10 01-12

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NUMBER: 10–01–12 2012 S.M. REF.: Listed in Table ENGINE: EPA07 Series 60 DATE: October SUBJECT: REFERENCES TO THE TURBOCHARGER PURGE ROUTINE ADDITIONS, REVISIONS, OR UPDATES Publication Number Platform Section Title Change Installation of the E3 Electronic Unit Injector Installation of Intake Manifold Installation of Charge Air Cooler Installation of Three-Piece Exhaust Manifold Installation of Cylinder Head DDC-SVC-MAN-0005 EPA07 Series 60 Installation of the EGR Cooler Procedures have been updated to reference the Turbocharger Purge Routine section Installation of EGR Heater Plate Installation of EGR Valve Installation of Delivery Pipe Installation of Adapter and Intake Throttle Valve Installation of the EGR Mixer NOTE: Page numbers are based on the most recent version of the individual publication and may be adjusted throughout the annual print cycle. INSTALLATION OF THE E3 ELECTRONIC UNIT INJECTOR Install the E3 injector as follows: 1. If the fuel system is contaminated: [a] Drain the fuel tanks and refill with clean fuel. Refer to section . [b] Replace both filters with new, and clean the fuel/water separator, if equipped. Refer to section . [c] Inspect fuel injectors for damage and replace as required. 2. If the coolant system is contaminated with fuel, flush and reverse flush the system. Refer to section . 3. If the oil system is contaminated, change the engine oil and filters. Refer to section . EYE INJURY To avoid injury from flying debris when using compressed air, wear adequate eye protection (face shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure. NOTICE: Leftover fuel must be removed from the injector bore before injector installation. If fuel is trapped between the top of the injector hole tube and the lower injector O-ring seal, it may seep down to the injector hole tube seal ring, causing swelling and possible seal leakage. NOTICE: Injector O-ring seals, injector washers and injector hold down clamp bolts are considered one-use items and cannot be reused. Any time an injector is removed, the two injector O-ring seals injector washer and injector hold down clamp bolt must be replaced with new parts. Failure to replace O-ring seals, injector washer and injector hold down clamp bolts can result in leakage. 4. Check to make sure the injector bore is thoroughly clean. NOTICE: The injector tube bore should be cleaned and inspected for damage before installation of the E3 Electronic Unit Injector. Refer to section . NOTICE: Take extra precautions when cleaning the injectors sleeves in the cylinder head to ensure that debris does not enter the fuel supply or return galleries. Do not use power tools to clean the injector sleeves; use hand brush J–47374 and a rag. Do not use compressed air to blow out the debris in sleeves. 5. Install a new washer on the injector. NOTE: All external O-rings must be lubricated prior to installation into the cylinder head. 6. Apply a thin coat of clean fuel to the injector seal rings and install them in the injector nut ring grooves. Make sure the seals are properly seated. See Figure 1 E3 Injector Seal Rings. Figure 1 E3 Injector Seal Rings 7. Record the injector calibration code. See Figure 2. 1. Injector Body Figure 2 2. Injector Calibration Code Location E3 Injector Calibration Code Location 8. Remove injector nozzle tip protector. 9. Install a new injector hold-down clamp washer. The curved side of the washer fits into a corresponding curved cup in the injector hold-down clamp. See Figure 3. 1. Hold-down Clamp 3. E3 Injector 2. Washer Figure 3 E3 Injector 10. Replace the injector hold-down clamp bolt with a new bolt. Align the hold-down clamp over the retaining bolt hole and install the new bolt into the injector clamp and torque using the procedure below. No additional torque of the bolt is necessary. See Figure 4. [a] Torque the bolt to 50 N·m (37 lb·ft). [b] Loosen the bolt 60 degrees (1/6 of a turn, or one bolt flat). Do not fully loosen the bolt. [c] Torque the bolt to 35 N·m (26 lb·ft).