Detroit Diesel 60 User manual

SECTION 01: ENGINE
01-1
CONTENTS
1. ENGINE.............................................................................................................................................01-3
2. ENGINE-MOUNTED COMPONENTS .............................................................................................. 01-3
2.1 ELECTRONIC CONTROL MODULE ...................................................................................................01-4
2.2 ELECTRONIC UNIT INJECTOR.........................................................................................................01-4
3. SYNCHRONOUS REFERENCE SENSOR ...................................................................................... 01-4
3.1 TIMING REFERENCE SENSOR ........................................................................................................01-5
3.2 TURBO BOOST PRESSURE SENSOR...............................................................................................01-5
3.3 COOLANT TEMPERATURE SENSOR ................................................................................................01-6
3.4 FUEL TEMPERATURE SENSOR.......................................................................................................01-6
3.5 AIR TEMPERATURE SENSOR..........................................................................................................01-6
3.6 OIL PRESSURE SENSOR ...............................................................................................................01-6
3.7 OIL TEMPERATURE SENSOR..........................................................................................................01-6
4. ENGINE-RELATED COMPONENTS ...............................................................................................01-6
4.1 COOLANT LEVEL SYSTEM (CLS)...................................................................................................01-7
4.2 ELECTRONIC FOOT PEDAL ASSEMBLY (EFPA) &THROTTLE POSITION SENSOR ..............................01-7
4.3 CRUISE CONTROL SWITCHES (CCS).............................................................................................01-7
4.4 DIAGNOSTIC SYSTEM ACCESSORIES (DSA)...................................................................................01-8
4.4.1 Check Engine Telltale Light................................................................................................01-8
4.4.2 Stop Engine Warning Light.................................................................................................01-8
4.4.3 Stop Engine Override Switch..............................................................................................01-8
4.4.4 Diagnostic Data Link (DDL) Connectors.............................................................................01-8
5. DDEC IV DIAGNOSTIC CODES ...................................................................................................... 01-8
5.1 READING DIAGNOSTIC CODES,FLASH METHOD:............................................................................01-8
6. ENGINE OIL LEVEL.......................................................................................................................01-11
7. ENGINE OIL AND FILTER CHANGE ............................................................................................01-11
8. RECOMMENDED ENGINE OIL TYPE...........................................................................................01-12
9. WELDING PRECAUTIONS............................................................................................................01-12
10. POWER PLANT ASSEMBLY REMOVAL..................................................................................01-12
11. POWER PLANT ASSY. INSTALLATION...................................................................................01-15
12. VALVE COVER REMOVAL........................................................................................................ 01-16
13. JAKE BRAKE .............................................................................................................................01-16
14. ENGINE MOUNTS ......................................................................................................................01-16
15. SPECIFICATIONS.......................................................................................................................01-17

Section 01: ENGINE
01-2
ILLUSTRATIONS
FIGURE 1: DETROIT DIESEL SERIES 60 ENGINE (TYPICAL)..............................................................01-3
FIGURE 2: ELECTRONIC CONTROL MODULE (ECM)..........................................................................01-4
FIGURE 3: UNIT INJECTOR CROSS SECTION .....................................................................................01-4
FIGURE 4: SRS LOCATION.....................................................................................................................01-5
FIGURE 5: BULL GEAR ...........................................................................................................................01-5
FIGURE 6: TIMING GEAR........................................................................................................................01-5
FIGURE 7: TURBO BOOST PRESSURE SENSOR ................................................................................01-6
FIGURE 8: FUEL TEMPERATURE SENSOR..........................................................................................01-6
FIGURE 9: CYLINDER BLOCK................................................................................................................01-6
FIGURE 10: ELECTRONIC FOOT PEDAL ASSEMBLY ..........................................................................01-7
FIGURE 11: ENGINE OIL LEVEL DIPSTICK .........................................................................................01-11
FIGURE 12: ENGINE COMPARTMENT ................................................................................................01-11
FIGURE 13: UNDER VEHICLE VIEW....................................................................................................01-12
FIGURE 14: ENGINE COMPARTMENT ................................................................................................01-13
FIGURE 15: ENGINE COMPARTMENT ................................................................................................01-13
FIGURE 16: ENGINE COMPARTMENT ................................................................................................01-14
FIGURE 17: RUBBER DAMPER TOLERANCE.....................................................................................01-16
FIGURE 18: POWER PLANT CRADLE INSTALLATION.......................................................................01-17

