NHTSA ID Number: 10120486
Manufacturer Communication Number: 1104-14
TSB/Document Date: 2017-10-21
Summary
1104-14 Metal in the Fuel System
11 04-14
1
11 04-14
SUBJECT
DATE
Metal in the Fuel System
November 2014
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Metal in the Fuel System
- Two-Filter Fuel System
DDC-SVC-MAN-0084
DDC-SVC-MAN-S184
DD Platform
EuroIV DD
Metal in the Fuel System
- Three-Filter Fuel
System
Metal in the Fuel System
- Two-Filter Fuel System
Change
Two- and three-filter system procedures modified to clean the OEM
supply and return lines instead of replacing them.
Two-filter system procedures modified to clean the OEM supply
and return lines instead of replacing them.
All information subject to change without notice.
11 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
3
2 Metal in the Fuel System – Two-Filter Fuel System
2
Metal in the Fuel System – Two-Filter Fuel System
Table 1.
Service Tools Used in the Procedure
Tool Number
Tool Description
Tool Graphic
J-48707
Fuel Filter Module Inlet Outlet Hose
J-48708-1
Fuel Flow Tool
W470589039100
Fuel System Tool Update Kit Without Motor
Control Module (MCM) Cooler
Check as follows:
1. Remove the fuel filters from the fuel filter module. Inspect the fuel filters and inside of the fuel filter module for metal
debris.
Refer to section "Removal of the Fuel Prefilter – Two Filter System".
Refer to section "Removal of the Coalescer/Final Filter – Two Filter System ".
Is any metal debris present?
a. Yes; Go to step 2.
4
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 11 04-14
11 04-14
b. No; reinstall the fuel filters.
Refer to section "Installation of the Fuel Prefilter – Two Filter System".
Refer to section "Installation of the Coalescer/Final Filter - Two Filter System".
2. Using a magnet, check the fuel filters and inside of the fuel filter module for magnetic debris. Is any magnetic debris
present on the fuel filters or inside of the fuel filter module?
a. Yes; Go to step 3.
b. No; replace the fuel filters. Inspect the fuel tank(s) for metal debris. If debris is found in the fuel tank(s), clean the
fuel tank(s). Refer to OEM procedures.
Refer to section "Installation of the Fuel Prefilter – Two Filter System".
Refer to section "Installation of the Coalescer/Final Filter - Two Filter System".
3. Remove the high pressure flange from the high pressure fuel pump. Refer to section "Removal of the High Pressure
Fuel Flange - Two-Filter System". Using a magnet, insert the magnet in to the high pressure fuel pump outlet port (1)
and check for magnetic debris. Is any magnetic debris present?
Table 2.
The illustration below shows the location of the high pressure fuel pump outlet port (1) on the KM59 GEN1 high pressure
fuel pump.
All information subject to change without notice.
11 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
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2 Metal in the Fuel System – Two-Filter Fuel System
Table 3.
The illustration below shows the location of the high pressure fuel pump outlet port (1) on the KM63 GEN2 high pressure
fuel pump.
a. Yes; Go to step 5.
b. No; reinstall the high pressure flange. Refer to section "Installation of the High Pressure Fuel Flange – Two-Filter
System", then Go to step 4.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
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.
4. Remove the chassis return line from the fuel filter module. Install J-48707 fuel filter module inlet/outlet hose and
W470589039100 Fuel System Tool Update Kit without a Motor Control Module (MCM) cooler on to the chassis return
line fitting on the fuel filter module. Install the opposite end of J-48707 on to J-48708-1 fuel flow tool. Run the engine
at idle until J-48708-1 is full with fuel. Using a magnet, check the fuel in J-48708 for magnetic debris. Is any magnetic
debris present?
