Export SAFETY RECALL BULLETIN
Subject: Safety Recall D19R5 DD15TC High Pressure Fuel Lines

Issue Involved
Detroit Diesel Corporation (DDC) has determined that certain Heavy Duty Engine Platform DD15TC
EPA07/ADR80/03 engines sold in Australia and New Zealand will require inspection and possible
replacement of the two high pressure fuel rail feed lines and supporting hardware from the high pressure
fuel pump to the fuel rail.
A small number of vehicles have experienced a leak from the high pressure fuel rail feed lines. In an effort
to maximize customer safety and satisfaction, Detroit Diesel Corporation has included in this recall
vehicles with the affected fuel line configuration and vehicle application.
There are two groups of vehicles involved in this recall - Group A and Group B - which will specify the
group of each specific engine. Please refer to the Online Warranty Link (OWL) to determine specific
engine coverage and applicable group.
Group A will REQUIRE REPLACEMENT of the high pressure fuel rail feed lines and supporting hardware
from the high pressure fuel pump to the fuel rail. Refer to Group A Corrective Procedure.
Group B will REQUIRE INSPECTION and possible replacement of the high pressure fuel rail feed lines
and supporting hardware from the high pressure fuel pump to the fuel rail. Refer to Group B Corrective
Procedure.
There are approximately 6760 engines affected by this Campaign.

Engines Involved
A list of engines located in your area of responsibility that require this correction is attached.
The table below gives descriptive information to help identify the affected units.

Group

Model
Series

Model
Number

Model
Year

Inclusive Engine Mfg.
Date
(From) (To)

Descriptive
Information

DD15

D472907S

20172019

January 1, 2017 to
August 31, 2019

Export (AU/NZ)

DD15

D472907R

20102019

June 3, 2010, to
August 31, 2019

Remanufactured
Export (AU/NZ)

DD15

D472907S

20102016

June 3, 2010, to
December 31, 2016

Export (AU/NZ)

Group A

Group B

pg. 1

Owner Notification
Detroit Diesel will notify owners of equipment incorporating engines identified with this Safety Recall
Bulletin. A copy of the owner letter that will be used by Detroit Diesel is enclosed with this Safety
Recall Bulletin.

Distributor / Dealer Campaign Responsibility
Detroit Diesel repair facilities are to service all engines subject to this Safety Recall Bulletin. Safety
Recall Bulletin D19R5 is to be performed at no charge to owners on all affected engines.
Please use the appropriate steps, noted below, for indicating that Safety Recall Bulletin D19R5 has
been completed.

Freightliner and Western Star Vehicles
Australian recall completion procedures (door jamb sticker etc.) are to be defined by Freightliner and
Western Star distributors in compliance with the local requirements.

Parts Information
See below table for a list of parts required for this Field Service Campaign. Part numbers can be validated
using PartsPro for the applicable engine serial number.

pg. 2

Description

Qty.

Part Number

Two-Filter KM59 Gen1
DD15/16

1

DDE A4720709132

Three-Filter DD15/16

1

DDE A4720709232

Corrective Procedure
Note: The corrective procedures in this Safety Recall Bulletin are only required for vehicles included in the
list of affected vehicles. Refer to OWL to identify if unit is included in Recall and for Group A/B
identification. See steps below.
1. Record the Engine Serial Number for the vehicle.
2. Refer to OWL to determine if the unit is in Group A or Group B.
3. Go to OWL and select “Coverage Info”. See Figure 1.

Figure1
4. Enter the Engine Serial Number and click the Search icon.

Figure 2

pg. 3

5. Refer to Figure 3 to determine if unit is in Group A or Group B.

Figure 3
6. Continue to either Group A OR Group B Procedure below based on OWL identifier.

pg. 4

Group A Procedure:

PERSONAL INJURY
Incorrect installation, replacement or maintenance of high pressure fuel line components may result in the failure
of a high pressure fuel line, including the possibility of a fuel leak, resulting in possible fire and/or personal injury.

PERSONAL INJURY
The high pressure fuel rail feed lines, vibration dampers, P-clamps, mounting bracket and hardware 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.

