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4 0210-14
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«)) DETROIT
Service Information Bulletin
SUBJECT DATE
High Pressure Fuel Rail Feed Lines - Three-Filter System February 2014

Additions, Revisions, or Updates

Publication Number / Title | Platform Section Title Change

Removal of the High
Pressure Fuel Rail Feed
Lines - Three-Filter
System

Inspection of the High
Pressure Fuel Rail Feed
Lines - Three-Filter

‘System
DDC-SVC-MAN-0082 DD Platform Updating procedures due to new permanent dampers on lines.
Installation of the High

Pressure Fuel Rail Feed
Lines - Three-Filter
System
Installation of the DD15
and DD16 High Pressure
Fuel Rail Feed Lines -
Three-Filter System

ty) DETROIT

DEMAND PERFORMANCE-

13400 Outer Drive, West, Detroit, Michigan 48239-4001
Telephone: 313-592-5000
www.demanddetroit.com

All information subject to change without notice. 3
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION

2 Removal of the High Pressure Fuel Rail Feed Lines - Three-Filter System

2 Removal of the High Pressure Fuel Rail Feed Lines - Three-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.
2. Remove and discard the return lines P-clip bolt from the mounting bracket (1).

a. The graphic below illustrates the DD15/16 engines with a serial number before 472901S0012796.

470116

b. The graphic below illustrates a DD15/16 engines with a serial number after 472901S0012796 and all DD13
engines.

All information subject to change without notice.
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470099

c. The graphic below illustrates DD engines with permanent vibration dampers on the high pressure fuel rail feed
lines,

d470099b

3. For high pressure fuel rail feed lines with bolted vibration dampers, remove and discard the two bolts and P-clips (6)
from the mounting bracket (1). For high pressure fuel rail feed lines with permanent vibration dampers, remove and
discard the two bolts and P-clips (5) from the mounting bracket (1).

4. Remove and discard the mounting bracket bolts (2) from the intake manifold and discard the mounting bracket (1).

NOTE: When using tool J-48770 to remove the high pressure pump rail feed lines, hold the high pressure pump
fitting with a 24mm wrench. If the high pressure pump fittings are loosened while removing the high pressure fuel
rail feed lines, re-torque the fittings to 75 N-m (55 lb-ft).

5. For high pressure fuel rail feed lines with bolted vibration dampers, using tool J-48770, remove and discard the high
pressure pump rail feed lines (5) and vibration dampers (4) from the fuel rail and high pressure fuel pump. For high
pressure fuel rail feed lines with permanent vibration dampers, using tool J-48770, remove and discard the high
pressure pump rail feed lines (4) from the fuel rail and high pressure fuel pump.

6. Remove and discard the return lines P-clip (3).

All information subject to change without notice. 5
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION

3 Inspection of the High Pressure Fuel Rail Feed Lines - Three-Filter System

3 Inspection of the High Pressure Fuel Rail Feed Lines - Three-Filter
System

Inspect as follows:

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. sj

WARNING: PERSONAL INJURY ;
All parts provided within this kit must be installed in the proper locations, and MUST be fastened to

NOTICE: Failure to follow these instructions will result in. catastrophic damage to the engine and will not be
covered under warranty... : : a idee 2 eo

1. For high pressure fuel rail feed lines with bolted vibration dampers, inspect and verify the mounting bracket (1) and its

attaching bolts (2), the two P-clips (6), the high pressure fuel feed lines (5), and the two vibration dampers (4) are not
missing or loose. Do not attempt to loosen, tighten or otherwise disturb any of the parts.

a. The graphic below illustrates the DD15/16 engines with a serial number before 472901S0012796.

470116

b. The graphic below illustrates the DD15/16 engines with a serial number after 472901S0012796 and all DD13
engines.

All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 2 10-14

210-14

2. For high pressure fuel rail feed lines with permanent vibration dampers, inspect and verify the mounting bracket (1)
and its attaching bolts (2), the two P-clips (5), the high pressure fuel feed lines (4), the two vibration dampers (4) are
not missing or loose. Do not attempt to loosen, tighten or otherwise disturb any of the parts. The graphic below
illustrates DD engines with permanent vibration dampers on the high pressure fuel rail feed lines.

d470099b

All information subject to change without notice. 7
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION

4 Installation of the DD13 High Pressure Fuel Rail Feed Lines - Three-Filter System

4 Installation of the DD13 High Pressure Fuel Rail Feed Lines - Three-
Filter System

Install as follows:

NOTICE: Failure to follow these instructions will result in catastrophic damage to the engine and will not be
covered under warranty.

