liner, piston and connecting rod assembly. (Rev. 2005) All information subject to change without notice. 1-340 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 403 19. Ensure arrow on piston dome is pointing toward the front of the engine during installation. See Figure 1-315. Figure 1-315 Piston Dome One Piece Piston Assembly All information subject to change without notice. (Rev. 2005) 1-341 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 404 It is necessary to leave the cylinder kit installation tool in place until after the liner protrusion is measured. Figure 1-317 Cylinder Liner Installation Tools (Rev. 2005) All information subject to change without notice. 1-342 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 405 28. Push or tap the piston and connecting rod within the liner until the upper rod bearing is ﬁrmly seated on the appropriate crankshaft journal. 29. Remove the oil nozzle protectors. All information subject to change without notice. (Rev. 2005) 1-343 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 406 14.6.4, for reﬁlling procedure and refer to section 5.4. NOTE: Coolant system maintenance is very important. Bleed off all the air from the system and top off. (Rev. 2005) All information subject to change without notice. 1-344 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 407: Connecting Rod
6. Connecting Rod Bearing Cap 3. Connecting Rod 7. Bearing Shells 4. Spacer Washer (2) Figure 1-319 Connecting Rod and Bearing Shells (Open-End Rod) All information subject to change without notice. (Rev. 2005) 1-345 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 408 These bearings are identiﬁed by the satin silver sheen of the tin when new, and a dull gray of the overlay after being in service. (Rev. 2005) All information subject to change without notice. 1-346 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 409 The former bearing shells will be available for engines built prior to the unit serial numbers as listed in Table 1-7. All information subject to change without notice. (Rev. 2005) 1-347 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 410 The current connecting rod for 14 L engines and model year 2000 12.7 L engines use a drilled passage way through the rod to lubricate the piston pin bushing. These (Rev. 2005) All information subject to change without notice. 1-348 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 411 Spray oil entering these scallops lubricates the piston pin and bushing during engine operation. The piston pin ﬂoats in the bushings of both the piston and the connecting rod. All information subject to change without notice. (Rev. 2005) 1-349 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 412 Orientation of the cap to the upper end is identiﬁed by stamped numbers. (Rev. 2005) All information subject to change without notice. 1-350 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 413 The upper and lower bearings are identical . The upper and lower bearing shells are located in the connecting rod by a tang at the parting line at one end of each bearing shell. All information subject to change without notice. (Rev. 2005) 1-351 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 414 These bearings are identiﬁed by the satin silver sheen of the tin when new and a dull gray of the overlay after being in service. (Rev. 2005) All information subject to change without notice. 1-352 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 415 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-325. Figure 1-325 Flowchart for Repair or Replacement of Connecting Rod All information subject to change without notice. (Rev. 2005) 1-353 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 416: Inspection Of Connecting Rod
1. Inspect the connecting rod saddle at the piston pin contact surface for traces of fretting and corrosion. 2. To repair, wet with fuel oil and smooth with crocus cloth. (Rev. 2005) All information subject to change without notice. 1-354 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 417 Be sure the connecting rod bolt has not turned in the connecting rod before torque is applied to the nut. 3. Torque the bolt nuts to 160-185 N·m (118-137 lb·ft). All information subject to change without notice. (Rev. 2005) 1-355 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 418 [a] For 12.7 and 11.1 L; 91.288 and 91.313 mm (3.594 and 3.595 in.). [b] For 14L and 12.7 EGR On-Highway; 101.288 and 101.3133 mm (3.988 and 3.989 in.). (Rev. 2005) All information subject to change without notice. 1-356 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 419 If the overlay is worn through to the copper across the bearing shell, all the bearing shells must be replaced. [b] If any of these conditions are detected, replace the bearings. All information subject to change without notice. (Rev. 2005) 1-357 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 420 Refer to section ADDITIONAL INFORMATION, "Checking Bearing Clearances" in "Shop Notes" section. (Rev. 2005) All information subject to change without notice. 1-358 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 421: Model Year
0.030 in.) undersize for service with reground crankshafts. The bearing size speciﬁcations are listed in Table 1-25. 1.22.5 Installation of Connecting Rod Refer to section 1.21.5 to install the piston and connecting rod assembly. All information subject to change without notice. (Rev. 2005) 1-359 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 422: Cylinder Liner
ﬂange. Coolant ﬂow through this channel and around the rest of the liner controls critical ring and liner temperatures for long cylinder component life. (Rev. 2005) All information subject to change without notice. 1-360 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 423 The cylinder liner, piston and connecting rod must be installed as a assembly in 14L engines and 12.7L EGR On-Highway engines. Refer to section 1.21. All information subject to change without notice. (Rev. 2005) 1-361 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 424 See Figure 1-331. Figure 1-331 Cylinder Liner Seal Ring Cross-section (Rev. 2005) All information subject to change without notice. 1-362 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 425 At the same time it allows leaking oil or coolant a path out of the engine for detection. Figure 1-332 Weep Hole Plug Locations All information subject to change without notice. (Rev. 2005) 1-363 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 426 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-333. Figure 1-333 Flowchart for Repair or Replacement of Cylinder Liner (Rev. 2005) All information subject to change without notice. 1-364 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 427 [a] Ease the liner removal tool down into the liner. [b] Turn the nut on tool (J–45876). in a clockwise direction to remove liner from the block. All information subject to change without notice. (Rev. 2005) 1-365 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 428 7. If a dark residue appears on the towels, repeat the oiling and wiping procedure until residue no longer appears. 1.23.2.2 Inspection of Cylinder Liner Inspect the cylinder liner as follows: (Rev. 2005) All information subject to change without notice. 1-366 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 429 [b] If any fretting is found, remove it from the surface of the liner with a coarse, ﬂat stone. 3. Inspect the liner ﬂange. All information subject to change without notice. (Rev. 2005) 1-367 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 430 Table 1-17. The block speciﬁcations are listed in Table 1-16. Refer to section 1.1.3.3 for procedures. [b] If the liner does not meet speciﬁcation, replace with a new part. (Rev. 2005) All information subject to change without notice. 1-368 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 431 [a] Check the seal ring and crevice seal grooves for burrs or sharp edges. [b] If any are detected, smooth with an emery cloth. All information subject to change without notice. (Rev. 2005) 1-369 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 432 4. Insert the cylinder liner into the cylinder bore. NOTE: Do not exert excessive force on the liner, while pushing it down. (Rev. 2005) All information subject to change without notice. 1-370 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 433 60 N·m (44 lb·ft) to the installation tool center bolt. 10. Install a dial indicator sled gage. See Figure 1-318. All information subject to change without notice. (Rev. 2005) 1-371 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 434 13. With all of the cylinder liners installed and the liner protrusion measurements within speciﬁcations, install the piston and connecting rod assemblies. Refer to section 1.21.5. (Rev. 2005) All information subject to change without notice. 1-372 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 435: Gear Train And Engine Timing
(through the bull gear), drives the fuel pump drive gear, air compressor and power steering pump drive gear, accessory pulley drive gear and water pump drive gear. All information subject to change without notice. (Rev. 2005) 1-373 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 436 (Rev. 2005) All information subject to change without notice. 1-374 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 437 4. Bull Gear 2. Adjustable Idler Gear 5. Crankshaft Timing Gear 3. Camshaft Drive Gear Figure 1-341 Engine Gear Train and Timing Marks All information subject to change without notice. (Rev. 2005) 1-375 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 438 See Figure 1-342. Gear Train Lubricating Oil Hole Locations Figure 1-342 (Rev. 2005) All information subject to change without notice. 1-376 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 439 Repair or Replacement of Gear Train and Engine Timing To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-343. All information subject to change without notice. (Rev. 2005) 1-377 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 440 Go to "A", see Figure 1-344. Figure 1-343 Flowchart for Repair or Replacement of Gear Train and Engine Timing - Part 1 of 3 (Rev. 2005) All information subject to change without notice. 1-378 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 441 Go to "B", see Figure 1-345. Figure 1-344 Flowchart for Repair or Replacement of Gear Train and Engine Timing - Part 2 of 3 All information subject to change without notice. (Rev. 2005) 1-379 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 442 GEAR TRAIN AND ENGINE TIMING Figure 1-345 Flowchart for Repair or Replacement of Gear Train and Engine Timing - Part 3 of 3 (Rev. 2005) All information subject to change without notice. 1-380 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 443 [d] If any gears are removed or installed, or if lash between any two gears is out of speciﬁcation, check the lash between the mating gears. All information subject to change without notice. (Rev. 2005) 1-381 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 444 The lash between the crankshaft timing gear and oil pump drive gear must be measured with the engine in a running position. See Figure 1-346. (Rev. 2005) All information subject to change without notice. 1-382 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 445 [g] If the use of shims cannot bring gear lash within acceptable limits, the gear or gears for that gear set must be replaced. All information subject to change without notice. (Rev. 2005) 1-383 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 446 0.305 mm (0.012 in.) for used parts. [g] If lash measurement is exceeded, replace gear with a new part. (Rev. 2005) All information subject to change without notice. 1-384 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 447 Refer to step 3 and perform step 3[a], as the ﬁrst step and refer to step 3[g], as the ﬁnal step. NOTE: These gears can be measured with the pump installed. All information subject to change without notice. (Rev. 2005) 1-385 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 448 DDC logo. See Figure 1-349. Use care to ensure that the rocker arm shaft assemblies are replaced exactly as removed. Figure 1-349 Rocker Arm Shaft Identiﬁcation Mark (Rev. 2005) All information subject to change without notice. 1-386 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 449 See Figure 1-350. All information subject to change without notice. (Rev. 2005) 1-387 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 450 [k] Turn the adjusting screw of the gear lash adjusting tool (J–35596–A) approximately 1-1/2 turns or until the proper gear lash is obtained. (Rev. 2005) All information subject to change without notice. 1-388 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 451 The torque speciﬁcation is 101-116 N·m (75-86 lb·ft). [u] Install the rocker arm shaft assemblies to the cylinder head. Refer to section 1.3.3. All information subject to change without notice. (Rev. 2005) 1-389 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 452 58-73 N·m (43-54 lb·ft) 160-200 N·m (118-148 lb·ft) 6 to 10 30-38 N·m (22-28 lb·ft) Figure 1-353 Fan Support Bracket Bolt Torque Sequence (Rev. 2005) All information subject to change without notice. 1-390 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 453 [e] If proper lash measurement cannot be obtained, replace gear with a new part. Refer to section 1.33.2. [f] Remove the dial indicator and gear lash tool. All information subject to change without notice. (Rev. 2005) 1-391 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 454 [b] Install the water pump impeller slip tester (J–35687), to the water pump impeller with two 5/16-18 bolts, using the instructions supplied with the tool. See Figure 1-355. Figure 1-355 Water Pump Impeller Slip Tester Method (Rev. 2005) All information subject to change without notice. 1-392 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 455 [g] Inspect the water pump cover seal for cracks or splitting. Refer to section 4.2.3.1gear mounted or refer to section 4.3.3.1 for front mounted water pump. Replace seal if damage is found. All information subject to change without notice. (Rev. 2005) 1-393 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 456 (J–35687), or by inserting a bolt into one of the tapped holes in the water pump impeller. The lash can then be measured using a dial indicator. (Rev. 2005) All information subject to change without notice. 1-394 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 457 Gear lash speciﬁcations are 0.051-0.229 mm (0.002 -0.009 in.). [c] If proper lash measurement cannot be obtained, replace the gear with a new part. Refer to section 1.33.2. All information subject to change without notice. (Rev. 2005) 1-395 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 458: Water Pump Impeller
[k] Install the two bolts that secure the water pump cover to the water pump housing. Torque the bolts to 30-38 N·m (22-28 lb·ft). (Rev. 2005) All information subject to change without notice. 1-396 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 459 [k] Install and torque the retaining bolts to 30-38 N·m (22-28 lb·ft), using a star-shaped pattern. All information subject to change without notice. (Rev. 2005) 1-397 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 460 8. Fill the engine crankcase. Refer to section 14.6.1. 9. Refer to section 12.7for veriﬁcation of proper gear train and engine timing. (Rev. 2005) All information subject to change without notice. 1-398 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 461: Compact Gear Train And Engine Timing
(through the bull gear), drives the air compressor and power steering pump drive gear, accessory pulley drive gear and water pump drive gear. All information subject to change without notice. (Rev. 2005) 1-399 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 462 Repair or Replacement of Gear Train and Engine Timing To determine if repair is possible or replacement is necessary, perform the following procedure. See Figures 1-360, 1-361 and 1-362. (Rev. 2005) All information subject to change without notice. 1-400 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 463 SERIES 60 SERVICE MANUAL Figure 1-360 Flowchart for Repair or Replacement of Gear Train and Engine Timing – Part 1 of 3 All information subject to change without notice. (Rev. 2005) 1-401 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 464 COMPACT GEAR TRAIN AND ENGINE TIMING Figure 1-361 Flowchart for Repair or Replacement of Gear Train and Engine Timing – Part 2 of 3 (Rev. 2005) All information subject to change without notice. 1-402 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 465 SERIES 60 SERVICE MANUAL Figure 1-362 Flowchart for Repair or Replacement of Gear Train and Engine Timing – Part 3 of 3 All information subject to change without notice. (Rev. 2005) 1-403 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 466: Engine Timing
A rattling noise usually indicates excessive gear lash. A whining noise indicates too little gear lash. 1. Check engine timing as follows: (Rev. 2005) All information subject to change without notice. 1-404 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 467 [c] If any gears are removed or installed, or if lash between any two gears is out of speciﬁcation, check the lash between the mating gears. 2. Check the crankshaft timing gear-to-oil pump idler gear lash measurement as follows: All information subject to change without notice. (Rev. 2005) 1-405 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 468 The lash between the crankshaft timing gear and oil pump drive gear must be measured with the engine assembled and positioned to run. See Figure 1-364. (Rev. 2005) All information subject to change without notice. 1-406 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 469 [g] If the use of shims cannot bring gear lash within acceptable limits, the gear or gears for that gear set must be replaced. 3. Check the crankshaft timing gear-to-bull gear lash measurement as follows: All information subject to change without notice. (Rev. 2005) 1-407 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 470 Refer to step 3 and perform step 3[a], as the ﬁrst step and refer to step 3[g], as the ﬁnal step. Gear case cover (Rev. 2005) All information subject to change without notice. 1-408 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 471 3[g], as the ﬁnal step. NOTE: These gears can be measured with the pump installed. 8. Check the bull gear-to-accessory drive gear lash measurement as follows: All information subject to change without notice. (Rev. 2005) 1-409 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 472 [e] If proper lash measurement cannot be obtained, replace gear with a new part. [f] Remove the dial indicator and gear lash tool. (Rev. 2005) All information subject to change without notice. 1-410 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 473 [e] If proper lash cannot be obtained, replace the gear with a new part. [f] Remove the dial indicator and magnetic base. All information subject to change without notice. (Rev. 2005) 1-411 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 474 The procedures for measuring and adjusting the gear lash for the compact gear train are as follows: 1. If the camshaft gear assembly has been removed, refer to section 1.26.5 for installation instructions. (Rev. 2005) All information subject to change without notice. 1-412 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 475 ( J–46306–A ) see Figure 1-369 and camshaft gear alignment tool ( J–45946 ). See Figure 1-370. Figure 1-369 Idler Gear Centering Tool (J–46306–A) Figure 1-370 Camshaft Gear Alignment Tool (J–45946) All information subject to change without notice. (Rev. 2005) 1-413 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 476 4. Install the gear lash measuring tool (J–46303) onto the center of the camshaft drive gear at the three o'clock position. See Figure 1-372. (Rev. 2005) All information subject to change without notice. 1-414 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 477 NOTE: Do not apply side load with the screwdriver; prying the gears will result in incorrect lash measurement readings. All information subject to change without notice. (Rev. 2005) 1-415 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 478 If there is zero lash between the two gears, the dial indicator pointer will not move from zero. NOTE: Torque idler gear nuts ﬁrst to prevent any gear movement which would change gear lash settings. (Rev. 2005) All information subject to change without notice. 1-416 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 479 8. Fill the engine crankcase. Refer to section 14.6.1. 9. Refer to section 12.7for veriﬁcation of proper gear train and engine timing. All information subject to change without notice. (Rev. 2005) 1-417 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 480: Camshaft Gear Assembly Series 60 Exhaust Gas Recirculation (Egr) Model
