SB-10054681-1948

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12 01-13

12 01-13

SUBJECT

DATE

Removal and Installation of the Needle, Amplifier and Pressure
Limiting Valve Return Lines -Two-Filter and Three-Filter Systems

December 2013

Additions, Revisions, or Updates
Publication Number / Title

DDC-SVC-MAN-0082

Platform

DD Platform

Section Title
Removal and Installation
of the Needle, Amplifier
and Pressure Limiting
Valve Return Lines-TwoFilter System
Removal and Installation
of the Needle, Amplifier
and Pressure Limiting
Valve Return LinesThree-Filter System

All information subject to change without notice.

12 01-13

Copyright © 2014 DETROIT DIESEL CORPORATION

Change

Updated whole procedure.

3

2 Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System

2

Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV)
Return Lines – Two-Filter System

Remove as follows:
NOTE: KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
NOTE: KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Remove the return line p-clip bolt securing the return lines to the mounting bracket.
2. Remove the return line p-clip from the engine.
3. Using J-48836 to hold the cylinder head fitting, remove the needle return line from the cylinder head fitting using
J-48770.
4. Remove the PLV return line from the fuel rail and discard sealing washers.
5. Using J-48836 to hold the cylinder head fitting, remove the amplifier return line from the cylinder head fitting using
J-48770.
6. For KM63 GEN2: Remove the two bolts securing the return lines to the fuel filter module. For all others: Remove the
three banjo bolts securing the needle, amplifier and PLV from the fuel filter module.
7. For KM63 GEN2: Remove the needle, amplifier and PLV from the fuel filter module and discard the O-ring seals.
8. Remove the needle, amplifier and PLV return lines from the engine.
9. Remove both cylinder head fittings from the cylinder head and discard the sealing washers.

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All information subject to change without notice.

Copyright © 2014 DETROIT DIESEL CORPORATION

12 01-13

12 01-13

3

Installation of the Needle, Amplifier, and Pressure Limiting Valve (PLV)
Return Lines – Two-Filter System

Install as follows:
NOTE: KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
NOTE: KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Using new sealing washers, install both cylinder head fittings at the rear of the cylinder head. Torque to 55 to 60 N·m
(40 to 44 lb·ft).
2. For KM63 GEN2: Lubricate new O-rings with a light coat of clean diesel fuel and install them on to the needle,
amplifier and PLV return lines.
3. Install the needle, amplifier and PLV return lines on to the engine.
4. For KM63 GEN2: Install the needle, amplifier and PLV return lines on to the fuel filter module.
5. Install the needle and amplifier return lines on to the cylinder head fittings at the rear of the cylinder head. Hand-tighten
the return lines. Do not torque at this time.
6. Install the PLV return line on to the fuel rail with new sealing washers. Hand-tighten the line. Do not torque at this
time.
7. For KM59 GEN1: Install the return lines on to the fuel filter module with new sealing washers. Hand-tighten the lines.
Do not torque at this time.
8. Install the return lines p-clip on to the return lines.
9. Install the return lines p-clip on to the mounting bracket. Torque to 15 N·m (11 lb·ft).
10. Using J-48770, torque the needle and amplifier return lines on to the cylinder head fittings at the rear of the cylinder
head to 25 N·m (18 lb·ft).
11. Torque the PLV line to the fuel rail to 30 to 33 N·m (22 to 24 lb·ft).

All information subject to change without notice.

12 01-13

Copyright © 2014 DETROIT DIESEL CORPORATION

5

3 Installation of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System

NOTICE: For KM59 GEN1 only, when tightening to the specified torque, ensure the amplifier return line to the fuel
filter module does not come in to contact with the intake manifold.
12. For KM63 GEN2: Install the two bolts securing the return lines to the fuel module. Torque to 30 N·m (22 lb·ft ).
For KM59 GEN1: Torque the return lines to the fuel module to 30 to 33 N·m (22 to 24 lb·ft).

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All information subject to change without notice.

