0602-17 Service Bulletin/Repair Instructions

06 02-17
1
06 02-17
SUBJECT
DATE
Cylinder Liner - Testing of the Cylinder Liner Upper O-Ring
June 2017
Additions, Revisions, or Updates

Publication Number / Title

DDC-SVC-MAN-0081
DDC-SVC-MAN-0190
Platform
Heavy Duty

- All
Section Title

Testing of the Cylinder

Liner Upper O-Ring

Testing of the Cylinder

Liner Upper O-Ring
Change
This is a new section. Test procedure with DKI470E16024 - Heavy

Duty Cylinder Liner Seal Leak Tester.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
3
2 Testing of the Cylinder Liner Upper O-Ring
2
Testing of the Cylinder Liner Upper O-Ring
Table 1.

Service Tools Used in the Procedure

DKI470E16024 - Heavy Duty Cylinder Liner Seal Leak Tester
Kit Contents:

Part #
Description
QTY
Serviceable (Yes/No)
DKI470E16024-1
Cylinder 1 Top Plate (left)
1
Yes
DKI470E16024-2
Cylinder Top Plate
11
Yes
4
Tool Images
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
Service Tools Used in the Procedure

DKI470E16024-3
Oil Coolant Module Plate
1
Yes
DKI470E16024-4
Bolt (Oil Coolant Module

Plate) M10-1.5 x 35mm
10
No
DKI470E16024-5
Washer (Oil Coolant

Module Plate) M10 Flat

Washer
10
No
DKI470E16024-6
Spacer
32
Yes
DKI470E16024-7
Washer (Spacer Bottom)
32
Yes
DKI470E16024-8
Washer (Spacer Top) M16

Flat Washer
32
No
DKI470E16024-9
Fuel Filter Module (FFM)

Coolant Line Plate
1
Yes
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
5
2 Testing of the Cylinder Liner Upper O-Ring
Service Tools Used in the Procedure

DKI470E16024-10
Bolt (FFM Coolant Line

Plate) M5-0.8 x 20mm
2
No
DKI470E16024-11
Fuel Filter Module (FFM)

Plug
1
Yes
DKI470E16024-12
Bolt (FFM Plug) M10-1.5 X

20mm
2
No
DKI470E16024-13
Threaded plug (M18)
4
Yes
DKI470E16024-14
Threaded plug (M14)
4
Yes
DKI470E16024-15
Cap - Coolant Line Fitting
2
Yes
DKI470E16024-16
Cap - Coolant Crossover

(EPA07-GHG14)
1
Yes
6
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
Service Tools Used in the Procedure

DKI470E16024-17
Cap - Coolant Crossover

(GHG17)
1
Yes
DKI470E16024-18
Cap - Coolant Inlet Elbow

(Port A)
1
Yes
DKI470E16024-19
Cap - Coolant Inlet Elbow

(Port B)
1
Yes
DKI470E16024-20
Cap - Coolant Inlet (lower

radiator hose)
1
Yes
DKI470E16024-21
Kit Case (Foam & Case

Included)
1
Yes
An external coolant leak found between the cylinder head and cylinder block could be misdiagnosed or over-repaired. The

use of the Heavy Duty Cylinder Liner Upper Seal Leak Tester will enable technicians to verify if just the head gasket is

leaking or if the upper cylinder liner seal(s) are leaking.

Cylinder block corrosion on the fire deck surface, as well as the counter bore area, is often misdiagnosed as a non-repairable

cylinder block. Corrosion is only a concern if the sealing surface of the cooling passage(s) is compromised.

The following test procedure is performed with the cylinder head removed.

The test procedure can be performed with or without the following components installed:

•

•

•

•

•

•
Oil Coolant Module

Fuel Filter Module (FFM)

Air Compressor Coolant Supply Line

Air Compressor Coolant Return Line

Air Compressor

Coolant Drain Plug
Set up as follows:
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
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2 Testing of the Cylinder Liner Upper O-Ring

1. Clean the cylinder block fire deck, making sure there are no grommets stuck in the counter bores of the coolant

passages.

2. Clean 32 of the original cylinder head bolts.

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.

3. Using compressed air, clean all cylinder head bolt bores.

4. On each of the 32 cylinder head bolts (3), slide one small washer (1), one spacer (2), and one large flat washer (4).

This will be referred to as the "cylinder head bolt assembly" throughout the rest of the procedure.
1. DKI470E16024-8 - Washer (Spacer Top)

2. DKI470E16024-6 - Spacer
3. Cylinder Head Bolt

4. DKI470E16024-7 - Washer (Spacer Bottom)
NOTE: Each cylinder liner should come into contact with a portion of the bottom washer of a cylinder head bolt

assembly in two locations. Reference image below.

5. Install seven cylinder head bolt assemblies (5) into the center cylinder head bolt bores using a crisscross pattern.

Hand-tighten.
8
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
1. DKI470E16024-8 - Washer (Spacer Top)

2. DKI470E16024-6 - Spacer

3. Cylinder Head Bolt
4. DKI470E16024-7 - Washer (Spacer Bottom)

5. Cylinder Head Bolt Assembly
6. Install the cylinder #1 top plate (1) using three cylinder head bolt assemblies. Hand-tighten.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
9
2 Testing of the Cylinder Liner Upper O-Ring
Figure 3. DKI470E16024-1 - Cylinder 1 Top Plate (left)

7. Install the remaining 11 cylinder top plates (1) using the remaining cylinder head bolt assemblies.
Figure 4. DKI470E16024-2 - Cylinder Top Plate