NOT be interchanged with other caps of the same part number from stock or from a different cylinder head. See Figure 1-375. (Rev. 2005) All information subject to change without notice. 1-418 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 481 9. Camshaft Bearing Caps 4. Camshaft Gear Cover 10. Camshaft 5. Seal 11. Cylinder Head 6. Key Figure 1-375 Camshaft Assembly and Related Parts All information subject to change without notice. (Rev. 2005) 1-419 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 482 NOT be interchanged with other caps of the same part number from stock or from a different cylinder head. See Figure 1-375. (Rev. 2005) All information subject to change without notice. 1-420 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 483 Refer to section 1.24.2.1 for gear train information and camshaft drive gear lash measurement and adjustment procedures. See Figure 1-377. Figure 1-377 Engine Gear Series 60 EGR All information subject to change without notice. (Rev. 2005) 1-421 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 484 “Y” drilled, forming an oil path connection between the front and rear rocker arm shafts, to ensure complete lubrication. See Figure 1-379. (Rev. 2005) All information subject to change without notice. 1-422 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 485 Repair or Replacement of Camshaft Gear Assembly To determine if repair or replacement of the camshaft gear assembly is neccessary, perform the following procedure: see Figure 1-380. All information subject to change without notice. (Rev. 2005) 1-423 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 486 Figure 1-380 Flowchart for Repair or Replacement of Camshaft Gear Assembly 1.26.2 Removal of Camshaft Gear Assembly Remove camshaft gear assembly as follows: (Rev. 2005) All information subject to change without notice. 1-424 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 487 4. Remove the ﬁve bolts for the camshaft gear cover inspection plate and remove the plate. See Figure 1-382. 1. Bolt 3. Gasket 2. Cover Figure 1-382 Gear Case Assembly Cover All information subject to change without notice. (Rev. 2005) 1-425 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 488 Refer to steps 6[a] and 6[b]. 1. Camshaft Gear Cover 2. Timing Hole Figure 1-383 Timing Veriﬁcation (Rev. 2005) All information subject to change without notice. 1-426 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 489 This procedure will make assembly easier. 8. Remove four camshaft gear cover bolts (1). See Figure 1-385. 1. Bolt Figure 1-385 Camshaft Gear Cover Bolts All information subject to change without notice. (Rev. 2005) 1-427 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 490 No. 1 and 7, remove camshaft caps. See Figure 1-387 and see Figure 1-388. 1. Bolt 2. Stud Bolt Figure 1-387 Camshaft Cap Bolt and Stud Bolt (Rev. 2005) All information subject to change without notice. 1-428 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 491 Keep the caps and shells together for possible later installation Tag the bearing cap location, as they must always be installed in the same location. All information subject to change without notice. (Rev. 2005) 1-429 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 492 Disassembly of Camshaft Gear Assembly EGR Model Disassemble the camshaft from the camshaft gear as follows. 1. Use suitable ﬁxture to secure the camshaft assembly from movement. (Rev. 2005) All information subject to change without notice. 1-430 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 493 These blemishes do not adversely affect engine performance or the durability of the camshaft and followers. Camshafts with this condition may be reused. All information subject to change without notice. (Rev. 2005) 1-431 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 494 Camshafts Acceptable for Reuse NOTE: Camshafts exhibiting extensive wear and pitting must be replaced. See Figure 1-391. Figure 1-391 Camshafts Not Acceptable for Reuse (Rev. 2005) All information subject to change without notice. 1-432 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 495 [d] Replace camshaft bearings as necessary. NOTE: If one camshaft bearing needs to be replaced, replace both of the camshaft bearing shells. All information subject to change without notice. (Rev. 2005) 1-433 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 496 [n] Using a dial indicator with magnetic base, check the run-out of the camshaft at the No. 4 bearing journal. See Figure 1-393. Figure 1-393 Camshaft Run-out Measurement (Rev. 2005) All information subject to change without notice. 1-434 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 497 Note the position of oil holes and locating tangs. 2. Coat the lobes and journals of the camshaft with clean engine lubricating oil. All information subject to change without notice. (Rev. 2005) 1-435 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 498 See Figure 1-394. Figure 1-394 Camshaft Alignment Tool (Rev. 2005) All information subject to change without notice. 1-436 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 499 5. If the adjustable idler gear was removed or replaced, remove the cover plate and loosen the three hub retaining nuts so the gear hub can be easily moved. Install the centering tool All information subject to change without notice. (Rev. 2005) 1-437 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 500 Idler Gear Centering Tool J–46306–A 6. Ensure two seals are properly installed in camshaft gear cover. See Figure 1-397 . Figure 1-397 Camshaft Cover Seals (Rev. 2005) All information subject to change without notice. 1-438 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 501 Using lifting tool (J–46305), place front lifting hook between the number two injector lobe and intake valve and the rear hook between number four injector lobe and intake valve. All information subject to change without notice. (Rev. 2005) 1-439 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 502 1. Camshaft Gear Cover 2. Timing Hole Figure 1-399 Timing Veriﬁcation (Rev. 2005) All information subject to change without notice. 1-440 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 503 12. Apply RTV to grooves in camshaft cap No.1 and Gasket Eliminator® to camshaft cap No. 7. See Figure 1-400 . Figure 1-400 Sealant Application All information subject to change without notice. (Rev. 2005) 1-441 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 504 15. Install three bolts inside camshaft gear cover, hand tighten to prevent seal damage. 16. To seat the cover, torque the three inside camshaft gear cover bolts to 10 N·m (7 ft·lb). (Rev. 2005) All information subject to change without notice. 1-442 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 505 19. Torque the three bolts previously installed inside camshaft gear cover to 40 N·m (30 lb·ft). See Figure 1-403. 1. Bolt Figure 1-403 Camshaft Gear Cover Bolts All information subject to change without notice. (Rev. 2005) 1-443 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 506 23. Check camshaft gear lash and adjust if necessary. Refer to Section 1.25.2.2. 24. Torque idler gear nuts to 103-113 N·m (76-83 lb·ft). 25. Install Synchronous Reference Sensor/Crankshaft Position Sensor (SRS/CMP). (Rev. 2005) All information subject to change without notice. 1-444 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 507: Thrust Plate Perimeter Seal
If the seal should require replacement due to leakage, the seal can be replaced without removing the cylinder head. The following procedure should be used if the perimeter seal requires replacement. All information subject to change without notice. (Rev. 2005) 1-445 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 508 To determine if repair or replacement of the thrust plate perimeter seal is necessary, perform the following procedure. See Figure 1-405. Figure 1-405 Flowchart for Repair or Replacement of Camshaft Thrust Plate Perimeter Seal (Rev. 2005) All information subject to change without notice. 1-446 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 509 7. Using LPS® Contact Cleaner or equivalent residue-free solvent, clean the gear case back/thrust plate area to improve visual access to the seal area. Wipe the area dry with paper towels. All information subject to change without notice. (Rev. 2005) 1-447 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 510 11. Insert the shoe of the camshaft drive gear torque retaining tool (J–35652–B) through a lightening hole of the camshaft drive gear. See Figure 1-408. Figure 1-408 Installation of Camshaft Drive Gear Torque Holding Tool (Rev. 2005) All information subject to change without notice. 1-448 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 511 The gap between the end of the camshaft and the thrust plate should be wide enough to permit the perimeter seal to pass through. All information subject to change without notice. (Rev. 2005) 1-449 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 512 2. Wipe the groove clean after inspection. 1.27.3 Installation of Thrust Plate Perimeter Seal Install the thrust plate perimeter seal as follows: (Rev. 2005) All information subject to change without notice. 1-450 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 513 The former thrust plate perimeter seal was redesigned to provide greater reliability and less susceptibility to twisting during installation. See Figure 1-410 for design conﬁguration. Figure 1-410 Thrust Plate Perimeter Seal All information subject to change without notice. (Rev. 2005) 1-451 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 514 LPS Contact Cleaner or equivalent residue-free cleaner. Do not use mineral spirits, since this will leave a residue. Wipe and dry the area thoroughly with clean paper towels. (Rev. 2005) All information subject to change without notice. 1-452 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 515 May 1999, apply DDC gasket eliminator 23523064, or equivalent, to the joint surfaces of the number 1 camshaft bearing cap. See Figure 1-412. To help ensure proper adhesion of All information subject to change without notice. (Rev. 2005) 1-453 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 516 1 cam bearing or journal before installation of the bearing cap. Figure 1-412 Gasket Eliminator Application (Rev. 2005) All information subject to change without notice. 1-454 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 517 6. Oil Passage Seal Ring 3. Cylinder Head 7. Shim (If Required) 4. Camshaft Bearing Cap Figure 1-413 Cross-sectional View of Cylinder Head and Camshaft Bearing All information subject to change without notice. (Rev. 2005) 1-455 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 518 30 - 38 N·m (22 - 28 lb-ft). To avoid excessive tightening and possible bolt stretching, do not use an air wrench, since this may not provide an accurate torque. (Rev. 2005) All information subject to change without notice. 1-456 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 519 24. Install the valve rocker cover. Refer to section 1.6.7 or refer to section . Install or reconnect any other components that were removed or disconnected for this procedure1.6.8 . All information subject to change without notice. (Rev. 2005) 1-457 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 520: Camshaft And Camshaft Bearing
ﬁnished. Caps are numbered and must NOT be interchanged with other caps of the same part number from stock or from a different cylinder head. (Rev. 2005) All information subject to change without notice. 1-458 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 521 8. Camshaft 4. Rear, Camshaft Access Cover 9. O-ring 5. Bolt, Camshaft Cap (13) 10. Cylinder Head Figure 1-415 Camshaft and Related Parts All information subject to change without notice. (Rev. 2005) 1-459 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 522 See Figure 1-416. 1. Camshaft Cap Bolt (13) 2. Camshaft Cap Stud and Nut (2) Figure 1-416 Camshaft Bolt and Cap Location (Rev. 2005) All information subject to change without notice. 1-460 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 523 Refer to section 1.24.2.1 for gear train information and camshaft drive gear lash measurement and adjustment procedures. See Figure 1-417. Figure 1-417 Engine Gear Train All information subject to change without notice. (Rev. 2005) 1-461 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 524 6. Camshaft Dowel Hole 3. Camshaft Drive Gear 7. Camshaft Thrust Plate 4. O-ring Groove Figure 1-418 Cross-Section of Camshaft Drive Gear and Related Parts (Rev. 2005) All information subject to change without notice. 1-462 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 525 3. Drive Gear, Camshaft 8. Camshaft 4. Thrust Plate, Camshaft 9. Key 5. O-ring 10. Hub Figure 1-419 Camshaft Thrust Plate and Related Parts All information subject to change without notice. (Rev. 2005) 1-463 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 526 A cover is provided at the rear end of the camshaft and is secured to the No. 7 camshaft bearing cap and the cylinder head by three bolts.See Figure 1-421. Figure 1-421 Rear Camshaft Access Cover (Rev. 2005) All information subject to change without notice. 1-464 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 527 The No. 4 camshaft cap is “Y” drilled, forming an oil path connection between the front and rear rocker arm shafts, to ensure complete lubrication. See Figure 1-422. All information subject to change without notice. (Rev. 2005) 1-465 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 528 2. Rocker Arm, Fuel Injector 5. Cylinder Head 3. Camshaft Cap 6. Rocker Arm, Intake Valve Figure 1-422 Cylinder Head Lubrication Schematic (Rev. 2005) All information subject to change without notice. 1-466 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 529 To determine if repair or replacement of the camshaft and camshaft bearings is necessary, perform the following procedure. See Figure 1-423. Figure 1-423 Flowchart for Repair or Replacement of Camshaft and Related Parts All information subject to change without notice. (Rev. 2005) 1-467 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 530 7. Use a long 3/4 in. drive breaker bar and a 27 mm impact socket to remove the camshaft drive gear-to-camshaft bolt. 8. Remove the camshaft drive gear torque holding tool from the gear case. (Rev. 2005) All information subject to change without notice. 1-468 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 531 Engage the puller screw in the threads of the camshaft drive gear hub, until the screw is tight. See Figure 1-426. Figure 1-426 Camshaft Thrust Plate Remover All information subject to change without notice. (Rev. 2005) 1-469 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 532 15. Remove the seven camshaft bearing caps and the upper bearing shells. Keep the caps and shells together for possible later installation. Tag the bearing cap location, as they must always be installed in the same location. (Rev. 2005) All information subject to change without notice. 1-470 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 533 17. Slide the camshaft rearward to completely disengage the dowel from the hub. Lift out the camshaft. 18. Remove the lower camshaft bearing shells, and group them with the upper shells and caps for possible reuse. All information subject to change without notice. (Rev. 2005) 1-471 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 534 3. Dry with compressed air. 4. Inspect the rocker arm components for scoring. Refer to section 1.3.2.2. 5. Replace damaged rocker arm components. (Rev. 2005) All information subject to change without notice. 1-472 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 535 These blemishes do not adversely affect engine performance or the durability of the camshaft and followers. Camshafts with this condition may be reused. All information subject to change without notice. (Rev. 2005) 1-473 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 536 Camshafts Acceptable for Reuse NOTE: Camshafts exhibiting extensive wear and pitting must be replaced. See Figure 1-430. Figure 1-430 Camshafts Not Acceptable for Reuse (Rev. 2005) All information subject to change without notice. 1-474 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 537 [d] Replace camshaft bearings as necessary. NOTE: If one camshaft bearing needs to be replaced, replace both of the camshaft bearing shells. All information subject to change without notice. (Rev. 2005) 1-475 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 538 No. 4 bearing journal. See Figure 1-432. If camshaft run-out exceeds 0.050 mm (0.002 in.), replace the camshaft Figure 1-432 Camshaft Run-out Measurement (Rev. 2005) All information subject to change without notice. 1-476 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 539 12 o'clock position to properly position bolt holes to cam cap and cylinder head. See Figure 1-433. Figure 1-433 Indexing Camshaft Dowel All information subject to change without notice. (Rev. 2005) 1-477 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 540 These areas must be clean and dry for proper sealant adhesion. Use LPS®, Permatex®, or an equivalent non-ﬁlming degreaser. (Rev. 2005) All information subject to change without notice. 1-478 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 541 No. 1 camshaft cap. All information subject to change without notice. (Rev. 2005) 1-479 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 542 21. Install two of the access cover bolts to secure the tool to the gear case. 22. Torque bolt to 75 N·m (55 lb·ft). (Rev. 2005) All information subject to change without notice. 1-480 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 543 1.28.5.1 Test of Camshaft End Play Measure the camshaft end play, using a dial indicator and magnetic base, as follows: All information subject to change without notice. (Rev. 2005) 1-481 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 544 6. If the end play is still beyond the maximum limit, remove and replace the camshaft thrust plate. Refer to section 1.28.2 for removal and refer to section 1.28.3 for installation. (Rev. 2005) All information subject to change without notice. 1-482 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 545 NOTE: Jake Brakes are not on a natural gas engine. Figure 1-437 Camshaft Cap Bolts and Rocker Arm Shaft Nut Torque Sequence All information subject to change without notice. (Rev. 2005) 1-483 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 546 15. Install the fan hub, fan, (refer to section 4.6.6), and drive belts; refer to section 14.6.9. 16. Install any other components that were removed for this procedure. (Rev. 2005) All information subject to change without notice. 1-484 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 547 25.4 mm (1 in.). Provide an extension for the indicator spindle. The extension must be long enough to contact the piston just before it reaches the end of its upward stroke. All information subject to change without notice. (Rev. 2005) 1-485 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 548 24. Turn the crankshaft slowly, in the direction of engine rotation, until the center mark on the vibration damper lines up with the pointer. (Rev. 2005) All information subject to change without notice. 1-486 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 549 1. Remove the valve cover. Refer to section 1.6.2 for one-piece rocker cover. Refer to section 1.6.3 for two-piece rocker cover. Refer to section 1.6.5 for three-piece rocker cover. All information subject to change without notice. (Rev. 2005) 1-487 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 550 Continue turning the crankshaft until the indicator hand starts to move again. 12. Reset the dial to zero. 13. Turn the crankshaft until the indicator reading is 0.254 mm (0.010 in.). (Rev. 2005) All information subject to change without notice. 1-488 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 551 26. If the camshaft lift is incorrect, re-time the engine. Refer to section 1.24.2.1. 27. Refer to section 12.7 for veriﬁcation of proper camshaft and camshaft bearing installation. All information subject to change without notice. (Rev. 2005) 1-489 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 552: Camshaft Drive Gear
4. Bull Gear 2. Idler Gear, Adjustable 5. Timing Gear, Crankshaft 3. Drive Gear, Camshaft Figure 1-441 Engine Gear Train and Timing Marks (Rev. 2005) All information subject to change without notice. 1-490 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 553 One of these bolts screws into the cylinder head, while the other bolt screws into the No. 1 camshaft bearing cap. All information subject to change without notice. (Rev. 2005) 1-491 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 554 The camshaft drive gear will stay in mesh with its mating gear, and may be returned to its original position without re-timing the gears. (Rev. 2005) All information subject to change without notice. 1-492 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 555 To determine if repair or replacement of the camshaft drive gear is necessary, preform the following procedure. See Figure 1-444. Figure 1-444 Flowchart for Repair or Replacement of Camshaft Drive Gear All information subject to change without notice. (Rev. 2005) 1-493 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 556 (former) bolts that retain the camshaft thrust plate to the cylinder head and No. 1 camshaft bearing cap. See Figure 1-445. 1. Camshaft Thrust Plate Mounting Bolt Locations Figure 1-445 Camshaft Thrust Plate Mounting Bolt Locations (Rev. 2005) All information subject to change without notice. 1-494 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 557 9. Press the hub out of the camshaft drive gear until the hub separates from the camshaft thrust plate. See Figure 1-447. Figure 1-447 Camshaft Hub Removal All information subject to change without notice. (Rev. 2005) 1-495 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 558 10. Remove the O-ring and seal from grooves in the camshaft thrust plate. Discard O-ring and seal. 11. Using a hooked seal extractor, remove the diamond seal from the thrust plate groove. (Rev. 2005) All information subject to change without notice. 1-496 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 559 Woodruff Key slot. If damage is found, replace as required. 4. Visually examine the camshaft drive gear hub for scoring, pitting, galling or cracking. If damaged, replace drive gear hub. All information subject to change without notice. (Rev. 2005) 1-497 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 560 6. Dowel Hole, Camshaft 3. Drive Gear, Camshaft 7. Thrust Plate, Camshaft 4. Groove, O-ring Figure 1-448 Cross-Section of Camshaft Drive and Related Parts (Rev. 2005) All information subject to change without notice. 1-498 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 561 [b] If the measured value is more than 0.114 mm (0.0045 in.), the drive gear assembly parts must be replaced. All information subject to change without notice. (Rev. 2005) 1-499 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 562 (Rev. 2005) All information subject to change without notice. 1-500 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 563 [c] Torque bolt to 75 N·m (55 lb·ft). [d] Turn the bolt an additional 120 degrees. See Figure 1-449. Figure 1-449 Torque Turn Limits All information subject to change without notice. (Rev. 2005) 1-501 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 564 15. Check the coolant level. Refer to section 14.6.4. 16. Refer to section 12.7 for veriﬁcation of proper camshaft drive gear installation. (Rev. 2005) All information subject to change without notice. 1-502 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 565 The adjustable idler gear is pressure lubricated by engine oil fed to a gallery drilled into the gear case. This gallery indexes with the cylinder block oil gallery. See Figure 1-451. Figure 1-451 Adjustable Idler Gear Oil Gallery Location All information subject to change without notice. (Rev. 2005) 1-503 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 566: Adjustable Idler Gear Assembly