Section 01: ENGINE
01-3
1. ENGINE
This vehicle is powered by a 6-cylinder, four-
cycle, Detroit Diesel series 60 engine, equipped
with an electronic control system (DDEC IV).
Series 60 engines come in either of two
displacement volumes: 11 liters or 12.7 liters.
Summary information on the Electronic Control
System is given in this section.
Complete maintenance and repair information on
the engine will be found in the current DDEC IV
Service Manual #6SE483. This maintenance
manual covers engine accessories, controls and
related components.
Procedures for engine removal and installation
are given at the end of this section. The DDEC
system is self-diagnostic. It can identify faulty
components and other engine-related problems
by providing the technician with a diagnostic
code. Refer to DDEC Troubleshooting Guide
#6SE492 published by Detroit Diesel for more
complete information on diagnosis of
components and system problems.
DDEC IV (Detroit Diesel Electronic Control)
controls the timing and amount of fuel injected
by the electronic unit injectors (EUI). The system
also monitors several engine functions using
electrical sensors, which send electrical signals
to the Electronic Control Module (ECM). The
ECM computes the electrical signals and
determines the correct fuel output and timing for
optimum power, fuel economy and emissions.
The ECM also has the ability to display warnings
or shut down the engine completely (depending
on option selection) in the event of damaging
engine conditions, such as low oil pressure, low
coolant level, or high oil temperature.
Two categories divide system components:
engine-mounted components and engine-related
components.
2. ENGINE-MOUNTED COMPONENTS
FIGURE 1: DETROIT DIESEL SERIES 60 ENGINE (TYPICAL) 01015
Engine-mounted components are as follows:
• Electronic Control Module
• Electronic Unit Injector
• Synchronous Reference Sensor
• Timing Reference Sensor
• Turbo Boost Pressure Sensor
• Coolant Temperature Sensor
• Fuel Temperature Sensor
• Air Temperature Sensor
• Oil Pressure Sensor
• Oil Temperature Sensor

Section 01: ENGINE
01-4
2.1 ELECTRONIC CONTROL MODULE
The Electronic Control Module is mounted, on
the starter side of the engine (Fig. 2).
Considered the "Brain" of the DDEC IV system,
it provides overall monitoring and control of the
engine. It does so by comparing input data from
the various sensors to a set of calibration data
stored in the EEPROM (Electrically Erasable,
Programmable, Read-Only Memory) within the
Electronic Control Module. After comparing the
input data with the calibration data, the ECM
sends high-current command pulses to the
Electronic Unit Injectors (EUI) to initiate fuel
injection. The ECM also receives feedback
regarding the start and end of injection for a
given cylinder. The EEPROM within the
Electronic Control Module is factory programmed
by Detroit Diesel. Reprogramming must be done
at a Detroit Diesel authorized service center.
However, some changes may be performed to
the cruise control and road speed limiter using a
diagnostic data reader (see paragraph "DDEC IV
Diagnostic Codes" in this section).
FIGURE 2: ELECTRONIC CONTROL MODULE (ECM)
2.2 ELECTRONIC UNIT INJECTOR
The Electronic Unit Injector is a compact device
that injects diesel fuel directly into the
combustion chamber (Fig. 3). The amount of
fuel injected and the Electronic Control Module
(ECM) determines the beginning of injection
timing. The ECM sends a command pulse, which
activates the injector solenoid. The EUI performs
four functions:
•Creates the high-fuel pressure required for
efficient injection;
• Meters and injects the exact amount of fuel
required to handle the load;
• Atomizes the fuel for mixing with the air in the
combustion chamber;
• Permits continuous fuel flow for component
cooling.
FIGURE 3: UNIT INJECTOR CROSS SECTION 01019
3. SYNCHRONOUS REFERENCE SENSOR
The Synchronous Reference Sensor (SRS) is an
electronic component, mounted to the rear of the
gear case (Fig. 4). The SRS senses a raised
metal pin on the rear of the bull gear and sends
a signal to the ECM via a black connector wire.
The SRS sensor extends through a hole in the
gear case. It is positioned near the rear of the
bull gear. A bolt, inserted through a hole in the
SRS bracket, secures the SRS assembly to the
gear case.

Section 01: ENGINE
01-5
FIGURE 4: SRS LOCATION 01020
FIGURE 5: BULL GEAR 01021
The bull gear pin passes by the SRS as piston
number one crank pin reaches 45°before Top-
Dead-Center. The ECM uses this information to
determine engine speed.
The SRS is non-serviceable and must be
replaced as a unit. No adjustment is required.
3.1 TIMING REFERENCE SENSOR
The Timing Reference Sensor (TRS) is an
electronic component mounted on the left side of
the gear case (right side of coach), near the
crankshaft centerline. The TRS sensor,
positioned near the timing wheel gear teeth,
extends through an opening in the gear case. A
bolt, inserted through a hole in the TRS bracket,
secures the TRS assembly to the gear case.
The TRS connector is gray. The TRS sensor
sends a signal to the ECM. The TRS senses a
series of evenly spaced special teeth on the
timing wheel. A tooth passes by the TRS as
each cylinder crank pin reaches 10°before Top-
Dead-Center.
The ECM uses these signals to determine
injector solenoid operation time. The TRS is
non-serviceable and must be replaced as a unit.
No adjustment is required.
FIGURE 6: TIMING GEAR 01022
3.2 TURBO BOOST PRESSURE SENSOR
Two bolts mount the Turbo Boost Pressure
Sensor to the intake manifold. A rubber O-ring
seals the sensor to the manifold (Fig. 7). This
device is a pressure sensor that sends an
electrical signal to the ECM. The ECM uses this
information to compute the amount of air
entering the engine. Turbo boost sensor
information regulates fuel supply to control
engine exhaust.
The turbo boost sensor is non-serviceable and
must be replaced as an assembly. No
adjustment is required.

