NHTSA ID Number: 10146325
Manufacturer Communication Number: 0504-18
TSB/Document Date: 2018-10-29
Summary
0504-18 Fuel System - Fuel Injectors
05 04-18
1
05 04-18
SUBJECT
DATE
Fuel System - Fuel Injectors
May 2018
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0194
DDC-SVC-MAN-0198
Platform
GHG17
DD5
934912(C)
GHG17
DD8
Section Title
Change
Removal of the Fuel
Injectors
Changes due to new tools and different steps
Inspection of the Fuel
Injectors
This is a new section
Installation of the Fuel
Injectors
Changes due to new tools and different steps
Removal of the Fuel
Injectors
Changes due to new tools and different steps
Inspection of the Fuel
Injectors
This is a new section
Installation of the Fuel
Injectors
Changes due to new tools and different steps
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
3
2 Removal of the Fuel Injector
2
Removal of the Fuel Injector
Table 1.
Service Tools Used in the Procedure
Tool Number
Tool Name
W936589003300 or DSN930E17004
Injector Puller
Tool Graphic
W936589013300
Injector Seal Installer
W936589033300 or DSN930E17002
Injector Heat Protection Sleeve Tool Kit
Remove as follows:
4
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
Figure 1. Fuel Injector
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. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2. Disconnect the batteries.
3. Open the hood.
4. If necessary, remove the bumper end(s). Refer to the Original Equipment Manufacturer (OEM) procedures.
WARNING: FIRE HAZARD
Do not power wash or steam clean the engine bay in the area of vehicle electrical components,
unless specified by vehicle manuals or service literature. Power washing/steam cleaning can
permanently damage these components, which could result in fire, personal injury, or property
damage.
5. Steam clean the rocker cover and rocker cover mounting area.
6. Remove the air compressor resonator and the rocker cover. Refer to section "Removal of the Rocker Cover".
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
5
2 Removal of the Fuel Injector
7. Disconnect the fuel injector electrical wiring harness from the fuel injectors and position aside. Refer to section
"Removal of the Fuel Injector Wiring Harness".
8. Remove the high pressure fuel injector feed lines. Refer to section "Removal of the High Pressure Fuel Injector
Lines".
9. Remove the fuel injector hold-down bolt (1). Discard bolt.
10. Using tool W936589003300 or DSN930E17004, lift the fuel injector clamp and fuel injector from its seat in the
cylinder head.
11. Inspect for the copper heat protection sleeve on the injector tip; if present, remove and discard. If the copper sleeve is
missing, use tool W936589033300 or DSN930E17002 to extract it from the cylinder head and discard.
12. Cover the fuel injector hole in the cylinder head to keep out foreign material.
NOTICE: Avoid cleaning (wire brushing etc.) the fuel injector tip spray holes to prevent damage and plugging.
13. Using a clean rag soaked with clean diesel fuel, carefully remove any carbon material from the fuel injector exterior.
NOTICE: Fuel injector O-ring seals, fuel injector clamp bolts and the copper heat protection sleeves are
considered one-use items and cannot be reused. Any time a fuel injector is removed, the fuel injector bolt, two
fuel injector O-ring seals and copper heat protection sleeve must be replaced with new parts. Failure to replace
the O-ring seals, heat protection sleeve and bolt can result in leakage.
14. Inspect the fuel injector body for visible damage. Replace the fuel injector if damaged.
15. If the fuel injector is intended to be reused, remove and discard the two fuel injector O-rings and the copper sleeve.
6
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
3
Inspection of the Fuel Injector
Inspect as follows:
1. Visually inspect the fuel injector body for cracks or damage. If damage is found, replace the injector.
2. Visually inspect for debris in the fuel inlet or signs of fuel contamination in the fuel inlet. If contamination is found,
further troubleshooting is required.
3. Visually inspect the injector tips for cracks or damage from excessive heat. If damage is found, replace the injector.
4. Visually inspect the threads of the fuel injector inlet. If the threads are damaged, replace the injector.
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
7
4 Installation of the Fuel Injector
4
Installation of the Fuel Injector
Table 2.
Service Tools Used in the Procedure
Tool Number
Tool Name
W936589013300
Injector Seal Installer
W936589033300
Injector Heat Protection Sleeve Tool Kit
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
Tool Graphic
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
Figure 2. Fuel Injector
Install as follows:
8
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
NOTE: Ensure excess fuel is removed from the top of the piston dome before fuel injector installation.