The adjustable idler gear retaining plate has a ﬂat on the bottom to clear the bull gear for removal and installation. See Figure 1-453. Figure 1-453 Adjustable Idler Gear Retaining Plate (Rev. 2005) All information subject to change without notice. 1-504 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 567 To determine if repair or replacement of the adjustable idler gear assembly is necessary, perform the following procedure. See Figure 1-454. Figure 1-454 Flowchart for Repair or Replacement of Adjustable Idler Gear Assembly All information subject to change without notice. (Rev. 2005) 1-505 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 568 4. Bull Gear 2. Idler Gear, Adjustable 5. Timing Gear, Crankshaft 3. Drive Gear, Camshaft Figure 1-455 Engine Gear Train and Timing Marks (Rev. 2005) All information subject to change without notice. 1-506 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 569 4. Remove the gear case cover. Refer to section 1.10.2. 5. Secure J–36237 to the front of the crankshaft. See Figure 1-456. Figure 1-456 Barring Engine Over All information subject to change without notice. (Rev. 2005) 1-507 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 570 11. Remove the three adjustable idler gear ﬂanged locknuts. 12. Remove the adjustable idler gear hub retaining plate. 13. Remove the adjustable idler gear and hub. (Rev. 2005) All information subject to change without notice. 1-508 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 571 [b] If the clearance is to speciﬁcation, 0.033 - 0.076 mm (0.0013 -0.0030 in.), reuse the gear and bushing assembly. All information subject to change without notice. (Rev. 2005) 1-509 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 572 4. Bull Gear 2. Idler Gear, Adjustable 5. Timing Gear, Crankshaft 3. Drive Gear, Camshaft Figure 1-458 Engine Gear Train and Timing Marks (Rev. 2005) All information subject to change without notice. 1-510 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 573 12. Install any other components that were removed for access to the gear case cover. 13. Refer to section 12.7 for veriﬁcation of proper adjustable idler gear assembly installation. All information subject to change without notice. (Rev. 2005) 1-511 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 574: Adjustable Idler Gear Compact Gear Train
2. Retaining Plate, Adjustable Idler Gear Hub 6. Stud Bolts 3. Idler Gear 4.Idler Hub Figure 1-459 Adjustable Idler Gear and Related Parts (Rev. 2005) All information subject to change without notice. 1-512 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 575 Repair or Replacement of Adjustable Idler Gear Assembly To determine if repair or replacement of the adjustable idler gear assembly is necessary, perform the following procedure. See Figure 1-460. All information subject to change without notice. (Rev. 2005) 1-513 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 576 Flowchart for Repair or Replacement of Adjustable Idler Gear Assembly 1.31.2 Removal of Adjustable Idler Gear Assembly Remove the adjustable as follows: (Rev. 2005) All information subject to change without notice. 1-514 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 577 Inspect the adjustable idler gear as follows 1. Wash the adjustable idler gear, idler hub, and retaining plate thoroughly in clean fuel oil. All information subject to change without notice. (Rev. 2005) 1-515 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 578 Install the adjustable idler gear as follows: 1. Coat the contact surfaces of the hub and idler gear bushing with clean engine oil. (Rev. 2005) All information subject to change without notice. 1-516 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 579 10. Install any other components that were removed for access to the gear case cover. 11. Refer to section 12for veriﬁcation of proper camshaft drive gear installation. All information subject to change without notice. (Rev. 2005) 1-517 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 580: Bull Gear And Camshaft Idler Gear For The Compact Gear Train
See Figure 1-463. (Rev. 2005) All information subject to change without notice. 1-518 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 581 -0.009 in.), and should not exceed 0.305 mm (0.012 in.) backlash between worn gears. NOTE: All gear lash measurements should be taken with engine in an upright position. All information subject to change without notice. (Rev. 2005) 1-519 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 582 To determine if repair or replacement of the bull gear and camshaft idler gear assembly is necessary, perform the following procedure. 1. Remove the engine gear case cover. Refer to section 1.11.2. (Rev. 2005) All information subject to change without notice. 1-520 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 583 [a] If either gear is damaged, replace the bull gear and idler gear assembly. [b] If either gear is not damaged, reuse the bull gear and idler gear assembly. All information subject to change without notice. (Rev. 2005) 1-521 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 584 The bull gear is not attached and will slide off if engine is rotated. 4. Coat the contact areas of the bull gear and camshaft idler gear assembly with clean engine oil. (Rev. 2005) All information subject to change without notice. 1-522 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 585 5. Align timing marks on bull gear and crankshaft timing gear. See Figure 1-467. 1. Crankshaft Timing Gear 3. Timing Marks 2. Bull Gear Figure 1-467 Compact Gear Train and Engine Timing Marks All information subject to change without notice. (Rev. 2005) 1-523 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 586 11. Check bull gear to accessory drive gear lash. Refer to section 1.25.2.1. 12. Refer to section 12 for veriﬁcation of proper bull gear and camshaft idler gear assembly installation. (Rev. 2005) All information subject to change without notice. 1-524 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 587: Bull Gear And Camshaft Idler Gear Assembly
The adjustable idler gear drives the camshaft drive gear. The gear ratio of each gear in relationship to the crankshaft timing gear is shown directly below the gear title. All information subject to change without notice. (Rev. 2005) 1-525 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 588 NOTE: The bull gear and camshaft idler gear assembly is retained to the hub by a left-hand threaded nut. (Rev. 2005) All information subject to change without notice. 1-526 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 589 4. Bull Gear 2. Idler Gear, Adjustable 5. Timing Gear, Crankshaft 3. Drive Gear, Camshaft Figure 1-471 Engine Gear Train and Timing Marks All information subject to change without notice. (Rev. 2005) 1-527 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 590 (Rev. 2005) All information subject to change without notice. 1-528 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 591 See Figure 1-473. Figure 1-473 Flowchart for Repair or Replacement of Bull Gear and Camshaft Idler Gear Assembly All information subject to change without notice. (Rev. 2005) 1-529 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 592 1. Remove the engine gear case cover. Refer to section 1.10.2. 2. Install J–35994 to the oil seal contact area of the crankshaft. See Figure 1-474. Figure 1-474 Bull Gear Guide Studs (Rev. 2005) All information subject to change without notice. 1-530 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 593 5. Remove the two remaining bull gear retaining bolts. 6. Grasp the bull gear and pull the assembly straight out of the recess in the cylinder block. All information subject to change without notice. (Rev. 2005) 1-531 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 594 [a] If the gears do not rotate freely on the hub, replace the bull gear and idler gear assembly. [b] If the gears rotate freely, reuse the bull gear and idle gear assembly. (Rev. 2005) All information subject to change without notice. 1-532 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 595 Reference Sensor (SRS). Damage to pin will cause loss of engine performance. Inspect the SRS pin in the bull gear as follows. See Figure 1-476. Figure 1-476 SRS Pin Location All information subject to change without notice. (Rev. 2005) 1-533 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 596 [a] If pin is not ﬂush to 0.25 mm (0.010 in.) below bull gear surface, replace the pin. [b] If the pin is to speciﬁcations 0.25 mm (0.010 in.), reuse the part. (Rev. 2005) All information subject to change without notice. 1-534 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 598 4. Bull Gear 2. Idler Gear, Adjustable 5. Timing Gear, Crankshaft 3. Drive Gear, Camshaft Figure 1-478 Engine Gear Train and Timing Marks (Rev. 2005) All information subject to change without notice. 1-536 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 599 17. Check bull gear to accessory drive gear lash. Refer to section 1.24.2.1. 18. Refer to section 12.7 for veriﬁcation of proper bull gear and camshaft idler gear assembly installation. All information subject to change without notice. (Rev. 2005) 1-537 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 600: Crankshaft Timing Gear And Timing Wheel
2. 12.7L Gear 5. Timing Wheel, DDEC III 3. 11.1L Gear 6. Woodruff Key 7. Crankshaft Figure 1-479 Crankshaft Timing Gear and Related Parts (Rev. 2005) All information subject to change without notice. 1-538 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 601 The crankshaft timing gear directly drives the bull gear and oil pump drive gear. The bull gear drives the various accessories, and drives the camshaft through the idler gear. See Figure 1-480. Figure 1-480 Engine Gear Train All information subject to change without notice. (Rev. 2005) 1-539 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 602 To determine if repair or replacement of the crankshaft timing gear and timing wheel are necessary, perform the following procedure. See Figure 1-482. (Rev. 2005) All information subject to change without notice. 1-540 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 603 SERIES 60 SERVICE MANUAL Figure 1-482 Flowchart for Repair or Replacement of Crankshaft Timing Gear and Timing Wheel All information subject to change without notice. (Rev. 2005) 1-541 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 604 Protector (J–35994) on end of crankshaft or oil leaks may result. 9. Remove the bull gear and camshaft idler gear assembly. Refer to section 1.33.2. (Rev. 2005) All information subject to change without notice. 1-542 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 605 The crankshaft removal values are shown with the crankshaft installed in the engine. The crankshaft timing gear may be removed with the crankshaft in or out of the engine. All information subject to change without notice. (Rev. 2005) 1-543 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 606 12. Slide the hydraulic ram (J–35951–175) over the center rod of J–35642–1 (part of tool set J–35642) and all the way to the base. See Figure 1-484. Figure 1-484 Hydraulic Ram Installation (Rev. 2005) All information subject to change without notice. 1-544 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 607 13. Install J–35642–4 (part of tool set J–35642) to the three guide studs ((J–35642–2, part of tool set J–35642). See Figure 1-485. Figure 1-485 Pressure Plate Installation All information subject to change without notice. (Rev. 2005) 1-545 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 608 14. Install the three retaining nuts to the legs. Tighten the nuts to the pressure plate. Finger-tighten the nuts. See Figure 1-486. Figure 1-486 Retaining Nuts Installation (Rev. 2005) All information subject to change without notice. 1-546 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 609 80 kN (9 tons) of force to remove the crankshaft timing gear. Figure 1-487 Crankshaft Timing Gear Removal All information subject to change without notice. (Rev. 2005) 1-547 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 610 The timing wheel is a slip ﬁt to the crankshaft, and no special tools are required for removal. A three-jaw adjustable puller, however, may be necessary. (Rev. 2005) All information subject to change without notice. 1-548 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 611 [a] If wheel is pitted or gear teeth damaged, replace timing wheel. [b] If the wheel is not damaged, reuse the part. All information subject to change without notice. (Rev. 2005) 1-549 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 612 Torque the bolts to 190 - 203 N·m (140 - 150 lb·ft). See Figure 1-488. Figure 1-488 Installation of Crankshaft Timing Gear and Timing Wheel Installation Tools (Rev. 2005) All information subject to change without notice. 1-550 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 613 See Figure 1-490. Figure 1-490 Timing Wheel Installation 4. Coat the bore of the crankshaft timing gear with a ﬁlm of Lubriplate. All information subject to change without notice. (Rev. 2005) 1-551 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 614 6. Install the three guide studs (J–35642–2, part of tool set J–35642) to the threaded holes in the crankshaft timing gear. Tighten the three legs, but do not torque. See Figure 1-492. Figure 1-492 Puller and Leg Installation (Rev. 2005) All information subject to change without notice. 1-552 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 615 7. Install J–35642–4 (part of tool set J–35642) to the three pulley legs. Seat the pressure plate against the ﬂanges on the puller legs. See Figure 1-493. Figure 1-493 Pressure Plate Installation All information subject to change without notice. (Rev. 2005) 1-553 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 616 9. Install J–35951–175 to the base post rod. See Figure 1-494. 10. Install J–35642–3 (part of tool set J–35642) to the end of the base post threaded rod. Tighten the stop nut. (Rev. 2005) All information subject to change without notice. 1-554 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 617 A minimum force of 30 kN (3.37 tons) must be obtained when pressing the gear on the crankshaft. Figure 1-495 Crankshaft Timing Gear Installation All information subject to change without notice. (Rev. 2005) 1-555 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 618 20. Install any components that were removed for access to the gear case cover. 21. Refer to section 12.3 for veriﬁcation of proper crankshaft timing gear and timing wheel installation. (Rev. 2005) All information subject to change without notice. 1-556 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 619: Accessory Drive
5. Ball Bearing 6. Snap Ring (Large) 13. Oil Seal 7. Drive Shaft 14. Pulley Figure 1-496 Accessory Drive Assembly Related Parts (Former Design) All information subject to change without notice. (Rev. 2005) 1-557 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 620 5. Ball Bearing 12. Oil Seal 6. Snap Ring (Large) 13. Pulley 7. Drive Shaft Figure 1-497 Accessory Drive Assembly Related Parts (Current Design) (Rev. 2005) All information subject to change without notice. 1-558 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 621 See Figure 1-496, and see Figure 1-497. An O-ring is used to seal the accessory drive housing to the gear case cover. All information subject to change without notice. (Rev. 2005) 1-559 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 622 To determine if repair is possible or replacement is necessary, perform the following procedures. See Figure 1-498. Figure 1-498 Flowchart for Repair or Replacement of Accessory Drive (Rev. 2005) All information subject to change without notice. 1-560 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 623 3. Remove the accessory drive assembly by pulling it straight out of the gear case cover to avoid damaging the rubber O-ring. See Figure 1-499. Figure 1-499 Accessory Drive Assembly Removal All information subject to change without notice. (Rev. 2005) 1-561 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 624 The seal, pulley and pulley nut are the only serviceable parts of the accessory drive assemblies with unitized oil seal. Figure 1-500 Accessory Drive Service Tool Set (J–36024–C) (Rev. 2005) All information subject to change without notice. 1-562 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 625 2. Place the accessory drive assembly holding ﬁxture into a vise. See Figure 1-502. Figure 1-502 Accessory Drive Pulley Locknut Removal 3. Remove the accessory drive pulley locknut. See Figure 1-502. All information subject to change without notice. (Rev. 2005) 1-563 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 626 [b] Place inside jaws of tool over sleeve. See Figure 1-503. [c] Finger tighten hex bolt on side of tool. [d] Remove sleeve by tightening puller bolt. (Rev. 2005) All information subject to change without notice. 1-564 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 627 [d] Finger tighten hex bolt on side of tool. [e] Remove seal by tightening puller bolt. 7. Clean accessory drive housing at seal location. All information subject to change without notice. (Rev. 2005) 1-565 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 628: Support Plate
(J–36024–3, part of toolset J–36024–C) and press the drive shaft out of the gear. See Figure 1-505. 10. Remove the snap ring from the accessory drive housing. See Figure 1-506. Figure 1-506 Snap Ring Removal (Rev. 2005) All information subject to change without notice. 1-566 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 629 14. Install J–36024–9 (part of toolset J–36024–C) and apply pressure to remove the needle bearing. See Figure 1-507. Figure 1-507 Needle Bearing Removal All information subject to change without notice. (Rev. 2005) 1-567 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 630 Bearing Inner Race Removal 16. Remove the snap ring from the accessory drive shaft. See Figure 1-509. Figure 1-509 Snap Ring Removal (Rev. 2005) All information subject to change without notice. 1-568 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 631 18. Use a press to apply pressure to the top of the shaft and remove the ball bearing from the shaft. All information subject to change without notice. (Rev. 2005) 1-569 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 632 If any damage is detected, replace with a new part. If no damage is found, reuse the part. 1.35.4 Assembly of the Accessory Drive Assemble the accessory drive as follows: (Rev. 2005) All information subject to change without notice. 1-570 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 633: Bearing Installation
J–36024–8 (part of toolset J–36024–C) and a press to install the bearing onto the shaft until it bottoms out against the shoulder of the drive shaft. See Figure 1-511. Figure 1-511 Bearing Installation All information subject to change without notice. (Rev. 2005) 1-571 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 634 2. Install the snap ring to the accessory drive shaft making sure it is fully seated in the groove a full 360 degrees See Figure 1-512. Figure 1-512 Snap Ring Installation (Rev. 2005) All information subject to change without notice. 1-572 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 635 On current design accessory drive shaft, the needle bearing inner race is incorporated into the shaft. Figure 1-513 Needle Bearing Inner Race Installation All information subject to change without notice. (Rev. 2005) 1-573 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 636 NOTE: The word INSTALL and an arrow are etched into the tool, J–36024–9 (part of toolset J–36024–C), to facilitate correct bearing installation. (Rev. 2005) All information subject to change without notice. 1-574 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 637 8. Support the holding ﬁxture (J–36024–3, part of toolset J–36024–C) on two steel plates and position the accessory drive housing into the hole in the ﬁxture. See Figure 1-506. All information subject to change without notice. (Rev. 2005) 1-575 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 638: Drive Shaft Assembly
Drive Shaft Installation 10. Press the drive shaft into the housing by placing tool J–36024–8 (part of toolset J–36024–C) on the bearing outer race. (Rev. 2005) All information subject to change without notice. 1-576 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 639 11. Press the bearing into the housing until the bearing is seated against the shoulder of the housing. See Figure 1-517. Figure 1-517 Bearing Installation All information subject to change without notice. (Rev. 2005) 1-577 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 640 14. A ﬁlm of Lubriplate® must be applied to the drive gear end of the accessory drive shaft. See Figure 1-519. Figure 1-519 Drive Gear Installation Preparation (Rev. 2005) All information subject to change without notice. 1-578 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 641 For accessory drive assemblies with unitized seals, effective with engines built after December 2000 perform the procedures in steps 16 and 17. All information subject to change without notice. (Rev. 2005) 1-579 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 642 16. Install seal using tool J–45833 by tightening installer nut until a positive stop is obtained. See Figure 1-521. 1. Vise Figure 1-521 (J–45833) Accessory Drive Seal Installer (Rev. 2005) All information subject to change without notice. 1-580 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 643 19. Attach J–36024–3 (part of toolset J–36024–C) to the drive gear. See Figure 1-500. 20. Place the accessory drive assembly holding ﬁxture into a vise. See Figure 1-523. All information subject to change without notice. (Rev. 2005) 1-581 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 644 Figure 1-523 Accessory Drive Pulley Locknut Tightening 22. Support the accessory drive assembly. See Figure 1-524. Figure 1-524 Accessory Drive Gear TIR Measurement (Rev. 2005) All information subject to change without notice. 1-582 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 645 26. The total amount the dial indicator needle moves to the left and right of zero, added together, gives the total indicated run-out (TIR). The speciﬁed TIR is 0.04 mm (0.0015 in.). All information subject to change without notice. (Rev. 2005) 1-583 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 646 7. Tighten the alternator mounting bolts. 8. Install any other components removed for this procedure. 9. Refer to section 12.3 for veriﬁcation of proper accessory drive installation. (Rev. 2005) All information subject to change without notice. 1-584 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 647: Jake Brake
0.660 mm (0.026 in.) 6067GU40 1991 12.7L 0.660 mm (0.026 in.) 6067GU28 1991 12.7L 0.660 mm (0.026 in.) 6067GU91 1991 12.7L 0.660 mm (0.026 in.) All information subject to change without notice. (Rev. 2005) 1-585 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 648 All slave piston adjustments shown here are current as of the date of this manual and supersede all previous adjustments. XXXX = Model numbers to be determined. Table 1-9 Jake Brake Model Information (Rev. 2005) All information subject to change without notice. 1-586 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 649 Former Jake Brake production models for the Series 60 engine were the 760A (which replaced model 760), 760B, 765, 765A, 770 and 790. Detroit Diesel engine model Nos. 6067GU28 and 6067GK28 are for bus/coach applications. Due to interference ﬁts on some coach chassis, a two-housing Jake Brake kit may be required. Contact your Detroit Diesel Distributor for information on these kits.