Section 01: ENGINE
01-6
FIGURE 7: TURBO BOOST PRESSURE SENSOR 01023
3.3 COOLANT TEMPERATURE SENSOR
The coolant temperature sensor is mounted on
the engine's right side (vehicle's left side). The
sensor helps protect the engine against
overheating by sensing coolant temperature.
3.4 FUEL TEMPERATURE SENSOR
The Fuel Temperature Sensor (FTS) is installed
on the secondary fuel filter (Fig. 8).
The FTS sends an electrical signal to the ECM
indicating fuel inlet temperature. The ECM uses
this information to calculate fuel consumption.
The FTS is non-serviceable and must be
replaced as a unit. No adjustment is required.
FUEL TEMPERATURE SENSOR
FIGURE 8: FUEL TEMPERATURE SENSOR 01024
3.5 AIR TEMPERATURE SENSOR
The Air Temperature Sensor (Fig. 1) located on
the engine (starter side) near the intake manifold
provides input data to vary hot idle speed and
injection timing. This helps to improve cold starts
and reduces white exhaust smoke.
3.6 OIL PRESSURE SENSOR
The Oil Pressure Sensor (OPS) is installed in the
main engine-oil gallery. A typical location is the
left rear corner of the cylinder block (Fig. 9).
The OPS sends an electrical signal to the ECM
indicating the engine oil pressure at any given
speed. A low oil pressure signal exceeding
seven seconds is used by the ECM to begin the
stop engine or warning function. The OPS is
non-serviceable and must be replaced as a unit.
No adjustment is required.
OIL
PRESSURE
SENSOR
OIL TEMPERATURE SENSOR
FIGURE 9: CYLINDER BLOCK 01025
3.7 OIL TEMPERATURE SENSOR
The Oil Temperature Sensor (OTS) is installed
on the main engine-oil gallery. A typical location
is the left rear corner of the cylinder block as
shown in Figure 9. The OTS sends an electrical
signal to the ECM indicating engine oil
temperature. The ECM uses this information to
modify engine speed for better cold weather
starts and faster warm-ups. Oil temperatures
exceeding engine specifications for two seconds
or more will illuminate the Check Engine Light.
The OTS is non-serviceable and must be
replaced as a unit. No adjustment is required.
4. ENGINE-RELATED COMPONENTS
Engine-related components include:
• Coolant Level System (CLS)
• Electronic Foot Pedal Assembly (EFPA) and
Throttle Position Sensor

Section 01: ENGINE
01-7
• Cruise Control Switch (CCS)
• Diagnostic System Accessories (DSA)
4.1 COOLANT LEVEL SYSTEM (CLS)
The coolant level system consists of a
conductivity probe mounted in the surge tank
and an electronic interface module located inside
the rear junction box. Coolant level is
determined by the change in impedance of the
probe and its brass mount when immersed in
coolant. The electronic device in the module
conditions the signal to levels compatible with
DDEC. A low coolant level will trigger the engine
warning functions.
The probe and electronic interface module are
non-serviceable items and should be replaced
as units, if found defective. No adjustment is
required.
4.2 ELECTRONIC FOOT PEDAL ASSEMBLY
(EFPA) & THROTTLE POSITION SENSOR
The Electronic Foot Pedal Assembly (EFPA)
connects the accelerator pedal to a Throttle
Position Sensor (TPS). The (TPS) is a device,
which sends an electrical signal to the Electronic
Control Module (ECM). The TPS varies in
voltage depending on how far the pedal is
depressed. The system is installed in the space
normally occupied by a mechanical foot pedal.
The (EFPA) has maximum and minimum stops
that are built into the unit during manufacturing
(Fig. 10). The (TPS) converts the operator's foot
pedal input into a signal for the ECM. The
(EFPA) is shown in Figure 10.
When installed by the equipment manufacturer,
the TPS should not require adjustment. If the
TPS is suspected of being misadjusted, confirm
that the sensor is installed in accordance with
the manufacturer's specifications. It is
recommended that the idle count be at 50 or
higher with a full throttle count of up to 200.
The TPS is self-calibrating and therefore has no
optimum closed throttle or wide open throttle
count value. If the counts are within the 50 to
200 range, the sensor is properly set.
FIGURE 10: ELECTRONIC FOOT PEDAL ASSEMBLY01026
Monitor the (TPS) as the controls move it
through its full stroke. Be sure there is no
misalignment or obstruction preventing the
smooth movement of the TPS through the full
stroke. Using a diagnostic data reader, check
that the idle and full throttle position counts do
not fall within the error zones. The error zones
occur when the idle position is less than 14
counts, or when the full throttle position is more
than 233 counts. Should these conditions occur,
the ECU will signal diagnostic codes of 21-12 for
idle error and 21-23 for wide-open throttle error.
4.3 CRUISE CONTROL SWITCHES (CCS)
The four cruise control switches are located in
the driver's area on the L.H. side control panel.
1. Cruise: This is the main switch that actuates
the ECM memory in order to use the speed-
regulating mode.
2. Set: This switch is used to set the cruise
control speed or to decrease the set speed
by 2 MPH at each application.
Note:Cruise control system will not accept
speed settings, nor will the "Resume" switch
operate below 20 mph (32 km/h) and the engine
speed must be above 1100 RPM.
3. Resume: Each time this switch is actuated,
the speed will be increased by 2 mph (3,5
km/h). This switch allows the driver return to
the last regulated speed following a brake or
"DECEL" switch application.
Note:On-off switch must be in the "ON" position
in order to return to the last regulated speed.

