IK1200782 - High Pressure Fuel Line Inspection and Replacement Procedure

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SB-10045801-5118

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BRAZIL, MEXICO Document ID: IK1200782

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ENGINES

Created:

7/16/2012

Current Language : English

Last Modified : 8/13/2012

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Fabricio Sartori Trani

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Title: High Pressure Fuel Line Inspection and Replacement Procedure
Applies To: MWM I4 - MaxxForce 4.8 Engines; MWM I6 - MaxxForce 7.2 Engines
DESCRIPTION

Certain High Pressure Fuel Lines (tubes) may have been incorrectly manufactured.
Follow the following High Pressure Fuel Line inspection and replacement of pipes not meeting the inspection
criteria.
NOTES:



Check the tubes for leakage when the engine is running
Only the tubes that show leakage should be replaced

SYMPTOMS


High Pressure Fuel Line fuel leakage can occur due to manufacturing deviation.

PARTS INFORMATION

MWM Part # (MWM I4)

Navistar Part # (MWM I4)

Description

9.412.0.906.066.5
9.412.0.906.067.5

2600941C1
2600942C1

High pressure fuel line
High pressure fuel line

Position
Cyl 2, 3 and 4
Cyl 1

Qty.
3
1

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IK1200782 - High Pressure Fuel Line Inspection and Replacement Procedure

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9.612.0.906.081.5

2600943C1

High pressure fuel line

Pump to Rail

1

MWM Part # (MWM I6)
9.612.0.906.081.5
9.612.0.906.082.5
9.612.0.906.083.5
9.612.0.906.084.5

Navistar Part # (MWM I6)
2600943C1
2600946C1
2600947C1
2600949C1

Description
High pressure fuel line
High pressure fuel line
High pressure fuel line
High pressure fuel line

Position
Pump to Rail
Cyl 1 and 2
Cyl 3 and 4
Cyl 5 and 6

Qty.
1
2
2
2

TROUBLESHOOTING
For better understanding of this bulletin, we divided it into the following topics:
1) How to identify the Traceability date engraved on the High Pressure Fuel Line hex nuts;
2) Cautions during the replacement of high-pressure lines.
3) Procedure of removal and installation of high pressure lines and respective torques to be applied.
4) Air Bleeding of Low-Pressure system after reworking.
5) Devolution and impairing of replaced pipes.
1. How to identify the traceability date engraved on the nuts that had 100% quality inspections in order to
avoid the possible manufacturing deviation in which condition could occurs leakage.
1. Clean the High Pressure Fuel Line hex nuts with mild solvent and shop towel when necessary for inspection.
2. Use a mechanics inspection mirror and flash light to Inspect the high pressure line hex nut for the following :

a. High Pressure Lines that have a second date stamp have been inspected and corrected and are within
specifications and should not be replaced (After BP)- See Figure 1 for example second date stamp.
b.

The High Pressure Line hex nut stamp contains part number, supplier code, cylinder number,
date, among others. One of these fields refers to the day and year of production of the tube. So
considering that the first tube produced after correction was at July 15th , we have as BP the day 197 of the
year 11, so all tubes with values ​equal to or greater than 197 ,of year 11 are within specification and should
not replace.

3. Inspect all inventoried parts ( Spare Parts) before using them as replacements.
4. Use the following procedures to replace all high pressure lines not meeting the above inspection criteria.

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IK1200782 - High Pressure Fuel Line Inspection and Replacement Procedure

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Figure 1 All High Pressure Lines with a second date stamp on the hex have been inspected and
corrected and should not be replaced.

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IK1200782 - High Pressure Fuel Line Inspection and Replacement Procedure

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Figure 2 All High Pressure Lines with a day of the year of 197 - 11 and greater are within
specification and should not be replace.
If date day of the year is less than 197 - 11 then inspect for second date stamp as shown
in Figure 1.

2. SERVICE PROCEDURE -HIGH PRESSURE LINE REPLACEMENT

WARNING:
To prevent unexpected movement of the vehicle and possible serious personal injury or death, park the
vehicle on a flat, level surface, set the parking brake, turn the engine off and chock the wheels to prevent
vehicle from moving in both directions.

WARNING:
To avoid personal injury or death, disconnect main negative battery cable before disconnecting or
connecting electrical components. If both battery cables are disconnected, always connect main
negative battery cable last.

WARNING:
To prevent personal injury or death, allow engine to cool before working with components.

WARNING:











The repairing of injection system only shall be done after 30 second since the engine is turned off.
This time is necessary to assure the total depressurization of the manifold pipe (Rail).
Do not loosen the connections of high-pressure pipes while the engine is running. The high
pressure fuel within the system may cause serious injuries.
Never service any fuel system component while the engine is running.
Do not smoke while working on the fuel system or other engine systems.
Avoid contacting electrical components that may produce sparks.
While the engine is running, do not touch the fuel injectors. This could cause injuries.
The sensors installed on fuel manifold pipes (Rail) should not be disassembled.
Always check the reservoirs, tubing, hoses and other fuel system components for leakages after
the rework.

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IK1200782 - High Pressure Fuel Line Inspection and Replacement Procedure

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3. Procedure of removal and installation of high-pressure pipes and respective torques to be applied:
Removal:

Loosen the connections and highpressure pipes from fuel injectors
(A) and feeder pipe from common-rail (B) After loosening the
connections, remove the high-pressure pipes. (The used pipes shall
be disposed of.)

Installation:

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First, place the high-pressure pipes (A) and (B) manually on both
ends (Fuel Injectors and Common-rail Pipe) (Highpressure pump
and Common-rail Pipe).
The high-pressure pipes shall be installed free of tensions,
avoiding damages, and kinks on pipes and flarenuts.

After manually positioning the manifold
pipe(common-rail) to the fuel injectors
pipes, apply the torque of 30 to 33 Nm. (A).

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On connections of high-pressure pipes to pipe rail and
high-pressure pump, apply the torque of 30 to 33 Nm.
(B).
NOTE:
The torque must be applied by using a torque wrench and the range should be from 30 to 33 Nm.

4. Air Bleeding of Low-Pressure System after reworking.

After completion of maintenance of fuel injection system, start the engine. If the engine does not start, prime the
fuel system using a manual pump (pump it until you feel a small resistance to the movement) and then try to start
the engine again. Repeat the procedure until the engine gets running on; after the start up, let the engine idle
running for 5 minutes. Check the engine for leakages and repair it if necessary.

5. Devolution and impairing of replaced pipes:

Aiming to impair the usage of removed pipes, these ones shall have their flare nuts crushed, this way
preventing their reusage.
They shall follow the normal procedures for analysis and warranty reimbursement of values, or be kept for audit
and later disposal of, by MWM-International Technical Representative during his/her regular visits.

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