6
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 11 04-14
11 04-14
a. Yes; Go to step 5.
b. No; drain the fuel out of J-48708-1 and repeat step 4. If magnetic debris is found after repeating step 4, Go to step
5. If magnetic debris is not found after repeating step 4, replace the fuel filters and inspect the fuel tank(s) for
debris. If metal debris is found in the fuel tank(s), clean the fuel tank(s). Refer to OEM procedures.
Refer to section "Installation of the Fuel Prefilter – Two Filter System".
Refer to section "Installation of the Coalescer/Final Filter - Two Filter System".
Remove
the Pressure Limiting Valve (PLV). Refer to section "Removal of the Pressure Limiting Valve - Two-Filter
5.
System". Using a magnet, check the inside of the fuel rail for magnetic debris. Is any magnetic debris present?
a. Yes; replace the following components:
• High pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump – Two-Filter System".
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System".
• High pressure fuel injector lines. Refer to section "Removal of the High Pressure Fuel Injector Lines - TwoFilter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - TwoFilter System".
• Fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter System".
• Frame-mounted filter (if equipped).
Clean the following components:
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System".
• Doser supply line.
• Return lines. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return
Lines – Two-Filter System".
• Fuel rail. Refer to section "Removal of the Fuel Rail - Two-Filter System".
• Frame-mounted filter housing (if equipped).
• Fuel tank(s). Refer to OEM procedures.
• OEM Supply and return lines. Refer to OEM procedures.
b. No; replace the following:
• High pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump – Two-Filter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines - TwoFilter System".
All information subject to change without notice.
11 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
7
2 Metal in the Fuel System – Two-Filter Fuel System
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter System".
• Frame-mounted filter (if equipped).
Clean the following components:
• Fuel tank(s). Refer to OEM procedures.
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System".
• Doser supply line.
• Return lines. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return
Lines – Two-Filter System"
• Frame-mounted filter housing (if equipped).
• OEM supply and return lines. Refer to OEM procedures.
8
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 11 04-14
11 04-14
3
Metal in the Fuel System – Three-Filter Fuel System
Table 4.
Service Tools Used in the Procedure
Tool Number
Tool Description
J-48707
Fuel Filter Module Inlet Outlet Hose
J-48708-1
Fuel Flow Tool
W470589039100
Fuel System Tool Update Kit Without Motor
Control Module (MCM) Cooler
Tool Graphic
Check as follows:
1. Remove the fuel filters from the fuel filter module. Inspect the fuel filters and inside of the fuel filter module for metal
debris.
Refer to section "Removal of the Fuel Prefilter - Three-Filter System".
Refer to section "Removal of the Water Separator/Coalescer - Three-Filter System".
Refer to section "Removal of the Final Filter - Three-Filter System".
Is any metal debris present?
All information subject to change without notice.
11 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
9
3 Metal in the Fuel System – Three-Filter Fuel System
a. Yes; Go to step 2.
b. No; reinstall the fuel filters.
Refer to section "Installation of the Fuel Prefilter - Three-Filter System".
Refer to section "Installation of the Water Separator/Coalescer - Three-Filter System".
Refer to section "Installation of the Final Filter - Three-Filter System".
2. Using a magnet, check the fuel filters and inside of the fuel filter module for magnetic debris. Is any magnetic debris
present on the fuel filters or inside of the fuel filter module?
a. Yes; Go to step 3.
b. No; replace the fuel filters and inspect the fuel tank(s) for metal debris. If debris is found in the fuel tank(s), clean
the fuel tank(s). Refer to OEM procedures.
Refer to section "Installation of the Fuel Prefilter - Three-Filter System".
Refer to section "Installation of the Water Separator/Coalescer - Three-Filter System".
Refer to section "Installation of the Final Filter - Three-Filter System".
NOTICE: Every time a high pressure flange is installed on the three-filter fuel system, a new high pressure flange
gasket MUST be installed with the high pressure flange.