Page 650 The ball check valve in the control valve traps high-pressure oil in the master-slave piston system. (Rev. 2005) All information subject to change without notice. 1-588 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 651 The Jake Brake is electronically controlled. Jake Brake control system wiring will vary depending on the vehicle manufacturer. For a general overview of the Jake Brake, see Figure 1-528 and see Figure 1-529. All information subject to change without notice. (Rev. 2005) 1-589 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 652 13. Seal Rings 20. Return Spring 7. Collar 14. Accumulator Piston 21. Screw Figure 1-528 Typical Model 760, 765, or 770 Jake Brake Assembly (Rev. 2005) All information subject to change without notice. 1-590 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 653 This application and adjustment information must be strictly followed. Failure to follow these instructions may result in serious engine or engine brake damage. All information subject to change without notice. (Rev. 2005) 1-591 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 654 To determine if repair is possible or replacement is necessary, perform the following procedure. See Figure 1-530. Figure 1-530 Jake Brake® Repair or Replacement Flowchart (Rev. 2005) All information subject to change without notice. 1-592 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 655 3. Note the location of the rocker arm shaft, the exhaust valve rocker arm, the fuel injector rocker arm, and the intake valve rocker arm. All information subject to change without notice. (Rev. 2005) 1-593 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 656 (4.72 in.) long, are used on the exhaust side of the engine. Three bolts, 110 mm (4.33 in.) long, are used on the intake side of the engine. These bolts must be reinstalled in their correct positions. (Rev. 2005) All information subject to change without notice. 1-594 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 657 3. Snap Ring Retainer 2. Spring 4. Snap Ring Pliers Figure 1-532 Relieving Spring Pressure 2. Using retaining ring pliers, remove retaining ring. All information subject to change without notice. (Rev. 2005) 1-595 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 658 4. Using needle-nose pliers, reach into the bore and grasp the stem of the control valve. Remove control valve. Remove the slave piston adjusting screw as follows: 1. Loosen slave piston adjusting screw locknut. (Rev. 2005) All information subject to change without notice. 1-596 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 659 2. Using a 7/8 in. socket and extension for former solenoids or a 3/4 in. 6 point socket and extension for current solenoids, unscrew solenoid valve. All information subject to change without notice. (Rev. 2005) 1-597 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 660 4. If the lower ring stays in the bottom of the housing bore, remove with a piece of wire. Remove the accumulator as follows: (Rev. 2005) All information subject to change without notice. 1-598 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 661 3. Retaining Ring Pliers 2. Retaining Ring Figure 1-536 Removing Retaining Ring 2. Relieve pressure on the accumulator cover. 3. Remove the cover and spring. All information subject to change without notice. (Rev. 2005) 1-599 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 662 Removing Piston from Accumulator Bore with Magnet Remove the master piston as follows: 1. Remove the screw, washer, and master piston spring from the housing. (Rev. 2005) All information subject to change without notice. 1-600 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 663 2. Remove the ball check valve and spring. Remove the slave piston as follows: 1. Remove the screw and washer that retains the slave piston return spring. All information subject to change without notice. (Rev. 2005) 1-601 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 664 The injector rocker arm contains a pin and roller for actuating the engine brake master piston. If excessive wear or damage to the roller is present, replace the rocker arm assembly. Refer to section 1.6.2. (Rev. 2005) All information subject to change without notice. 1-602 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 665 Use the following procedures to keep the engine brake in top condition. Inspect the Jake Brake as follows: All information subject to change without notice. (Rev. 2005) 1-603 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 666 [b] If not worn or damaged, proceed with inspection. 7. Inspect slave piston components for excessive wear or damage. [a] If worn or damaged, replace slave piston component. (Rev. 2005) All information subject to change without notice. 1-604 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 667: Installing The Control Valve
2. Control Valve 6. Collar Spring 3. Collar 7. Control Valve Spring 4. Snap Ring Retainer Figure 1-541 Installing the Control Valve All information subject to change without notice. (Rev. 2005) 1-605 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 668 1. Coat new solenoid valve seal rings with clean lube oil. NOTE: Use current upper seals when installing current solenoids. New seals are identiﬁed with yellow stripes. (Rev. 2005) All information subject to change without notice. 1-606 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 669 3. Push down the accumulator cover, and insert retaining ring. Install the master piston as follows: 1. Apply clean lube oil to the piston. All information subject to change without notice. (Rev. 2005) 1-607 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 670 Make sure spring legs are centered around master piston boss. 4. Torque screw to 10 N·m (7.4 lb·ft). On model 760 only, install the ball check valve as follows: (Rev. 2005) All information subject to change without notice. 1-608 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 671 Install the slave piston as follows: 1. Install the screw from the slave piston side of the bridge. 2. Install the leveling screw locknut. All information subject to change without notice. (Rev. 2005) 1-609 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 672 Figure 1-547 Installing the Slave Piston Assembly Torsion Spring 5. Install the screw and washer over the center part of the spring. (Rev. 2005) All information subject to change without notice. 1-610 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 673 3. Cover the holes with hand towels to minimize oil spray. NOTE: Removing the oil from the bolt holes prevents the cylinder head from cracking when tightening the bolts. All information subject to change without notice. (Rev. 2005) 1-611 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 674 5. Place the three engine brake housings over the rocker shafts with the solenoid valves toward the camshaft side of the engine. NOTE: Be sure housings do not interfere with wiring harness. (Rev. 2005) All information subject to change without notice. 1-612 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 675 [c] Jake Brake model 760 requires two bolts along with one bolt and new washers. NOTE: Be sure that only Jake Brake bolts, see Figure 1-550, are installed in the Jake Brake housing. All information subject to change without notice. (Rev. 2005) 1-613 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 676 (two per housing). See Figure 1-551. 1. Washer 2. Long Bolt Figure 1-551 Installation of Jake Brake Housing Bolts on Exhaust Manifold Side (Rev. 2005) All information subject to change without notice. 1-614 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 677 9. On models 760A, 760B, 765, and 765A, install a washer on each bolt, and install into housings (three bolts per housing). All information subject to change without notice. (Rev. 2005) 1-615 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 678 [a] Verify tie strap is properly seated on the spacer bar. See Figure 1-554 [b] Verify tie strap is tight on spacer bar and does not move. (Rev. 2005) All information subject to change without notice. 1-616 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 679 Injector Harness Tie Strap Location 14. Connect wiring harness solenoid connectors to solenoids. See Figure 1-555 Figure 1-555 Jake Brake Wire Terminal Connection Identiﬁcation All information subject to change without notice. (Rev. 2005) 1-617 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 680 1. Refer to section 1.36 for proper slave piston clearance setting. (Rev. 2005) All information subject to change without notice. 1-618 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 681 4. On models 760, 760A, 760B, 765, and 765A, turn the slave piston adjusting screw clockwise until a slight drag is felt on the feeler gage. See Figure 1-557. All information subject to change without notice. (Rev. 2005) 1-619 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 682 If unsure of the adjustment, repeat the J-Lash adjustment procedure. 6. On all models, hold the screw in position, and torque the locknut to 34 N·m (25 lb·ft). (Rev. 2005) All information subject to change without notice. 1-620 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 683 15. Connect starting power for the engine. 16. Verify proper Jake Brake installation by driving the vehicle, then checking engine brake performance. All information subject to change without notice. (Rev. 2005) 1-621 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 684 2. Note the location of the rocker arm shaft, the exhaust valve rocker arm, the fuel injector rocker arm, and the intake valve rocker arm. (Rev. 2005) All information subject to change without notice. 1-622 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 685 *Note that Model 790 Jake Brake uses a J-Lash assembly. Model 795 Jake Brake uses a solid screw. Figure 1-559 Typical Model 790/795 Jake Brake Assembly All information subject to change without notice. (Rev. 2005) 1-623 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 686 Disassemble Model 790/795 Jake Brake as follows: NOTICE: To avoid possible engine damage, do not disassemble or tamper with the solenoid valve. (Rev. 2005) All information subject to change without notice. 1-624 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 687 *Note that Model 790 Jake Brake uses a J-Lash assembly. Model 795 Jake Brake uses a solid screw. Figure 1-561 Typical Model 790/795 Jake Brake Assembly 2. Repeat step1 for removal of the remaining solenoid valves. All information subject to change without notice. (Rev. 2005) 1-625 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 688 1.36.6.2 Cleaning of Model 790/795 Jake Brake Clean the Jake Brake as follows: 1. Clean all parts in an OSHA-approved cleaning solvent. (Rev. 2005) All information subject to change without notice. 1-626 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 689 4. Inspect slave piston components for excessive wear or damage. [a] If worn or damaged, replace slave piston component. [b] If not worn or damaged, proceed with inspection. All information subject to change without notice. (Rev. 2005) 1-627 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 690 The burr on the slave piston bore will not affect the performance of the brake. It only affects the ability to reset the lash. (Rev. 2005) All information subject to change without notice. 1-628 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 691 1.36.7 Assembly of Model 790/795 Jake Brake Assemble Model 790/795 Jake Brake as follows: All information subject to change without notice. (Rev. 2005) 1-629 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 692 3. Install new springs and shoulder bolt. Torque bolts to 23 N·m (17 lb·ft). See Figure 1-563. 4. Repeat step1 through step 3 for installing the remaining slave pistons. (Rev. 2005) All information subject to change without notice. 1-630 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 693 [j] Reassemble the slave piston of the brake with step1 through step 3. [k] Adjust slave piston lash, refer to section 1.36.8.1. All information subject to change without notice. (Rev. 2005) 1-631 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 694 Rotate the retaining ring 90 degrees to ensure that the retaining ring is seated in the groove. 18. Repeat step14 through step 17 for installing the remaining control valves. (Rev. 2005) All information subject to change without notice. 1-632 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 695 Torque to 20 N·m (15 lb·ft). See Figure 1-563. 23. Repeat step19 through step 22 for installing the remaining solenoid valves. All information subject to change without notice. (Rev. 2005) 1-633 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 696 3. Lubricate each hold-down capscrew with clean engine oil. (Rev. 2005) All information subject to change without notice. 1-634 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 697 8. Connect the lead wires to the solenoid valves passing the wires through the wire clips. 9. Torque solenoid screw to 1 N·m (9 lb·in.). NOTE: Pull the lead wires away from the housing. All information subject to change without notice. (Rev. 2005) 1-635 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 698 (below 16 °C [61°F]), wait at least two minutes for oil to be purged from the J-Lash adjusting screw. (Rev. 2005) All information subject to change without notice. 1-636 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 699 J-Lash adjusting screws. This is because of oil retained in the J-Lash adjusting screw. If unsure of the adjustment, repeat step1 and step 4. All information subject to change without notice. (Rev. 2005) 1-637 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 700 9. Complete the installation by installing the rocker cover. Refer to section 1.6. 10. Start and drive the vehicle to verify proper Jake Brake performance. (Rev. 2005) All information subject to change without notice. 1-638 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 701: Aadditional Information
Pre-1991 Engines ................... 1-664 SPECIFICATIONS ..................... 1-671 Speciﬁcations, New Clearances, and Wear Limits ......... 1-671 Exceptions to Standard Fastener Torque Speciﬁcations ........ 1-684 All information subject to change without notice. (Rev. 2005) 1-639 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 702: Shop Notes
2. Place a piece of plastic strip the full width of the bearing shell, about 1/4 inch off center. See Figure 1-568. Figure 1-568 Using Plastic Strip to Measure Bearing-to-Crankshaft Clearance (Rev. 2005) All information subject to change without notice. 1-640 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 703 ﬂattened plastic strip is wider than the other. [b] Measure each end of the plastic strip. The difference between the two readings is the approximate amount of taper. All information subject to change without notice. (Rev. 2005) 1-641 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 704: Crankshaft Remanufacturing Procedures
2. Inspect connecting rod and main bearing journals for discoloration due to excessive overheating from bearing failure. NOTE: Crankshafts with discoloration are not acceptable for rework. (Rev. 2005) All information subject to change without notice. 1-642 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 705 3. Inspect keyway conditions using width gages and micrometers. Compare with the speciﬁcations. See Figure 1-569. Figure 1-569 Standard Crankshaft Keyway Dimensions All information subject to change without notice. (Rev. 2005) 1-643 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 706 8. When high spots of run-out adjacent journals are at right angles to each other, the sum shall not exceed 0.10 mm (0.004 in.) TIR or 0.05 mm (0.002 in.) on each journal. (Rev. 2005) All information subject to change without notice. 1-644 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 707 Table 1-13 Crankshaft Speciﬁcations 10. Visually inspect the entire crankshaft for any serious deviations from normal wear patterns, cracks, nicks or other damage. All information subject to change without notice. (Rev. 2005) 1-645 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 708 ﬁllets, thrust, and all widths to determine whether or not enough stock remains to warrant regrinding. See Figure 1-570 for location of crankshaft dimensions. Listed in Table 1-14 are crankshaft remanufacturing tolerances. (Rev. 2005) All information subject to change without notice. 1-646 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 709 Crankshaft - Convex – 0.013 mm (0.0005 in.) 0.043 mm (0.0017 in.) Butt Face Concave – 0.03 mm (0.0011 in.) 0.043 mm (0.0017 in.) All information subject to change without notice. (Rev. 2005) 1-647 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 710 17. Inspect the hardness of all journals. Crankshafts to be 47-55 Rc. (Rev. 2005) All information subject to change without notice. 1-648 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 711 19. After a visual inspection, the crankshaft should be magnetically inspected using one of the two following methods: [a] Magnetic Particle Method: Refer to section 1.7.2.6. [b] Fluorescent Magnetic Particle Method: Refer to section 1.7.2.8. All information subject to change without notice. (Rev. 2005) 1-649 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 712: Machining Operations
5. No journal may have any sharp grind marks. The ﬁllet must blend smoothly into the journal and the crank cheek and must be free of scratches. (Rev. 2005) All information subject to change without notice. 1-650 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 713: Grinding Connection Rod Journals (Pins)
5. If there are deep interruptions, gouges or nicks that do not extend into ﬁllets, smooth the edges with 120 grit emery cloth. Grinding Main Bearing Journals Perform the following steps for grinding main bearing journals: All information subject to change without notice. (Rev. 2005) 1-651 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 714: Other Machining Operations