1. Apply the parking brake, disconnect the batteries, chock the wheels, and perform any other
applicable safety steps.
2. Replace the two High Pressure Fuel Rail Feed Lines and supporting hardware using service kit P/N
A4720709132 and follow the procedure set forth in Installation of the High Pressure Fuel Rail
Feed Lines - Two-Filter System in EPA07/10/GHG14 Fuel Manual (DDC-SVC-MAN-0082)
3. Using a paint pen, write the campaign number “D19R5” on the Fuel Rail under the High Pressure
Fuel Feed Line fittings. See Figure 4.

Figure 4 – D19R5 Identification on Fuel Rail
4. Repairs are complete.

pg. 5

Group B Procedure

PERSONAL INJURY
Incorrect installation, replacement or maintenance of high pressure fuel line components may result in the
failure of a high pressure fuel line, including the possibility of a fuel leak, resulting in possible fire and/or
personal injury.

PERSONAL INJURY
The high pressure fuel rail feed lines, vibration dampers, P-clamps, mounting bracket and hardware 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.

1. Apply the parking brake, disconnect the batteries, chock the wheels, and perform any other
applicable safety steps.
2. Check the date code [YYMMDD] on the high pressure fuel rail feed line fitting. See Figure 6.
a. If the date code is lower than 170101, the high pressure fuel rail feed lines and supporting
hardware will need to be inspected. Proceed to step 3.
b. If the date code is between 170101 and 190801, the high pressure fuel rail feed lines and
supporting hardware will need to be replaced. Proceed to step 5.
c. If the date code is missing or cannot be read, the high pressure fuel rail feed lines and
supporting hardware will need to be replaced. Proceed to step 5.
d. If the date code is higher than 190801, this unit is not included in this recall.
Proceed to step 3.

Figure 5 – Sample Date Code
pg. 6

3. Perform a visual inspection of the High Pressure Fuel Line area for loose, damaged or missing
parts, signs of wear or evidence of fuel leaks. Do not use any tools as part of this inspection.
a. For engines with three-filter fuel system and 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. See Figure 6.

Figure 6 – Three-Filter Fuel System
with Bolted Vibration Dampers

Figure 7 – Three-Filter Fuel System
with Permanent Vibration Dampers

b. For engines with three-filter fuel system and 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. See Figure 7.
c. For engines with Two-filter fuel system, 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
permanent vibration dampers or bolted vibration dampers (6) are not missing or loose. Do
not attempt to loosen, tighten or otherwise disturb any of the parts. See Figures 8 and 9.

Figure 8 – Two-Filter System with
KM59 GEN1 with Bolted Vibration
Damper

pg. 7

Figure 9 – Two-Filter System with
KM59 GEN1 with Permanent Vibration
Dampers

4. Inspection results:
a. If any loose, damaged or missing parts, signs of wear or evidence of fuel leaks are found,
proceed to step 5.
b. If no parts are missing or damaged, and no evidence of fuel leaks are observed, proceed to
step 6.
5. Replace the two High Pressure Fuel Rail Feed Lines and supporting hardware using one of the
following service kits.
a. For DD15 engines with a three-filter fuel system, order service kit P/N A4720709232 and
follow the procedure Installation of the DD15 and DD16 High Pressure Fuel Rail Feed
Lines - Three-Filter System in EPA07/10/GHG14 Fuel Manual (DDC-SVC-MAN-0082)
b. For DD15 engines with a two-filter fuel system, order service kit P/N A4720709132 and
follow the procedure Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter
System in EPA07/10/GHG14 Fuel Manual (DDC-SVC-MAN-0082)
6. Using a paint pen, write the campaign number “D19R5” on the Fuel Rail under the High Pressure
Fuel Feed Line fittings. See Figure 10.

Figure 10 – D19R5 Identification on Fuel Rail
7. Repairs are complete.

pg. 8

Notice
Claim administration time, SRT 939-6010A, for 0.3 hours will automatically be added.
No additional operation is required or will be allowed.

Warranty Information
Claim Type:
Modification
Cause Code:
Primary Failed Part:

RECALL
D19R5
A1-CAMPAIGN
DDE A4720780310

Labor Code:

996-R195A Use this operation for vehicles in Group
A that require fuel line/hardware replacement only.
Use for FTL Coronado 114 and Western Star 4900.
1.6 Hours

Labor:
Labor Code:

Labor:
Labor Code:

Labor:
Labor Code:

Labor:
Labor Code:

