NHTSA ID Number: 10055091
Manufacturer Communication Number: SIB-01-04-14
TSB/Document Date: 2014-04-09
Summary
DETROIT: PROCEDURAL INFORMATION REGARDING THE REMOVAL AND INSTALLATION OF THE FUEL RAIL TWO AND THREE FILTER SYSTEM FOR THE HIGH PRESSURE FUEL INJECTOR LINE SEALS. *PE
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- Restores fuel economy
- Stabilizes ethanol
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TSB/Document ID: SIB-01-04-14
Replacement Service Bulletin Number:
MFR Communication Date: 2014-01-04
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE:FUEL INJECTION SYSTEM:FUEL RAIL
MFR Component System:
MFR Component Subsystem:
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01 04-14
1
01 04-14
SB-10055091-5114
SUBJECT
DATE
Removal and Installation of the Fuel Rail - Two -Filter and ThreeFilter System
January 2014
Additions, Revisions, or Updates
Publication Number / Title
Platform
EPA07/
EPA10/
GHG14 DD
Platform
DDC-SVC-MAN-0082
EPA10/
GHG14 DD
Platform
DDC-SVC-MAN-0182
EuroIV DD
Platform
Section Title
Change
Removal of the Fuel Rail
– Three-Filter System
Installation of the Fuel
Rail – Three-Filter
System
Removal of the Fuel Rail
– Two-Filter System
Installation of the Fuel
Rail – Two-Filter System
Adding instructions to discard old and install new high pressure
fuel injector line seals.
Removal of the Fuel Rail
– Two-Filter System
Installation of the Fuel
Rail – Two-Filter System
All information subject to change without notice.
01 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
3
2 Removal of the Fuel Rail - Three-Filter System
2
Removal of the Fuel Rail - Three-Filter System
Remove as follows:
1. Steam clean the engine.
2. Disconnect the batteries.
3. Disconnect the fuel rail pressure sensor electrical harness connector.
WARNING: PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been
shut down for a minimum of 10 minutes before servicing any component within the high pressure
circuit. Residual high fuel pressure may be present within the circuit.
NOTICE: When removing the fuel rail feed tubes, cover the ends to ensure debris does not enter the tubes.
4. Remove the high pressure fuel injector lines with tool J-48770 and discard the high pressure fuel injector line seal.
Refer to section "Removal of the High Pressure Fuel Injector Lines - Three-Filter System".
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.
5. Remove the high pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Injector Lines Three-Filter System".
6. Remove the pressure limiting valve (PLV) line from fuel rail. Refer to section "Removal of the Needle, Amplifier, and
Pressure Limiting Valve Return Lines - Three-Filter System".
7. Remove the fuel rail bolts and clamps connecting the fuel rail to the camshaft housing and remove the fuel rail, discard
the fuel rail clamps and bolts.
4
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
01 04-14
01 04-14
3
Installation of the Fuel Rail - Three-Filter System
Install as follows:
NOTICE: Fuel rail clamp bolts are single-use items and cannot be re-used.
1. Install fuel rail to camshaft frame with three clamps and six new fuel rail bolts; hand-tighten bolts.
2. Using tool J-48770, install the high pressure fuel injector lines to the fuel rail and fuel injectors with new high pressure
fuel injector line seals; hand-tighten the high pressure fuel injector lines.
3. Install new high-pressure fuel rail feed lines to fuel rail and high-pressure pump with tool J-48770 and hand-tighten.
4. Install Pressure Limiting Valve (PLV) fuel return line to the fuel filter module and fuel rail with tool J-48770 and handtighten.
5. Torque the following in this sequence:
a. Fuel rail clamp bolts to 14 N·m (120 lb·in.).
b. High pressure fuel injector line seal bolts to 15 N·m (11 lb·ft).
c. High pressure fuel injector line to 40 N·m (30 lb·ft).
d. New high pressure pump rail lines to 40 N·m (30 lb·ft).
e. Pressure Limiting Valve (PLV) banjo bolt to 35 N·m (26 lb·ft).
