NHTSA ID Number: 10079020
Manufacturer Communication Number: 16 TL-11
TSB/Document Date: 2016-08-31
Summary
BUSINESS CLASS M2 DD5 Essential Tool Release
No.: 16 TL-11
June 21, 2016
TO:
Service Locations
FROM:
Service Systems Development
SUBJECT:
DDS™ Essential Tool Release
GENERAL INFORMATION
The Detroit™ special tools group is pleased to announce the release of the DDS™ essential tool
program. These tools will be automatically shipped and invoiced to all DD certified repair
locations. The estimated cost of the complete tool package is $5750.00
In an effort to support our 42 pre-series trucks, tool shipments will begin in July 2016, and all
essential tools should arrive at your facility no later than September 2016. All locations should
be fully equipped for the DDS start of production in October 2016.
The table below shows all of the DDS essential tools and their basic functions.
Tool
W936589003300
W936589000700
W936589013300
W936589019100
W936589003100
W936589053300
W936589033300
W936589043300
W936589049100
DSN930E16003
W936589001500
W936589021500
W936589002300
W936589014000
W904589041500
W936589001400
W457589014300
W936589011400
W936589006300
W936589006100
W936589016100
Description
Fuel Injector Removal Tool
Fuel Injector Cup Removal/ Installation Tool
Fuel Injector O-ring Installer
High Pressure Fuel Rail Test Caps
Adaptor for High Pressure Fuel Pump Holding
High Pressure Fuel Pump Gear Puller
Fuel Injector Heat Protection Sleeve Tool Kit
High Pressure Fuel Injector Line Seal Extractor
Fuel Injector Fuel Return Adaptor
Compression Test Adaptor
Top-Dead-Center (TDC) Locating Tool
Flywheel Guide Pins
Camshaft Timing Tool
Crankshaft Holding Tool
Front Crankshaft Seal Installer
Front Crankshaft Seal Installing Spacer
Rear Crankshaft Seal Installer
Rear Crankshaft Seal Installing Spacer
Oil Priming Adaptor
Cylinder Head Valve Tool Set
Piston Cooling Nozzle Tool Set
Use
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Repair
Diagnostic
Diagnostic
Repair
Repair
Repair
Major Repair
Repair
Repair
Reoair
Repair
Repair
Major Repair
Major Repair
16 TL-11
W936589003700
DSN930E16006
DSN930E16004
W638589111500
DSN930E16005
W111589030900
DSN930E16010
W936589046300
W936589056300
DSN930E16009
2
Piston Ring Compressor
EGR Cooler Pressure Tester
Engine Brake Tester
High Pressure Line Seal Installer
Injector Test Harness
02 Sensor Socket
LP Leak Test Tool
Test MCM
Test ACM
Flue Flow Hoses
6/21/2016
Major Repair
Diagnostic
Diagnostic
Repair
Diagnostic
Repair
Diagnostic
Diagnostic
Diagnostic
Diagnostic
Table 1. Essential Tools for DDS™ Engine
Figure 1. W936589003300 - Injector Removal Tool
Removes the fuel injector from the cylinder head
Figure 2. W936589000700 - Injector Cup Removal / Installation Tool
Removes and installs the injector cup into the cylinder head. A four-tooth design and spreading
jaws securely engage the injector cup.
Figure 3. W936589013300 - Injector O-ring Installer
16 TL-11
3
6/21/2016
Installs the injector O-rings.
Figure 4. W936589019100 - HP Fuel Rail Test Caps
Blocks off fuel rail to injector fittings when performing fuel system diagnostics.
Figure 5. W936589003100 -Adaptor for HP Fuel Pump Holding Fixture
Used in combination with current HDEP holding fixture W470589084000 to remove the high
pressure fuel pump drive gear.
Figure 6. W936589053300 - High Pressure Pump Gear Puller
Used in combination with current HDEP holding fixture W470589084000 to remove the high
pressure fuel pump drive gear.
Figure 7. W936589033300 - Injector Heat Protection Sleeve Tool Kit
16 TL-11
4
6/21/2016
Tool kit used to install the copper heat protection sleeve onto the injector tip and extract the old
heat protection sleeve from the cylinder head. Used in combination with impact extractor
W355589016300.
