5 02-13

1

5 02-13

SUBJECT

DATE

Needle, Amplifier, and Pressure Limiting Valve Return Lines – ThreeFilter System, Fuel Rail - Three-Filter System

February 2013

Additions, Revisions, or Updates
Publication Number / Title

Platform

Section Title

Change

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

DDC-SVC-MAN-0082

DD Platform
– All Years

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

Adding approved warnings and notices to procedures that have a
step to remove and install the high pressure fuel rail feed lines.
Updated the removal and installation of the high pressure fuel rail
feed lines step to be consistent across all procedures.

Removal of the Fuel Rail
- Three-Filter System
Installation of the Fuel
Rail - Three-Filter
System

All information subject to change without notice.

5 02-13

Copyright © 2013 DETROIT DIESEL CORPORATION

3

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

2

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 and J-48770, remove the needle return line from the rear of the cylinder head and discard the sealing
washers.
3. Remove the needle return line from the fuel filter module and the high pressure flange.
4. Remove the Pressure Limiting Valve (PLV) return line from the fuel rail and discard sealing washers.
5. Remove the PLV return line from the fuel filter module.
6. Using J-48836 and J-48770, remove the amplifier return line from the rear of the cylinder head and discard the sealing
washers.
7. Remove the amplifier return line from the fuel filter module.

4

All information subject to change without notice.

Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-13

5 02-13

3

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

Install as follows:
1. Install the amplifier and needle return line fittings to the cylinder head. Using J-48770, torque M18 x 1.5 to 55 to 60
N·m (40 to 44 lb·ft) and M16 x 1.5 to 45 to 50 N·m (33 to 37 lb·ft).
2. Install the amplifier return line from the fitting on the rear of the cylinder head, using new sealing washers to the fuel
filter module.
a. Use J-48770 and J-48836 to torque the line fitting to the fitting in the cylinder head; torque to 23 to 25 N·m (17
to 19 lb·ft).
b. Use an appropriate tool to hold the fitting on the fuel filter module; torque to 28 to 30 N·m (21 to 22 lb·ft).
3. Install the Pressure Limiting Valve (PLV) return line from the fuel rail to the fuel filter module with new banjo
washers. Use an appropriate tool; torque to 28 to 30 N·m (21 to 22 lb·ft). Torque the banjo bolt to 30 to 32 N·m (22 to
24 lb·ft).
4. Install the needle return line to the cylinder head using new sealing washers, the fuel filter module and the highpressure flange.
a. Use J-48770 and J-48836 to torque the line fitting to the fitting in the cylinder head; torque to 23 to 25 N·m (17
to 19 lb·ft).
b. Use an appropriate tool to hold the fitting on the fuel filter module and to the high-pressure flange; torque to 28 to
30 N·m (17 to 19 lb·ft).
c. Torque the check valve to 50 to 55 N·m (37 to 41 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.
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 (http://www.ddcsn.com/cps/rde/xbcr/
ddcsn/11TL12.pdf)for the high-pressure fuel line kit numbers to repair these engines.
5. Install the high pressure fuel rail feed lines. Refer to section "Installation of the High Pressure Fuel Rail Feed Lines".

All information subject to change without notice.

5 02-13

Copyright © 2013 DETROIT DIESEL CORPORATION

5

4 Removal of the Fuel Rail - Three-Filter System

4

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. 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 bolts and clamps connecting the fuel rail to the camshaft housing and remove the fuel rail.

6

All information subject to change without notice.

Copyright © 2013 DETROIT DIESEL CORPORATION 5 02-13

5 02-13

5

Installation of the Fuel Rail - Three-Filter System

Install as follows:
1. Install the fuel rail to the camshaft frame with three clamps and six bolts; hand-tighten bolts.
2. Using tool J-48770, install the fuel injector feed tubes to the fuel rail and injectors; hand-tighten the fuel injector feed
tubes.
3. Install the high pressure fuel rail feed lines to the fuel rail and high pressure pump with tool J-48770; hand-tighten.
4. Install the Pressure Limiting Valve (PLV) fuel return line to the fuel filter module and fuel rail with tool J-48770; 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 lines to 40 N·m (30 lb·ft).
c. High-pressure fuel rail feed lines to 40 N·m (30 lb·ft).
d. 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 the 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.
NOTICE: Engine size/model year specific service kits, containing all of the 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.
8. Install the new vibration dampers, P-clips and mounting bracket. Refer to section "Installation of the High Pressure
Fuel Rail Feed Lines".
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
9. Connect the batteries.
10. 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.

WARNING: ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.
11. Start the engine and check for leaks.

All information subject to change without notice.

5 02-13

Copyright © 2013 DETROIT DIESEL CORPORATION

7