8. Torque all 32 cylinder head bolt assemblies to 25 N·m (18 lb·ft).

10
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17

9. If still attached to cylinder block, remove the Exhaust Gas Recirculation (EGR) actuator coolant supply line.

10. Install threaded plug (1) into the cylinder block. Hand-tighten.
Figure 5. DKI470E16024-14 - Threaded Plug (M14)

11. Torque threaded plug to 25 N·m (18 lb·ft).

12. Install the associated caps on each coolant port of the oil coolant module. Hand-tighten. See figure below.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
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2 Testing of the Cylinder Liner Upper O-Ring
1. DKI470E16024-19 - Cap - Coolant Inlet Elbow

(Port B)

2. DKI470E16024-18 - Cap - Coolant Inlet Elbow

(Port A)

3. DKI470E16024-16 - Cap - Coolant Crossover

(EPA07-GHG14)
4. DKI470E16024-15 - Cap - Coolant Line Fitting

5. DKI470E16024-20 - Cap - Coolant Inlet (lower

radiator hose)
Figure 6. EPA07-GHG14 Oil Coolant Module

13. Torque all worm clamps to 6 N·m (4 lb·ft).

NOTE: Steps 14-16 are only required if the oil coolant module is removed from the engine.

14. Remove alignment dowel(s) if still in the engine block. Save dowels for reassembly.
12
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
1. DKI470E16024-3 - Oil Coolant Module Plate

2. DKI470E16024-4 - Bolt (Oil Coolant Module

Plate)
3. DKI470E16024-5 - Washer (Coolant Module

Plate)
Figure 7. Oil Coolant Module Removed

15. If needed, install oil coolant module plate (1) with supplied bolts (2) and washers (3). Hand-tighten.

16. In a crisscross pattern, torque mounting bolts to 25 N·m (18 lb·ft).

NOTE: Steps 17-22 are only required if the air compressor coolant supply and/or return line(s) are removed from

the engine.

17. Install threaded plug (1) on the coolant supply port for the air compressor on the cylinder block.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
13
2 Testing of the Cylinder Liner Upper O-Ring
1. DKI470E16024-13 - Threaded Plug (M18)
Figure 8. Both Lines Disconnected

18. Torque threaded plug to 30 N·m (22 lb·ft).

19. Install Cap - Coolant Line Fitting (2) over the air compressor coolant outlet line fitting.
14
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
Figure 9. One Line Disconnected - Use Cap with Coolant Fitting

20. Torque worm clamp on cap to 6 N·m (4 lb·ft).

21. Install threaded plug (1) into the coolant outlet line port of the air compressor.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
15
2 Testing of the Cylinder Liner Upper O-Ring

1. DKI470E16024-13 - Threaded Plug (M18)
Figure 10. One Line Disconnected - Use Threaded Cap

22. Torque threaded plug to 30 N·m (22 lb·ft).

NOTE: Steps 23-25 are only required if the Fuel Filter Module (FFM) is removed from the engine. This coolant

port may be phased out depending on the vintage of the cylinder block.

23. If needed, install Fuel Filter Module (FFM) Plug (1). Hand-tighten the two captured bolts (2) making sure the rubber

stop is not coming in contact with the cylinder block.
1. DKI470E16024-11 - Fuel Filter Module (FFM)

Plug
2. DKI470E16024-12 - Bolt (FFM Plug)
Figure 11. Fuel Filter Module (FFM) Removed

24. Torque captured bolts to 25 N·m (18 lb·ft).

25. By hand, thread the rubber stop into the coolant port on the cylinder block. Once the rubber stop has made contact use

only as much force as needed to achieve a seal between the cylinder block and rubber stop.

NOTE: Steps 26-27 are only used on units equipped with an air compressor coolant return line that connects the

air compressor, fuel filter module, and oil/coolant module and is removed from the engine.

26. If needed, install the Fuel Filter Module (FFM) Line Plate (1). Hand-tighten the two captured bolts (2).
16
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
1. DKI470E16024-9 - Fuel Filter Module (FFM)

Coolant Line Plate
2. DKI470E16024-10 - Bolt (FFM Coolant Line

Plate)
Figure 12. Fuel Filter Module (FFM) Coolant Line Port

27. Torque captured bolts to 15 N·m (11 lb·ft).

NOTE: Steps 28-29 are only required if the coolant drain fitting is removed from the engine.

28. If needed, install threaded plug (1) into the cylinder block coolant port for the coolant drain plug.
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
17
2 Testing of the Cylinder Liner Upper O-Ring
1. DKI470E16024-13 - Threaded plug (M18)
29.

30.

31.

32.

33.

34.
18
Figure 13. Coolant Drain Plug Removed

Torque threaded plug to 30 N·m (22 lb·ft).

Perform the test as follows; using a regulated air source, supply 20 psi to the system, let stabilize for five minutes.

Shut off the air supply to the regulator.

Spray down all plates/plugs/regulator, etc. with soapy water and verify no leaks are present. Address any tool leaks.

Spray soapy water around the cylinder liners and cylinder block.

Observe the gap where the liner and fire deck meet. Apply more soapy water as needed until the visual inspection for

bubbles (air leak) has been completed 360° around all six cylinders.
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 06 02-17
06 02-17
Table 2.

Example A - Multiple Upper Liner Seals Leaking
All information subject to change without notice.
06 02-17
Copyright © 2017 DETROIT DIESEL CORPORATION
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2 Testing of the Cylinder Liner Upper O-Ring
Table 3.

Example B - Single Upper Liner Seal Leaking
35. If system pressure drops below 20 psi in 10 minutes after the initial five-minute stabilization period, identify the leak.

A failed upper cylinder liner seal can only be confirmed by a soapy water mix bubbling. A drop in pressure only

indicates a gross leak. A poor tooling seal can cause a gross leak.

36. Perform the repair as follows; if one or more upper cylinder liner seals are found to be leaking, remove the cylinder

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