NHTSA ID Number: 10055263
Manufacturer Communication Number: SIB-02-09-14
TSB/Document Date: 2014-05-02
Summary
DETROIT: INFORMATION PROVIDED REGARDING THE UPDATING PROCEDURE, ON THE HIGH PRESSURE FUEL RAIL FEED LINES TWO FILTER SYSTEM, DUE TO PERMANENT NEW DAMPERS ON LINES. *PE
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TSB/Document ID: SIB-02-09-14
Replacement Service Bulletin Number:
MFR Communication Date: 2014-02-01
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, OTHER:FUEL FILTER
MFR Component System:
MFR Component Subsystem:
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02 09-14
1
02 09-14
SB-10055263-7286
SUBJECT
DATE
High Pressure Fuel Rail Feed Lines - Two-Filter System
February 2014
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
Description and
Operation of the High
Pressure Fuel Rail Feed
Lines and Related Parts
- Two-Filter System
DDC-SVC-MAN-0082
DD Platform
Removal of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
System
Updating procedures due to new permanent dampers on lines.
Inspection of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
System
Installation of the High
Pressure Fuel Rail Feed
Lines - Two-Filter
System
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
3
2 Description and Operation of the High Pressure Fuel Rail Feed Lines and Related Parts - Two-Filter System
2
Description and Operation of the High Pressure Fuel Rail Feed Lines
and Related Parts - Two-Filter System
NOTICE: The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and hardware are
one-time use components and MUST be replaced any time they are removed.
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
PLV return line.
• Return lines P-clip mounting bolt is used to secure the return lines P-clip to the mounting bracket. This is a reusable bolt.
• Return lines P-clip is used to secure the return lines to the mounting bracket. This is a reusable P-clip.
• Mounting bracket is used to secure the high pressure fuel rail feed lines and return lines to rear rail clamp. This is a onetime-use component.
• High pressure fuel rail feed lines are used to transfer high pressure fuel from the high pressure fuel pump to the fuel rail.
This is a one-time-use component.
• Vibration dampers are used to lower the vibration in the high pressure fuel rail feed lines. This is a one-time-use
component.
• Mounting bracket bolts are used to secure the mounting bracket to the rear rail clamp. This is a one-time use component.
• P-clips are used to lower vibration and secure the high pressure fuel rail feed lines to the mounting bracket. This is a onetime-use component.
1. Reusable Return Lines P-clip Bolt
2. Mounting Bracket
3. High Pressure Fuel Feed Lines
4. Mounting Bracket Bolts
5. P-clips and Bolts
6. Vibration Dampers and Bolts
Figure 1. KM59 GEN1 with Bolted Vibration Dampers High Pressure Fuel Rail Feed Lines and Related
Parts
4
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
1. Reusable Return Lines P-clip Bolt
2. Mounting Bracket
3. High Pressure Fuel Feed Lines
4. Mounting Bracket Bolts
5. P-clips and Bolts
Figure 2. KM59 GEN1 with Permanent Vibration Dampers High Pressure Fuel Rail Feed Lines and Related
Parts
1. Reusable Return Lines P-clip Bolt
2. Mounting Bracket
3. High Pressure Fuel Feed Lines
4. Mounting Bracket Bolts
5. P-clips and Bolts
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
5
2 Description and Operation of the High Pressure Fuel Rail Feed Lines and Related Parts - Two-Filter System
Figure 3. KM63 GEN2 High Pressure Fuel Rail Feed Lines and Related Parts
6
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
3
Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System
Remove as follows:
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.
1. Disconnect batteries.
NOTE: Do not discard the return lines P-clip and bolt. They will be reused on the installation of the high pressure
fuel rail feed lines.
2. Remove the return lines P-clip bolt (1) from the mounting bracket (2).
Table 1.
KM59 GEN1 with Bolted Vibration Dampers
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
7
3 Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System
Table 2.
KM59 GEN1 with Permanent Vibration Dampers
8
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
Table 3.
KM63 GEN2 with Permanent Vibration Dampers
3. Remove and discard the two bolts and P-clips (5) from the mounting bracket (2). See illustrations above.
4. Remove and discard the mounting bracket bolts (4) from the fuel rail clamp and discard the mounting bracket (2). See
illustrations above.