Section 01: ENGINE
01-8
4. DECEL: Will cancel the cruise temporarily
and let the vehicle coast. Set speed is still in
memory for resume.
For additional information, see the "Operator's
Manual" or the "Owner's Manual".
4.4 DIAGNOSTIC SYSTEM ACCESSORIES
(DSA)
The DDEC IV engine Diagnostic System
Accessories include the following:
• Check Engine telltale light;
• Stop Engine telltale light;
• Stop Engine Override switch;
• Diagnostic Data Link (DDL) connectors.
4.4.1 Check Engine Telltale Light
The Check Engine telltale, mounted on the
telltale light panel indicates that a problem has
been detected and that a code has been stored
in the ECM memory. This light also has a 5-
second bulb check when the ignition is first
turned on. The Check Engine telltale illuminates
when the temperature at coolant sensors
exceeds 217°F (103°C) and the temperature at
oil sensors exceeds 260°F (127°C). When
sensors reach those temperatures, DDEC starts
to decrease engine power linearly.
4.4.2 Stop Engine Warning Light
This light, also mounted on the telltale light
panel, illuminates to indicate that a major engine
problem is occurring (with the exception of a 5-
second bulb check when the ignition is first
turned on). The Stop Engine Light illuminates
when the temperature at coolant sensors
exceeds 222°F (106°C) and the temperature at
oil sensors exceeds 239°F (115°C). When
sensors detect such temperatures, DDEC shuts
the engine down after a 30 seconds grace
period. This 30-second delay may be extended
another 30 seconds (if absolutely necessary) by
using the STOP ENGINE OVERRIDE switch.
Note: Once engine is stopped, it can not be
restarted until the malfunction is corrected.
4.4.3 Stop Engine Override Switch
This switch, mounted on the dashboard, may be
used to extend the 30-second delay period
before engine shutdown when the Stop engine
telltale light is illuminated. This switch can be
repeatedly depressed in order to move the
vehicle out of traffic.
Note: The stop engine override switch will be
operative only if it has been depressed before
the end of the 30 second delay period.
Caution: The OVERRIDE switch must be used
only in emergency cases, such as to move the
vehicle out of traffic. Excessive use of this switch
can cause serious damage to the engine.
This switch is also used for DDEC diagnostic
code requests. Press this switch with the engine
at idle or off but with the ignition in the "ON"
position and active codes will be flashed on the
CHECK ENGINE and STOP ENGINE telltale
lights alternately. Refer to “DDEC IV
DIAGNOSTIC CODES” in this section for more
information.
4.4.4 Diagnostic Data Link (DDL) Connectors
A connector is mounted on the L.H. footwell wall.
Another connector is located in the rear electric
compartment. They allow the connection of the
Diagnostic Data Reader (DDR) to read the
codes or to access pertinent data on the
condition of the engine. This enables a more
complete analysis of any defect found in the
DDEC system operation. For more information,
see Detroit Diesel Troubleshooting Guide
#6SE492.
5. DDEC IV DIAGNOSTIC CODES
5.1 READING DIAGNOSTIC CODES, FLASH
METHOD:
DDEC IV makes use of two types of codes:
Active and inactive. The difference between the
two types of codes is as follows:
Active Codes: Codes that are currently keeping
the Check Engine or Stop Engine telltale light
illuminated. Active codes are flashed via the
Stop Engine Light when checked with the stop-
engine-override switch.
Inactive Codes: These are all the codes logged
in the ECM (whether or not they are currently
turning on the Stop or Check Engine Light).
Inactive codes are flashed via the Check Engine
telltale light when checked with the stop-engine-
override switch. In most instances, only the DDR