Labor:
pg. 9

996-R195A Use this operation for vehicles in Group
A that require fuel line/hardware replacement only.
Use for FTL Coronado 122, FTL Century Class 120,
and FTL Argosy.
0.9 Hours
996-R195B Inspection Only. Use this operation for
vehicles in Group B where inspection was
performed and no additional repairs were needed.
Use for FTL Coronado 114 and Western Star 4900.
0.5 Hours
996-R195B Inspection Only. Use this operation for
vehicles in Group B where inspection was
performed and no additional repairs were needed.
Use for FTL Coronado 122, FTL Century Class 120,
and FTL Argosy.
0.3 Hours
996-R195C Inspection and Replacement. Use this
operation for vehicles in Group B where inspection
was performed AND fuel lines/hardware were
replaced. Use for FTL Coronado 114 and Western
Star 4900.
2.1 Hours

Labor Code:

Labor:

996-R195C Inspection and Replacement. Use this
operation for vehicles in Group B where inspection
was performed AND fuel lines/hardware were
replaced. Use for FTL Coronado 122, FTL Century
Class 120, and FTL Argosy.
1.2 Hours

Parts Return:

None

Please contact the Detroit™ Customer Support Center at 800-445-1980 or email
[email protected] if you have any questions.
DETROIT DIESEL
13400 Outer Drive West

Detroit, Michigan 48239-4001
BULLETIN

pg. 10

Daimler Trucks
North America LLC

Daimler Trucks North America LLC
\
Detroit Diesel Corporation

13400 Outer Drive, West
Detroit, Michigan 48239-4001
Telephone: 313-592-5000

Equipment Owner

Subject: EXPORT SAFETY RECALL D19R5

DD15 High Pressure Fuel Lines
This notice is sent to you due to the fact that Detroit Diesel Corporation (DDC) has determined that
some Heavy Duty Engine Platform DD15 EPA07/ADR80/03 engines sold in Australia and New Zealand
will require inspection and possible replacement of the two high pressure fuel rail feed lines and
supporting hardware from the high pressure fuel pump to the fuel rail.
A small number of vehicles have experienced a leak from the high pressure fuel rail feed lines. In an
effort to maximize customer safety and satisfaction, Detroit Diesel Corporation has included in this recall
all vehicles with the affected fuel line configuration and vehicle application.
There are two groups of vehicles involved in this recall Group A and Group B which will specify the
group of each specific engine. Our records indicate that your vehicle has one of these affected engines
that falls into either Group A or Group B.


Group A units will REQUIRE REPLACEMENT of the high pressure fuel rail feed lines and
supporting hardware from the high pressure fuel pump to the fuel rail.



Group B units will REQUIRE INSPECTION and possible replacement of the high pressure fuel
rail feed lines and supporting hardware from the high pressure fuel pump to the fuel rail.

The procedure will be completed at no cost to you when performed by an Authorized Detroit Diesel
Repair Facility. By inspecting and replacing the appropriate parts will prevent performance issues that
may result in customer dissatisfaction. The scheduled time for this repair is approximately 2.1 hours or
less.
If you do not own the vehicle that corresponds to the identification number(s), which appears on the
Recall Notification, please return the notification to the Warranty Department, Attention Campaign
Coordinator, with any information you can furnish that will assist us in locating the present owner.
If you have paid to have this recall condition corrected prior to this notice, you may be eligible to receive
reimbursement. Requests for reimbursement may include parts and labor. Reimbursement may be
limited to the amount the repair would have cost if completed by a Detroit Authorized Repair Facility.

-

2-

The following documentation must be presented to your dealer for consideration for reimbursement.
Please provide original or clear copies of all receipts, invoices, and repair orders that show:


The name and address of the person who paid for the repair.



The Vehicle Identification Number (VIN) of the vehicle that was repaired.



What problem occurred, what repair was done, when the repair was done.



Who repaired the vehicle.



The total cost of the repair expense that is being claimed.



Proof of payment for the repair (such as the front and back of a cancelled check or a
credit card receipt).

Reimbursement will be made by check from your Detroit Diesel dealer. Please speak with your
Detroit Diesel authorized dealer concerning this matter.
For those customers who had this issue and paid for the service prior to this recall, they can send in their
receipts to DDC for reimbursement consideration”
We regret any inconvenience this action may cause but feel certain you understand our interest in
conforming to required regulations and environmental protection.
If you have any questions or need further information, please contact the Customer Support Center at
(800) 445-1980.

DETROIT DIESEL WARRANTY CAMPAIGNS DEPARTMENT
Enclosure