0805-17 Service Bulletin/Repair Instructions

08 05-17
1
08 05-17
SUBJECT
DATE
Contaminated Fluids
August 2017
Additions, Revisions, or Updates

Publication Number / Title

DDC-SVC-MAN-0191
Platform
DDC-SVC-MAN-0084
DD Heavy

Duty
DDC-SVC-MAN-0184
Euro IV
Section Title
Change
Fuel in Coolant/Coolant

in Fuel
Updated HD diagnostic procedures
DiagnosticLink users: Please update the troubleshooting guides in DiagnosticLink with this newest version. To update the

tool troubleshooting guide, open DiagnosticLink and from the Help – Troubleshooting Guides menu, select the appropriate

troubleshooting manual, then click Update.
All information subject to change without notice.
08 05-17
Copyright © 2017 DETROIT DIESEL CORPORATION
3
2 Fuel in Coolant/Coolant in Fuel
2
Fuel in Coolant/Coolant in Fuel
Table 1.

Service Tool Used in the Procedure

Tool Number
Description
W470589012500
DD13 Cylinder Head Leak Tool
W470589002500
DD15/16 Cylinder Head Leak Tool
NOTE: DEF contamination in the fuel system can be mistaken for coolant in the fuel. When DEF is found to be a

contaminant of the fuel system, its appearance will be a brown or rusty color most notable in the fuel filter module.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

2. Verify that fuel/coolant contamination is present.

3. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for external

coolant leaks. Are any leaks present?

a. Yes; repair as necessary. Then, Go to step 9.

b. No; Go to step 4.

NOTE: The fuel injector O-rings and the fuel injector clamp hold-down bolts must be replaced each time they are

removed from the cylinder head.

4. Release the pressure from the cooling system.

5. Remove all six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System".

NOTICE: Failure to reinstall the fuel injector hold-down clamps may damage the cylinder head coolant gallery

plugs (1).

6. Reinstall the fuel injector hold-down clamps with old fuel injector bolts. Torque bolts to 20 N·m (15 lb·ft) + 90-degree

torque turn.
7. Pressurize the cooling system per OEM specifications. Inspect for coolant leaks around the fuel injector cups. Are any

leaks present?

4
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 05-17
08 05-17

a. Yes; clean the injector cups and replace all six injector cup O-rings. Refer to section "Removal of the Fuel

Injector - Two-Filter System". Then Go to step 9.

b. No; Go to step 8.

8. Remove the cylinder head. Pressure test the cylinder head. For DD13 engines, use tool W470589012500. For DD15

and DD16 engines, use tool W470589002500. Are there any leaks present?

For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly".

a. Yes; replace or repair as necessary. Then Go to step 9.

For the DD13: Refer to section "Installation of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly".

b. No; review the results of the above troubleshooting steps. Then Go to step 9.

9. If fuel has been identified as a contaminant in the coolant, replace the components listed below. All fuel system repairs

should now be complete. If the WIF Light is on refer to Power Service Literature for the fault that is present.

Table 2.

Description
Qty.
Comments
Fuel Injector Cup Seals
1
This is a kit consisting of six seals.
Coolant Line - Air Compressor To Fuel

Filter Module
1
Coolant Line - Air Compressor To Cylinder

1

Block

Coolant Line - Fuel Filter Module To Oil/

Coolant Module
1
Gasket - Fuel Injector Jumper Lines
6
Fuel Injector O-Ring Seal Kit
6
Coolant Filter (if equipped)
1
Use applicable coolant filter. Note that

some engines may not have a coolant

filter if previously removed by the

customer.
Coolant
NA
Use applicable coolant as listed in the

"Coolant Selections" manual (DDC-SVCBRO-0002)
All information subject to change without notice.
08 05-17
Copyright © 2017 DETROIT DIESEL CORPORATION
5
3 Fuel in Coolant/Coolant in Fuel
3
Fuel in Coolant/Coolant in Fuel
Table 3.

Service Tool Used in the Procedure

Tool Number
Description
W470589012500
DD13 Cylinder Head Leak Tool
W470589002500
DD15/16 Cylinder Head Leak Tool
NOTE: DEF contamination in the fuel system can be mistaken for coolant in the fuel. When DEF is found to be a

contaminant of the fuel system, its appearance will be a brown or rusty color most notable in the fuel filter module.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

2. Verify that fuel/coolant contamination is present.

3. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for external

coolant leaks. Are any leaks present?

a. Yes; repair as necessary. Then, Go to step 13.

b. No; Go to step 4.

NOTE: The fuel injector O-rings and the fuel injector clamp hold-down bolts must be replaced each time they are

removed from the cylinder head.

4. Release the pressure from the cooling system.

5. Remove all six fuel injectors.

For the three-filter fuel system, Refer to section "Removal of the Fuel Injector - Three-Filter System".