1. If the fuel system, cooling system, or lubrication system is contaminated; refer to the appropriate troubleshooting.
NOTICE: The inside of the fuel injector cup and cylinder head bore should be cleaned and inspected for damage
or leakage of coolant before installation of the fuel injector.
2. Check to make sure the fuel injector cup and cylinder head bore are thoroughly clean.
3. If the fuel injector is being replaced, record the fuel injector calibration code, the injector part number, and note the
cylinder location where the injector will be installed.
4. If the fuel injector is being replaced, remove the fuel injector nozzle tip protector. Apply a thin coat of acid-free grease
or clean engine oil to the fuel injector seal rings and then use W936589013300 (Fuel Injector O-ring Installer) to
install them onto the fuel injector. Make sure they are properly seated.
5. Using tool W936589033300, install the copper heat protection sleeve on the fuel injector tip.
6. Install the fuel injector and clamp as an assembly into its respective fuel injector bore. Align the clamp over the bolt
hole, install the new bolt into fuel injector clamp and snug until the fuel injector fully seats, then release the fuel
injector bolt. DO NOT torque.
7. Install the high pressure fuel injector feed lines. Refer to section "Installation of the High Pressure Fuel Injector
Lines".
8. Torque the fuel injector hold-down bolt to 25 N·m (18 lb·ft) + 90 degree torque turn.
9. Install the fuel injector wiring harness. Refer to section "Installation of the Fuel Injector Wiring Harness".
10. If the fuel injector was replaced, input the fuel injector calibration code and injector part number that were recorded
earlier into DiagnosticLink ® using the service routine.
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
9
4 Installation of the Fuel Injector
11. If the fuel injector was replaced because of a tip failure or leak, the EGR cooler must be cleaned. Refer to section
"Cleaning of the Exhaust Gas Recirculation Cooler".
12. Install the rocker cover. Refer to section "Installation of the Rocker Cover".
13. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
14. Connect the batteries.
WARNING: PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
15. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".
16. If necessary, install the bumper end(s). Refer to the Original Equipment Manufacturer (OEM) procedures.
17. Close hood.
10
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
5
Removal of the Fuel Injector
Table 3.
Service Tools Used in the Procedure
Tool Number
Tool Name
W936589003300 or DSN930E17004
Injector Puller
W936589013300
Injector Seal Installer
W936589033300 or DSN930E17002
Injector Heat Protection Sleeve Tool Kit
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
Tool Graphic
11
5 Removal of the Fuel Injector
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
Figure 3. Fuel Injector
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. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
2. Disconnect the batteries.
3. Open the hood.
4. If necessary, remove the bumper end(s). Refer to the Original Equipment Manufacturer (OEM) procedures.
WARNING: FIRE HAZARD
Do not power wash or steam clean the engine bay in the area of vehicle electrical components,
unless specified by vehicle manuals or service literature. Power washing/steam cleaning can
permanently damage these components, which could result in fire, personal injury, or property
damage.
5. Steam clean the rocker cover and rocker cover mounting area.
12
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
6. Remove the air compressor resonator and the rocker cover. Refer to section "Removal of the Rocker Cover".
7. Disconnect the fuel injector electrical wiring harness from the fuel injectors and position aside. Refer to section
"Removal of the Fuel Injector Wiring Harness".
8. Remove the high pressure fuel injector feed line and discard. Refer to section "Removal of the High Pressure Fuel
Injector Lines".
9. Remove the fuel injector hold-down bolt (1). Discard bolt.
10. Using tool W936589003300 or DSN930E17004, lift the fuel injector clamp and fuel injector from its seat in the
cylinder head.
11. Inspect for the copper heat protection sleeve on the injector tip; if present, remove and discard. If the copper sleeve is
missing, use tool W936589033300 or DSN930E17002 to extract it from the cylinder head and discard.
12. Cover the fuel injector bore in the cylinder head to keep out foreign material.
NOTICE: Avoid cleaning (wire brushing etc.) the fuel injector tip spray holes to prevent damage and plugging.
13. Using a clean rag soaked with clean diesel fuel, carefully remove any carbon material from the fuel injector exterior.