+ 90° (1/4 of a turn). 1. Injector Hold-down Clamp 4. E3 Injector 2. Bolt 5. E3 Injector (Installed) 3. Washer Figure 4 E3 Injector and Related Parts NOTE: Ensure the injector wiring harness connector is installed into the lower rocker cover with the notch facing upwards. If the connector is installed incorrectly the mating connector cannot be installed. See Figure 5. 1. Locating Notch Figure 5 Injector Wiring Harness Connector 11. Install the E3 EUI harness plug into the injector connector using installer tool J–47408, making sure the locking tang clicks into place. 12. Before installing the rocker arm shaft, apply clean engine oil to the plunger area of the fuel injector. See Figure 6. 1. Follower/ Rocker Interface 4. Nozzle Nuts/ O-rings 2. Plunger/Body Size 10 mm 5. Spring Cage 3. Magnetic Coil of Module (42 Turns) 6. Nozzle Figure 6 E3 Injector Oil Hole Location 13. Adjust the intake and exhaust valve clearances and injector clearance. Refer to section. 14. Install the Jake Brakes. Refer to section . 15. On DDEC VI engines, enter the calibration code recorded in step 7 with the proper cylinder location and enter calibration codes using DDDL 7.X service routine. 16. Bar the engine over a minimum of two complete revoultions. 17. Install the valve rocker cover. Refer to section . 18. For two-piece and three-piece valve rocker cover, refer to section . 19. Reconnect the vehicle battery power. 20. Prime the fuel system using J–47912.. 21. Refer to section for necessary cautions and warnings. 22. Using the starter, crank the engine three times for 15 seconds each time. Allow sufficient time between cranking periods to allow the starter to cool. 23. Install any other components that were removed for this procedure. 24. Carry out the turbocharger purge routine. Refer to section . 25. Verify installation of E3 Electronic Unit Injector. Refer to section . INSTALLATION OF INTAKE MANIFOLD Install the intake manifold as follows: NOTICE: It is necessary to completely seal the intake manifold to the cylinder head, due to the high pressure of the intake charge provided by the turbocharger. The arrow on the gasket must point to the front of the engine. Gasket eliminator can not be used with intake manifold seals. Failure to seal this interface will reduce engine performance. 1. Install three new manifold gaskets to the mating surfaces of the intake manifold with the arrow on the gasket pointing to the front of the engine. See Figure 7. Figure 7 Intake Manifold Gasket Orientation 2. Install bolts ten and eleven through the intake manifold and into the cylinder head and hand-tighten. 3. Install the ten remaining bolts through the intake manifold and into the cylinder head. Torque all of the intake manifold retaining bolts to 58-73 N·m (43-54 lb·ft) in the proper torque sequence. See Figure 8. Figure 8 Intake Manifold Bolt Position and Torque Sequence 4. Install the intake manifold pressure sensor. Refer to Section . 5. Plug in the intake manifold pressure sensor wiring connector by pressing the connector into the body of the sensor until the locking tang snaps into place. 6. Install the intake manifold air temperature sensor. Refer to Section . 7. Plug in the intake manifold air temperature sensor wiring connector by pressing the connector into the body of the sensor until the locking tang snaps into place. NOTICE: Do not use any type of lubricant on the inside of any air inlet hose or on the hose contact surfaces of the turbocharger compressor housing, CAC, CAC ducting or the intake throttle. Use of lubricant can cause the hose to blow off when the turbocharger builds boost pressure. 8. Install EGR mixer onto intake manifold. Refer to Section 9. Install intake throttle valve and adaptor onto EGR mixer. Refer to Section 10. Plug in the intake throttle valve wiring connector by pressing the connector into the body of the sensor until the locking tang snaps into place 11. Install the Exhaust Gas Recirculation valve (EGR). Refer to Section . 