NOTE: For KM59 GEN1: When using tool J-48770 to remove the high pressure pump rail feed lines, hold the high
pressure pump fitting with a 24mm wrench.
5. Using tool J-48770, remove and discard the high pressure pump rail feed lines (3) and vibration dampers from the fuel
rail and high pressure fuel pump. See illustrations above.
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
9
4 Inspection of the High Pressure Fuel Rail Feed Lines – Two Filter System
4
Inspection of the High Pressure Fuel Rail Feed Lines – Two Filter
System
Inspect as follows:
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.
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.
NOTICE: Failure to follow these instructions will result in catastrophic damage to the engine and will not be
covered under warranty.
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
PLV return line.
1. Inspect and verify the mounting bracket (2) and its attaching bolts (4), the two P-clips (5), and the high pressure fuel
feed lines (3) with two vibration dampers are not missing or loose. Do not attempt to loosen, tighten or otherwise
disturb any of the parts.
10
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
Table 4.
KM59 GEN1 with Bolted Vibration Dampers
Table 5.
KM59 GEN1 with Permanent Vibration Dampers
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
11
4 Inspection of the High Pressure Fuel Rail Feed Lines – Two Filter System
Table 6.
KM63 GEN2 with Permanent Vibration Dampers
12
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
5
Installation of the High Pressure Fuel Rail Feed 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
PLV return line.
NOTE: DO NOT install bolts and fittings using power tools. All bolts and fittings MUST be installed using hand
tools.
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.
1. Clean the sealing area inside the high pressure fuel pump fittings using a clean lint free cloth.
a. The illustration shown below is a KM59 GEN1 High Pressure Fuel Pump Fittings; KM63 GEN2 High Pressure
Fuel Pump Fittings is similar.
2. Clean the sealing area inside the high pressure fuel rail using a clean lint free cloth.
a. The illustration shown below is a KM59 GEN1 High Pressure Fuel Rail; KM63 GEN2 High Pressure Fuel Rail is
similar.
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
13
5 Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System
3. Install the rear high pressure fuel line (3) to the fuel rail and the high pressure fuel pump. Hand-tighten the nuts.
Table 7.
KM59 GEN1 with Bolted Vibration Dampers
14
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
Table 8.
KM59 GEN1 with Permanent Vibration Dampers
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
15
5 Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System
Table 9.
KM63 GEN2 with Permanent Vibration Dampers
4. Using tool J-48770, torque the rear high pressure fuel line nuts to 40 N·m (30 lb·ft).
5. Install the front high pressure fuel line (3) (see illustrations above) to the fuel rail and the high pressure fuel pump.
Hand-tighten the nuts.
6. Using tool J-48770, torque the front high pressure fuel line nuts to 40 N·m (30 lb·ft).
7. Install the new mounting bracket (2) and two new mounting bracket bolts (4) to the fuel rail clamp. Torque to 15 N·m
(132 lb·in.). See illustrations above.
NOTICE: New P-clip MUST be installed on to the high pressure fuel rail feed lines with the lower P-clip plate
inserted in to the P-clip window.
8. Install new P-clips on to the high pressure fuel rail feed lines with the lower P-clip plate (1) inserted in to the P-clip
window (2).
16
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
9. Install two new P-clips (5) and two new bolts to the high pressure fuel rail feed lines (3) and the mounting bracket (2).
Torque to 15 N·m (132 lb·in.).
Table 10.
KM59 GEN1 with Bolted Vibration Dampers
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
17
5 Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System
Table 11.
KM59 GEN1 with Permanent Vibration Dampers
18
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION
02 09-14
02 09-14
Table 12.
KM63 GEN2 with Permanent Vibration Dampers
10. Reinstall the return lines P-clip (1). Torque to 15 N·m (132 lb·in.) See illustrations above.
NOTE: DO NOT use high pressure fuel lines without new vibration dampers and new bolts installed.
CAUTION: ELECTRICAL SHOCK
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 - Two-Filter
System".
13. Perform the Rail Pressure Bleed-Off test to verify that there are no leaks.
Refer to section "Rail Pressure Bleed Off Test Using DDDL- Two-Filter Fuel System".
Refer to section "FIS Low Pressure Leak Test-Two-Filter Fuel System".
14. If there are leaks, find the leak and repair, as necessary.
All information subject to change without notice.
02 09-14
Copyright © 2014 DETROIT DIESEL CORPORATION
19
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