NOTICE: The fuel injector O-ring seals, fuel injector clamp bolt and the copper heat protection sleeve are
considered one-use items and cannot be reused. Any time a fuel injector is removed, the fuel injector bolt, two
fuel injector O-ring seals and copper heat protection sleeve must be replaced with new parts. Failure to replace
the O-ring seals, heat protection sleeve and bolt can result in leakage.
14. Inspect the fuel injector body for visible damage. Replace the fuel injector if damaged.
15. If the fuel injector is intended to be reused, remove and discard the two fuel injector O-rings and the copper sleeve.
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
13
6 Inspection of the Fuel Injector
6
Inspection of the Fuel Injector
Inspect as follows:
1. Visually inspect the fuel injector body for cracks or damage. If damage is found, replace the injector.
2. Visually inspect for debris in the fuel inlet or signs of fuel contamination in the fuel inlet. If contamination is found,
further troubleshooting is required.
3. Visually inspect the injector tips for cracks or damage from excessive heat. If damage is found, replace the injector.
4. Visually inspect the threads of the fuel injector inlet. If the threads are damaged, replace the injector.
14
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION
05 04-18
05 04-18
7
Installation of the Fuel Injector
Table 4.
Service Tools Used in the Procedure
Tool Number
Tool Name
W936589013300
Injector Seal Installer
W936589033300
Injector Heat Protection Sleeve Tool Kit
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
Tool Graphic
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
Figure 4. Fuel Injector
Install as follows:
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
15
7 Installation of the Fuel Injector
NOTE: Ensure excess fuel is removed from the top of the piston dome before fuel injector installation.
1. If the fuel system, cooling system, or lubrication system is contaminated; refer to the appropriate troubleshooting.
NOTICE: The inside of the fuel injector cup and cylinder head bore should be cleaned and inspected for damage
or leakage of coolant before installation of the fuel injector.
2. Check to make sure the fuel injector cup and cylinder head bore are thoroughly clean.
3. If the fuel injector is being replaced, record the fuel injector calibration code, the injector part number, and note the
cylinder location where the injector will be installed.
4. If the fuel injector is being replaced, remove the fuel injector nozzle tip protector.
5. Apply a thin coat of acid-free grease or clean engine oil to the fuel injector seal rings and then use W936589013300
(Fuel Injector O-ring Installer) to install them onto the fuel injector. Make sure they are properly seated.
6. Using tool W936589033300, install the copper heat protection sleeve on the fuel injector tip.
7. Install the fuel injector and clamp as an assembly into its respective fuel injector bore. Align the clamp over the bolt
hole, install the new bolt into fuel injector clamp and snug until the fuel injector fully seats, then release the fuel
injector bolt. DO NOT torque.
8. Install the high pressure fuel injector feed line. Refer to section "Installation of the High Pressure Fuel Injector Lines".
9. Torque the fuel injector hold-down bolt to 25 N·m (18 lb·ft) + 90 degree torque turn.
10. Install the fuel injector wiring harness. Refer to section "Installation of the Fuel Injector Wiring Harness".
11. If the fuel injector was replaced, input the fuel injector calibration code and injector part number that were recorded
earlier into DiagnosticLink ® using the service routine.
16
All information subject to change without notice.
Copyright © 2018 DETROIT DIESEL CORPORATION 05 04-18
05 04-18
12. If the fuel injector was replaced because of a tip failure or leak, the EGR cooler must be cleaned. Refer to section
"Installation of the Exhaust Gas Recirculation Cooler".
13. Install the rocker cover. Refer to section "Installation of the Rocker Cover".
14. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION: ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
15. Connect the batteries.
WARNING: PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
16. Prime the fuel system. Verify the repair and check for fuel leaks. Refer to section "Priming the Fuel System".
17. If necessary, install the bumper end(s). Refer to the Original Equipment Manufacturer (OEM) procedures.
18. Close hood.
All information subject to change without notice.
05 04-18
Copyright © 2018 DETROIT DIESEL CORPORATION
17
- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
- DESIGNED TO EXCEED EXPECTATIONS: Red Line complete SI-1 fuel...
- PERFORM AND PROTECT: Fuel additive cleans injectors...
- EFFICIENT FUEL BURN: Gas treatment that enhances gasoline...
- EASY TO USE: Use one bottle per tank for most effective...
- 15 Ounce (2 Pack)
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TSB/Document ID: 0504-18
Replacement Service Bulletin Number:
MFR Communication Date: 2018-05-04
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, GASOLINE
MFR Component System:
MFR Component Subsystem:
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