6. If removed, install the fuel rail pressure sensor; torque to 65 to 70 N·m (48 to 52 lb·ft) and then install connector.
7. If removed, install PLV and torque to 100 N·m (74 lb·ft)
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.
8. Install new bracket to the high pressure fuel lines.
9. Install the new fuel line retaining bracket. Torque to 10 N·m (8 lb·ft).
WARNING: PERSONAL INJURY
All parts provided within this kit are single-use items and cannot be re-used. Re-use of hardware/
component items may result in the failure of a high pressure fuel line, resulting in possible fire
and/or personal injury.
10. Install three new P-clips that retain the fuel lines to the bracket. Torque to 10 N·m (8 lb·ft).
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
11. Connect the batteries.
12. Prime the fuel system. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter
System".
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
All information subject to change without notice.
01 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
5
3 Installation of the Fuel Rail - Three-Filter System
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
13. Start the engine and check for leaks.
6
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
01 04-14
01 04-14
4
Removal of the Fuel Rail - Two-Filter System
Remove as follows:
1. Steam clean the engine.
2. Disconnect the batteries.
3. Disconnect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2) and intake temperature
sensor (1).
WARNING: PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been
shut down for a minimum of 10 minutes before servicing any component within the high pressure
circuit. Residual high fuel pressure may be present within the circuit.
4. Remove and discard the high pressure fuel rail feed lines from the high pressure pump to the fuel rail. Refer to section
"Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System"
5. Remove the high pressure fuel injector feed lines with tool J-48770 and discard the high pressure fuel injector line
seals. Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System".
6. Remove pressure limiting valve (PLV) return line from fuel rail and discard the sealing washers. Refer to section
"Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System".
7. Remove the fuel rail clamp bolts (1) and fuel rail clamps (2) from the camshaft housing (3) and remove the fuel rail (4)
from the engine, discard the fuel rail clamp bolts.
All information subject to change without notice.
01 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
7
4 Removal of the Fuel Rail - Two-Filter System
8
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
01 04-14
01 04-14
5
Installation of the Fuel Rail – Two-Filter System
NOTICE: Fuel rail clamps MUST be installed with arrows pointing upwards. (See Item 5 in figure below).
NOTE: The rear fuel rail clamp has mounting holes for the high pressure fuel lines mounting bracket.
Install as follows:
NOTICE: Fuel rail clamp bolts are single-use items and cannot be re-used
1. Install the fuel rail (4) on to the camshaft housing (3). With the arrows pointing upwards (5), install the three fuel rail
clamps (2) and six new fuel rail clamp bolts (1) on to the camshaft housing (3). Hand-tighten the fuel rail clamp bolts.
2. Using tool J-48770, install the high pressure fuel injector lines on to the fuel rail and fuel injectors with new high
pressure fuel injector line seals. Refer to section "Installation of the High Pressure Fuel Injector Lines - Two-Filter
System". Hand-tighten the high pressure fuel injector lines.
3. Install Pressure Limiting Valve (PLV) return line with new sealing washers on to the fuel rail. Refer to section
"Installation of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System".
4. Torque the high pressure fuel injector lines to 40 N·m (30 lb·ft).
5. Torque the fuel rail clamps bolts to 14 N·m (120 lb·in.).
NOTICE: The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware are one-time
use components and MUST be replaced any time they are removed.
6. Install the new high pressure fuel rail feed lines on to the high pressure pump and fuel rail. Refer to section "Installation
of the High Pressure Fuel Rail Feed Lines - Two-Filter System".
7. Connect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2), and intake temperature
sensor (1).
All information subject to change without notice.
01 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
9
5 Installation of the Fuel Rail – Two-Filter System
8. Connect the batteries.
9. Prime the fuel system. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter
System".
WARNING: PERSONAL INJURY
To avoid injury before starting and running the engine, ensure the vehicle is parked on a level
surface, parking brake is set, and the wheels are blocked.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
10. Start the engine and check for leaks.
10
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
01 04-14
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