[c] If wear is 0.0508 mm (0.002 in.) or more, regrind to restore ﬂatness to the thrust wall. See Figure 1-573. Figure 1-573 No. 6 Main Journal Thrust Wall Dimensions (Rev. 2005) All information subject to change without notice. 1-652 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 715 Avoid localized heating, which often produces grinding cracks. Cool the crankshaft generously with coolant while grinding. Do not crowd the grinding wheel into the work. All information subject to change without notice. (Rev. 2005) 1-653 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 716 Oil Hole Speciﬁcations - Connecting Rod Journals - 11.1 L Crankshaft (139 mm stroke) Figure 1-575 Oil Hole Speciﬁcations - Connecting Rod Journals - 12.7 L Crankshaft (160 mm stroke) (Rev. 2005) All information subject to change without notice. 1-654 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 717 SERIES 60 SERVICE MANUAL Figure 1-576 Connecting Rod Journal Oil Hole Chamfer Limits All information subject to change without notice. (Rev. 2005) 1-655 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 718 The crankshaft face must be 0.013 mm (0.0005 in.) convex to 0.025 mm (0.001 in.) concave. (Rev. 2005) All information subject to change without notice. 1-656 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 719: After-Grinding Inspection
(face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. 5. Dry the crankshaft with compressed air. All information subject to change without notice. (Rev. 2005) 1-657 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 720: Glossary
Chatter might be the result of vibration or deﬂection of a cutting tool, of some part of the machine, or the work itself. (Rev. 2005) All information subject to change without notice. 1-658 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 721: Engine Plug And Dowel Charts
See Figure 1-578; see Figure 1-579; see Figure 1-580; see Figure 1-581; see Figure 1-582; and see Figure 1-583 for plug and dowel information supporting 1991 model year and later Series 60 Engines. All information subject to change without notice. (Rev. 2005) 1-659 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 722: Right Side View
Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite® 620 (or equivalent) before installing. Figure 1-578 Right Side View (Rev. 2005) All information subject to change without notice. 1-660 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 723: Left Side View
Required only for pressure testing of cylinder block. In service, these plugs are replaced by the oil pressure sensor (OPS), refer to section 2.25.1, and the oil temperature sensor (OTS), refer to section 2.26.1. Figure 1-579 Left Side View All information subject to change without notice. (Rev. 2005) 1-661 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 724 Figure 1-580 Cylinder Head Deck Figure 1-581 Front View (Rev. 2005) All information subject to change without notice. 1-662 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 725: Rear View
Figure 1-582 No. 6 Main Bearing Cap 1.8929022 Dowel (Diamond-2 Places) 3.8929015 Dowel (Round) 2.5139988 Cup Plug (2 Places) Figure 1-583 Rear View All information subject to change without notice. (Rev. 2005) 1-663 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 726: Pre-1991 Engines
Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite® 620 (or equivalent) before installing. Figure 1-584 Right Side View (Rev. 2005) All information subject to change without notice. 1-664 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 727 † Use tool(J–36224–1) to install. ‡ Use tool (J–36224–2) to install. § Refer to illustration for orientation of dowels. Figure 1-585 Left Side View All information subject to change without notice. (Rev. 2005) 1-665 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 728 1. 8929022 Dowel (Diamond-2 Places) 3. 5139988 Cup Plug (2 Places) 2. 8920062 Dowel Pin 4. Bull Gear Pilot Bore Figure 1-587 Front View (Rev. 2005) All information subject to change without notice. 1-666 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 729 No. 6 Main Bearing Cap 1. 8929022 Dowel (Diamond-2 Places) 3. 8929015 Dowel (Round) 2. 5139988 Cup Plug (2 Places) Figure 1-589 Rear View All information subject to change without notice. (Rev. 2005) 1-667 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 730 6. 5143033 Dowel (Diamond) (3 places). Install to a height of 6.1 mm ± 0.5 mm (0.240 in. ± 0.010 in.) Figure 1-590 Cylinder Head Dowel Chart (Rev. 2005) All information subject to change without notice. 1-668 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 731 † Use tool set (J–35653) to install the cup plugs. Coat the outside sealing edge of the cup plugs with a good grade of non-hardening sealant such as Loctite® 620 (or equivalent) before installing. Figure 1-591 Cylinder Head Cup, Pipe Plug, and Dowel Chart All information subject to change without notice. (Rev. 2005) 1-669 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 732 Figure 1-592 Gear Case Dowel Chart (Rev. 2005) All information subject to change without notice. 1-670 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 733: Specifications
Table 1-34 Exhaust valve (diesel) seat insert listed in Table 1-35 Exhaust valve (natural gas) seat insert listed in Table 1-36 All information subject to change without notice. (Rev. 2005) 1-671 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 734 Series 60 Gas valve lash and camshaft timing listed in Table 1-51 speciﬁcations Table 1-15 Engine Component Reference Table (Rev. 2005) All information subject to change without notice. 1-672 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 735 * The bottom of the counterbore must not vary in depth more than 0.04 mm (0.0016 in.). No two adjacent counterbores can vary in depth more than 0.025 mm (0.001 in.) when gaged longitudinally. Table 1-16 Cylinder Block All information subject to change without notice. (Rev. 2005) 1-673 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 736 0.0762 mm (0.003 in.) – Block Variation in Height between – – 0.0508 mm (0.002 in.) Adjacent Liners Table 1-17 Cylinder Liner (Rev. 2005) All information subject to change without notice. 1-674 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 737 – faces) (0.0020 in.) * Both ends must be measured on vertical and horizontal planes. Table 1-18 Cross-head Piston and Piston Rings All information subject to change without notice. (Rev. 2005) 1-675 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 738 Steel Piston Pin Diameter 54.992 mm (2.1650 in.) 55.000 mm (2.1653 in.) 54.96 mm (2.1638 in.) Table 1-21 Articulated Steel Piston Pin (Rev. 2005) All information subject to change without notice. 1-676 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 739 0.076 mm (0.003 in.) total indicator reading. When the run-out on adjacent journals is in the same direction, the difference must not exceed 0.076 (0.003 in.) total indicator reading. Table 1-22 Crankshaft All information subject to change without notice. (Rev. 2005) 1-677 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 740 0.191 mm (0.0075 in.) Clearance Bearing Thickness (90 1.941 mm (0.0764 in.) 1.954 mm (0.0769 in.) – degrees from Parting Line) Table 1-27 Camshaft Bearing (Rev. 2005) All information subject to change without notice. 1-678 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 741 Accessory, Fuel Pump 0.051 mm (0.002 in.) 0.305 mm (0.012 in.) (0.009 in.) or Air Compressor Drive Gears) Table 1-31 Bull Gear All information subject to change without notice. (Rev. 2005) 1-679 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 742 (0.002 in.) 6.858 mm Standard Seat Thickness 6.756 mm (0.266 in.) – (0.133 in.) Table 1-34 Intake Valve Seat Inserts (Natural Gas) (Rev. 2005) All information subject to change without notice. 1-680 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 743 (0.3435 in.) Valve Head-to-Cylinder Head 30 degrees 0.80 mm 1.47 mm – (recess) (0.031 in.) (0.058 in.) Table 1-38 Intake Valves (Natural Gas) All information subject to change without notice. (Rev. 2005) 1-681 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 744 Clearance (valve-to- – – 0.152 mm guide, maximum) (0.006 in.) Exhaust Valve P/N 23524521 0.101 mm (0.004 in.) Table 1-41 Valve Guides (Diesel) (Rev. 2005) All information subject to change without notice. 1-682 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 745 0.08 mm – – (maximum) (horizontal) (0.003 in.) Side Clearance 0.40 mm (roller-to-follower) – – (0.015 in.) (maximum) Table 1-45 Cam Follower Roller All information subject to change without notice. (Rev. 2005) 1-683 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 746 Refer to section 1.24 Nut, Adjustable Idler Assy. M12 X 1.75 57-67 (42-49) Table 1-46 Exceptions to Standard Fastener Torque Speciﬁcations (1 of 2) (Rev. 2005) All information subject to change without notice. 1-684 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 747 Refer to section Bolt, Injector Hold-Down Clamp — 58-66 (43-49) 2.3.5 Table 1-47 Exceptions to Standard Fastener Torque Speciﬁcations (2 of 2) All information subject to change without notice. (Rev. 2005) 1-685 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 748 *GU40 is equipped with a Model 760A Jake Brake. Use 760A lash speciﬁcations when servicing. Table 1-48 Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Speciﬁcations (1 of 3) (Rev. 2005) All information subject to change without notice. 1-686 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 749 **MK and BK models with 0712 Valve Mechanism are equipped with a model 770 Jake Brake. Use 770 lash speciﬁcations when servicing. Table 1-49 Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Speciﬁcations ( 2 of 3) All information subject to change without notice. (Rev. 2005) 1-687 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 750 0.299 in.) Table 1-50 Series 60 Diesel Valve Lash, Jake Brake Lash and Camshaft Timing Speciﬁcations (3 of 3) (Rev. 2005) All information subject to change without notice. 1-688 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 751 23524909 / 910 (0.011 in) 2.87 mm (0.036 (0.086- in.) 0.113 in.) Table 1-51 Series 60 Gas Valve Lash and Camshaft Timing Speciﬁcations All information subject to change without notice. (Rev. 2005) 1-689 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 752 (Rev. 2005) All information subject to change without notice. 1-690 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 753: Fuel System
FUEL SYSTEM Section Page DIESEL FUEL SYSTEM OVERVIEW ............VEHICLE SAFETY FOR THE NATURAL GAS ENGINE ......N2 ELECTRONIC UNIT INJECTOR ............2-11 N2 FUEL INJECTOR TUBE AND O-RING ..........2-28 N3 ELECTRONIC UNIT INJECTOR ............2-42 N3 FUEL INJECTOR TUBE ..............2-55 FUEL PUMP WITH SEPARATE DRIVE SHAFT AND HUB .....
Page 754 HIGH PRESSURE FUEL REGULATOR FOR THE SERIES 60G ENGINE ....................2-229 2.44 PULSE WIDTH MODULATED STEPPER MOTOR VALVE (PSV) FOR SERIES 60G AUTOMOTIVE ENGINES ..........2-231 (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 755 FUEL MIXER FOR THE SERIES 60G LOW PRESSURE SYSTEM ..2-252 2.51 VENTING AND LEAK CHECKING PROCEDURES FOR NATURAL GAS ENGINE (LOW PRESSURE SYSTEM) ..........2-255 ADDITIONAL INFORMATION ..............2-257 All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 756 (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 757: Diesel Fuel System Overview
3. Effective with unit 6R13060, a fuel system check valve is installed in the secondary fuel ﬁlter head to prevent fuel drainback when ﬁlters are changed. Figure 2-1 Schematic Diagram of the Diesel Fuel System All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 758 ﬁlter to prevent fuel drainback when ﬁlters are changed. NOTE: Effective with 6R56762, a manually operated fuel shutoff valve has replaced the former valve. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 759: Vehicle Safety For The Natural Gas Engine
LPG. Check with your gas company or contractor to be certain, but you shouldn't have to augment your existing air-handling system to service NGVs. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 760: Safety Standards
100 degrees beyond that. Cylinders must also pass a pressure test that subjects them to 18,000 cycles of pressurization and depressurization. (Rev. 2005) All information subject to change without notice. 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 761: Safety Training
To do their jobs safely, your technicians and drivers need to know what the differences are and how to work with them. All information subject to change without notice. (Rev. 2005) 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 762 Home dispensers normally use the "timed ﬁll" principle so a vehicle can be fueled overnight. (Rev. 2005) All information subject to change without notice. 2-10 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 763: N2 Electronic Unit Injector
□ Meters and injects the exact amount of fuel required to handle the load. □ Atomizes the fuel for mixing with the air in the combustion chamber. □ Permits continuous fuel ﬂow for component cooling. All information subject to change without notice. (Rev. 2005) 2-11 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 764 Effective with September, 1988 production, Series 60 engine EUI nuts incorporate one upper seal ring groove and seal ring, instead of two. See Figure 2-4. (Rev. 2005) All information subject to change without notice. 2-12 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 765 When the pressure is low enough the needle valve closes and ends injection. All information subject to change without notice. (Rev. 2005) 2-13 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 766 To determine if repair is possible or replacement is necessary perform the following procedure. See Figure 2-5. Figure 2-5 Flowchart for Repair or Replacement of N2 Electronic Unit Injector (Rev. 2005) All information subject to change without notice. 2-14 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 767 Loosening the fuel line at the inlet ﬁtting will allow fuel to ﬂow faster. Carefully collect the drained fuel in an appropriate container. All information subject to change without notice. (Rev. 2005) 2-15 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 768 Extreme care should be used when handling an EUI to avoid costly damage by dropping or otherwise mishandling the EUI. NOTE: When replacing an EUI, always replace the injector O-rings. (Rev. 2005) All information subject to change without notice. 2-16 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 769 4. Cover the injector hole in the cylinder head to keep out foreign material. Remove carbon from the injector exterior in the area where the tip joins the nut, using wire bufﬁng wheel (J–7944). All information subject to change without notice. (Rev. 2005) 2-17 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 770 3. Inspect the O-rings for damage or foreign material. Replace O-rings. 4. Inspect the fuel injector tubes at the injector seat. If required, replace the fuel injector tubes. (Rev. 2005) All information subject to change without notice. 2-18 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 771 1. Spacer Seals 4. Screw 2. Solenoid 5. Follower Retainer 3. Load Plate 6. Spacer Figure 2-8 Electronic Unit Injector Solenoid Assembly All information subject to change without notice. (Rev. 2005) 2-19 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 772 9. Install new screws through the load plate and follower retainer, solenoid, and spacer. (Rev. 2005) All information subject to change without notice. 2-20 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 773 12. On DDEC II injectors only, etch the last four digits of injector part number on the load plate. See Figure 2-9. All information subject to change without notice. (Rev. 2005) 2-21 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 774 If the engine is equipped with an auxiliary injector tube seal, replace it with a new seal when the injector is removed. (Rev. 2005) All information subject to change without notice. 2-22 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 775 O-ring seals must be replaced with new seals. Failure to replace seals can result in seal leakage. 4. Detroit Diesel encourages the use of an additional service seal (5104701) that is impervious to both coolant and fuel. This seal should be used in situations where injector tube seal leakage or deterioration is suspected or conﬁrmed.
Page 776 3. Injector Tube O-ring 7. Hold-down Clamp Washer 4. Injector Tube 8. Hold-down Clamp Bolt Figure 2-10 N2 Electronic Unit Injector and Related Parts (Rev. 2005) All information subject to change without notice. 2-24 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 777 11. Torque the hold-down bolt to 55-66 N·m (43-49 lb·ft). Figure 2-11 Hold-down Clamp Washer Installation All information subject to change without notice. (Rev. 2005) 2-25 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 778 Torque the terminal screws to 1.08–1.13 N·m (9.5–10.0 lb·in.). Do not bend the terminals down after installation. See Figure 2-12. Figure 2-12 N2 Electronic Unit Injector Terminal Installation (Rev. 2005) All information subject to change without notice. 2-26 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 779 18. For one-piece valve rocker cover, refer to section 1.6.8. For two-piece and three-piece valve rocker cover, refer to section 1.6.9. 19. Verify repair of electronic unit injector. Refer to section 12.7. All information subject to change without notice. (Rev. 2005) 2-27 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 780: N2 Fuel Injector Tube And O-Ring
2. Place J–33880–4 (part of tool set J–33880), in the injector tube. Insert J–5286–5 (part of tool set J–33880), through the small opening of the injector tube and (Rev. 2005) All information subject to change without notice. 2-28 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 781 2.4.3 N2 Injector Tube Crevice Volume Removal Tool Detroit Diesel has made a machining improvement on the Series 60 cylinder head injector tube bore. This machining improvement removes cast iron material from the head at the crevice area, located just above the injector tube to cylinder head sealing land. See Figure 2-15...