12. Slide the CAC ducting over the intake throttle valve adaptor and position it to its original location. 13. Slide the hose clamps into place over the CAC ducting and tighten them alternately. 14. Carry out the turbocharger purge routine. Refer to section . 15. Refer to section for verification of proper intake manifold installation. INSTALLATION OF CHARGE AIR COOLER Refer to the OEM guidelines for CAC installation procedures. Carry out the turbocharger purge routine. Refer to section . When installation is completed, refer to section for engine test. INSTALLATION OF THREE-PIECE EXHAUST MANIFOLD Perform the following steps to install the exhaust manifold. 1. Install six exhaust manifold guide studs (J–36107) into the cylinder head in locations 1, 2, 3, 4, 5, and 6 to hold the three exhaust manifold gaskets in the correct position and facilitate manifold installation see Figure 9.. Figure 9 Exhaust Manifold Guide Stud Location NOTE: The exhaust gasket can be positioned either way. Ensure the guide studs and gaskets are positioned correctly for the manifold being installed. 2. Install the exhaust gaskets to the guide studs. 3. Install the assembled exhaust manifold to the guide studs in locations 1, 2, 3, 4, 5, and 6. NOTE: To avoid torsional stress on the bellows, verify that the bellows clamps are not torqued and the exhaust manifolds can twist on the bellows pipe. 4. Install mounting bolts and spacers in locations 7, 8, 9, 10, 11, and 12 . Torque mounting bolts to 25-35 N·m (18-25 lb·ft). The bolts should be tightened enough to hold the exhaust manifold assembly in place when the guide studs are removed. 5. Remove the guide studs, from location 1, 2, 3, 4, 5, and 6 making sure the exhaust manifold has not moved. NOTE: If the manifold moves while removing the guide studs, loosen all bolts and go back to step 4. NOTE: If guide pins are used verify gasket position before installing bolts. 6. Install mounting bolts and spacers in locations 1, 2, 3, 4, 5, and 6 and torque bolts to 55-66 N·m (41-49 lb·ft). 7. Torque bolts to 55-66 N·m (41-49 lb·ft) in locations 7, 8, 9, 10, 11 and 12. 8. Torque the four bellows clamps to 12-14 N·m (9-10 lb·ft). NOTE: Ensure the bellows clamps are orientated correctly. Incorrect orientation will interfere with turbocharger installation. See Figure 10. 1. Rear Exhaust Manifold Clamp Orientation 3. EGR Upper Pipe Clamp Orientation 2. Front Exhaust Manifold Clamp Orientation Figure 10 Exhaust Manifold Clamp Orientation 9. Install the front and rear exhaust shields and EGR tube bracket and secure with bolts. See Figure 11. 1. Bolt 9. Exhaust Manifold Gasket 2. Spacer 10. Front Exhaust Manifold 3. Rear Exhaust Manifold 11. Front Exhaust Shield 4. Stud 12. EGR Delivery Pipe Bracket 5. Center Exhaust Manifold 13. Bolt 6.Inner Tube 14. Stud 7. Bellows 15. Rear Exhaust Manifold Shield 8. Clamp Figure 11 Three Piece Exhaust Manifold and Related Parts 10. Torque bolts to 58-73 N·m (43-54 lb·ft) using the proper tightening sequence. 11. Install any other equipment that was removed for this procedure. 12. Carry out the turbocharger purge routine. Refer to section . ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 13. Start the engine and check for exhaust leaks. 14. If exhaust gas leaks are detected, contact the Detroit™ Customer Support Center for further information (800–445–1980). INSTALLATION OF CYLINDER HEAD Perform the following steps for cylinder head installation: 1. Ensure piston domes, cylinder head and cylinder block firedeck surfaces are clean and free of foreign matter. Inspect the head bolt holes in both block and head for the presence of oil, water, dirt, or damaged threads. Clean or retap as necessary. 