NHTSA ID Number: 10172739
Manufacturer Communication Number: SIB0201-20
TSB/Document Date: 2020-03-23
Summary
Service Information Bulletin for Cylinder Block Porosity Repair for DD5 and DD8 egnines. Use this procedure to repair oil leaks caused by cylinder block porosity. The low oil pressure, cast areas of the cylinder block can be repaired using this method. J-B Weld is the recommended two-part epoxy for this repair.
02 01-20
1
02 01-20
SUBJECT
DATE
Cylinder Block Porosity Repair
February 2020
Additions, Revisions, or Updates
Publication Number / Title
Platform
DDC-SVC-MAN-0194
Medium
Duty-DD5
934912(C)
DDC-SVC-MAN-0201
Medium
Duty-DD5
934914(S)
DDC-SVC-MAN-0198
Medium
Duty-DD8
Section Title
Change
Cylinder Block Porosity
Repair
New Procedure
All information subject to change without notice.
02 01-20
Copyright © 2020 DETROIT DIESEL CORPORATION
3
2 Cylinder Block Porosity Repair
2
Cylinder Block Porosity Repair
Use this procedure to repair oil leaks caused by cylinder block porosity. The low oil pressure, cast areas of the cylinder block
can be repaired using this method. J-B Weld is the recommended two-part epoxy for this repair.
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: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2. Disconnect the batteries.
3. Open the hood.
4. Remove any necessary components from the engine to gain access to the area leaking oil.
NOTE: The origin of the oil leak should have been properly identified during the oil leak troubleshooting.
5. Is the oil leaking from a machined surface on the cylinder block?
a. Yes, replace the engine. Cylinder block machined surfaces cannot be reconditioned or repaired. Refer to section
"Removal of the Complete Powertrain Assembly".
b. No, Go to step 6.
6. Is oil leaking from an area of the cylinder block, shown in yellow on the illustrations below?
a. Yes, replace the engine. High-pressure oil galleries and passages cannot be repaired. Refer to section "Removal
of the Complete Powertrain Assembly".
b. No, Go to step 7.
4
All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION
02 01-20
02 01-20
Figure 1. Right Side of Cylinder Block
Figure 2. Left Side of Cylinder Block
All information subject to change without notice.
02 01-20
Copyright © 2020 DETROIT DIESEL CORPORATION
5
2 Cylinder Block Porosity Repair
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.
7. Clean the cylinder block surface with a suitable cleaning agent and dry with compressed air.
8. Use a 3M Roloc bristle disc or course sandpaper to remove any loose debris, paint, or surface rust at the porous area of
the cylinder block.
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.
9. Use compressed air to remove any contaminants from the surface of the cylinder block.
10. Inspect the porous area of the cylinder block to ensure the surface is clean and dry. A clean and dry surface is required
for proper adhesion of the J-B Weld epoxy.
11. Follow the J-B Weld instructions to mix the two parts of the epoxy.
12. Apply the epoxy mix to the cylinder block. Use enough epoxy to completely cover the porous area.
13. Install the components that were removed from the engine to gain access to the porous area.
14. Allow the epoxy to cure per the J-B Weld instructions.
15. To prevent corrosion, use a high temperature gray engine paint and coat the repaired surface of the cylinder block.
Paint is not required if the area is no longer accessible.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
16. Reconnect the batteries.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
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.
17. Start engine and visually inspect for oil leaks.
18. Close the hood.
6
All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION
02 01-20
02 01-20
3
Cylinder Block Porosity Repair
Use this procedure to repair oil leaks caused by cylinder block porosity. The low oil pressure, cast areas of the cylinder block
can be repaired using this method. J-B Weld is the recommended two-part epoxy for this repair.
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: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2. Disconnect the batteries.
3. Open the hood.
4. Remove any necessary components from the engine to gain access to the area leaking oil.
NOTE: The origin of the oil leak should have been properly identified during the oil leak troubleshooting.
5. Is the oil leaking from a machined surface on the cylinder block?
a. Yes, replace the engine. Cylinder block machined surfaces cannot be reconditioned or repaired. Refer to section
"Removal of the Complete Powertrain Assembly".
b. No, Go to step 6.
6. Is the oil leaking from an area of the cylinder block, shown in yellow on the illustrations below?
a. Yes, replace the engine. High-pressure oil galleries and passages cannot be repaired. Refer to section "Removal
of the Complete Powertrain Assembly".
b. No, Go to step 7.
All information subject to change without notice.