Page 782 90 degrees. Replacement bits (J–45723–1, part of tool set J–45723) are available. 6. Thoroughly ﬂush metal shavings from injector tube bores. (Rev. 2005) All information subject to change without notice. 2-30 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 783 Do not use a metal dowel to install the auxiliary injector seal, as this may damage the seal. 1. Place the auxiliary seal in the injector hole. All information subject to change without notice. (Rev. 2005) 2-31 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 784 2. Seat it against the top of the injector tube with a 1-5/8 in. diameter wood or plastic dowel. See Figure 2-17. Figure 2-17 Auxiliary Injector Seal Location (Rev. 2005) All information subject to change without notice. 2-32 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 785 Ensure the tip of the injector tube goes through the small hole in the ﬁre deck. Tap lightly on the end of the tool, if necessary, to seat the tube. All information subject to change without notice. (Rev. 2005) 2-33 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 786 J–5286–6 (part of tool set J–33880) into J–33880–4 (part of tool set J–33880) until it begins to ﬂare the tube. See Figure 2-20. Figure 2-20 Flaring Injector Tube Tip (Rev. 2005) All information subject to change without notice. 2-34 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 787 See Figure 2-22. 11. Install J–33880–10 (part of tool set J–33880), into the seat reamer pilot until it bottoms. See Figure 2-22. All information subject to change without notice. (Rev. 2005) 2-35 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 788 14. Remove J–33880–5 (part of tool set J–33880) and J–33880–10 (part of tool set J–33880). Blow out the injector tube and tip with compressed air to remove all metal shavings. (Rev. 2005) All information subject to change without notice. 2-36 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 789 16. Install J–33880–3 (part of tool set J–33880), into the injector tube bore until it contacts the cylinder head. See Figure 2-24. All information subject to change without notice. (Rev. 2005) 2-37 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 790 18. Using a speed handle with 15/16 in. socket attached, turn the seat reamer in a clockwise direction with light pressure. Continue until J–33880–1 (part of tool set J–33880) bottoms against J–33880–20 (part of tool set J–33880). (Rev. 2005) All information subject to change without notice. 2-38 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 791 20. Remove the reamer and pilot. Clean out the injector tube with compressed air. 21. Remove the two head bolts and J–33880–20 (part of tool set J–33880) from the cylinder head. All information subject to change without notice. (Rev. 2005) 2-39 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 792 276 kPa (40 psi) air pressure. [c] Remove the chips from the injector tube with compressed air. See Figure 2-26. (Rev. 2005) All information subject to change without notice. 2-40 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 793 3. Check injector tip protrusion using J–22273–01. Hold protrusion gage against pilot while measuring tip protrusion. This measurement should be ﬂush to -0.20 mm (-0.008 in.). All information subject to change without notice. (Rev. 2005) 2-41 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 794: N3 Electronic Unit Injector
The advantages of the N3 injector are: □ Improved strength. □ Reduced external leakage potential. □ Compact design. □ Reduced weight. (Rev. 2005) All information subject to change without notice. 2-42 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 795 Fuel enters the injector through the fuel inlet opening located around the injector body. See Figure 2-29. Figure 2-29 N3 Fuel Injector Body All information subject to change without notice. (Rev. 2005) 2-43 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 796: Fuel Supply
Outlet openings through which the excess fuel oil returns to the fuel return manifold and then back to the fuel tank, are located around the injector nut. See Figure 2-30. Figure 2-30 N3 Electronic Unit Injector (Rev. 2005) All information subject to change without notice. 2-44 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 797 The constant circulation of fuel through the injector renews the fuel supply in the chamber and aids the cooling of the injector. All information subject to change without notice. (Rev. 2005) 2-45 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 798 [b] To remove the two-piece rocker cover, refer to section 1.6.3. [c] To remove the three-piece rocker cover, refer to section 1.6.5. (Rev. 2005) All information subject to change without notice. 2-46 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 799 Loosening the fuel line at the inlet ﬁtting will allow fuel to ﬂow faster. Carefully collect the drained fuel in an appropriate container. All information subject to change without notice. (Rev. 2005) 2-47 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 800 2. Disengage the locking tang on the harness plug connector. Grasp the connector and gently pull it from the socket. 3. Remove injector hold down bolt and washer. (Rev. 2005) All information subject to change without notice. 2-48 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 801 4. Lift the injector from its seat in the cylinder head by inserting a pry bar under the hold down clamp and remove as a assembly both clamp and injector. See Figure 2-34. Figure 2-34 Removal of the N3 Injector All information subject to change without notice. (Rev. 2005) 2-49 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 802 [a] Drain the fuel tanks and reﬁll with clean fuel. Refer to section 14.6.2. [b] Replace both ﬁlters with new, and clean the fuel/water separator, if equipped. Refer to section 2.10.2. (Rev. 2005) All information subject to change without notice. 2-50 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 803 The stepped side of the washer must face up to the injector. NOTE: All external O-rings must be lubricated prior to installation into the cylinder head. All information subject to change without notice. (Rev. 2005) 2-51 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 804 6. Apply a thin coat of clean fuel oil to the injector seal rings and install them in the injector nut ring grooves. Make sure the seals are properly seated see Figure 2-36. Figure 2-36 N3 Injector Seal Rings (Rev. 2005) All information subject to change without notice. 2-52 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 805 70 N·m (52 lb·ft). See Figure 2-37. 1. Injector Clamp 4. N3 Injector 2. Bolt 5. N3 Injector Installed 3. Washer Figure 2-37 N3 Injector and Related Parts All information subject to change without notice. (Rev. 2005) 2-53 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 806: Customer Calibration
1.6.9. 15. Reconnect the vehicle battery power. 16. Verify installation of N3 Electronic Unit Injector. Refer to section 12.7. (Rev. 2005) All information subject to change without notice. 2-54 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 807: N3 Fuel Injector Tube
3. Clean the injector tube interior sealing surface, a chemical solvent maybe used for cleaning interior sealing surface. All information subject to change without notice. (Rev. 2005) 2-55 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 808 4. Install the injector tube on cup (J–46904). See Figure 2-40. Figure 2-40 Installation of N3 Injector Tube on Cup Tool (J–46904) (Rev. 2005) All information subject to change without notice. 2-56 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 809 8. Torque injector tube to 35-45 N·m (26-33 lb·ft) ensure the tip of the injector tube is ﬂush or below the ﬁre deck, the tube should not protrude. All information subject to change without notice. (Rev. 2005) 2-57 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 810: Fuel Pump With Separate Drive Shaft And Hub
7. Key 17. Needle Bearing 8. Gasket 9. C-clip Figure 2-42 Former Fuel Pump Assembly with Separate Drive Shaft and Hub Assembly (Rev. 2005) All information subject to change without notice. 2-58 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 811 3. Key 8. Fuel Pump Coupling 4. Set Screw 9. Fuel Fitting 5. C-clip 10. Plug Figure 2-43 Fuel Pump Drive Coupling All information subject to change without notice. (Rev. 2005) 2-59 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 812 Part of the relief valve may be seen through the passage to the head of the relief valve (6). (Rev. 2005) All information subject to change without notice. 2-60 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 813: Fuel Pump
15. Pin 16. O-ring 7. Gear Teeth Vent Cavity 8. Cover 17. Plug 9. Driven Gear 18. Spacer Figure 2-45 Fuel Pump All information subject to change without notice. (Rev. 2005) 2-61 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 814 However, if leakage exceeds one drop per minute, replace the pump. The drain hole should be checked for plugging at normal scheduled maintenance. (Rev. 2005) All information subject to change without notice. 2-62 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 815 (65 to 75 psi). The fuel pump should maintain the fuel pressure as shown in the maintenance section. Refer to section 12.5. All information subject to change without notice. (Rev. 2005) 2-63 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 816 To determine if repair or replacement of the fuel pump is necessary. See Figure 2-47. Figure 2-47 Flowchart for Repair or Replacement of Former Fuel Pump (Rev. 2005) All information subject to change without notice. 2-64 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 817 7. Use snap ring pliers (J–4880) and remove inner drive hub positioning C-clip. 8. Position pump on holding ﬁxture (J–38767–1) hub side down. See Figure 2-48. Figure 2-48 Fuel Pump Holding Fixture All information subject to change without notice. (Rev. 2005) 2-65 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 818 14. Use needle bearing remover (J–33853) with slide hammer and remove the needle bearing assemblies from the pump body and cover. See Figure 2-49. Figure 2-49 Needle Bearing Removal (Rev. 2005) All information subject to change without notice. 2-66 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 819: Oil Seal Removal
18. Remove the spacer from the relief valve plug. 19. Remove and discard the O-ring seal under the head of the plug. All information subject to change without notice. (Rev. 2005) 2-67 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 820 [a] If the relief valve is scored and cannot be cleaned up with ﬁne emery cloth, replace the relief valve. [b] If the relief valve is not damaged, reuse the part. (Rev. 2005) All information subject to change without notice. 2-68 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 821 Use a light hammer and drive the seal into the bore until the adaptor is bottomed against the pump body. See Figure 2-51. Figure 2-51 Installing Inner Oil Seal All information subject to change without notice. (Rev. 2005) 2-69 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 822 13. Press a second C-clip directly into the groove behind the gear to retain it in position. NOTE: The bearing numbers should always be against the tool during installation. (Rev. 2005) All information subject to change without notice. 2-70 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 823 16. With the pump body on a bench, hub side down, lubricate the outside of seal protector (J–33021–A) with clean engine oil. Install the solid end of the protector down through All information subject to change without notice. (Rev. 2005) 2-71 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 824 See Figure 2-54. Approximately 3 mm (1/8 in.) of the open end of the protector should remain above the inner seal. Figure 2-54 Seal Protector Installation (Rev. 2005) All information subject to change without notice. 2-72 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 825 SERIES 60 SERVICE MANUAL 17. Install a new needle bearing assembly in the drive shaft bore. See Figure 2-55. Figure 2-55 Drive Shaft Bearing Installation All information subject to change without notice. (Rev. 2005) 2-73 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 826 6.333-6.338 mm (0.24935-0.24955 in.) Gold 6.339-6.344 mm (0.24956-0.24975 in.) Silver Table 2-1 Gasket Color vs. Gear Cavity Depth Chart (Former Fuel Pump) (Rev. 2005) All information subject to change without notice. 2-74 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 827 Torque the set screw to 3.8 N·m (2.8 lb·ft). 34. Install access hole plug. 35. Install fuel inlet and outlet ﬁttings in the pump cover. All information subject to change without notice. (Rev. 2005) 2-75 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 828 5. Connect fuel inlet and outlet lines to the fuel pump and tighten. 6. Prime the fuel system before starting the engine. (Rev. 2005) All information subject to change without notice. 2-76 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 829 □ Do not modify or tamper with the exhaust system or emission control system. 7. Start the engine and check for leaks. 8. Shut down the engine upon completion of tests. All information subject to change without notice. (Rev. 2005) 2-77 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 830 5. Connect the fuel inlet and outlet lines to the fuel pump and tighten. 6. Prime engine fuel system before starting engine to ensure pump seal lubrication and prompt engine starting. (Rev. 2005) All information subject to change without notice. 2-78 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 831: Fuel Pump With One-Piece Drive Shaft And Hub Assembly
Current Compressor-Mounted Fuel Pump Assembly with One-Piece Drive Shaft and Hub Assembly The former pump has a separate drive shaft and drive hub. See Figure 2-58. All information subject to change without notice. (Rev. 2005) 2-79 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 832 Both current assemblies must be used together. Components of former and current pump assemblies and drive assemblies are not interchangeable. (Rev. 2005) All information subject to change without notice. 2-80 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 833 The mating surfaces of the pump body and cover are perfectly ﬂat ground surfaces. A gasket is used between the cover and body. All information subject to change without notice. (Rev. 2005) 2-81 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 834 15. Pin 7. Gear Teeth Vent Cavity 16. O-ring 8. Cover 17. Plug 18. Spacer 9. Driven Gear Figure 2-60 Fuel Pump (Rev. 2005) All information subject to change without notice. 2-82 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 835 448 to 517 kPa (65 to 75 psi). All information subject to change without notice. (Rev. 2005) 2-83 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 836 - kPa (in. Hg): Clean system 20 (6) 20 (6) Dirty system 41 (12) 41 (12) Table 2-2 Series 60 Engine Fuel System Parameters (Rev. 2005) All information subject to change without notice. 2-84 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 837 To determine if repair or replacement of the fuel pump is necessary. See Figure 2-62. Figure 2-62 Flowchart for Repair or Replacement of Fuel Pump All information subject to change without notice. (Rev. 2005) 2-85 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 838 3. Remove the pump from the vise and position pump on holding ﬁxture (J–38767–1) hub side down. See Figure 2-63. Clamp the holding ﬁxture in the vise. Figure 2-63 Fuel Pump Holding Fixture (Rev. 2005) All information subject to change without notice. 2-86 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 839 When the drive shaft is removed, the drive shaft needle bearing assembly in the pump body must also be removed to allow installation of the oil seal protector used during reassembly. All information subject to change without notice. (Rev. 2005) 2-87 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 840 11. Repeat the process, removing the inner seal by placing the tool lip against the inside of the seal case. Discard the inner seal. (Rev. 2005) All information subject to change without notice. 2-88 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 841 13. Remove the spacer from the relief valve cover. 14. Remove and discard the O-ring seal under the head of the cover. All information subject to change without notice. (Rev. 2005) 2-89 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 842 [a] If the relief valve is scored and cannot be cleaned up with ﬁne emery cloth, replace the relief valve. [b] If the relief valve is not damaged, reuse the part. (Rev. 2005) All information subject to change without notice. 2-90 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 843 Use a light hammer and drive the inner seal into the bore until the adaptor is bottomed against the pump body. See Figure 2-66. Figure 2-66 Installing Inner Oil Seal All information subject to change without notice. (Rev. 2005) 2-91 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 844 Remove seal protector. See Figure 2-68. Figure 2-68 Seal Protector Installation NOTE: The bearing numbers should always be against the tool during installation. (Rev. 2005) All information subject to change without notice. 2-92 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 845 Hold the shaft in position with the gear against the pump body while handling to ensure the drive hub C-clip grooves do not contact the oil seals. All information subject to change without notice. (Rev. 2005) 2-93 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 846 9.508-9.513 mm (0.37435-0.37455 in.) Gold 9.514-9.518 mm (0.37456-0.37475 in.) Silver Table 2-4 Gasket Color vs. Gear Cavity Depth Chart (Air Compressor-Driven Pumps) (Rev. 2005) All information subject to change without notice. 2-94 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 847 20. Place the pump assembly on a bench, hub side up. Install the coupling onto the hub. 21. Install fuel inlet and outlet ﬁttings in the pump cover. All information subject to change without notice. (Rev. 2005) 2-95 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 848 2. Install the fuel pump drive bolts and torque to 30-34 N·m (22-25 lb·ft) using the torque pattern shown. See Figure 2-70. Figure 2-70 Fuel Pump Drive Retaining Bolt Torque Sequence (Rev. 2005) All information subject to change without notice. 2-96 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 849 5. Reconnect fuel inlet and outlet hoses, prime the fuel system, start the engine, and check for leaks. 6. Shut down engine upon completion. All information subject to change without notice. (Rev. 2005) 2-97 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 850 7. Refer to section2.8.5 for the exhaust caution before proceeding. Start and run the engine. Visually observe fuel pump for any leaks. Repair as necessary. 8. Shut down engine upon completion of test. (Rev. 2005) All information subject to change without notice. 2-98 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 851: Fuel Pump Drive
1. Air Compressor Drive Assembly 3. Fuel Pump Drive 2. Fuel Pump Figure 2-71 Fuel Pump Drive Location All information subject to change without notice. (Rev. 2005) 2-99 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 852 The coupling between the fuel pump and fuel pump drive hubs is plastic, and acts as a shock absorber in the fuel pump drive line. (Rev. 2005) All information subject to change without notice. 2-100 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 853 Perform the following to inspect the fuel pump drive assembly: 1. The fuel pump drive assembly is nonserviceable if the bearing is worn or scored. Replace the fuel pump drive assembly. All information subject to change without notice. (Rev. 2005) 2-101 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 854 6. Install the fuel pump. Refer to section 2.8.5for gear train-driven fuel pump. Refer to section 2.8.6 for air compressor-driven fuel pump. 7. Install any other components that were removed for this procedure. (Rev. 2005) All information subject to change without notice. 2-102 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 855 8. Start the engine and check for leaks, if leaks are found. Repair as necessary. 9. Shut down the engine upon completion of inspection. All information subject to change without notice. (Rev. 2005) 2-103 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 856: Diesel Fuel Filters (Spin-On)
The secondary ﬁlter has a 13/16 in. x 12 thread. The word "Primary" or "Secondary" is cast onto the top of the respective adaptor. See Figure 2-74. Figure 2-74 Fuel Filters (Rev. 2005) All information subject to change without notice. 2-104 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 857 □ Primary fuel ﬁlter adaptor □ Spin-on secondary fuel ﬁlter □ Secondary fuel ﬁlter adaptor □ Fuel shutoff valve or check valve All information subject to change without notice. (Rev. 2005) 2-105 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 858: Diesel Fuel Filters (Spin-On)
To determine if replacement of fuel ﬁlter element is necessary. See Figure 2-75. Figure 2-75 Flowchart for Replacement of Fuel Filter Element (Rev. 2005) All information subject to change without notice. 2-106 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 859 ﬁlter element must be replaced every 250 hours or every year, whichever comes ﬁrst. Fuel Pro ® is a registered trademark of Davco Manufacturing, L.L.C. All information subject to change without notice. (Rev. 2005) 2-107 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 860 Then rotate an additional one-half turn by hand. 6. Turn the handle on the shutoff valve (if installed) to the open position (in line with the valve). (Rev. 2005) All information subject to change without notice. 2-108 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 861 ﬁlters. If the engine fails to start after ﬁlter replacement, the fuel system will require priming using tool J–5956. Authorized Detroit Diesel service outlets are properly equipped to perform this service. All information subject to change without notice.
