Detroit Diesel — Power Plant Assembly Removal
Repair & overhaul
From a Detroit Diesel service manual — check it applies to your exact model before use.
Applies to: Detroit Diesel Series 60 engine
Before you start
- Due to the heavy load of the rear bumper assembly, it must be adequately supported before attempting to remove it.
- To avoid damage to turbocharger, cover the turbocharger inlet and outlet openings to prevent foreign material from entering.
- 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.
Procedure
- Disconnect the battery or batteries from the starting system by removing one or both battery cables from each battery system.
- Remove the rear bumper assembly from the vehicle (Section 18, BODY).
- Drain the engine cooling system (Section 05, COOLING).
- Turn the belt tensioner control valve handle counterclockwise to release belt-tensioner air bellows pressure; remove the belts.
- Release all pressure from the air system (Section 12, BRAKES & AIR SYSTEM).
- Disconnect and remove air intake ducts (air cleaner to turbocharger inlet, air cooler outlet to engine intake, turbocharger outlet to air cooler inlet).
- Disconnect and remove coolant pipe sections, coolant delivery hose, two vent hoses and small heater hoses.
- Disconnect and remove the exhaust pipe between turbocharger outlet and exhaust bellows.
- Disconnect the block heater connector, A/C compressor air bellows airline and oil delivery hose from the reserve tank drain valve.
- Disconnect the power steering pump supply and discharge hoses; cap hose openings immediately; remove retaining clips from cradle.
- Close engine fuel supply shutoff valve on primary fuel filter; disconnect the fuel line from the inlet port and the fuel return line from the cylinder head bulkhead.
- Disconnect the air compressor discharge, governor steel-braided airlines and manual filling airlines; disconnect the hose from compressor head to sump tank.
- Disconnect ground cables at the rear subframe ground-stud and the positive cable from starting motor solenoid; disconnect power plant wiring-harness main connectors from ECM.
- Disconnect transmission connectors, retarder pressure regulator airline and the propeller shaft; for manual transmission disconnect gearshift linkage and remove clutch slave cylinder.
- Remove the six retaining bolts securing the power plant cradle to the vehicle rear subframe and pull the engine out slowly using a forklift.
Tools required
- forklift with minimum capacity of 4,000 lbs (1 800 kg) Amazon
Tool links are Amazon searches (affiliate links); manufacturer special tools may only be available from a dealer.
Specs & values
- Clearance between power plant cradle and mounting rail should range between 1/4" and 1/2" (6-12 mm)
Full service-parts list: Detroit Diesel Series 60 engine →
Source: Detroit Diesel service manual. Steps and values are as documented; always cross-check against the official manual and any later revisions for your exact serial number before servicing.