NHTSA ID Number: 10199596
Manufacturer Communication Number: 0206-16
TSB/Document Date: 2021-08-02
Summary
Fuel Rail. Three-Filter System.
02 06-16
1
02 06-16
SUBJECT
DATE
Fuel Rail - Three-Filter System
February 2016
Additions, Revisions, or Updates
Publication Number / Title
DDC-SVC-MAN-0082
Platform
DD Platform
- All Years
Section Title
Change
Removal of the Fuel Rail
- Three-Filter System
Added basic safety steps.
Added graphic for step 5.
Changed links in step 6 and 7.
Installation of the Fuel
Rail - Three-Filter
System
Added links to steps 3 and 12.
Added graphic to step 11.
All information subject to change without notice.
02 06-16
Copyright © 2016 DETROIT DIESEL CORPORATION
3
2 Removal of the Fuel Rail - Three-Filter System
2
Removal of the Fuel Rail - Three-Filter System
Remove as follows:
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.
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic
switch studs are at battery voltage.
1.
2.
3.
4.
5.
4
Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
Disconnect the batteries. Refer to OEM procedures.
Open the hood.
Steam clean the engine.
Disconnect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2) and intake temperature
sensor (1).
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 06-16
02 06-16
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.
6. Remove the high pressure fuel injector lines with tool J-48770 and discard the high pressure fuel injector line seal.
Refer to section "Removal of the High Pressure Fuel Injector Lines - Three-Filter System".
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 14 TS 19Rev for the high pressure fuel line kit numbers
to repair these engines.
7. Remove the high pressure fuel rail feed lines. Refer to section "Removal of the High Pressure Fuel Rail Feed Lines Three-Filter System".
8. 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".
9. Remove the fuel rail bolts and clamps connecting the fuel rail to the camshaft housing and remove the fuel rail; discard
the fuel rail clamps and bolts.
All information subject to change without notice.
02 06-16
Copyright © 2016 DETROIT DIESEL CORPORATION
5
3 Installation of the Fuel Rail - Three-Filter System
3
Installation of the Fuel Rail - Three-Filter System
NOTICE: DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts and fittings
MUST be installed using hand tools.
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.
Install as follows:
NOTICE: Fuel rail clamp bolts are single-use items and cannot be reused.
1. Install fuel rail to camshaft frame with three new clamps and six new fuel rail bolts; hand-tighten bolts.
2. Using tool J-48770, install the high pressure fuel injector lines to the fuel rail and fuel injectors with new high pressure
fuel injector line seals. Refer to section "Installation of the High Pressure Fuel Injector Lines - Three-Filter System".
Hand-tighten the high pressure fuel injector lines.
3. Install Pressure Limiting Valve (PLV) fuel return line to the fuel filter module and fuel rail with tool J-48770 and handtighten. Refer to section "Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines - Three-Filter
System".
4. Torque new fuel rail clamp bolts to 14 N·m (120 lb·in.).
5. Torque the high pressure fuel injector line seal bolts to 15 N·m (11 lb·ft).
6. Torque the high pressure fuel injector lines to 40 N·m (30 lb·ft).
7. Torque the Pressure Limiting Valve (PLV) banjo bolt to 35 N·m (26 lb·ft).
8. If removed, install the fuel rail pressure sensor; torque to 65 to 70 N·m (48 to 52 lb·ft) and then install connector.
9. If removed, install PLV and torque to 100 N·m (74 lb·ft)
10. Connect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2), and intake temperature
sensor (1).
6
All information subject to change without notice.
Copyright © 2016 DETROIT DIESEL CORPORATION 02 06-16
02 06-16
NOTICE: The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware are one-time
use components and MUST be replaced any time they are removed.
WARNING: PERSONAL INJURY
All parts provided with this kit, and those they are replacing on the engine, function as a complete
system and are single-use items. The old parts cannot be reused. Reusing parts or failing to use all
new parts contained in the kit may result in the failure of high pressure fuel lines, possibly resulting
in a fire.
11. Install the new high pressure fuel rail feed lines on to the high pressure pump and fuel rail.
• Refer to section "Installation of the DD13 High Pressure Fuel Rail Feed Lines - Three-Filter System".
• Refer to section "Installation of the DD15 and DD16 High Pressure Fuel Rail Feed Lines - Three-Filter System".
All information subject to change without notice.
02 06-16
Copyright © 2016 DETROIT DIESEL CORPORATION
7
- Restores fuel economy
- Stabilizes ethanol
- Maximizes horsepower
- Improves responsiveness
- For use in both gasoline and diesel engines
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TSB/Document ID: 0206-16
Replacement Service Bulletin Number:
MFR Communication Date: 2016-02-06
MFR Internal Campaign ID/Software Version:
Communication Type: Service Bulletin/Repair Instructions
NHTSA Components: FUEL SYSTEM, DIESEL:FUEL INJECTION SYSTEM:FUEL RAIL
MFR Component System:
MFR Component Subsystem:
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