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 12. NOTE: Effective with engine serial number 06R1012531, Series 60 engines will use a new cylinder head gasket. The new gasket will be identified with a new part number and is a metal sandwich-type compared to a woven appearance. The new gasket must be used with the new style cylinder head bolts. See Figure 14 Figure 12 Cylinder Head Guide Studs 3. Lift the head into position with lift bracket (J–35641–A). See Figure 13. Lower it into place over the guide studs (J–35784) until it seats on the block deck dowels. See Figure 12. Figure 13 Cylinder Head Installation 4. Remove the guide studs. 5. Install the head bolts with special hardened washers, lubricating the threads and bolt-head contact areas with a small amount of International Compound #2®, or equivalent. NOTE: Effective with engine serial number 06R0718942, a new style cylinder head bolt will be used for all Series 60 On-Highway engines. The new bolt will be identified with a groove on top of bolt. See Figure 14. Torque the new head bolts to 298 N·m (220 lb·ft). 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. Figure 14 Bolt Identification For Series 60 Engines 6. Torque the cylinder head bolts to 298 N·m (220 lb·ft) following the sequence shown in Figure 15. Figure 15 Cylinder Head Bolt Tightening Sequence NOTICE: Failure to repeat the cylinder head bolt torque tightening sequence can result in some head bolts losing their torque when others are tightened resulting in insufficient clamp load. 7. Repeat the torque sequence to verify all of the head bolts are torqued to specification. NOTICE: The hemispherical portion of the injector hold-down clamp washers must be installed facing the clamp (pointing down) in order to prevent damage to the washers. 8. Visually inspect each injector hole tube to ensure they are clean. Install the fuel injectors. Refer to section . Be sure the injector hold-down clamps are clear of the valve and injector springs. 9. Install the camshaft. Refer to section . NOTE: If a cylinder head other than the one removed from the engine, or if a resurfaced cylinder head is being installed, the three nuts retaining the adjustable idler gear must be loosened before installing and torquing the camshaft drive gear retaining bolt. NOTICE: The camshaft drive gear-to-adjustable idler gear lash must be measured/adjusted before the rocker arm shaft assemblies are installed. 10. Measure and adjust the camshaft drive gear-to-adjustable idler gear lash. Refer to section 11. Install the rocker arm shaft assemblies. Refer to section . 12. Install Jacob's Brake assemblies (if equipped). Refer to section . 13. Connect the injector harness into the opening in the side of the rocker cover. 14. Connect the injector harness wires to their respective injectors. Refer to section . 15. Install the thermostats and seals to the thermostat housing. Refer to section . 16. Clean the coolant outlet surfaces of the head and thermostat housing. 17. With the thermostats seated in the housing counterbores, install the housing to the cylinder head. Torque the housing bolts to 58-73 N·m (43-54 lb·ft). Connect the radiator or heat exchanger, bypass hose couplings and vent line. 18. Remove all traces of the old gasket from the cylinder head and exhaust manifold joint surfaces. Install the exhaust manifold with new gaskets. Refer to section . 19. Clean the exhaust manifold and turbocharger joint surfaces and install the turbocharger with a new gasket. Refer to section . If turbocharger is water cooled, connect coolant supply and return lines. 20. Fill and vent the cooling system. Refer to section . Fill the engine lubrication system. Refer to section . 21. Connect the exhaust and air-to-air cooler air ducting and install the air cleaner or air separator. 22. Install any other components that were removed and fill with the required fluids, as recommended. Refer to OEM guidelines. 23. Carry out the turbocharger purge routine. Refer to section . ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic. PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. 24. Start the engine and check for fuel, coolant or oil leaks. Keep the engine running while you check. 