Copyright © 2014 DETROIT DIESEL CORPORATION

12 01-13

12 01-13

4

Removal of the Needle, Amplifier, and Pressure Limiting Valve Return
Lines - Three-Filter System

Remove as follows:
WARNING: PERSONAL INJURY
All hardware/components must be installed in the proper locations, and MUST be fastened to the
specified torque. Failure to properly torque hardware/components will result in failure of a high
pressure fuel feed line, resulting in possible fire and/or personal injury.

NOTICE: Engine size/model year specific service kits, containing all necessary parts to replace the high pressure
fuel rail feed lines have been released. Refer to TS letter 12 TS-9 for the high pressure fuel line kit numbers to
repair these engines.
1. Remove and discard the high pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail
Feed Lines - Three-Filter System".
2. Using J-48836 to hold the cylinder head fitting, remove the needle return line from the cylinder head fitting using
J-48770.
3. Remove the needle return line from the high pressure flange.
4. Remove the needle return line from the needle return pressure control valve.
5. Remove the needle return pressure control valve from the fuel filter module.
6. Using J-48836 to hold the cylinder head fitting, remove the amplifier return line from the cylinder head fitting using
J-48770.
7. Remove the amplifier return line from the fuel filter module.
8. Remove both cylinder head fittings from the cylinder head and discard the sealing washers.
9. Remove the Pressure Limiting Valve (PLV) return line from the fuel filter module.
10. Remove the PLV return line from the fuel rail and discard the sealing washers.

All information subject to change without notice.

12 01-13

Copyright © 2014 DETROIT DIESEL CORPORATION

7

5 Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter System

5

Installation of the Needle, Amplifier, and Pressure Limiting Valve
Return Lines - Three-Filter System

Install as follows:
1. Install the PLV return line on to the fuel rail with new sealing washers. Hand-tighten the line. Do not torque at this
time.
2. Install the PLV return line on to the fuel filter module.
3. Torque PLV return line to the fuel filter module to 28 to 30 N·m (21 to 22 lb·ft) and to the fuel rail 30 to 32 N·m (22 to
24 lb·ft).
4. Using new sealing washers, install both cylinder head fittings at the rear of the cylinder head.
NOTE: EPA07 engines have a M18x1.5 and an M16x1.5 cylinder head fittings. EPA10 and newer engines use
M18x1.5 only.
5. Torque the cylinder head fittings M18 x 1.5 to 55 to 60 N·m (40 to 44 lb·ft) and M16 x 1.5 to 45-50 N·m (33 to 37
lb·ft).
6. Install the amplifier line on to the cylinder head fitting and fuel filter module.
7. Torque the amplifier return line to the cylinder head fitting to 23 to 25 N·m (17 to 19 lb·ft) and to the fuel filter module
to 28 to 30 N·m (21 to 22 lb·ft).
8. Lubricate the O-ring and the threads on the needle return pressure control valve with a light coat of clean diesel fuel.
9. Install the needle return pressure control valve. Torque to 50 N·m (37 lb·ft).
10. Install the needle return line on to the cylinder head fitting, fuel filter module and high pressure flange.
11. Torque the needle return to the cylinder head fitting to 23 to 25 N·m (17 to 19 lb·ft), to the fuel filter module to 28 to
30 N·m (21 to 22 lb·ft) and to the high pressure flange to 25 N·m (18 lb·ft).
WARNING: PERSONAL INJURY
All parts provided within this kit must be installed in the proper locations, and MUST be fastened to
the specified torque. Failure to properly torque hardware/components will result in failure of a high
pressure fuel feed line, resulting in possible fire and/or personal injury.
NOTICE: Engine size/model year specific service kits, containing all of the necessary parts to replace the highpressure fuel rail feed lines have been released. Refer to TS letter 12 TS-9 for the high-pressure fuel line kit
numbers to repair these engines.
12. Install the high pressure fuel rail feed lines. Refer to section "Installation of the High Pressure Fuel Rail Feed Lines" .

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All information subject to change without notice.

Copyright © 2014 DETROIT DIESEL CORPORATION

12 01-13