For the two-filter fuel system, Refer to section "Removal of the Fuel Injector - Two-Filter System".

NOTICE: Failure to reinstall the fuel injector hold-down clamps may damage the cylinder head coolant gallery

plugs (1).

6. Reinstall the fuel injector hold-down clamps with old fuel injector bolts. Torque bolts to 20 N·m (15 lb·ft) + 90-degree

torque turn.
6
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 05-17
08 05-17

7. Pressurize the cooling system per OEM specifications. Inspect for coolant leaks around the fuel injector cups. Are any

leaks present?

a. Yes; clean the injector cups and replace all six injector cup O-rings. Then Go to step 13.

For the three-filter fuel system, Refer to section "Removal of the Fuel Injector Cup - Three-Filter System".

For the two-filter fuel system, Refer to section "Removal of the Fuel Injector Cup - Two-Filter System"

b. No; Go to step 8.

8. Is the engine equipped with a two-filter fuel system?

a. Yes; Go to step 9.

b. No; Go to step 10.

Table 4.

NOTE:
Beginning in May 2, 2014, engines with the two-filter fuel system are built with a fuel cooler delete bypass

plate in place of the fuel cooler. The updated module with the fuel cooler delete bypass plate is

backwards-compatible with engines built with a fuel cooler.
Figure 1 - Module with Fuel Cooler Delete Bypass Plate
Figure 2 - Module with Fuel Cooler
9. Using a mirror, look between the fuel filter module and the cylinder block to identify if the fuel filter module is

equipped with a fuel cooler. A fuel cooler can be identified by the ribbed exterior as shown in Figure 2. Is the engine

equipped with a fuel cooler?

a. Yes; Go to step 10.

b. No; Go to step 12.

10. Test the fuel cooler for leaks. Refer to section "Fuel Cooler Leak Test Procedure - Three-Filter Fuel System" or Refer

to section "Fuel Cooler Leak Test Procedure - Two-Filter Fuel System". Are any leaks present?

a. Yes; Go to step 11.

b. No; Go to step 12.

11. Is the engine equipped with a two-filter system?

All information subject to change without notice.
08 05-17
Copyright © 2017 DETROIT DIESEL CORPORATION
7
3 Fuel in Coolant/Coolant in Fuel

a. Yes; replace the fuel cooler with a Fuel Cooler Delete Bypass Plate. Refer to section "Installation of the Fuel

Cooler Delete Bypass Plate - Two Filter System". Then, Go to step 13.

b. No; replace the fuel cooler. Refer to section "Installation of the Fuel Cooler - Three-Filter System". Then, Go to

step 13.

12. Remove the cylinder head. Pressure test the cylinder head. For DD13 engines, use tool W470589012500. For DD15

and DD16 engines, use tool W470589002500. Are there any leaks present?

For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly".

a. Yes; replace or repair as necessary. Then Go to step 13.

For the DD13: Refer to section "Installation of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly".

b. No; review the results of the above troubleshooting steps. Then Go to step 13.

13. If fuel has been identified as a contaminant in the coolant, replace the components listed below. All fuel system repairs

should now be complete. If the WIF Light is on refer to Power Service Literature for the fault that is present.

Table 5.

Description
Qty.
Comments
Fuel Injector Cup Seals
1
This is a kit consisting of six seals.
Seal between Coolant Collector and

Cylinder Head
1
Only for DD15/16 engine S/N (last five

digits) 32840 built before March 22, 2010.

Do not replace for DD13 engines.
Coolant Line - Air Compressor To Fuel

Filter Module
1
Coolant Line - Fuel Filter Module To Oil/

Coolant Module
1
Coolant Line - Air Compressor To Cylinder 1

Block
8
Gasket - Fuel Injector Jumper Lines
6
Fuel Injector O-Ring Seal Kit
6
Coolant Filter (if equipped)
1
Use applicable coolant filter. Note that

some engines may not have a coolant

filter if previously removed by the

customer.
Coolant
NA
Use applicable coolant as listed in the

"Coolant Selections" manual (DDC-SVCBRO-0002)
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 05-17
08 05-17
4
Fuel in Coolant/Coolant in Fuel
Table 6.

Service Tool Used in the Procedure

Tool Number
Description
W470589012500
DD13 Cylinder Head Leak Tool
W470589002500
DD15/16 Cylinder Head Leak Tool
NOTE: DEF contamination in the fuel system can be mistaken for coolant in the fuel. When DEF is found to be a

contaminant of the fuel system, its appearance will be a brown or rusty color most notable in the fuel filter module.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

2. Verify that fuel/coolant contamination is present.

3. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for external

coolant leaks. Are any leaks present?

a. Yes; repair as necessary. Then, Go to step 13.

b. No; Go to step 4.