02 01-20
Copyright © 2020 DETROIT DIESEL CORPORATION
7
3 Cylinder Block Porosity Repair
Figure 3. Right Side of Cylinder Block
Figure 4. Left Side of Cylinder Block
8
All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION
02 01-20
02 01-20
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.
7. Clean the cylinder block surface with a suitable cleaning agent and dry with compressed air.
8. Use a 3M Roloc bristle disc or course sandpaper to remove any loose debris, paint, or surface rust at the porous area of
the cylinder block.
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.
9. Use compressed air to remove any contaminants from the surface of the cylinder block.
10. Inspect the porous area of the cylinder block to ensure the surface is clean and dry. A clean and dry surface is required
for proper adhesion of the J-B Weld epoxy.
11. Follow the J-B Weld instructions to mix the two parts of the epoxy.
12. Apply the epoxy mix to the cylinder block. Use enough epoxy to completely cover the porous area.
13. Install the components that were removed from the engine to gain access to the porous area.
14. Allow the epoxy to cure per the J-B Weld instructions.
15. To prevent corrosion, use a high temperature gray engine paint and coat the repaired surface of the cylinder block.
Paint is not required if the area is no longer accessible.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
16. Reconnect the batteries.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
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.
17. Start engine and visually inspect for oil leaks.
18. Close the hood.
All information subject to change without notice.
02 01-20
Copyright © 2020 DETROIT DIESEL CORPORATION
9
4 Cylinder Block Porosity Repair
4
Cylinder Block Porosity Repair
Use this procedure to repair oil leaks caused by cylinder block porosity. The low oil pressure, cast areas of the cylinder block
can be repaired using this method. J-B Weld is the recommended two-part epoxy for this repair.
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: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2. Disconnect the batteries.
3. Open the hood.
4. Remove any necessary components from the engine to gain access to the area leaking oil.
NOTE: The origin of the oil leak should have been properly identified during the oil leak troubleshooting.
5. Is the oil leaking from a machined surface on the cylinder block?
a. Yes, replace the engine. Cylinder block machined surfaces cannot be reconditioned or repaired. Refer to section
"Removal of the Complete Powertrain Assembly".
b. No, Go to step 6.
6. Is the oil leaking from an area of the cylinder block, shown in yellow on the illustrations below?
a. Yes, replace the engine. High-pressure oil galleries and passages cannot be repaired. Refer to section "Removal
of the Complete Powertrain Assembly".
b. No, Go to step 7.
10
All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION
02 01-20
02 01-20
Figure 5. Right Side of Cylinder Block
Figure 6. Left Side of Cylinder Block
All information subject to change without notice.
02 01-20
Copyright © 2020 DETROIT DIESEL CORPORATION
11
4 Cylinder Block Porosity Repair
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.
7. Clean the cylinder block surface with a suitable cleaning agent and dry with compressed air.
8. Use a 3M Roloc bristle disc or course sandpaper to remove any loose debris, paint, or surface rust at the porous area of
the cylinder block.
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.
9. Use compressed air to remove any contaminants from the surface of the cylinder block.
10. Inspect the porous area of the cylinder block to ensure the surface is clean and dry. A clean and dry surface is required
for proper adhesion of the J-B Weld epoxy.
11. Follow the J-B Weld instructions to mix the two parts of the epoxy.
12. Apply the epoxy mix to the cylinder block. Use enough epoxy to completely cover the porous area.
13. Install the components that were removed from the engine to gain access to the porous area.
14. Allow the epoxy to cure per the J-B Weld instructions.
15. To prevent corrosion, use a high temperature gray engine paint and coat the repaired surface of the cylinder block.
Paint is not required if the area is no longer accessible.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
16. Reconnect the batteries.
WARNING: PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to cause
cancer, birth defects, and other reproductive harm.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
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.
17. Start engine and visually inspect for oil leaks.
18. Close the hood.
12
All information subject to change without notice.
Copyright © 2020 DETROIT DIESEL CORPORATION
02 01-20
- 3X Stronger than the leading full synthetic*
- 10X Better high stress performance**
- 20,000 miles between oil changes***
- Viscosity breakdown as measured in Kurt Orbahn test on 5W...
- As measured in Seq IX test under high load/torque conditions...
- Phosphorus Replacement Technology to help extend the life of...
- Reduces leaks, oil burnoff and power robbing deposits
- 15,000 miles between oil changes*
- Meets or exceeds the following specifications: API SP/SN...
- Or one year, whichever comes first
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TSB/Document ID: SIB0201-20
Replacement Service Bulletin Number:
MFR Communication Date: 2020-03-23
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: ENGINE AND ENGINE COOLING
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