Page 862 □ Do not modify or tamper with the exhaust system or emission control system. 7. Start the engine, and check for leaks. Correct any leaks with the engine off. (Rev. 2005) All information subject to change without notice. 2-110 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 863: Installation Of Fuel Filter
□ Do not modify or tamper with the exhaust system or emission control system. 2. Start and run the engine. Check for leaks. 3. Shut down engine upon completion of test. All information subject to change without notice. (Rev. 2005) 2-111 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 864: Fuel Pro 380/380E Fuel Filter System
The secondary fuel ﬁlter must be changed at regular mile or hour intervals, depending on the engine application. Refer to section 14.6.13. (Rev. 2005) All information subject to change without notice. 2-112 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 865 10. Check Valve and Thermostat 5. Cover 11. Fuel Processor Assembly 12. Drain Valve 6. Cover Seal Figure 2-76 Fuel Pro 380E Fuel Processor Assembly All information subject to change without notice. (Rev. 2005) 2-113 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 866 The Fuel Pro 380E system also includes the following: □ A fuel heater element □ A thermostat switch □ A wiring harness (Rev. 2005) All information subject to change without notice. 2-114 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 867 5. Dispose of the used ﬁlter element and grommet in an environmentally responsible manner, according to state and/or federal (EPA) recommendations. Fuel Pro® is a registered trademark of Davco Manufacturing Corporation, L.L.C. All information subject to change without notice. (Rev. 2005) 2-115 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 868 4. Open the fuel shutoff valve (if installed) and start the engine. When the lubrication system reaches its normal operating pressure, increase engine speed to high idle for 2 to 3 minutes. (Rev. 2005) All information subject to change without notice. 2-116 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 869 The secondary fuel ﬁlter must be changed at regular mile or hour intervals, depending on the engine application. Refer to section 14.6.13. All information subject to change without notice. (Rev. 2005) 2-117 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 870: Fuel Filter Type For The Series 60G Engine
2.12 FUEL FILTER TYPE FOR THE SERIES 60G ENGINE The primary (High Pressure) natural gas ﬁlter and secondary (Low Pressure) natural gas ﬁlter must be a coalescing 0.3 micron @ 99.97% efﬁciency fuel ﬁlter. Detroit Diesel recommended ﬁlters include the following: □...
Page 871: Replacement Of The Fuel Filter
Prior to removal or replacement of the fuel ﬁlter, the fuel system must be vented. Refer to section 2.42.1 and refer to section 2.42.2. All information subject to change without notice. (Rev. 2005) 2-119 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 872 (freezing). □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. (Rev. 2005) All information subject to change without notice. 2-120 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 873 Note: Fuel ﬁlter seal is located on top of the fuel ﬁlter. Figure 2-78 Current Fuel Filter Assemblies 2. Remove the two bolts from fuel ﬁlter housing head. All information subject to change without notice. (Rev. 2005) 2-121 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 874 4. Remove the center tube by gently tapping the metal end of the screwdriver, down away from the ﬁlter head. NOTE: Discard bypass spring and former center tube with holes. (Rev. 2005) All information subject to change without notice. 2-122 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 875 [a] If the fuel ﬁlter seal is worn, ripped, torn; replace the fuel ﬁlter. [b] If no damage is found on the fuel ﬁlter seal ; reuse the fuel ﬁlter. All information subject to change without notice. (Rev. 2005) 2-123 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 876 (freezing). □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. (Rev. 2005) All information subject to change without notice. 2-124 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 877 5. Insert the O-ring and install bottom fuel ﬁlter housing and torque to 33.90–47.45 N·m (25–35 lb·ft). 6. Pressurize fuel system. 7. Refer to section 2.42.3 a for leak checking procedure. All information subject to change without notice. (Rev. 2005) 2-125 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 878: Assembly Fuel Filter And Water Separator
5. Filter Head to Transfer Pump Hose 3. Priming Pump 6. Hose to Secondary Fuel Filter Figure 2-80 Typical Fuel Filter and Water Separator Installation (Rev. 2005) All information subject to change without notice. 2-126 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 879 □ Do not modify or tamper with the exhaust system or emission control system. 5. Start the engine and check for fuel leaks. Correct any leaks with the engine shut off. All information subject to change without notice. (Rev. 2005) 2-127 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 880 A check valve is connected to a hose in the fuel return line coming from the rear of the cylinder head or at the cylinder head restricted ﬁtting, depending on individual installation requirements. See Figure 2-81. (Rev. 2005) All information subject to change without notice. 2-128 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 881 [a] If the PRO-CHEK valve has no cracks, leaks, or other signs of damage, reuse the valve. [b] If the PRO-CHEK valve has cracks, leaks, or other signs of damage, replace the valve. All information subject to change without notice. (Rev. 2005) 2-129 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 882 4. Air Purge Line 2. Fuel Inlet 5. Fuel Outlet 3. PRO-CHEK Valve 6. Fuel Spill Line Typical Side-mounted PRO-CHEK Installation Figure 2-82 (Rev. 2005) All information subject to change without notice. 2-130 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 883 □ The male ﬁtting with the long, solid pipe is installed in the fuel in port. See Figure 2-84. All information subject to change without notice. (Rev. 2005) 2-131 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 884 3. Torque the Fuel In ﬁtting and top elbow to 14-19 N·m (10-14 lb·ft). 4. Torque the Fuel Out ﬁtting to 19-24 N·m (14-18 lb·ft). (Rev. 2005) All information subject to change without notice. 2-132 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 885: Electronic Engine Control
SERIES 60 SERVICE MANUAL 2.14 ELECTRONIC ENGINE CONTROL The Detroit Diesel Electronic Control System (DDEC) controls fuel injection timing and output by the electronic unit injectors (EUI) on the Series 60 Diesel engine. DDEC controls throttle, gas valve and the ignition system on the Series 60G engine. The system also monitors several engine functions using electrical sensors which send electrical signals to the Electronic Control Module (ECM).
Page 886 ELECTRONIC ENGINE CONTROL The replacement of DDEC components is based on indicated diagnostic codes leading to faulty components. Check the Detroit Diesel Single ECM Troubleshooting Manual (6SE497) for more complete information on diagnosis of components and system problems. DDEC III/IV and DDEC II Electronic Control Module (ECM)
Page 887: Ddec V Electronic Control Unit
DDEC V provides an indication of engine and vehicle malfunctions. The ECU continually monitors the DDEC V system. See Figure 2-87. Figure 2-87 DDEC V System Series 60 Diesel Engine All information subject to change without notice. (Rev. 2005) 2-135 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 888: Ddec V Electronic Control Unit
The Detroit Diesel Diagnostic Link® (DDDL) is a sophisticated PC software package that requests and receives engine data and diagnostic codes. The Detroit Diesel Diagnostic Link®...
Page 889 Supply Fuel Temperature Sensor (SFT Sensor) Turbo Compressor Temperature Out Sensor Turbo Speed Sensor (TSS) Table 2-9 Standard Sensors for DDEC V All information subject to change without notice. (Rev. 2005) 2-137 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 890 Fire Truck Pump Pressure Sensor * Turbo Compressor In Temperature Sensor Vehicle Speed Sensor (VSS) Table 2-10 OEM Installed Sensors * Available in some applications (Rev. 2005) All information subject to change without notice. 2-138 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 891 4. Install the engine harness connector and shroud to the ECU. Torque center screw and two nuts to 5.6 N·m (50 in.· lb). 5. Reconnect vehicle battery power. All information subject to change without notice. (Rev. 2005) 2-139 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 892 □ Do not modify or tamper with the exhaust system or emission control system. 7. Start the engine, and check for leaks. (Rev. 2005) All information subject to change without notice. 2-140 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 893: Ddec Iii/Iv Electronic Control Module
DDEC III/IV provides an indication of engine and vehicle malfunctions. The ECM continually monitors the DDEC III/IV system. See Figure 2-89 and see Figure 2-90. Figure 2-89 DDEC III/IV System Series 60 Diesel Engine All information subject to change without notice. (Rev. 2005) 2-141 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 894: Ddec Iii/Iv Electronic Control Module
2.16 DDEC III/IV ELECTRONIC CONTROL MODULE Figure 2-90 DDEC III/IV System Series 60 Natural Gas Engine (Rev. 2005) All information subject to change without notice. 2-142 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 895 □ Idle timer shutdown □ Idle timer between air temperatures □ Vehicle ID number (VIN) □ Idle adjustment □ Progressive shifting □ Engine protection All information subject to change without notice. (Rev. 2005) 2-143 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 896 SAE J1922 protocol on J1708 hardware Traction control systems Transmission controls SAE J1939 high speed data link Vehicle controls Table 2-11 SAE Standard Communications for DDEC III/IV (Rev. 2005) All information subject to change without notice. 2-144 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 897 16 gauge wire, 4 Power, 2 Ground 12 gauge wire (Eliminates Splicing), 2 Power, 2 Ground Table 2-14 DDEC II vs DDEC III/IV All information subject to change without notice. (Rev. 2005) 2-145 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 898 Table 2-15 Standard Sensors DDEC II DDEC III/IV Fuel Pressure Fuel Pressure Pressure Governor (Firetruck) Pressure Governor (Firetruck) Table 2-16 Optional Sensors (Rev. 2005) All information subject to change without notice. 2-146 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 899 6. Engage the lock tab on the power harness and injector harness connectors. 7. Turn the ignition to the "ON" position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel DDEC III/IV Single ECM Troubleshooting Manual (6SE497).
Page 900 □ Do not modify or tamper with the exhaust system or emission control system. 8. Start the engine, and check for leaks. (Rev. 2005) All information subject to change without notice. 2-148 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 901: Ddec Ii Electronic Control Module
The DDEC II ECM is a microprocessor. It is the control center of the DDEC II system. See Figure 2-92. Figure 2-92 Schematic Diagram of DDEC II All information subject to change without notice. (Rev. 2005) 2-149 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 902: Ddec Ii Electronic Control Module
If the basic mechanical checks fail to locate the problem, refer the Detroit Diesel Single ECM Troubleshooting Manual, (6SE497). Start by reading the "Basic Knowledge Required" section before attempting to diagnosis electrical faults.
Page 903 5. Connect the ﬁve (5) wire harness connections at the ECM. 6. Engage the lock tab on the power harness and injector harness connectors. All information subject to change without notice. (Rev. 2005) 2-151 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 904: Dashboard Warning Lights
DDEC II ELECTRONIC CONTROL MODULE 7. Turn the ignition to the "ON" position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). PERSONAL INJURY...
Page 905 A and M (on DDEC II engines only). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). Fault codes can be cleared from the DDEC II and III/IV systems only by using a diagnostic reader.
Page 906 The following tools are required to replace the former EPROM with the improved EPROM stabilizer kit: □ 1/4 in. Nut Driver □ Thin-head standard screwdriver □ Kent-Moore antistatic wrist strap BT-8639-B (for electrostatic discharge) (Rev. 2005) All information subject to change without notice. 2-154 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 907 SERIES 60 SERVICE MANUAL To replace a DDEC II EPROM, see Figure 2-97. Figure 2-97 Replacement Flowchart for DDEC II EPROM All information subject to change without notice. (Rev. 2005) 2-155 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 908 EPROM. Then, using a suitable narrow diameter tool, remove the locking tabs by carefully pressing out the pins holding the tabs to the socket. Discard the tabs and pins. (Rev. 2005) All information subject to change without notice. 2-156 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 909 Fasten the stabilizer plate to the case with three #8-32 x 1 3/4 in. screws. Torque screws to 3.0-3.7 N·m (26.6-32.7 lb·in.). Figure 2-98 EPROM and Spacer Locations All information subject to change without notice. (Rev. 2005) 2-157 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 910 1. With the six-pin connector unplugged, connect the leads of an ohmmeter between the ECM case and the engine. 2. Return the removed EPROM assembly to an authorized Detroit Diesel distributor. (Rev. 2005) All information subject to change without notice.
Page 911: Ddec I
The DDEC I ECM is a microprocessor. It is the control center of the DDEC I system. See Figure 2-99. Figure 2-99 Schematic Diagram of DDEC I All information subject to change without notice. (Rev. 2005) 2-159 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 912: Ddec I
□ Connections to various engine sensors, operational displays, power and fuel injectors Figure 2-100 Electronic Control Module - DDEC I It is usually mounted inside the passenger compartment of the vehicle. (Rev. 2005) All information subject to change without notice. 2-160 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 913 If the basic mechanical checks fail to locate the problem, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). Start by reading the "Basic Knowledge Required" section before attempting to diagnosis electrical faults.
Page 914 This ﬂashing code will be repeated until the diagnostic switch is turned OFF or the jumper wire is removed from pins A and M. If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 915 The following section(s) are basic replacement procedures for the DDEC components. Components should NOT be replaced unless a defective unit has been concluded by the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). All information subject to change without notice. (Rev. 2005) 2-163 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 916 3. Tighten the two hold-down screws attaching the wire harness connectors to the ECM. 4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 917: Programmable Read-Only Memory (Prom) Ddec I
When plugged in, it becomes part of the circuits of the ECM. The PROM is used to establish engine operating speciﬁcations. Each PROM has an individual part number. All information subject to change without notice. (Rev. 2005) 2-165 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 918: Programmable Read-Only Memory (Prom) Ddec I
Repeat this process until the PROM carrier and PROM are free of the socket. When done correctly, the PROM and carrier should easily lift free of the socket. (Rev. 2005) All information subject to change without notice. 2-166 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 919 PROM carrier should be installed in the same position as the numeral one located on the socket. See Figure 2-105. Figure 2-105 Indexing PROM for Installation All information subject to change without notice. (Rev. 2005) 2-167 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 920 If bent pins break or crack during straightening, discard the PROM and replace it. □ If found defective, replace the PROM. □ If the PROM is installed backwards, replace it. □ (Rev. 2005) All information subject to change without notice. 2-168 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 921: Electronic Distributor Unit Ddec I
The main function of the EDU is to generate electrical signals to operate the injector solenoids. These electrical signals are controlled by the ECM. All information subject to change without notice. (Rev. 2005) 2-169 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 922 5. Remove the EDU and cold plate from the engine. 6. Remove the screws securing the cold plate to the EDU. Remove the cold plate from the EDU. (Rev. 2005) All information subject to change without notice. 2-170 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 923 6. Connect the fuel line (at the secondary fuel ﬁlter) that runs from the EDU cold plate. 7. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 924: Electronic Foot Pedal Assembly
Replacement of Electronic Foot Pedal Assembly The EFPA assembly is supplied by the vehicle manufacturer. Refer to the guidelines for service procedure. (Rev. 2005) All information subject to change without notice. 2-172 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 925: Turbo Speed Sensor (Tss)
NOTE: If the turbocharger speed sensor is difﬁcult to access, removal of the turbocharger may be required. Refer to section 6.6.2. All information subject to change without notice. (Rev. 2005) 2-173 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 926: Turbo Speed Sensor (Tss)
1. Sensor Lead Wire 2. Turbocharger Speed Sensor Socket Figure 2-111 Removal of Turbocharger Speed Sensor (Rev. 2005) All information subject to change without notice. 2-174 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 927 ﬂat on the center housing and the sensor is ﬁnger tight. 4. Turn the turbocharger rotor to ensure it spins freely with minimal resistance. If binding occurs, repeat speed sensor installation. All information subject to change without notice. (Rev. 2005) 2-175 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 928 6. Turn the turbocharger rotor to ensure it spins freely. If binding occurs it is not aligned properly. Refer to step 3. (Rev. 2005) All information subject to change without notice. 2-176 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 929: Turbo Boost Pressure Sensor
TBS information to control engine smoke. 2.23.1 Replacement of Turbo Boost Sensor The TBS is non-serviceable and must be replaced as an assembly. No adjustment is required. All information subject to change without notice. (Rev. 2005) 2-177 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 930 6. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). (Rev. 2005) All information subject to change without notice.