Section 01: ENGINE
01-9
can provide the information necessary for a
quick diagnosis of the problem. If you just need
to read out codes, however, and do not have a
DDR available, the following procedure will let
you read out codes. Make sure the rear-starting
switch (located in the engine compartment) is in
the normal position. With the ignition ON, the
engine idling or engine shut-off, momentarily
depress the Stop Engine Override switch. Active
codes will be flashed on the stop engine telltale,
followed by the inactive codes being flashed on
the check-engine telltale panel. The cycle
repeats itself until the operator depresses the
stop engine override switch again. A code "43"
consists of four flashes, followed by a short
pause, then three flashes in quick succession.
Refer to DDEC Troubleshooting Manual 6SE497
for more information and SAE codes.
Note: Active codes are flashed in ascending
numerical flash code order. Inactive codes are
flashed in most recent to least recent order.
Note: Fault codes can only be cleared using the
DDR.
DDEC
Code
Number
(Flashed)
DESCRIPTION
DDEC
Code
Number
(Flashed)
DESCRIPTION
11 Variable speed governor sensor
input voltage low 12 Variable speed governor sensor input voltage high
13 Coolant level sensor input voltage low
14 Oil, coolant or intercooler
temperature sensor input voltage
high
15 Oil, coolant or intercooler temperature sensor input voltage
low 16 Coolant level sensor input voltage
high
17 Bypass or throttle valve position
sensor input voltage high 18 Bypass or throttle valve position
sensor input voltage low
21 TPS input voltage high 22 TPS input voltage low
23 Fuel temperature sensor input
voltage high 24 Fuel temperature sensor input
voltage low
25 No active codes 26 Auxiliary shutdown #1 or #2, input
active
27 Air inlet or intake air temperature
sensor input voltage high 28 Air inlet or intake air temperature
sensor input voltage low
31 Auxiliary high side output open
circuit or short to ground 32 Check Engine Light or Stop Engine
Light short to battery (+) or open
circuit
33 Turbo boost pressure sensor input
voltage high 34 Turbo boost pressure sensor input voltage low
35 Oil pressure sensor input voltage
high 36 Oil pressure sensor input voltage low
37 Fuel pressure sensor input voltage
high 38 Fuel pressure sensor input voltage low
41 Too many SRS (missing TRS) 42 Too few SRS (missing SRS)

Section 01: ENGINE
01-10
DDEC
Code
Number
(Flashed)
DESCRIPTION
DDEC
Code
Number
(Flashed)
DESCRIPTION
43 Coolant level low 44 Oil, coolant, intercooler or intake air
temperature high
45 Oil pressure low 46 ECM battery voltage low
47 Fuel, air inlet or turbo boost
pressure high 48 Fuel or air inlet pressure low
52 ECM A/D conversion fault 53 ECM non volatile memory fault
54 Vehicle speed sensor fault 55 J1939 data link fault
56 J1587 data link fault 57 J1922 data link fault
58 Torque overload 61 Injector response time long
62 Auxiliary output short to battery (+)
or open circuit or mechanical fault 63 PWM drive short to battery (+) or open circuit
64 Turbo speed sensor input fault 65 Throttle valve position input fault
66 Engine knock sensor input fault 67 Coolant or air inlet pressure sensor
input voltage fault
68 TPS idle validation switch open
circuit or short to ground 71 Injector response time short
72 Vehicle overspeed 73 Gas valve position input fault or
ESS fault
74 Optimized idle safety loop short to
ground 75 ECM battery voltage high
76 Engine overspeed with engine
brake 77 Fuel temperature high
81 Oil level, crankcase pressure, dual fuel BOI or exhaust temperature
voltage high 82 Oil level, crankcase pressure, dual
fuel BOI or exhaust temperature
voltage low
83 Oil level, crankcase pressure, exhaust temperature or external
pump pressure high 84 Oil level low or crankcase pressure
low
85 Engine overspeed 86 External pump or barometer
pressure sensor input voltage high
87 External pump or barometer
pressure sensor input voltage low 88 Coolant pressure low
TABLE X-X: FLASH CODES AND DESCRIPTION

Section 01: ENGINE
01-11
6. ENGINE OIL LEVEL
Check the oil level daily with the engine stopped.
If the engine has just been stopped and is warm,
wait at least 10 minutes to allow the oil to drain
back to the oil pan before checking. Wipe the
dipstick clean then check oil level. The level
should always be within the safe range on the
dipstick (Fig. 11). Add the proper grade of oil to
maintain the correct level on the dipstick. All
diesel engines are designed to consume some
oil, so a periodic addition of oil is normal.
Warning:Touching a hot engine can cause
serious burns.
Caution:Do not overfill. Oil may be blown out
through the crankcase breather if the crankcase
is overfilled.
Caution:Clean end of tube before removing
the dipstick to prevent oil contamination.
FIGURE 11: ENGINE OIL LEVEL DIPSTICK 01027
Caution: If the oil level is constantly above
normal and excess lube oil has not been added
to the crankcase, consult with an authorized
Detroit Diesel service outlet for the cause. Fuel
or coolant dilution of lube oil can result in serious
engine damage.
The vehicle is provided with an oil reserve tank
in the engine. To adjust oil level, open the oil
reserve tank valve and allow oil to discharge into
the engine until the "Full" mark on the dipstick is
reached then close the valve. Check oil reserve
tank level and pour oil in the reserve tank if
necessary (Fig. 12).
FIGURE 12: ENGINE COMPARTMENT 01028
7. ENGINE OIL AND FILTER CHANGE
Both the oil and filter should be changed every
12,500 miles (20,000-km) or once a year,
whichever comes first. However, changes that
are more frequent may be required when the
engine is subject to high levels of contamination
and/or overheating. Change intervals may be
decreased or gradually increased with
experience on specific lubricants until the most
practical service condition has been established.
Always refer to the lubricant manufacturer's
recommendations (analysis of drained oil can be
helpful).
Caution:Do not use solvents to dilute the
engine oil when draining. Dilution of fresh oil can
occur which may be detrimental to the engine.
Change engine oil with the vehicle on a flat and
level surface and with the parking brake applied.
It is best to drain the oil when the engine is still
warm.
1. From under the vehicle, remove the engine
drain plug on the oil pan. Allow oil to drain
(Fig. 13).
Warning: Hot engine oil can cause serious
burns. Wear coveralls with sleeves pulled down
and gloves to protect hands.
2. Reinstall the drain plug.

