SERIES 60 SERVICE MANUAL
Contents
1. SERIES 60 SERVICE MANUAL before tightening the bolts This will help eliminate the potential for any interference between the flywheel housing and the oil pan 1 Drain Plug 6 Bolt 2 Nut 7 Plug 3 Isolator Seal 8 Insert 4 Sleeve 9 Seal 5 Isolator and Washer 10 Bolt ASM Replaces 4 5 6 Figure 3 38 Typical Oil Pan Assembly All information subject to change without notice Rev 2006 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 60 06 3 75 3 1 OIL PAN The plastic oil pan has side plugs that are threaded into a special stainless steel insert which is restrained by a nut inside the pan Sealing is provided by a fluoroelastomer seal ring that fits into a groove machined on the flange of the insert See Figure 3 39 1 4 a N D Z Ye a ia 20450 1 Plug 4 Nut 2 Insert 5 Oil Pan 3 Seal Figure 3 39 Side Plug Detail Rubber isolator washer assemblies and sleeves are used for attaching the oil pan The metal sleeve spacer is inserted through the isolator and limits the travel of the oil pan bolts to prevent over tightening and damaging the oil pan and isolator Effective August 1995 isolators made of an improved vibration absorbing material were released to reduce noise emissions In addition isolator bolt sleeve length was increased by 0 8 mm 0 032 in to accommodate the slightly longer isolators When installing a pipe plug coat the threads with Loctit2. ation subject to change without notice 3 78 From Bulletin 3 60 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 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 2 Dry with compressed air NOTICE Do not use solvents to clean isolators Damage to the isolator will result 3 Clean the surfaces of the cylinder block gear case and flywheel housing where they mate with the oil pan Use LPS Permatex or an equivalent non filming degreaser 3 1 3 1 Inspection of Oil Pan Inspect the oil pan inserts bolt isolators and isolator seal as follows 1 Check the isolators for dryness cracks or tears a If isolator is damaged replace with new part b If isolator is not damaged reuse the part 2 Check oil pan inserts and nut assemblies for tightness a If inserts and nut assemblies are loose torque to 183 197 N m 135 145 lb ft 3 Check oil pan for major dents cracks and other damage a If oil pan is damaged replace with new part b If oil pan is not damaged reuse the part 4 Check isolator seal for dryness cracks or tears a If seal is damaged replace with new part b If seal is not damaged clean off excess RTV clean seal with clean fuel oil dry completely and reuse part 5 If the oil pan has an oil pan adaptor servi
3. ce kit check the adaptor for flatness dents cracks and other damage a If oil pan adaptor is damaged replace with a new part b If oil pan adaptor is not damaged reuse the part All information subject to change without notice Rev 2006 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 60 06 3 79 3 1 3 1 4 OIL PAN Installation of Oil Pan Install the oil pan as follows 1 2 Insert the raised lip portion of the isolator seal into the groove in the oil pan Press down on the isolator seal and insert it completely around the oil pan Be careful not to stretch or bunch the seal For best results install the seal at each corner then at points half way between the corners Continue in this manner halving the distance and seating the seal Insert a metal sleeve spacer into each isolator and washer Install the ten oil pan bolts into isolator assemblies or install ten bolt assemblies Ensure the joint surfaces of the gear case and the cylinder block the gear case cover and gear case and the flywheel housing and the cylinder block are cleaned and there is no damage to prevent sealing Apply a 3 mm 1 8 in bead of RTV across joints shown See Figure 3 41 GEAR CASE TO CYLINDER BLOCK JOINT SURFACES FLYWHEEL HOUSING TO CYLINDER BLOCK JOINT SURFACES GEAR CASE COVER TO GEAR CASE JOINT SURFACE 20451 Figure 3 41 RTV Application l Ta 3 80 If the engin
4. e PT 7271 sealant or equivalent hold the insert to keep it from turning and torque the plug to 45 56 N m 33 41 lb ft Effective November 2005 an oil pan adaptor service kit became available for the 12 7L and 14L engines to increase oil capacity for approved engine applications The oil pan adaptor is only available for the vinyl rear sump vinyl front sump and aluminum low profile rear sump oil pans NOTE Customers who want to add an oil pan adaptor service kit should refer to publication 18SP626 or contact the Detroit Diesel Customer Support Center at 313 592 5800 with their engine data to see if the service kit is compatible with the engine Rev 2006 All information subject to change without notice 3 76 From Bulletin 3 60 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL 3 1 1 Repair or Replacement of Oil Pan To determine if repair is possible or replacement is necessary perform the following procedure See Figure 3 40 REMOVE OIL PAN amp GASKET CLEAN OFF RTV DAMAGED CLEAN WITH FUEL OIL INSPECT GASKET CRACKED CLEAN INSPECT OIL PAN MAJOR DENTS AND CRACKS REPLACE NEW GASKET INSTALL Figure 3 40 Flow Chart for Repair or Replacement of Oil Pan All information subject to change without notice Rev 2006 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 60 06 3 77 3 1 OIL PAN 3 1 2 Removal of Oil Pan Precl
