1 01 36-16

SUBJECT DATE

Cylinder Block Oil Gallery Cup Plug January 2016

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0081DDC-SVC-MAN-0181DDC-SVC-MAN-0190

DDPlatform;Euro IV;GHG17

Replacement of the Oil Gallery Cup Plugbelow the High Pressure Fuel Pump

New procedure specifically for the oil gallerycup plug below the high pressure fuel pump.

01 36-16

All information subject to change without notice. 301 36-16Copyright 2016 DETROIT DIESEL CORPORATION

2 Replacement of the Oil Gallery Cup below the High Pressure FuelPump

This procedure is for replacement of the oil gallery cup plug located in the cylinder block below the high pressure fuel pump.For all other oil gallery cup plugs, Refer to section "Cylinder Block Oil Gallery Cup Plug Replacement".

NOTICE: Cleanliness of this repair is very important. Serious engine damage could occur if debris is allowed toenter the clean side of the engine lubrication system.

WARNING: PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to causecancer, birth defects, and other reproductive harm.

Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

CAUTION: ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magneticswitch studs are at battery voltage.

Replace as follows:

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.2. Disconnect the batteries. Refer to the OEM procedure.3. Open the hood.4. If necessary, remove the bumper for access. Refer to the OEM procedure.5. If necessary, remove the left side fairing and inner fender for access. Refer to the OEM procedure.

NOTICE: The engine coolant can be reused if it is not contaminated and has been properly maintained.

6. Drain the engine cooling system. Refer to section "Cooling System Drain Procedure".7. Remove the air compressor. Refer to section "Removal of the Air Compressor".8. Carefully clean the area around the cup plug. Remove any oil, rust or loose debris.9. Remove the oil gallery cup plug using a punch. It is best to strike the plug in the cupped area at the 6 o'clock position.

The cup plug can then be removed using pliers. See illustrations below.

2 Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump

4 All information subject to change without notice.Copyright 2016 DETROIT DIESEL CORPORATION01 36-16

10. Clean cup plug sealing area using a brush and suitable cleaner.11. Use a vacuum to remove any loose debris created by cup plug removal and cleaning of the sealing area.12. Apply Loctite 540 Cup Plug Sealant, Permatex 26240 Cup Plug Sealant or an equivalent cup plug sealant to the

sides of the new cup plug. Follow instructions supplied with the sealant. Loctite 7471 Activator, if available, canalso be used to strengthen the curing process.

01 36-16

All information subject to change without notice. 501 36-16Copyright 2016 DETROIT DIESEL CORPORATION

NOTICE: The new cup plug must be installed into the cylinder block at the correct depth. Serious engine damagecould occur if plug is installed too deep, as it may block another oil gallery.

13. Carefully install new cup plug into the cylinder block using a suitable cup plug driver. Plug should be driven from theinside center of the plug, not from the rim of the cup, and should be driven squarely into the hole. New cup plug shouldbe installed so the outside rim of the cup is just past the lead in chamfer in the cylinder block.

14. Install the air compressor. Refer to section "Installation of the Air Compressor".15. Allow the sealant to cure for a minimum of one hour before starting the engine, although 24 hours is highly

recommended.16. Install the left side fairing and inner fender, if removed. Refer to the OEM procedure.17. Install the bumper, if removed. Refer to the OEM procedure.

CAUTION: ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magneticswitch studs are at battery voltage.

18. Reconnect the batteries. Refer to the OEM procedure.19. Fill the cooling system. Refer to section "Cooling System Fill Procedure".

WARNING: PERSONAL INJURY

Diesel engine exhaust and some of its constituents are known to the State of California to causecancer, birth defects, and other reproductive harm.

Always start and operate an engine in a well ventilated area. If operating an engine in an enclosed area, vent the exhaust to the outside. Do not modify or tamper with the exhaust system or emission control system.

WARNING: ENGINE EXHAUST

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

WARNING: PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a levelsurface, parking brake is set, and the wheels are blocked.

20. Start the engine and inspect for leaks.21. Close the hood.

2 Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump

6 All information subject to change without notice.Copyright 2016 DETROIT DIESEL CORPORATION01 36-16

1 01 36-162 Replacement of the Oil Gallery Cup below the High Pressure Fuel Pump