Section 01: ENGINE
01-12
FIGURE 13: UNDER VEHICLE VIEW 01029
3. Remove the spin-on filter cartridge using a
1/2" drive socket wrench and extension.
4. Dispose of the used oil and filter in an
environmentally responsible manner in
accordance with state and/or federal (EPA)
recommendations.
5. Clean the filter adapter with a clean rag.
6. Lightly coat the filter gasket (seal) with clean
engine oil.
7. Install the new filter on the adapter and
tighten manually until the gasket touches the
mounting adapter head. Tighten full-flow
filters an additional two-thirds of a turn
manually. Then, manually tighten bypass filter
one full turn.
Caution: Overtightening may distort or crack
the filter adapter.
8. Remove the engine-oil filler cap and pour oil
in the engine until it reaches the "FULL" mark
on the dipstick (Fig. 11).
9. Start and run the engine for a short period
and check for leaks. After any leaks have
been corrected, stop the engine long enough
for oil from various parts of the engine to
drain back to the crankcase (approximately
20 minutes).
10.Add oil as required to bring the level within
the safe range on the dipstick (Fig. 11).
8. RECOMMENDED ENGINE OIL TYPE
To provide maximum engine life, lubricants shall
meet the following specifications: SAE Viscosity
Grade: 15W-40 API Classification: CH-4
Note: Monograde oils should not be used in
these engines regardless of API Service
Classification.
Note: The use of supplemental oil additives is
discouraged from use in Detroit Diesel Engines.
Synthetic oils Synthetic oils may be used in
Detroit Diesel engines provided they are API-
licensed and meet the performance and
chemical requirements of non-synthetic oils
outlined previously. Synthetic oils do not permit
extension of recommended oil drain intervals.
Lubricant Selection World Wide Oils meeting
API CD or CC specifications may be used if they
also meet military specification MIL-L-2104 D or
E. Oils which meet European CCMC D4
specifications may also be used.
Modification of drain interval may be necessary,
depending on fuel quality. Contact Detroit Diesel
Corporation for further guidance.
9. WELDING PRECAUTIONS
1. Cut off battery power (battery master switch)
in rear electrical compartment.
2. Disconnect wiring harness connectors from
ECM (Electronic Control Module). The ECM
is mounted on the starter side of the engine.
3. For vehicles equipped with an automatic
transmission, disconnect wiring harness
connectors from ECU (Electronic Control
Unit). The ECU is located in rear electrical
compartment.
4. For vehicles equipped with ABS (Anti-Lock
Brake System), disconnect wiring harness
connectors from ABS Electronic Control Unit.
The ABS Electronic Control Unit is located in
the front service compartment.
5. Cover electronic control components and
wiring to protect from hot sparks, etc.
6. Do not connect welding cables to electronic
control components.
7. Do the appropriate welding on vehicle.
8. Connect ECM, ECU and ABS electronic
control units.
10. POWER PLANT ASSEMBLY REMOVAL
To access the engine or engine-related
components, the vehicle power plant assembly

Section 01: ENGINE
01-13
must be removed as a whole unit by means of a
slide-out cradle. The power plant assembly
includes the engine, transmission (including
retarder if so equipped), air compressor,
alternator and transmission oil cooler.
Remove the power plant assembly as follows:
Caution: Tag hoses and cables for
identification before disconnecting in order to
facilitate reinstallation. Plug all openings to
prevent dirt from entering the system.
Note: No parts within the ECM are serviceable.
If found defective, replace the complete ECM
unit.
1. Disconnect the battery or batteries from the
starting system by removing one or both of
the battery cables from each battery system.
With the electrical circuit disrupted, accidental
contact with the starter button will not
produce an engine start. In addition, the
Electronic Unit Injectors (EUI) will be
disabled, preventing any fuel delivery to the
injector tips.
Warning: Due to the heavy load of the rear
bumper assembly, it must be adequately
supported before attempting to remove it.
2. Remove the rear bumper assembly from the
vehicle. Refer to Section 18, BODY, under
"REAR BUMPER REMOVAL AND
INSTALLATION".
3. Drain the engine cooling system. Refer to
Section 05, COOLING under "DRAINING
COOLING SYSTEM".
FIGURE 14: ENGINE COMPARTMENT 01044
4. Locate the belt tensioner control valve
(Fig. 14). Turn handle counterclockwise in
order to release pressure in belt-tensioner air
bellows and loosen belts. Remove the belts.
5. Release all pressure from the air system.
Refer to Section 12, BRAKES & AIR
SYSTEM for instructions.
6. Disconnect and remove the engine-air intake
duct mounted between air cleaner housing
and turbocharger inlet (1, Fig. 15).
Caution: To avoid damage to turbocharger,
cover the turbocharger inlet opening to prevent
foreign material from entering.
7. Disconnect and remove the air intake duct
mounted between the air cooler outlet and
the engine intake (2, Fig. 16).
8. Disconnect and remove section of coolant
pipe assembly mounted between the radiator
outlet and the water pump inlet (3, Fig. 16).
9. Disconnect the coolant delivery hose located
close to the water pump.
10. Disconnect the electric fan-clutch connector,
close to the water pump (Fig. 15).
FIGURE 15: ENGINE COMPARTMENT 01056
11. Dismantle the air bellow from the upper
bracket of the fan-drive assembly tensioner.
Remove the upper bracket (4, Fig. 16).
12. If necessary, remove the fan drive from the
motor compartment by removing the four
retaining bolts, washers and nuts securing
the fan drive to the floor.