NOTE: DO NOT install bolts and fittings using power tools. All bolts and fittings MUST be installed using hand
tools.

specified torque. Failure to properly torque hardware/components will result in failure of a ‘high

WARNING: PERSONAL INJURY -
All hardware/components must be installed i in the proper locations, and MUST be fastened to the
pressure fuel feed line, resulting in possible fire and/or personal injury.

WARNING: PERSONAL INJURY i s :

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. i

1. Install the new return lines P-clip (3) on to the return lines.

d470099b

2. Clean the sealing area inside the high pressure fuel pump fittings using a clean lint-free cloth.

All information subject to change without notice.
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4470166

3. Clean the sealing area inside the high pressure fuel rail using a clean lint-free cloth.

4470167

4. Install the rear high pressure fuel line (4) to the fuel rail and the high pressure fuel pump. Hand tighten the nuts.

All information subject to change without notice. 9
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION

4 Installation of the DD13 High Pressure Fuel Rail Feed Lines - Three-Filter System

d470099b

5. Using tool J-48770, torque the rear high pressure fuel line nuts to 40 N-m (30 lb-ft).
6. Install the front high pressure fuel line (4) to the fuel rail and the high pressure fuel pump. Hand tighten the nuts.
7. Using tool J-48770, torque the front high pressure fuel line nuts to 40 N-m (30 lb-ft).

NOTICE: New P-clip/vibration dampers MUST be installed on to the high pressure fuel rail feed lines with the
Lower P-clip Plate (1) inserted in to the P-clip/vibration damper Window (2).

8. Install the new mounting bracket (1) and two new mounting bracket bolts (2) to the intake manifold. Torque to 30 N-m
(22 lb-ft).

4470247

9. Install two new vibration dampers (4) and two new bolts on to the high pressure fuel rail feed lines. (Refer to
illustration for proper location of the vibration dampers). Torque to 15 N-m (132 Ib-in.).
10. Install a new bolt on to the return lines P-clip. Torque to 15 N-m (132 Ib-in.).

10 All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 2 10-14

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CAUTION: ELECTRICAL SHOCK :
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic

switch studs are at battery voltage.

__ | WARNING: PERSONAL INJURY
The high-pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware

are single-use components that MUST be replaced if loosened or removed. 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. ; :

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".

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 (EPA07 and EPA 10) - Three-Filter Fuel System".
Refer to section "FIS Leak Detection-Three-Filter Fuel System".

14. If there are leaks, find the leak and repair, as necessary.

All information subject to change without notice. I
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION

5 Installation of the DD15 and DD16 High Pressure Fuel Rail Feed Lines - Three-Filter System

5 Installation of the DD15 and DD16 High Pressure Fuel Rail Feed Lines -
Three-Filter System

Install as follow:

NOTE: DO NOT install bolts and fittings using power tools. All bolts ae fittings ‘MUST be installed using hand
tools. :

specified torque. Failure to properly torque hardware/components will result in failure of a high

WARNING: PERSONAL INJURY
All hardware/components must be installed in the proper locations, and MUST be fastened to the
pressure fuel feed line, resulting in possible fire and/or personal injury:

WARNING: PERSONAL INJURY é L 4

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 Plessute fuel line, fesuting | in possible fire
and/or personal injury. - :

NOTE: The new return line P-clip is installed on the return ines so the mounting bracket i is under the return line
P-clip.

NOTICE: Failure to follow these instructions will result in patastrophic

image to the engine and will not be
covered under warranty. Z :

1. Install the new return lines P-clip (3) on to the return lines.

d470099b

2. Clean the sealing area inside the high pressure fuel pump fittings using a clean lint-free cloth.

12 All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 2 10-14

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3. Clean the sealing area inside the high pressure fuel rail using a clean lint-free cloth.

6470167

4. Install the rear high pressure fuel line (4) to the fuel rail and the high pressure fuel pump. Hand-tighten the nuts.
5. Using tool J-48770, torque the rear high pressure fue! line nuts to 40 N-m (30 Ib-ft).

6. Install the front high pressure fuel line (4) to the fuel rail and the high pressure fuel pump. Hand-tighten the nuts.
7. Using tool J-48770, torque the front high pressure fuel line nuts to 40 N-m (30 Ib-ft).

All information subject to change without notice. 13
210-14 Copyright © 2014 DETROIT DIESEL CORPORATION