Series 60 DDEC V Troubleshooting – Section 3.5 Worn or Damaged Valve or Cylinder Kit

Section 3.5
Worn or Damaged Valve or Cylinder Kit

Loss of compression in Series 60 engines may result from a variety of sources, including worn or broken fire or compression rings, holes in pistons, leaky valves, scored or worn cylinder walls, leaky or broken gaskets and cracked cylinder heads or cylinder liners. The detection and elimination of the cause or causes of cylinder pressure losses is vital to engine life and efficient operation. To assist the mechanic in effectively measuring the loss of cylinder pressure, and locating the source of abnormal leaks in individual cylinders, the following test procedure has been developed.‪

1. Move the vehicle requiring test to the chassis dynamometer; refer to OEM guidelines.
2. Disconnect air compressor; refer to the appropriate service manual, special equipment chapter.
3. Start the engine.
4. Run the engine and bring the engine coolant temperature to normal operating range.
5. Run vehicle to full load and rated speed.
6. Attach a manometer calibrated to read in kPa (in. H₂ O), to the oil dipstick opening.
7. Measure and record crankcase pressure. For crankcase pressure guidelines refer to Service Information Letter 02 TS-20 found on the DDC extranet.
8. Shut down engine.
9. Remove the vehicle from the chassis dynamometer.
10. Review the crankcase pressure test results.
    1. If the crankcase pressure was greater than 1.25 kPa (5 in. H₂ O); refer to "3.5.1 Worn or Damaged Valve or Cylinder Kit Repair" .
    2. If the crankcase pressure was less than 1.25 kPa (5 in. H₂ O); perform a cylinder compression test.Refer to "3.5.1.2 Cylinder Compression Test" .
11. Compare the cylinder compression test results to specifications.
    1. If cylinder pressure is below specifications, refer to "3.5.1 Worn or Damaged Valve or Cylinder Kit Repair" .
    2. If cylinder pressure is within specification, call Detroit Diesel Customer Support Center (313-592-5800).

Section 3.5.1
Worn or Damaged Valve or Cylinder Kit Repair

Perform the following steps for worn or damaged valve or cylinder kit:‪

1. Remove cylinder head; refer to the appropriate service manual, engine chapter.
2. Inspect the cylinder head for worn or damaged valves; refer to the appropriate service manual, engine chapter. For repair and replacement procedures, refer to the appropriate service manual, engine chapter.
3. Inspect the cylinder kit components for worn or damaged liners, pistons or piston rings; refer to the appropriate service manual, engine chapter.
4. Verification of repairs made to cylinder valve(s) or cylinder kit components is required; refer to "3.5.1.1 Verify Repairs" .

Section 3.5.1.1
Verify Repairs

Perform the following steps to verify repairs:‪

1. Start and run the engine.
2. Run the engine through its operating range with no-load for approximately five minutes, allowing the engine coolant to reach normal operating range, 88-96°C (190-210°F).
   1. If the engine is operating properly, no further troubleshooting is required. Shut down the engine.
   2. If there is any indication that the engine is not running properly, shut down the engine. Call Detroit Diesel Customer Support Center (313-592-5800).

Section 3.5.1.2
Cylinder Compression Test

Perform the following steps for a compression test on a Series 60 Engine:‪

ENGINE EXHAUST ‪
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

1. Start and run the engine until normal operating temperature is reached. Stop the engine.
2. Disconnect the batteries.
3. Disconnect the fuel pump feed line from the fuel tank. Place a suitable container under the line to catch the spilling fuel.
4. Turn the quarter turn valve off on the outlet fitting of the secondary fuel filter.
5. Disconnect the fuel supply line to the cylinder head. Place a suitable container under the line to catch the spilled fuel. Disconnect the fuel return line from the rear of the cylinder head and place a suitable container under the fitting to catch the spilled fuel.

   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.‪

   NOTICE: ‪

   All the fuel must be removed from the cylinder head before removing injectors. This prevents the fuel from entering the cylinder and causing cylinder wall lube oil wash down or a hydrostatic lock at startup.‪

6. Blow low pressure regulated air no more than 207 kPa (30 psi) into the fuel supply line fitting at the front of the cylinder head for 20 to 30 seconds or until all fuel is purged from the head.
7. Clean and remove the rocker cover. If equipped with Jake Brakes, remove the Jake Brake assembly.
8. Remove all the rocker shaft mounting bolts and nut from the front or rear rocker shaft assembly. Using removal tool (J–35996–A) , see Figure "Rocker Arm/Shaft Assembly Removal/Installation" , lift the assembly straight up and off of the head and place in a clean area on the bench.
   