Section 01: ENGINE
01-14
13. Disconnect and remove the air intake duct
mounted between the turbocharger outlet and
the air cooler inlet (5, Fig. 16).
14. Disconnect two vent hoses from the
thermostat housing and from the coolant pipe
assembly.
15. Disconnect and remove a section of coolant
pipe assembly mounted between the
thermostat housings and the radiator inlet.
16. Disconnect and remove the small hose
connected to the heater line valve and to the
water pump.
17. Disconnect the small heater hose located on
the cylinder head at the back of the engine.
18. Disconnect and remove the exhaust pipe
mounted between the turbocharger outlet and
the exhaust bellows. If necessary, refer to
Section 04: EXHAUST SYSTEM under
“Muffler Removal And Installation".
FIGURE 16: ENGINE COMPARTMENT 01057
Caution: To avoid damage to turbocharger,
cover the turbocharger outlet opening to prevent
foreign material from entering.
19. Disconnect the block heater connector
above the power steering pump (6, Fig. 16).
20. Disconnect the steel-braided airline from the
A/C compressor air bellows.
21. Disconnect the oil delivery hose from the
valve located at the reserve tank drain
(7, Fig. 16).
22. Disconnect the power steering pump supply
and discharge hoses. Cap hose openings
immediately to limit fluid loss. Remove
retaining clips from cradle (8, Fig. 16).
23. Close engine fuel supply shutoff valve on
primary fuel filter. Disconnect the fuel line
connected to inlet port. On vehicles
equipped with the optional water-separator-
fuel-filter, disconnect the connector and
remove cable ties from cradle.
24. Disconnect the air compressor discharge,
governor steel-braided airlines and manual
filling airlines from compressor. Remove
retaining clips.
25. Disconnect the hose connecting the
compressor head to the sump tank.
26. Disconnect ground cables from rear
subframe ground-stud located close to the
starter motor.

Section 01: ENGINE
01-15
27. Disconnect positive cable (red terminal) from
starting motor solenoid.
28. Disconnect the power plant wiring-harness
main connectors from ECM and remove
retaining clips from engine compartment
backwall.
29. On vehicles equipped with an automatic
transmission provided with a hydraulic output
retarder, disconnect steel-braided airline from
pressure regulator output. The pressure
regulator is mounted in the upper section of
engine compartment backwall and is
accessible through the engine compartment
R.H. side door.
30. Disconnect fuel return line from bulkhead
fixed on engine cylinder head end.
31. On vehicles equipped with an electrically
operated cold-starting aid, disconnect the
delivery hose from the starting-aid cylinder
solenoid valve. Remove cable ties securing
hoses.
32. Disconnect turbo boost pressure gauge
airline from engine air intake.
33. Only if the vehicle is equipped with a
retarder, remove the transmission rubber-
damper assembly above transmission by
removing: nut, bushing, rubber damper,
rubber damper guide, bolt and washer.
Remove the rubber damper bracket from
transmission
34. Disconnect connectors from transmission.
On the left side: four on rear side with one
close to yoke. On right side: close to the
solenoid valve of the output retarder.
35. From under the vehicle, disconnect the
propeller shaft as detailed in Section 09,
under heading "Propeller Shaft Removal".
Manual Transmission Only:
•Disconnect gearshift linkage.
•Remove clutch slave cylinder from
transmission without disconnecting the
hydraulic hose.
36. Inspect the power plant assembly to ensure
that nothing will interfere when sliding out the
cradle. Check for connections or hoses not
mentioned in this list as some vehicles are
equipped with special or aftermarket
components.
37. Remove the six retaining bolts, washers and
nuts securing the power plant cradle to the
vehicle rear subframe (Fig. 18).
Note:Check if any spacer(s) have been
installed between power plant cradle and vehicle
rear subframe, and if so, note position of each
washer for reinstallation purposes.
38. Using a forklift, with a minimum capacity of
4,000 lbs (1 800 kg), slightly raise the power
plant cradle.
39. Pull engine out slowly from the engine
compartment. Make sure all lines, wiring and
accessories are disconnected and are not
tangled.
Caution:Due to the minimum clearance
between the power plant equipment and the top
of the engine compartment, extreme care should
be used to raise the power plant cradle, just
enough to free the cradle. Clearance between
power plant cradle and mounting rail should
range between 1/4" and 1/2" (6-12 mm).
11. POWER PLANT ASSY. INSTALLATION
To install a power plant assembly, follow the
same procedure as in "Power Plant Assembly
Removal" except in reverse order, then proceed
with the following:
1. Torque the power plant cradle mounting
bolts to 113-144 lbf•ft (153-195 N•m).
•For vehicles is equipped with an automatic
transmission and a retarder:
a) Install transmission bracket (Fig. 17),
tighten to 71-81 lbf•ft (96-110 N•m).
b) Install the transmission's rubber damper
assembly above transmission by
assembling: bolt, washer, rubber damper
guide, rubber damper, bushing nut.
c) Respect damper tolerance of 58 mm
(Fig. 17)