25. Shut down the engine. INSTALLATION OF THE EGR COOLER Installation steps are as follows: 1. Install oil cooler inlet elbow to oil cooler with gasket and two bolts. Torque bolts to 30-38 N·m (22-28 lb·ft). See Figure 16. 1. Oil Cooler Inlet Elbow 4. EGR Cooler 2. Gasket 5. Bolt M8-1.25 x 65.0 3. Oil Cooler 6. Bolt M8-1.25 x 45.0 Figure 16 EGR Cooler and Related Parts. 2. Install the EGR water outlet hose and clamps onto the oil cooler inlet elbow. PERSONAL INJURY To avoid injury when removing or installing a heavy engine component, ensure the component is properly supported and securely attached to an adequate lifting device to prevent the component from falling. 3. Align the EGR cooler bracket holes with the four bosses on the cylinder block. 4. Thread four M10 bolts through the bracket and into the cylinder block. Torque bolts to 46-52 N·m (34-38 lb·ft). 5. Install the EGR cooler to the bracket utilizing the dowel pins installed on the bracket and cooler. Align bolt holes on EGR cooler to holes on bracket. 6. Insert EGR cooler outlet into hose on oil cooler inlet. 7. Thread four M10 bolts through the EGR cooler holes and into the bracket. Torque bolts to 46-52 N·m (34-38 lb·ft). 8. Install two clamps onto EGR cooler outlet and oil cooler elbow inlet hose. Torque the clamp nut to 12 N·m (106 in.·lbs). 9. Install the hose onto the EGR cooler water inlet. 10. Insert the water pump outlet elbow into the EGR cooler water inlet hose. Secure the hose with clamps. 11. Install a new seal ring on the water pump elbow and secure the elbow with two M10 bolts. Torque bolts to 58-73 N·m (43-54 lb·ft). 12. Install hose and clamp onto EGR cooler outlet. 13. Install delivery pipe. Refer to section . 14. If the upper hot pipe and gasket have not been installed, use the following procedure: NOTE: Verify that the gasket surface is clean on both the hot pipe and the manifold to prevent leakage. [a] Install gasket and upper hot pipe onto the exhaust manifold center section studs. [b] Install two nuts on the studs to secure the upper hot pipe. [c] Torque the nuts to 22-26 N·m (16-19 lb·ft). 15. Install the bellows to the EGR cooler inlet and secure using the bellows clamps. 16. Slip the remaining bellows clamp over the flange of the upper hot pipe. 17. Align the bellows with the upper hot pipe and secure with bellows clamp. 18. Torque nut on bellow clamps to 12 N·m (106 lb·in.). NOTE: Bellows clamps must be positioned correctly for exhaust manifold mid-setback and high-mount center sections. 1. Exhaust manifold Mid-Setback Center Section 5. Nuts 2. Stud 6. Clamp Orientation 3. Gasket 7. Bellows 4. Upper Hot Pipe Figure 17 Bellows Clamp Orientation 19. Carry out the turbocharger purge routine. Refer to section . INSTALLATION OF EGR HEATER PLATE Installation steps are as follows: 1. Install coolant hose fittings that were removed from original EGR heater plate. Torque fitting to 47 N·m (35 lb·ft). See Figure . 2. Install coolant feed and return hose on correct fitting location. Coolant return hose needs to be the farthest from the pipe plug. Torque coolant lines to 55 N·m (41 lb·ft). See Figure . 3. Install EGR heater plate, EGR valve and venturi or EGR valve inlet pipe (depending on engine configuration) onto mixer housing with new seals. Torque all bolts in a cross pattern to 30-38 N·m (22-28 lb·ft). See Figure . 4. Connect coolant supply hose for EGR heater plate to air compressor. Torque fitting to 55 N·m (41 lb·ft). See Figure . 5. Connect coolant return hose. Torque to 55 N·m (41 lb·ft). 6. Torque both clamps for EGR delivery pipe hose to 5 N·m (45 lb·in). Verify that venturi or EGR valve inlet pipe (depending on engine configuration) and delivery pipe are not touching each other. 7. Fill cooling system. 8. Carry out the turbocharger purge routine. Refer to section . PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked. To avoid injury or injury to bystanders, engine or vehicle fuel system service operations should be performed in a well-ventilated area. 9. Start engine and check for leaks. 