3. Remove the high pressure flange from the high pressure fuel pump. Refer to section "Removal of the High Pressure
Fuel Flange - Three-Filter System". Using a magnet, insert the magnet in to the high pressure fuel pump outlet port (1)
and check for magnetic debris. Is any magnetic debris present?
a. Yes; Go to step 5.
b. No; reinstall the high pressure flange. Refer to section "Installation of the High Pressure Fuel Flange - ThreeFilter System", then Go to step 4.
WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
10
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 11 04-14
11 04-14
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.
4. Remove the chassis return line from the fuel filter module. Install J-48707 fuel filter module inlet/ outlet hose and
W470589039100 Fuel System Tool Update Kit without a Motor Control Module (MCM) cooler on to the chassis return
line fitting on the fuel filter module. Install the opposite end of J-48707 on to J-48708-1 fuel flow tool. Run the engine
at idle until J-48708-1 is full with fuel. Using a magnet, check the fuel in J-48708 for magnetic debris. Is any magnetic
debris present?
a. Yes; Go to step 5.
b. No; drain the fuel out of J-48708-1 and repeat step 4. If magnetic debris is found after repeating step 4, Go to step
5. If magnetic debris is not found after repeating step 4, replace the fuel filters and inspect the fuel tank(s) for
metal debris. If metal debris is found in the fuel tank(s), clean the fuel tank(s). Refer to OEM procedures.
Refer to section "Installation of the Fuel Prefilter - Three-Filter System".
Refer to section "Installation of the Water Separator/Coalescer - Three-Filter System".
Refer to section "Installation of the Final Filter - Three-Filter System".
5. Remove the Pressure Limiting Valve (PLV). Refer to section "Removal of the Pressure Limiting Valve - Three-Filter
System". Using a magnet, check the inside of the fuel rail for magnetic debris. Is any magnetic debris present?
a. Yes; replace the following components:
• High pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Three-Filter System"
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module - Three-Filter System".
• High pressure fuel injector lines. Refer to section "Removal of the High Pressure Fuel Injector Lines - ThreeFilter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines Three-Filter System".
• Fuel injectors. Refer to section "Removal of the Fuel Injector - Three-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Three-Filter System".
• Frame-mounted filter (if equipped).
All information subject to change without notice.
11 04-14
Copyright © 2014 DETROIT DIESEL CORPORATION
11
3 Metal in the Fuel System – Three-Filter Fuel System
Clean the following components:
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Three-Filter System".
• Low pressure flange. Refer to section "Removal of the Low Pressure Fuel Flange - Three-Filter System".
• Doser supply line. Refer to section "Removal of the Hydrocarbon Doser Block Feed Line".
• Return lines. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines Three-Filter System".
• Fuel rail. Refer to section "Removal of the Fuel Rail - Three-Filter System".
• Frame-mounted filter housing (if equipped).
• OEM supply and return lines. Refer to OEM procedures.
• Fuel tank(s). Refer to OEM procedures.
b. No; replace the following:
• High pressure fuel pump. Refer to section "Removal of the Fuel Prefilter - Three-Filter System".
• Fuel filter module. Refer to section "Removal of the Fuel Filter Module - Three-Filter System".
• High pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines Three-Filter System".
• High pressure flange. Refer to section "Removal of the High Pressure Fuel Flange - Three-Filter System".
• Frame mounted filter (if equipped).
Clean the following components:
• Fuel tank(s). Refer to OEM procedures.
• Low pressure lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Three-Filter System".
• Doser supply line. Refer to section "Removal of the Hydrocarbon Doser Block Feed Line".
• Return lines. Refer to section "Removal of the Needle, Amplifier, and Pressure Limiting Valve Return Lines Three-Filter System".
• Frame-mounted filter housing (if equipped).
• OEM supply and return lines. Refer to OEM procedures.
12
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 11 04-14
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TSB/Document ID: 1104-14
Replacement Service Bulletin Number:
MFR Communication Date: 2014-11-04
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL
MFR Component System:
MFR Component Subsystem:
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