Page 931: Air Intake Pressure Sensor
The AIP sensor is non-serviceable and must be replaced as an assembly. No adjustment is required. 2.24.2 Removal of Air Intake Pressure Sensor Remove the AIP sensor as follows: All information subject to change without notice. (Rev. 2005) 2-179 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 932 2. Engage the locking tang on the AIP connector body. 3. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual(6SE497).
Page 933: Oil Pressure Sensor
OPS. 2. Use the appropriate wrench on the hex end of the OPS to unscrew it from the engine. All information subject to change without notice. (Rev. 2005) 2-181 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 934 3. Place the connector in the socket and engage the locking tang. 4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 935: Oil Temperature Sensor
Installation of Oil Temperature Sensor Install the OTS as follows: NOTE: The Oil Temperature Sensor is an electronic device. Use care in the installation process. All information subject to change without notice. (Rev. 2005) 2-183 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 936 3. Place the connector in the socket and engage the locking tang. 4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 937: Air Temperature Sensor
See Figure 2-117 1. Intake Manifold 2. Air Intake Sensor Figure 2-117 Air Temperature Sensor All information subject to change without notice. (Rev. 2005) 2-185 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 938 2. Grasp body of the connector and gently pull it from the socket. 3. Use the appropriate wrench on the hex portion of the sensor and unscrew it from manifold. (Rev. 2005) All information subject to change without notice. 2-186 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 939 4. Carefully fasten connector onto sensor and engage locking tang. 5. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 940: Air Temperature Sensor For High Pressure Fuel System
The ATS sends an electrical signal to the ECM indicating air inlet temperature. The ECM uses this information to adjust gas ﬂow and control air fuel ratio. (Rev. 2005) All information subject to change without notice. 2-188 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 941 4. Carefully fasten connector onto sensor and engage locking tang. 5. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual(6SE497).
Page 942: Coolant Temperature Sensor
The CTS activates engine protection if coolant temperature exceeds the speciﬁed limits. See Figure 2-120. 1. Air Intake Sensor Figure 2-120 Coolant Temperature Sensor Location (Rev. 2005) All information subject to change without notice. 2-190 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 943 2. Install CTS to the cylinder head. 3. Torque to 102-127 N·m (75-94 lb·ft). 4. Carefully fasten two-wire connector onto sensor and engage locking tang. All information subject to change without notice. (Rev. 2005) 2-191 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 944: Synchronous Reference Sensor Gear Case Mounted
The SRS sends a signal to the ECM. This signal is generated by a raised metal pin on the rear of the bull gear. See Figure 2-122. Figure 2-122 Bull Gear (Rev. 2005) All information subject to change without notice. 2-192 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 945 4. Plug the connectors together, making sure the locking tang clicks into place. 5. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497).
Page 946: Synchronous Reference Sensor \ Camshaft Position Sensor Camshaft Gear Cover Mounted
The SRS\CMP sends a signal to the Electronic Control Unit (ECU). This signal is generated by a raised metal pin on the rear of the camshaft gear. (Rev. 2005) All information subject to change without notice. 2-194 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 947 1. Camshaft Gear 3. Camshaft Gear 2. Pin 4. Pin Figure 2-125 Synchronous Reference Sensor \ Camshaft Position Sensor Pin Installation View All information subject to change without notice. (Rev. 2005) 2-195 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 948 4. Plug the connectors together, making sure the locking tang clicks into place. 5. Turn the ignition to the ON position. Observe the DDR or DDDL for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Series 60 Troubleshooting Guide(6SE570).
Page 949: Timing Reference Sensor
As the timing wheel rotates with the crankshaft, a tooth passes by the TRS. These signals are used by the ECM to determine injector solenoid operation times and engine speed. All information subject to change without notice. (Rev. 2005) 2-197 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 950 25 appears, refer to the required DDEC Troubleshooting Manual: 6SE477 (DDEC I), 6SE489 (DDEC II), or 6SE497 (DDEC III/IV). (Rev. 2005) All information subject to change without notice. 2-198 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 951: Coolant Level Sensor
The module sends an electrical signal to the ECM to indicate coolant level. Low coolant will activate the stop engine function or warning function. Figure 2-127 Coolant Level Sensors All information subject to change without notice. (Rev. 2005) 2-199 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 952 4. Turn the ignition to the ON position. Observe or read any diagnostic code(s). If any code other than code 25 appears, refer to the DDEC Troubleshooting Guide: 6SE477 (DDEC I), 6SE489 (DDEC II), or 6SE497 (DDEC III/IV). (Rev. 2005) All information subject to change without notice. 2-200 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 953 5. Start the engine and check for leaks. 6. Shut down engine upon completion of test. Perform necessary repairs. All information subject to change without notice. (Rev. 2005) 2-201 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 954 1. Insert the CLS module to the vehicle. 2. Grasp both connector bodies. Gently push them together and engage locking tang on the CLS module connector. (Rev. 2005) All information subject to change without notice. 2-202 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 955: Fuel Pressure Sensor
7. Air Temperature Sensor 4. Throttle 8. Fuel Pressure Sensor 9. Fuel Inlet Tee Fitting Figure 2-128 Fuel Pressure Sensor for Series 60G All information subject to change without notice. (Rev. 2005) 2-203 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 956 3. Engage locking tang. 4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). (Rev. 2005) All information subject to change without notice.
Page 957: Fuel Temperature Sensor
ﬁlter. See Figure 2-129. The FTS sends an electrical signal to the ECM indicating fuel inlet temperature. The ECM uses this information to calculate fuel consumption. Figure 2-129 Fuel Temperature Sensor Location (Series 60 Diesel Engine) All information subject to change without notice. (Rev. 2005) 2-205 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 958 8. Fuel Pressure Sensor 9. Fuel Inlet Tee Fitting Figure 2-130 Fuel Temperature Sensor Series 60G Engine with High Pressure Fuel System (Rev. 2005) All information subject to change without notice. 2-206 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 959 3. Engage locking tang. 4. Turn the ignition to the ON position. Observe the DDR for any diagnostic code(s). If any code(s) other than code 25 is logged, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). All information subject to change without notice.
Page 960: Exhaust Gas Oxygen Sensor For Series 60G Engines
ﬂywheel housing. See Figure 2-131 and see Figure 2-132. Figure 2-131 Exhaust Gas Oxygen Sensor Figure 2-132 Oxygen Sensor Interface Module (Rev. 2005) All information subject to change without notice. 2-208 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 961 3. Disconnect two–pin engine sensor wire harness connector at interface module. 4. Remove three M6 bolts that attach the module to the sensor bracket. 5. Remove module from bracket. All information subject to change without notice. (Rev. 2005) 2-209 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 962 5. Start engine and check for check engine or stop engine light or read any diagnostic codes. If any code other than 25 is obtained, refer to the Detroit Diesel Single ECM Troubleshooting Manual (6SE497). (Rev. 2005) All information subject to change without notice.
Page 963: Exhaust Temperature Sensor For The Series 60G Engines
4. Turn the ignition to the ON position. Observe or read any diagnostic codes. If any codes other than 25 appears, refer to the DDEC II/IV Troubleshooting Guide, 6SE497. All information subject to change without notice. (Rev. 2005) 2-211 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 964: Knock Sensor And Signal Noise Enhancement Filter Module
See Figure 2-133. 1. Knock Sensor 2. SNEF Module Figure 2-133 Location of Knock Sensor and Signal Noise Enhancement Filter Module (Rev. 2005) All information subject to change without notice. 2-212 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 965 Knock Sensor Diagnostic Codes for the Series 60G Engine Table 2-17 All information subject to change without notice. (Rev. 2005) 2-213 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 966 Install the SNEF module as follows: 1. Install the SNEF module to its mounting bracket and attach with two mounting bolts. 2. Engage locking tang. (Rev. 2005) All information subject to change without notice. 2-214 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 967: Barometric Pressure Sensor For The Series 60G Engine With High Pressure Fuel System
The ECM uses the data in controlling fuel delivery to the engine. See Figure 2-134. 1. Barometric Pressure Sensor 3. Sensor Bracket 2. Oxygen Sensor Interface Module Figure 2-134 Barometric Pressure Sensor for Series 60G Engines All information subject to change without notice. (Rev. 2005) 2-215 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 968 5. Turn ignition to the "ON" position. Observe or read any diagnostic codes. If any codes other than 25 appears, refer to the DDEC II/IV Troubleshooting Guide, 6SE497. (Rev. 2005) All information subject to change without notice. 2-216 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 969: Overview Of High Pressure Fuel System For Series 60G Engines
Schematic Diagram of Typical CNG Fuel System for 1998 and Later Series 60G Engines NOTE: The maximum distance between the second DDEC solenoid and the IMPCO regulator is 18 inches. All information subject to change without notice. (Rev. 2005) 2-217 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 970: Overview Of High Pressure Fuel System For Series 60G Engines
□ Manual Shutoff Valves □ Coalesing Fuel Filters □ High Pressure DDEC Controlled Gas Shutoff Valve □ Pressure Gages □ Fuel Heat Exchanger (Rev. 2005) All information subject to change without notice. 2-218 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 971 11. Ignitor Module 12. Oxygen Sensor Interface Module 6. Throttle Actuator 13. Barometric Air Pressure Sensor Figure 2-136 Series 60G Engine Component Location All information subject to change without notice. (Rev. 2005) 2-219 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 972 To avoid injury from the explosion of natural gas, the engine must be kept in a well ventilated area away from open ﬂames, sparks, and electrical resistance (heating) coils. (Rev. 2005) All information subject to change without notice. 2-220 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 973 Increases in pressure drop across the venturi increase the demand for fuel ﬂow required to maintain the fuel outlet pressure at the low pressure regulator. All information subject to change without notice. (Rev. 2005) 2-221 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 974 For fuel quality speciﬁcations refer to section 5.1. Refer to section 2.16 for details on the DDEC system for Series 60 Natural Gas engines. (Rev. 2005) All information subject to change without notice. 2-222 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 975: Fuel Pressure Gages For The Series 60G Engine With Ahigh Pressure Fuel System
1st stage regulator. The low pressure gage should have a range of 0 - 1380 kPa (0 - 200 psi). 2.41.1 Replacement of Fuel Pressure Gages for the Series 60G Engine Detroit Diesel does not service the fuel pressure gages. Refer to OEM to replace as necessary. 2.41.2 Removal of Fuel Pressure Gages for the Series 60G Engine Prior to removal or replacement of fuel system pressure gages, the fuel system must be vented.
Page 976 □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. Refer to section 2.42.3 for leak checking procedure. (Rev. 2005) All information subject to change without notice. 2-224 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 977: Venting And Leak Checking Procedures For A Natural Gas Engine (High Pressure System)
6. Completely open the ﬁtting that was slightly opened and allow to vent in a well-ventilated area. All information subject to change without notice. (Rev. 2005) 2-225 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 978: Venting And Leak Checking Procedures For A Natural Gas Engine (High Pressure System)
3. Open a ﬁtting to assure all pressure has been relieved in the natural gas vehicle fuel line. 4. Check all connections that were loosened for leaks after installation, service and troubleshooting are complete. (Rev. 2005) All information subject to change without notice. 2-226 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 979 1. Spray soapy water or commercially available leak checking solutions on connections which are pressurized to working pressure. Bubbles will form if there is a leak. All information subject to change without notice. (Rev. 2005) 2-227 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 980 5. Repair the leak using the procedure in step 2. (Rev. 2005) All information subject to change without notice. 2-228 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 981: High Pressure Fuel Regulator For The Series 60G Engine
1/4 NTPF connection. Coolant supply and return connections are 1/4 inch NPTF female pipe thread holes. See Figure 2-137. Figure 2-137 High Pressure Fuel Regulator for Series 60G Engines All information subject to change without notice. (Rev. 2005) 2-229 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 982 8. Connect vent pipe. 9. Open fuel shutoff valves and crank engine to supply fuel to regulator. 10. Check for leaks, refer to section 2.50. (Rev. 2005) All information subject to change without notice. 2-230 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 983: Pulse Width Modulated Stepper Motor Valve (Psv) For Series 60G Automotive Engines
2. Bolt 6. Connector O-rings 3. Washer 7. Connector Tube 4. PSV O-ring Figure 2-138 Series 60G Automotive PSV 1998 and Later Engines All information subject to change without notice. (Rev. 2005) 2-231 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 984 4. Secure PSV to the fuel mixer with four bolts and torque to 20 N·m (15 lb·ft). 5. Tighten fuel mixer to throttle attaching bolts. (Rev. 2005) All information subject to change without notice. 2-232 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 985 6. Clear AFR learn table using the Diagnostic Data Reader (DDR). 7. Check for diagnostic codes using DDR. 8. Check for leaks, refer to section 2.51. All information subject to change without notice. (Rev. 2005) 2-233 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 986: Fuel Mixer For The Series 60G High Pressure Fuel System
7. Air Temperature Sensor 4. Throttle 8. Fuel Pressure Sensor 9. Fuel Inlet Tee-Fitting Figure 2-139 Fuel Mixer for the Series 60G Engine (Rev. 2005) All information subject to change without notice. 2-234 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 987 4. Connect air balance hose to PSV and mixer. 5. Torque mixer bolts to 20 N·m (15 lb·ft). 6. Connect hose between mixer and charge cooler outlet tube. All information subject to change without notice. (Rev. 2005) 2-235 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 988 □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. 7. Perform a leak check procedure. Refer to section 2.51.3. (Rev. 2005) All information subject to change without notice. 2-236 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 989: Fuel Shutoff Valve For Series 60G Engine With High Pressure Fuel System
The gas inlet and outlet are female 1/2–inch NPTF connections. The shutoff valve comes with a mounting bracket attached. See Figure 2-140. Figure 2-140 Fuel Shutoff Valve for Series 60G Engine All information subject to change without notice. (Rev. 2005) 2-237 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 990 6. Connect solenoid electrical connector to connector in vehicle wire harness. 7. Open manual fuel shutoff valves and crank engine to supply fuel. 8. Check for leaks, refer to section 2.51.3. (Rev. 2005) All information subject to change without notice. 2-238 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 991: Impco Low Pressure Fuel Regulator For The Series 60G Engine High Pressure Fuel System
Replacement of the Low Pressure Regulator for the Series 60G Engine The low pressure fuel regulator is not serviceable and should be replaced as a unit. No adjustment is required. All information subject to change without notice. (Rev. 2005) 2-239 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 992 Use caution when installing hoses to avoid twisting or kinking the hose. This could result in increased ﬂow restriction and affect engine performance. (Rev. 2005) All information subject to change without notice. 2-240 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 993 1. Install gas inlet tee, fuel pressure sensor, coolant inlet ﬁttings, coolant outlet ﬁttings, balance hose ﬁtting, outlet connector tube and O-rings. 2. Lubricate connector O-rings. All information subject to change without notice. (Rev. 2005) 2-241 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 994 9. Connect fuel pressure sensor to engine sensor wiring harness. 10. Clear AFR learn table using DDR. 11. Start engine and check hoses and ﬁtting for leaks. Refer to section 2.39.3. (Rev. 2005) All information subject to change without notice. 2-242 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 995: Overview Of The Low Pressure Natural Gas Fuel System
The Series 60G engine requires an adequate fuel supply for proper performance and to develop full-rated power. This section describes the Detroit Diesel Series 60G compressed natural gas fuel system.
Page 996: Overview Of The Low Pressure Natural Gas Fuel System
5. Fresh Water Pump 11. Fuel Balance Hoses 6. Turbocharger 12. Low Pressure Regulator Figure 2-142 Low Pressure Fuel System (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 2-244 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 997 (freezing). □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. All information subject to change without notice. (Rev. 2005) 2-245 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 998 ﬂow. The opposite is true for conditions requiring a decrease in fuel ﬂow. See Figure 2-143. Figure 2-143 Low Pressure Natural Gas Fuel System (Series 60G Engine) (Rev. 2005) All information subject to change without notice. 2-246 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 999 Fuel from the PSV enters the venturi mixer where it is drawn into and mixed with the airstream ahead of the turbocharger compressor inlet, charge air cooler, throttle and intake manifold. All information subject to change without notice. (Rev. 2005) 2-247 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 1000: Low Pressure Fuel Regulator For The Series 60G Engine
5. Remove the low pressure fuel regulator and fuel inlet pipe from the mounting bracket. 6. Remove fuel inlet pipe from regulator. (Rev. 2005) All information subject to change without notice. 2-248 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 1001 This could result in increased ﬂow restriction and affect engine performance. 4. Connect the two 3/8 in. fuel pressure balance lines. 5. Connect the 1 in. air balance line. All information subject to change without notice. (Rev. 2005) 2-249 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 1002 (freezing). □ Vent systems on the equipment should be ducted to a safe area whenever equipment is in an enclosed area. (Rev. 2005) All information subject to change without notice. 2-250 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...
Page 1003 After installation of the low pressure fuel regulator, always check for leaks with a soapy water solution or equivalent. 6. Check hoses and ﬁttings for leaks; refer to section 2.51.3. All information subject to change without notice. (Rev. 2005) 2-251 6SE483 0507 Copyright © 2005 DETROIT DIESEL CORPORATION...

This manual is also suitable for:

60g series