| Contents
General information
DDECI System
DDEC II System
DDEC III / IV Systems
Basic technical data
Engine model, serial number and option plate
Replacement and repair
Dismantling the engine
Washing
Preparing for the first launch
Launch
Engine maintenance
Daily maintenance
Lubrication system
Fuel tanks
Fuel lines
Cooling system
Turbocharger
Battery
Drive belts
Air compressor
Air filter
Cooling system filter and pump
Intake system
Release system
Engine (steam wash)
Radiator
Oil pressure
Battery charging system generator
Powertrain mounts
Blow-by gas pressure
Fan clutch
Insulation and seals
Oil separator for crankcase ventilation
Engine adjustments
Compressed air intercooler / auxiliary pump
Heat exchanger
Fuel heat exchanger (fuel cooler)
Fuel injectors
Vibration damper (damper)
Generator and its mounts
Air conditioner compressor and mounting
Air compressor and its mounting
Periodic maintenance of car engines
DDEC Electronic control system
System description
System functions
System components
Location of system components
System diagnostics
General information
Reading codes using control lamps
Reading codes using the diagnostic panel
Fault code table
Preparing for troubleshooting
Troubleshooting by codes
Electrical connectors and diagrams
Electronic module
Engine wire harness connector
Engine wire harness diagram
Vehicle interface wiring harness connector
Car interface wiring diagram
ECM power connector and wiring diagram with one fuse
ECM power connector and wiring harness diagram with two fuses
Communication harness connector
Injector connector and wiring diagram
Connector and circuit for engine brake with ECM
Diagnostic panel
Functions of the electronic module
Function blocking
Function blocking scopes
Function lock password
Working with the diagnostic panel
Diagnostic codes
Cylinder shutdown sequence
Injector calibration update
Reprogram calibration
Snap function
Print
Control lamps
Yellow control lamp does not work
The yellow indicator lamp remains on
The yellow control lamp flashes irregularly and intermittently
The yellow control lamp lights up for up to seconds
The yellow control lamp does not light up
Troubleshooting by symptoms
Diagnostic hardware for DDEC IV and DDEC V
Description
DDEC IV Trouble codes
DDEC V Trouble codes
Abbreviations and terms
Repair manual
Removing the engine
Valve cover
Removing a conventional valve cover
Removing the valve cover with base
Removing the valve cover with base and spacer
Valve cover installation
Installing a valve cover with base and spacer
Cylinder head
Removing the cylinder head
Turbocharger oil lines
Leak test
Check for flatness of the block head
Installing the cylinder head
Cylinder block
Connecting rod-piston group
Removing pistons and connecting rods
Disassembly
Cast iron pistons
Steel pistons
Build
Cast iron pistons
Steel pistons
Installing a connecting rod with a piston in the engine
Installation of pistons in l engine
Pistons and piston rings
Disassembling the piston
Piston assembly
Installing piston rings
Rods
Closed head connecting rod
Checking the connecting rod
Checking bearings
Cylinder liners
Removing the sleeve
Cleaning and checking cylinder liners
Installation
Crankshaft main bearings
Withdrawal
Main bearing check
Installation
Crankshaft
Removing the crankshaft
Checking
Runout measurement
Neck diameter measurement
Method using magnetic particles
The method using fluorescent magnetic particles
Liquid method with phosphor
Bending fatigue
Torsion fatigue
Cracked crankshaft
Installation
Crankshaft oil seals
Removing the front oil seal
Removing the rear oil seal (with the flywheel housing installed)
Federal mogul seal
CR seal
Installing the front and rear crankshaft oil seal
Flywheel housing
Withdrawal
Installation
Flywheel
Withdrawal
Checking
Installation
Replacing the ring gear
Withdrawal
Installation
Crankshaft pulley
Removing the crankshaft pulley
Checking
Installation
Damper
Checking the vibration damper
Damper installation
Valve and injector drive mechanism
Removing the rocker arms
Inspection
Installation
Adjusting valve clearances, engine brake and injector heights
Valve adjustment procedure and nozzle height setting