   Figure 1. Rocker Arm/Shaft Assembly Removal/Installation

9. Use tool J-47383 to remove the electrical connector from all three injectors by disengaging the locking tang on the harness plug connection and gently pulling it from the socket.
10. Remove the injector hold down bolts and washers (3).

    NOTICE: ‪

    Use extreme care when handling injectors to avoid costly damage by dropping or mishandling. Always install new O-rings when replacing injectors.‪

11. Remove three injectors from the cylinder head using tool J-47372, see Figure "J-47372" .
    

    Figure 2. J-47372

12. Place the compression test adaptors (J-47908) into the injector holes. It is recommended to have three test adaptors (J-47908) when performing this routine.
13. Install the injector hold-down clamps and torque hold-down bolts to 58-66 N·m (43-49 lb·ft).
14. Carefully remove the shaft from the rocker arm assembly by slowly pulling it out of the assembly. Place the shaft on the bench. Do not disturb the stack-up of the rocker arm sets.
15. Remove the three injector rocker arms and replace with spacers (J–38768–5).
16. Lubricate the shaft with clean engine oil. With spacers in place, carefully reinstall the shaft through each rocker arm shaft. Make sure cup plug end faces inboard.

    NOTICE:
    Verify that the bolt holes for the rocker shafts are clean as not to hydro lock the bolts causing damage to the cylinder head.‪

17. Install the modified rocker arm shaft assembly on the head. If the engine is equipped with a Jake Brake®, use non-Jake Brake rocker arm shaft bolts (P/N:8929129). Torque the three bolts and the nut to 102-126 N·m (75-93 lb·ft).

    Note: Verify that the bolt holes for the rocker shafts are clean as not to hydro lock the bolts causing damage to the cylinder head.

18. Disconnect the electrical connection at the rear of the cylinder head for the injectors.

    PERSONAL INJURY ‪
    To avoid injury when working on or near an operating engine, wear protective clothing, eye protection, and hearing protection.‪

    PERSONAL INJURY ‪
    To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing any component.‪

    ENGINE EXHAUST ‪
    To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area. Engine exhaust is toxic.‪

19. Attach cylinder compression gauge (J–6692–B) to the first adaptor. See Figure "Attach Cylinder Compression Gauge J 6692–B" .
    

    Figure 3. Attach Cylinder Compression Gauge J 6692–B

20. Reconnect the batteries.
21. Crank the engine using the starter motor five compression strokes. Record the compression reading on the gauge.

    Note: Verify that the batteries voltage does not go low enough to affect engine cranking speed. If the cranking speed is affected then the results will be inaccurate. If needed, connect a battery charge to maintain battery voltage.

22. The compression reading should show no two cylinders differing by more than 276 kPa (40 psi). If compression readings are greater than 40 psi difference between cylinders, repeat step 20 to be certain of the reading.
23. After testing all three cylinders, remove bolts from the modified rocker arm shaft assembly and, using rocker arm lifter (J–35996), lift the assembly straight up and off the cylinder head. Place in a clean area on the bench.
24. Carefully remove the shaft from the rocker arm assembly, remove the three rocker arm sleeves. Replace the three injector rocker arms. Lubricate the shaft with clean engine oil and carefully reinstall through each rocker arm.
25. Remove the injector hold-down clamps, discard the hold-down bolt and remove the compression test adaptors from the cylinder head.
26. Using new sealing rings and injector hold-down bolt, install the injectors back into the cylinder head and torque to specifications:
    1. Torque bolt to 50 N·m (37 lb·ft).
    2. Loosen the bolt 60 degrees ( 1/6 of a turn or one bolt flat). Do not fully loosen the bolt.
    3. Torque the bolt to 35 N·m (26 lb·ft).
    4. Tighten the bolt an additional 90 degrees.
27. Replace the completed rocker arm shaft assembly on the engine and torque nut and bolts to specifications. Torque to 102-108 N·m (75-80 lb·ft)
28. Using J-47335, reinstall the electrical connectors back on the injectors.
29. Repeat steps 8 through for the three remaining cylinders.
30. Compare cylinder readings and repair as needed.
31. Install valve cover, insuring that the bolt holes are clear of dirt and oil.
32. To verify repairs, refer to "3.5.1.1 Verify Repairs" .