27. If removed, install the fan assembly. Refer to OEM procedures.
28. If removed, install the radiator assembly. Refer to OEM procedures.
29. If removed, install the hood. Refer to OEM procedures.
30. Install the coolant surge tank. Refer to OEM procedures.
31. Connect the coolant level sensor.
32. Install the Charge Air Cooler (CAC) hose clamp at the intake throttle adaptor inlet.
33. Install the compressor outlet elbow and inlet elbow. Connect the Charge Air Cooler (CAC) ducting from the turbo
compressor housing to the CAC.

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34. Reconnect the batteries. Refer to OEM procedures.
35. Prime fuel system.
Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter System".
Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter System".
36. Fill the cooling system. Refer to section "Cooling System Fill Procedure".
37. If removed, install the windshield wiper linkage. Refer to OEM procedures.
38. If removed, install the rain tray. Refer to OEM procedures.
39. If removed, install the bumper. Refer to OEM procedures.
WARNING: 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.

WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
40. Start the engine and check for fuel, coolant or oil leaks.

All information subject to change without notice.

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Copyright © 2015 DETROIT DIESEL CORPORATION

11

4 Removal of the DD15 and DD16 Cylinder Head

4

Removal of the DD15 and DD16 Cylinder Head

Remove as follows:
NOTE: If the cylinder head is to be replaced, the new head must be thoroughly cleaned before installation to
remove all rust and rust preventive compound, especially from the fuel and oil galleries.
WARNING: EYE INJURY
To avoid injury from flying debris when using compressed air, wear adequate eye protection (face
shield or safety goggles) and do not exceed 276 kPa (40 psi) air pressure.
NOTE: When clean, blow the head dry with compressed air.
WARNING: PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.

12

Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
Disconnect the batteries. Refer to OEM procedures.
Open the hood.
If needed, remove the bumper. Refer to OEM procedures.
If needed, remove the rain tray. Refer to OEM procedures.
If needed, remove the windshield wiper linkage. Refer to OEM procedures.
Drain the engine cooling system. Refer to section "Cooling System Drain Procedure".
Disconnect the coolant level sensor.
Remove the coolant surge tank. Refer to OEM procedures.
Remove the camshaft housing assembly. Refer to section "Removal of the Camshaft Housing Assembly".
Remove coolant lines (1) from the water manifold to the fuel doser injector housing.

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12. Disconnect the DEF heater lines at the chassis water manifold. Refer to OEM procedures.
13. Remove the Exhaust Gas Recirculation (EGR) vent (de-aeration) line.
14. Disconnect the EGR actuator connector and remove the heat shield. Refer to section "Removal of DD15 and DD16
Exhaust Gas Recirculation Valve Actuator".
15. Remove the EGR actuator coolant line (1) from the cylinder block.

16. Remove nut connecting actuator to linkage and remove linkage from Exhaust Gas Recirculation (EGR) valve.
All information subject to change without notice.

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13

4 Removal of the DD15 and DD16 Cylinder Head
17. Remove the turbocharger heat shield.
18. Remove the turbocharger flange bolts (1).

19.
20.
21.
22.
23.

Remove the Coolant Crossover Pipe. Refer to section "Removal of the Coolant Crossover Pipe".
Disconnect the Intake Throttle Valve (ITV) electrical harness connector.
Remove the Charge Air Cooler (CAC) hose clamp at the intake throttle adaptor inlet.
Remove the two bolts attaching the cold boost pipe to the cold boost pipe support bracket.
Disconnect the needle, amplifier, and pressure limiting valve return lines.
Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter
System".
Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter System".
24. Remove the two small cylinder head bolts (39 and 40). For EPA07 DD15, these bolts are located on the outside of the
cylinder head casting at the rear of the engine.

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25. Using the flywheel and main pulley socket tool (J-45390), remove the 38 bolts securing the cylinder head to the
cylinder block.
WARNING: 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.
26. Using cylinder head/engine lifting bar tool (W470589006200), remove the cylinder head from the cylinder block.
27. Remove and discard the cylinder head gasket.

All information subject to change without notice.

12 10-14

Copyright © 2015 DETROIT DIESEL CORPORATION

15

5 Installation of the DD15 and DD16 Cylinder Head

5

Installation of the DD15 and DD16 Cylinder Head

Install as follows:
NOTICE: Do not use any abrasive tools or methods to clean oil and coolant counter bores or gasket surfaces of
cylinder head or cylinder block. Foreign material may enter the oil system and cause serious engine damage.
NOTICE: Thoroughly clean oil and coolant counter bores in the cylinder block with a suitable scraper to remove
any foreign material before installation of cylinder head gasket. Counter bores must be clean and dry. Failure to
properly clean counter bores may result in cylinder head gasket failure.
NOTE: If the coolant seals on the head gasket have failed, do not proactively replace the cylinder liner seals
unless there is evidence of extensive cylinder block erosion.
1. Inspect the cylinder head bolt holes in the cylinder block for the presence of oil, water, dirt, rust or damaged threads.
Clean or re-tap as necessary. Ensure piston domes and cylinder block deck surfaces are clean, dry and free of oil, water
or any other foreign material.

