16TL11Rev3 Service Bulletin/Repair Instructions

No.: 16 TL-11Rev3

January 23, 2017

TO:
Service Locations
FROM:
Service Systems Development
SUBJECT:
DD5™ Essential Tool Release
GENERAL INFORMATION

The Detroit™ special tools group is pleased to announce the release of the DD5™ 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

NOTE: DD5™ essential tools will not ship to Western Star or Thomas Built Bus exclusive

dealers.

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 DD5 start of production in October 2016.

The table below shows all of the DD5 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
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
Use

Repair

Repair

Repair

Repair

Repair

Repair

Repair

Repair

Diagnostic

Diagnostic

Repair

Repair

Repair

Major Repair

Repair

Repair

Repair

Repair
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W936589006300

W936589006100

W936589016100
Oil Priming Adaptor

Cylinder Head Valve Tool Set

Piston Cooling Nozzle Tool Set
Repair

Major Repair

Major Repair
W936589003700

DSN930E16006

DSN930E16004

W638589111500

DSN930E16005

DSN930E16015

DSN930E16010

W936589046300

W936589056300

DSN930E16009
Piston Ring Compressor

EGR Cooler Pressure Tester

Engine Brake Tester

High Pressure Line Seal Installer

Injector Test Harness

O2 Sensor Socket

LP Leak Test Tool

Test MCM

Test ACM

Flue Flow Hoses
Major Repair

Diagnostic

Diagnostic

Repair

Diagnostic

Repair

Diagnostic

Diagnostic

Diagnostic

Diagnostic
Table 1. Essential Tools for DD5™ 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.
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Figure 3. W936589013300 – Injector O-ring Installer

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.
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Figure 7. W936589033300 - Injector Heat Protection Sleeve Tool Kit

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
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1/23/2017
Used to perform manual compression tests.
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
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Locates and holds the crankshaft and gear at number one TDC during gear train repair.
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.
16 TL-11Rev3
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1/23/2017
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.
16 TL-11Rev3
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Figure 22. W936589003700 – Piston Ring Compressor

Compresses piston rings during piston and connecting rod installation.
Figure 23. DSN930E16006 – EGR Cooler Pressure Tester

Used to diagnose EGR cooler leaks.
Figure 24. DSN930E16004 – 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.
1/23/2017
16 TL-11Rev3
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Figure 27. DSN930E16015 – O2 Sensor Socket

22mm socket used for removal and installation of the O2 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.
1/23/2017
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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 DD5 engine will be

shipped out as they become available.

Refer to Detroit DD5 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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