Section 01: ENGINE
01-16
FIGURE 17: RUBBER DAMPER TOLERANCE 07014
2. If fan drive has been removed, reinstall and
align as per Section 05, COOLING
SYSTEM, under "FAN DRIVE
ALIGNMENT".
3. Refill cooling system with saved fluid (refer
to Section 05, COOLANT SYSTEM).
4. Once engine fuel system has been drained,
it will aid restarting if fuel filters are filled with
fuel oil (refer to Section 03, FUEL SYSTEM).
5. Start engine for a visual check. Check fuel,
oil, cooling, pneumatic and hydraulic system
connections for leakage. Test operation of
engine controls and accessories.
12. VALVE COVER REMOVAL
The following instructions explain how to remove
the valve cover for valve, injector or Jake Brake
maintenance, without having to remove the
engine:
1. Remove air intake duct (1, Fig. 16).
2. Remove the air intake duct mounted
between the air cooler outlet and the engine
intake (2, Fig. 16).
3. Disconnect ventilation pipe from valve cover.
4. Remove engine cover.
5. Adjust Jake Brake (if applicable), injectors
and valves following instructions in the
Detroit Diesel service manual for series 60
engines.
6. Verify engine cover gasket and replace if
necessary.
Note: New gasket must be ordered directly from
Detroit Diesel.
7. Reinstall engine cover and tighten bolts to
18-22 Lbf·ft (25-30 N·m), in a criss-cross
pattern.
8. Reconnect ventilation pipe to engine cover.
9. Reinstall air ducts.
13. JAKE BRAKE
Refer to both "The Jake Brake Troubleshooting
and Maintenance Manual" and "Installation
Manual for Models 760/760A/765 Engine
Brakes" for troubleshooting and installation
procedures. They are annexed at the end of this
section.
14. ENGINE MOUNTS
The power plant assembly on a vehicle powered
with a series 60 engine is mounted to the cradle
by means of four rubber mounts.
Two rubber mounts are used at the front of the
engine while two others are mounted on each
side of the flywheel housing on vehicles
equipped with automatic and manual
transmissions (Fig. 18).
It is recommended that new rubber mounts be
installed at each major overhaul.

Section 01: ENGINE
01-17
FIGURE 18: POWER PLANT CRADLE INSTALLATION 01032

Section 01: ENGINE
01-18
15. SPECIFICATIONS
Series 60 Engine
Make .........................................................................................................................................Detroit Diesel
Type............................................................................................................... Diesel four cycle/in-line engine
Description.......................................................................................................Turbo/Air to air charge cooled
No. of cylinders............................................................................................................................................. 6
Operating range....................................................................................................................1200-2100 RPM
Maximum RPM........................................................................................................................................2100
Displacement, 11.1 Liters:
Bore & Stroke.............................................................................................5.12 X 5.47 in (130 X 139 mm)
Horsepower Range .......................................................................................................285 BHP, 350 BHP
Displacement, 12.7 Liters:
Bore & Stroke.............................................................................................5.12 X 6.30 in (130 X 160 mm)
Horsepower Range .......................................................................................................360 BHP, 500 BHP
Lubricant
Heavy-duty engine oil SAE Viscosity Grade 15W-40, API Classification CH-4 and meeting MIL-L-2104 D
or E specifications. Synthetic oil may be used if it meets the performance and chemical requirements of
non-synthetic oils outlined previously. Some engine operating conditions may require exceptions to this
recommendation.
Caution: To avoid possible engine damage, do not use single grade (Monograde) lubricants in Detroit
Diesel four-cycle Series 60 engines, regardless of API classification.
Capacity
Oil reserve tank ..................................................................................................................10 US qts (9.5 L)
Engine oil level quantity
Oil Pan Capacity, Low Limit..............................................................................................26 quarts/25 liters
Oil Pan Capacity, High Limit.............................................................................................32 quarts/30 liters
Total Engine Oil Capacity with Filters...............................................................................41 quarts/39 liters
Lubricating oil filter elements
Make.................................................................................................. AC Rochester Div. GMC # 25014505
Make.............................................................................................................................A/C Filter # PF-2100
Type................................................................................................................................................ Full Flow
Prévost number .................................................................................................................................510458
Torque specification
Engine oil filter..............................................................................Tighten 2/3 of a turn after gasket contact
Filters
Engine Air Cleaner Filter

Section 01: ENGINE
01-19
Make..............................................................................................................................Nelson # 70337-N
Prévost number .............................................................................................................................530197
Engine Coolant Filter/Conditioner
Make............................................................................................. Nalco Chemical Company # DDF3000
Make.................................................................................................................Detroit Diesel # 23507545
Prévost number..............................................................................................................................550630
Note: For primary and secondary fuel filters, refer to Specifications in section 03.