NOTE: The fuel injector O-rings and the fuel injector clamp hold-down bolts must be replaced each time they are

removed from the cylinder head.

4. Release the pressure from the cooling system.

5. Remove all six fuel injectors.

For the three-filter fuel system, Refer to section "Removal of the Fuel Injector - Three-Filter System".

For the two-filter fuel system, Refer to section "Removal of the Fuel Injector - Two-Filter System".

NOTICE: Failure to reinstall the fuel injector hold-down clamps may damage the cylinder head coolant gallery

plugs (1).

6. Reinstall the fuel injector hold-down clamps with old fuel injector bolts. Torque bolts to 20 N·m (15 lb·ft) + 90-degree

torque turn.
All information subject to change without notice.
08 05-17
Copyright © 2017 DETROIT DIESEL CORPORATION
9
4 Fuel in Coolant/Coolant in Fuel

7. Pressurize the cooling system per OEM specifications. Inspect for coolant leaks around the fuel injector cups. Are any

leaks present?

a. Yes; clean the injector cups and replace all six injector cup O-rings. Then Go to step 13.

For the three-filter fuel system, Refer to section "Removal of the Fuel Injector Cup - Three-Filter System".

For the two-filter fuel system, Refer to section "Removal of the Fuel Injector Cup - Two-Filter System"

b. No; Go to step 8.

8. Is the engine equipped with a two-filter fuel system?

a. Yes; Go to step 9.

b. No; Go to step 10.

Table 7.

NOTE:
Beginning in May 2, 2014, engines with the two-filter fuel system are built with a fuel cooler delete bypass

plate in place of the fuel cooler. The updated module with the fuel cooler delete bypass plate is

backwards-compatible with engines built with a fuel cooler.
Figure 1 - Module with Fuel Cooler Delete Bypass Plate
Figure 2 - Module with Fuel Cooler
9. Using a mirror, look between the fuel filter module and the cylinder block to identify if the fuel filter module is

equipped with a fuel cooler. A fuel cooler can be identified by the ribbed exterior as shown in Figure 2. Is the engine

equipped with a fuel cooler?

a. Yes; Go to step 10.

b. No; Go to step 12.

10. Test the fuel cooler for leaks. Refer to section "Fuel Cooler Leak Test Procedure - Three-Filter Fuel System" or Refer

to section "Fuel Cooler Leak Test Procedure - Two-Filter Fuel System". Are any leaks present?

a. Yes; Go to step 11.

b. No; Go to step 12.

11. Is the engine equipped with a two-filter system?

10
All information subject to change without notice.
Copyright © 2017 DETROIT DIESEL CORPORATION 08 05-17
08 05-17

a. Yes; replace the fuel cooler with a Fuel Cooler Delete Bypass Plate. Refer to section "Installation of the Fuel

Cooler Delete Bypass Plate - Two Filter System". Then, Go to step 13.

b. No; replace the fuel cooler. Refer to section "Installation of the Fuel Cooler - Three-Filter System". Then, Go to

step 13.

12. Remove the cylinder head. Pressure test the cylinder head. For DD13 engines, use tool W470589012500. For DD15

and DD16 engines, use tool W470589002500. Are there any leaks present?

For the DD13: Refer to section "Removal of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head Assembly".

a. Yes; replace or repair as necessary. Then Go to step 13.

For the DD13: Refer to section "Installation of the DD13 Cylinder Head Assembly".

For the DD15 and DD16: Refer to section "Installation of the DD15 and DD16 Cylinder Head Assembly".

b. No; review the results of the above troubleshooting steps. Then Go to step 13.

13. If fuel has been identified as a contaminant in the coolant, replace the components listed below. All fuel system repairs

should now be complete. If the WIF Light is on refer to Power Service Literature for the fault that is present.

Table 8.

Description
Qty.
Comments
Fuel Injector Cup Seals
1
This is a kit consisting of six seals.
Seal between Coolant Collector and

Cylinder Head
1
Only for DD15/16 engine S/N (last five

digits) 32840 built before March 22, 2010.

Do not replace for DD13 engines.
Coolant Line - Air Compressor To Fuel

Filter Module
1
Coolant Line - Fuel Filter Module To Oil/

Coolant Module
1
Coolant Line - Air Compressor To Cylinder 1

Block

Gasket - Fuel Injector Jumper Lines
6
Fuel Injector O-Ring Seal Kit
6
Coolant Filter (if equipped)
1
Use applicable coolant filter. Note that

some engines may not have a coolant

filter if previously removed by the

customer.
Coolant
NA
Use applicable coolant as listed in the

"Coolant Selections" manual (DDC-SVCBRO-0002)
All information subject to change without notice.
08 05-17
Copyright © 2017 DETROIT DIESEL CORPORATION
11

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