WARNING: 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.
2. Lift the cylinder head using cylinder head/engine lifting bar tool (W470589006200) so the cylinder head can hang at a
30 to 45 degree angle lengthwise for 10 minutes. The oil and coolant will need to drain before the head can be installed
on the engine. Use caution to avoid damage to the fuel injector tips.
NOTE: The area of the cylinder block between the cylinders is not a sealing surface and will not cause a coolant
leak.
3. Using liner protrusion tool J-47415A, verify that the cylinder liner protrusion heights are all within 0.0889 mm (0.0035
in.) prior to installing the cylinder head. Minimum liner protrusion is 0.1397 mm (0.0055 in.) and maximum liner
protrusion is 0.26924 mm (0.0106 in.).
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4. Alternate the cylinder head to hang in the opposite direction at the same 30 to 45 degree angle lengthwise for another
ten minutes. Use caution to avoid damage to the fuel injector tips.
5. Clean any oil, water or other foreign material from the cylinder head bolt holes and gasket surface of the cylinder head.
NOTE: Be sure both gasket surfaces on the cylinder block and the cylinder head are clean and dry, especially the
oil and coolant counter bores.
6. Position a new cylinder head gasket onto cylinder block.
WARNING: 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.
7. Lift the cylinder head into position using cylinder head/engine lifting bar tool (W470589006200). Install the guide
studs (J-35784) through the cylinder head into the cylinder block and carefully seat the cylinder head onto the cylinder
block.
8. Remove the cylinder head guide studs.
NOTICE: Do not dip the entire cylinder head mounting bolt in oil as the excessive oil could cause improper torque
results.
9. Coat the threads and underside of the bolt heads with clean engine oil before installation.
NOTE: If reusing the head bolts make sure they do not exceed the maximum bolt length of 194mm (7.638
inches).
10. Install the 40 cylinder head bolts into the cylinder head.
11. Torque the 38 large bolts in four steps to:
a. 50 N·m (37 lb·ft)
b. 250 N·m (184 lb·ft)
c. 90° torque turn
d. 90° torque turn
12. Torque the small bolts (39 and 40) to 60 N·m (44 lb·ft). For EPA07 DD15, these bolts are located on the outside of the
cylinder head casting at the rear of the engine.

13. Connect the needle, amplifier, and pressure limiting valve return lines.
All information subject to change without notice.

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17

5 Installation of the DD15 and DD16 Cylinder Head

14.
15.
16.
17.
18.

Refer to section "Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines – Two-Filter
System".
Refer to section "Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter
System".
Install the two bolts attaching the cold boost pipe to the cold boost pipe support bracket.
Install the Charge Air Cooler (CAC) hose clamp at the intake throttle adaptor inlet.
Connect the Intake Throttle Valve (ITV) electrical harness connector.
Install the Coolant Crossover Pipe. Refer to section "Installation of the Coolant Crossover Pipe".
Install the turbocharger flange bolts (1).

19. Connect linkage from Exhaust Gas Recirculation (EGR) valve and install nut.
20. Install the EGR actuator coolant line (1) from the cylinder block.

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21. Install the turbocharger heat shield.
22. Connect the EGR actuator connector and install the heat shield. Refer to section "Installation of the DD15 and DD16
Exhaust Gas Recirculation Valve Actuator".
23. Connect the DEF heater lines at the chassis water manifold. Refer to OEM procedures.
24. Install the EGR vent (de-aeration) line.
25. Install the coolant lines (1) from the water manifold to the fuel doser injector housing.

All information subject to change without notice.

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Copyright © 2015 DETROIT DIESEL CORPORATION

19

5 Installation of the DD15 and DD16 Cylinder Head
26.
27.
28.
29.
30.
31.
32.
33.
34.

Install the camshaft housing assembly. Refer to section "Installation of the Camshaft Housing Assembly".
Install the coolant surge tank. Refer to OEM procedures.
Connect the coolant level sensor.
Prime fuel system.
Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter System"
Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter System"
Reconnect the batteries. Refer to OEM procedures.
Fill the cooling system. Refer to section "Cooling System Fill Procedure".
If removed, install the windshield wiper linkage. Refer to OEM procedures.
If removed, install the rain tray. Refer to OEM procedures.
If removed, install the bumper. Refer to OEM procedures.
WARNING: 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.

WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
35. Start the engine and check for fuel, coolant or oil leaks.

20

All information subject to change without notice.

Copyright © 2015 DETROIT DIESEL CORPORATION 12 10-14