5. e application uses an oil pan adaptor service kit install the oil pan adaptor as follows a Position the oil adaptor under the cylinder block and secure with several of the oil pan extender bolts Ensure that the adaptor does not interfere with the flywheel housing If there is interference use a beveled adaptor to maintain clearance Rev 2006 All information subject to change without notice From Bulletin 3 60 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL b Remove the adaptor and place it on a flat table or the floor Apply a 3 mm 1 8 in high bead of sealant 23525918 SOmL or 23525919 330mL in the adaptor groove See Figure 3 41a l TOP VIEW 9 2 TORQUE SPECIFICATION 25 30 N m 18 22 lb ft Figure 3 41a Oil Pan Adaptor and Tightening Sequence c Place the adaptor in position on the cylinder block d Install and slightly tighten the ten extender bolts e Tighten the extender bolts to 24 30 N m 18 22 lb ft See Figure 3 41a for the torque sequence 8 Install the oil pan assembly in position on the cylinder block or oil pan adaptor 9 Ensure that the isolator seal has not been disturbed Torque the ten oil pan bolt assemblies to 24 30 N m 18 22 lb ft using the proper sequence See Figure 3 42 BOTTOM VIEW AZOuN Drm TORQUE SPECIFICATION 25 30 N m 18 22 lb ft 20452 Figure 3 42 Oil Pan Bolt Sequence 10 Instal
6. eaning is not necessary NOTICE Do not support the engine on the oil pan Damage to the oil pan or engine could result NOTE On almost all engine applications it is possible to remove the oil pan without removing the engine If the engine is to be removed from the vehicle the oil pan should be left in place until the engine is removed The procedure for removing the oil pan will vary with each installation However the following procedures will generally apply NOTICE When removing a side plug hold the flats of the insert with a 2 1 8 in open end or large adjustable wrench to keep it from turning If the insert is loosened it may be necessary to remove the oil pan and tighten the nut to prevent a possible oil leak If required torque the nut to 186 199 N m 137 147 lb ft Remove the oil pan as follows 1 Remove the drain plug and drain the engine oil 2 Remove the ten oil pan bolts washers isolators and sleeves or ten bolt assemblies Remove the counter bolts on each side last Remove the oil pan taking care not to damage the oil pump inlet pipe and screen 4 Remove the oil pan isolator seal and inspect for damage If the engine application uses an oil pan adaptor service kit remove the ten oil pan extender bolts and oil pan adaptor 3 1 3 Cleaning of Oil Pan Clean the oil pan prior to inspection as follows 1 Clean the oil pan and attaching hardware with clean fuel oil Rev 2006 All inform
7. l and torque the 3 4 in 14 square magnetic oil drain plug to 45 56 N m 33 41 lb ft All information subject to change without notice Rev 2006 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 60 06 3 80a 3 1 OIL PAN 11 Install and tighten any other plugs that were removed from the oil pan NOTE When installing a pipe plug coat the threads with Loctite PT 7271 sealant or equivalent 12 Refill the crankcase with lubricating oil Refer to section 14 6 1 13 Refer to section 12 3 for verification of proper oil pan installation Rev 2006 All information subject to change without notice 3 80b From Bulletin 3 60 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION SERIES 60 SERVICE MANUAL This page intentionally left blank All information subject to change without notice Rev 2 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION From Bulletin 3 60 06 3 81 3 12 VENTILATING SYSTEM 3 12 VENTILATING SYSTEM Vapors formed within the engine are removed from the crankcase gear train and valve compartment by a continuous pressurized ventilating system A slight pressure is maintained in the engine crankcase by the normal seepage of a small amount of air and combustion gases past the piston rings These gases are swept up through the engine and pass through a crankcase breather On vehicle engines the gases are then vented to the atmosphere Breather extension h
8. oses may be required on certain Series 60 engines used in on highway vehicle applications Under certain conditions the vapors from an operating engine may be circulated through the battery charging alternator by the alternator cooling fan Excessive ingestion of vapors may lead to alternator malfunction This can occur if the internal components of the alternator become coated with oil laden dust or road grit To minimize the potential for this condition check the length of the engine breather tube and add an extension hose if necessary For proper dissipation of vapors the end of the breather hose must extend at least 12 inches below the oil pan rail A wire mesh element is located inside the valve cover or in a separate housing on the valve cover cap or at the gear case cover This element traps excess engine oil particles in the vapor and returns them to the crankcase See Figure 3 43 NOTE The Series 60G automotive engine uses a closed crankcase breather system Refer to section 6 4 for more information Rev 2006 All information subject to change without notice 3 82 From Bulletin 3 60 06 6SE483 0507 Copyright 2005 DETROIT DIESEL CORPORATION
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