10. Shut down engine when completed. INSTALLATION OF EGR VALVE Installation steps are as follows: 1. Place a new EGR valve seal onto the EGR mixer inlet. 2. Install the venturi, seal and EGR valve onto the EGR mixer and secure to ERG mixer with four bolts. Torque bolts to 30-38 N·m (22-28 lb·ft). See Figure 18. 1. Bolt 9. Mixer 2. Nut 10. Bolt 3. P-clips 11. Bolt 4. Delivery Pipe 12. Seal 5. Clamp 13. EGR Valve 6. Hose 14. Venturi 7. Seal 15. Clamp 8. Bolt Figure 18 Exhaust Gas Recirculation (EGR) System and Related Parts 3. Install connector to EGR valve sensor. 4. Install the Delta P sensor tubes onto venturi with four clips. 5. Install delivery pipe refer to section . 6. Carry out the turbocharger purge routine. Refer to section . INSTALLATION OF DELIVERY PIPE Installation steps are as follows: NOTICE: Before the hose is installed on the delivery pipe ensure there are not any sharp edges present that can cut the hose liner. 1. Install the rubber hose on the EGR cooler and secure with clamp. 2. Insert EGR cooler side of delivery pipe into the rubber hose and secure with clamp. 3. Install the rubber hose to the venturi and secure with clamp. 4. Insert the venturi side of the delivery pipe into the rubber hose and secure with clamp. Ensure that the top of the delivery pipe is horizontal. 5. Install the delivery pipe to the forward exhaust manifold heat shield with a P-clip and bolt. Torque bolt to 30-38 N·m (22-28 lb·ft). 6. Install delivery pipe to delivery pipe bracket with two P-clips, two bolts and two nuts. Torque nuts to 30-38 N·m (22-28 lb·ft). See Figure 19. 1. Bracket 4. Clamp 2. P-clip 5. Hose 3. Delivery Pipe Figure 19 EGR Cooler Side of Delivery Pipe with Related Parts 7. Plug in the EGR Temperature Sensor (1). See Figure 20. Figure 20 EGR Temperature Sensor Location 8. Torque all delivery pipe clamps to 6.5 N·m (57.5 lb·in.). 9. Carry out the turbocharger purge routine. Refer to section . INSTALLATION OF ADAPTER AND INTAKE THROTTLE VALVE Install the adapter and intake throttle valve as follows: 1. Install the ITV along with the bracket verify that the longer bolts are used in the upper ITV mounting holes. Finger-tighten bolts. See Figure 21. 1. Bracket Bolts Figure 21 2. ITV Bolts M8 1.25x95mm Intake Throttle Valve and Bracket 2. Install the remaining intake throttle bolts. Finger-tighten bolts. 3. Torque all four intake throttle bolts to 27 N·m (20 lb·ft). Tighten bolts in a cross pattern. 4. Torque bracket bolt to 51 N·m (38 lb·ft). 5. Install O-ring seal on the ITV electrical connector. See Figure 22. 1. O-Ring Figure 22 O-Ring 6. Clean old terminal lubricant from the ITV electrical connection then apply a small amount of terminal lubricant (P/N X23538278) to the five female terminals. Connect the electrical connection to the ITV and install retainer clip. See Figure 23. 1. Retaining Clip Figure 23 Retaining Clip 7. Install CAC tubes going to intake throttle and torque clamps to 5 N·m (45 in·lbs). 8. Carry out the turbocharger purge routine. Refer to section . INSTALLATION OF THE EGR MIXER Install the EGR mixer as follows: 1. Install seal and EGR mixer onto intake manifold. 2. Secure EGR mixer to intake manifold with four bolts. Torque bolts to 58-73 N·m (43-54 lb·ft). See Figure 24. 1. Bolt M10 1.50 x 130 4. EGR Mixer 2. EGR Valve 5. Bolt M10 1.50 x 35 3. Seal Figure 24 EGR Mixer and Related Parts 3. Install EGR valve and venturi refer to section . 4. Install delivery pipe refer to section . 5. Install two seals, intake throttle valve and adaptor onto EGR mixer. Refer to section 6. Carry out the turbocharger purge routine. Refer to section . ADDITIONAL SERVICE INFORMATION Additional service information is available in Power Service Literature. Detroit TM , DDC®, Series 60® and the spinning arrows design are registered trademarks of Detroit Diesel Corporation. © Copyright 2012 Detroit Diesel Corporation. All rights reserved. Printed in U.S.A.