Figure 8. W936589043300 - HP Injector Line Seal Extractor
Removes the seal between the camshaft housing and the high pressure fuel injector feed line,
used in combination with impact extractor W355589016300.
Figure 9. W936589049100 - Injector Fuel Return Adaptor
Used to diagnose leaks in the high pressure side of the fuel system.
Figure 10. W936589009100 - Compression Test Adaptor
Performs cylinder compression tests.
16 TL-11
5
6/21/2016
Figure 11. W936589001500 -TDC Locating Tool
Inserts into the crankshaft position sensor hole and the tip protrudes into a hole in the flywheel
to accurately locate Top Dead Center (TDC) for cylinder number one.
Figure 12. W936589021500 - Flywheel Guide Pins
Aids in removal and installation of the flywheel.
Figure 13. W936589002300 - Camshaft Timing Tool
Verify camshaft timing during repair or for diagnostic purposes.
Figure 14. W936589014000 - Crankshaft Holding Tool
Locates and holds the crankshaft and gear at number one TDC during gear train repair.
16 TL-11
6
Figure 15. W904589041500 - Front Crankshaft Seal Installer
Installs the front crankshaft oil seal.
Figure 16. W936589001400 - Front Crankshaft Seal Spacer
Sets front crankshaft seal depth during installation. Used with W904589041500.
Figure 17. W457589014300 - Rear Crankshaft Seal Installer
Installs the rear crankshaft oil seal.
Figure 18. W936589011400 - Rear Crankshaft Seal Spacer
Sets rear crankshaft seal depth during installation. Used with W457589014300.
6/21/2016
16 TL-11
7
6/21/2016
Figure 19. W936589006300 - Oil Priming Adaptor
Adaptor for priming the lubrication system. Used in combination with Pre-Oiler Kit J-45299.
Figure 20. W936589006100 - Valve Tool Kit
Used for removing and installing valve springs and valve stem oil seals.
Figure 21. W936589016100 - Piston Cooling Nozzle Tool
Used for removing and installing pressed-fit piston cooling nozzles.
Figure 22. W936589003700 - Piston Ring Compressor
16 TL-11
8
Compresses piston rings during piston and connecting rod installation.
Figure 23. W936589029100 - EGR Cooler Pressure Tester
Used to diagnose EGR cooler leaks.
Figure 24. W936589039100 - Engine Brake Tester
Used to test the operation of the engine brake actuators.
Figure 25. W638589111500 - High Pressure Line Seal Installer
Used to install the high pressure fuel line seals into the cylinder head.
Figure 26. DSN930E16005 - Injector Test Harness
Breakout harness used with HDEP breakout box J-48671.
6/21/2016
16 TL-11
9
Figure 27. W111589030900 - 02 Sensor Socket
22mm socket used for removal and installation of the 02 sensor.
Figure 28. DSN930E16010 - Low Pressure Leak Test Tool
Used to diagnose leaks on the low pressure side of the fuel system.
Figure 29. W936589046300- Test MCM
Used to diagnose a faulty MCM.
Figure 30. W936589056300- Test ACM
Used to diagnose a faulty ACM.
6/21/2016
16 TL-11
10
6/21/2016
Figure 31. DSN930E16010 - Fuel Flow Hoses
Used with existing HDEP tool J-48708 to measure injector and needle return flow.
ADDITIONAL INFORMATION
Tools will be packaged together in lot shipments, generically addressed to the service
manager at each facility. Some tools on the list may not be included in the initial shipment,
depending on availability. Remaining tools and new essential tools for the DDS engine will be
shipped out as they become available.
Refer to Detroit DDS service manual DDC-SVC-MAN-0194 for individual tool usage and
procedures. If there are any questions or concerns about the usage of these tools, contact the
Detroit Customer Support Center immediately. Do not attempt to modify these tools in any
way; doing so may result in damage to the tool or damage to the engine.
CONTACT INFORMATION
Please contact the Detroit™ Customer Support Center at 1-800-445-1980 or email
[email protected] if you have any questions.
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TSB/Document ID: 16 TL-11
Replacement Service Bulletin Number:
MFR Communication Date: 2016-06-21
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: EQUIPMENT:OTHER:OWNERS/SERVICE/OTHER MANUAL
MFR Component System:
MFR Component Subsystem:
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