Control parameters
Valves, springs, guides, valve seats, caps and valve rotators
Removing valves
Removing the guides
Removing the intake and exhaust valve seat
Valve check
Checking the springs
Checking rails and seats
Installing intake and exhaust valve seats
Installing valve guides
Installing the valve, spring, cap and valve turning mechanism
Timing case cover
Removing the timing case
Checking
Installing the timing case cover
Installation of noise insulation
Timing gear case
Removing the gear housing
Installing the gear housing
Timing gears and engine timing
Gear Synchronization
Check engine timing
Auxiliary drive gear and main gear meshing clearance
Main gear and water pump gear meshing clearance
Air compressor main gear meshing clearance
Build
Camshaft thrust plate seal
Withdrawal
Installation
Camshaft and camshaft bearings
Removing the camshaft and bearings
Installing the camshaft
Checking the camshaft end play
Installation
Valve timing control
Camshaft gear
Removing the camshaft gear
Checking
Installation
Main gear and idler camshaft gears
Removing the main and intermediate gears
Checking
Installation
Adjustable idler gear
Withdrawal
Checking
Installation
Crankshaft gear and cogwheel
Withdrawal
Checking
Installing the crankshaft gear
Auxiliary drive
Withdrawal
Disassembly
Checking
Build
Engine brake
Removing the engine brake (model)
Installing the engine brake
Setting auxiliary piston clearance
Engine brake
Injectors
Removing the nozzle
Disassembly
Checking
Repair
Installing a nozzle
Fuel injector bowl & o-ring
Installing an additional seal
Bowl and o-ring installation
Checking
Fuel pump
Withdrawal
Disassembly
Checking
Build
Installing the fuel pump
Installing an air compressor driven fuel pump
Fuel pump drive
Removing the drive
Installing the drive
Fuel filters
Replacing the fuel filter
Removal / installation
Water separator replacement
Fuel filter FUEL PRO / E
Fuel filter and water separator
Fuel return control valve
DDEC III / IV Engine electronic control unit (ECM)
Replacing the DDEC III / IV electronic control unit
Removing the control unit
Installation
Turbocharger pressure sensor
Oil pressure sensor
Oil temperature sensor
Air temperature sensor
Removing the air temperature sensor
Coolant temperature sensor
Speed ??sensor
Crankshaft position sensor
Coolant level sensor
Fuel temperature sensor
Tightening torques
Lubrication system
Oil pump
Removing the oil pump
Disassembly
Build
Installation
Oil pressure regulating valve
Withdrawal
Disassembly
Build
Installation
Oil pressure reducing valve
Oil filter
Oil filter support
Thermostatic valve
Oil cooler
Oil dipstick
Oil pan
Removing the oil pan
Installation
Crankcase ventilation system
Withdrawal
Installation
Cooling system
Water pump
Removing and disassembling the water pump
Installation
Thermostat
Removing thermostats
Opening and full opening temperatures
Fan
Removing the fan hub
Installation
Radiator
Air system
Air filter
Air separator
Intake manifold
Removing the intake manifold
Intake manifold installation
Turbocharger
Withdrawal
Disassembly
Checking
Removing the bypass valve actuator
Installing the drive
Bypass valve installation
Assembling the turbocharger
Installation
Intermediate air cooler
Exhaust manifold
Removing the exhaust manifold
Installing the exhaust manifold
Electrical equipment
Generator
Removing the generator
Installing the generator
Battery
Withdrawal
Installation
Starter
Removing the starter
Installation
Tachometer drive
Power take-off shaft
Air compressor
Removing the compressor
Installation
Specifications
Cylinder block (dimensions in mm)
Sleeve
Piston and Rings
Piston and rings (l engine)
Crankshaft
Connecting rod bearings
Main bearings
Camshaft
Camshaft bearings
Camshaft gear
Crankshaft gear
Main gear
Exhaust Valve Seats
Inlet valves
Exhaust valves
Valve Guides
Rocker arms and axles
Rocker rollers
Tightening torques
Engine parts catalog detoit diesel 60 series
Engine models and serial numbers
Table of correspondence of model and serial numbers of engines to numbers of groups and types of parts used in them
Parts catalog |
Copyright (c) 2008 disc.allsave.info.