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6 20-14
SUBJECT
DATE
High Pressure Fuel Injector Lines
June 2014
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
Change
DDC-SVC-MAN-0082
DD Platform
DDC-SVC-MAN-0182
Euro IV
Removal of the High Pressure Fuel
Injector Lines - Two-Filter System
Step 6 deleted.
DDC-SVC-MAN-0082
DD Platform
DDC-SVC-MAN-0182
Euro IV
Installation of the High Pressure Fuel
Injector Lines - Two-Filter System
Step 2 deleted. Step 7 added.
DDC-SVC-MAN-0082
DD Platform
Removal of the High Pressure Fuel
Injector Lines - Three-Filter System
Step 7 deleted.
DDC-SVC-MAN-0082
DD Platform
Installation of the High Pressure Fuel
Injector Lines - Three-Filter System
Step 2 deleted. Step 8 added.
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
3
2 Removal of the High Pressure Fuel Injector Lines - Two-Filter System
2
Removal of the High Pressure Fuel Injector Lines - Two-Filter System
Remove as follows:
NOTICE: For DD15/16 engines: If removing the high pressure fuel line from fuel injector number one, remove the
intake manifold temperature sensor. Refer to section "Removal of the Intake Manifold Air Temperature Sensor".
NOTICE: For DD13 engines: If removing the high pressure fuel line from fuel injector number four, remove the
intake manifold temperature sensor. Refer to section "Removal of the Intake Manifold Air Temperature Sensor".
NOTICE: If removing the high pressure fuel line from fuel injector number six, remove the pressure limiting valve
return line banjo bolt and the rear high pressure fuel feed line P-clip.
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time use components and MUST be replaced any time they are loosened or removed.
NOTICE: Service kits have been released containing all of the necessary parts to replace the high pressure fuel
rail feed lines on EPA07/10 DD13, GHG14 DD13, EPA07/10 DD15/16, GHG14 DD15TC/DD16 and GHG14
DD15AT engines. Refer to TS letter 13 TS-24 (http://ddcsn-ddc.freightliner.com/cps/rde/xbcr/ddcsn/13TS24.pdf)
for the high pressure fuel line kit numbers to repair these engines.
1. Remove the two fuel injector seal mounting bolts (1) securing the high pressure fuel injector line seal to the camshaft
housing.
NOTE: Loosening high pressure injector lines from the rail first allows fuel to completely drain out, preventing oil
contamination.
2. Loosen the high pressure fuel line nut (1) at the fuel rail.
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
6 20-14
3. Loosen the high pressure fuel injector line nut (1) at the camshaft housing.
NOTE: The high pressure fuel injector line seal is a single-use item and cannot be reused.
4. Remove the high pressure fuel injector line and high pressure fuel injector line seal as an assembly from the engine.
5. Remove and discard the high pressure injector line seal from the high pressure fuel injector line.
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
5
3 Installation of the High Pressure Fuel Injector Lines - Two-Filter System
3
Installation of the High Pressure Fuel Injector Lines - Two-Filter System
Install 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: For DD15/16 engines: If the high pressure fuel line from fuel injector number one was removed, reinstall
the intake manifold temperature sensor. Refer to section "Installation of the Intake Manifold Air Temperature
Sensor".
NOTICE: For DD13 engines: If the high pressure fuel line from fuel injector number one was removed, reinstall
the intake manifold temperature sensor. Refer to section "Installation of the Intake Manifold Air Temperature
Sensor".
NOTICE: If the high pressure fuel line from fuel injector number six was removed, install the pressure limiting
valve return line banjo bolt and a high pressure fuel feed line service kit.
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time-use components and MUST be replaced any time they are loosened or removed
NOTICE: Service kits have been released containing all of the necessary parts to replace the high pressure fuel
rail feed lines on EPA07/10 DD13, GHG14 DD13, EPA07/10 DD15/16, GHG14 DD15TC/DD16 and GHG14
DD15AT engines. Refer to TS letter 13 TS-24 (http://ddcsn-ddc.freightliner.com/cps/rde/xbcr/ddcsn/13TS24.pdf)
for the high pressure fuel line kit numbers to repair these engines
NOTE: The high pressure fuel injector line seal is a single-use item and cannot be reused.
1. Lubricate the new high pressure fuel injector line O-ring with a light coat of clean diesel fuel.
2. Install the new high pressure fuel injector line seal on to the high pressure fuel injector line.
3. Install the high pressure fuel injector line and the new high pressure fuel injector line seal as an assembly onto the
engine. Hand-tighten the high pressure fuel injector line nut (1).
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
6 20-14
4. Tighten the high pressure fuel injector line nut to the fuel rail. Torque to 40 N·m (30 lb·ft).
5. Using tool J-48770, torque the high pressure fuel injector line nut (1) to 40 N·m (30 lb·ft).
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
7
3 Installation of the High Pressure Fuel Injector Lines - Two-Filter System
6. Install two high pressure fuel injector line seal mounting bolts (1). Torque to 15 N·m (11 lb·ft).
7. Prime the fuel system, Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter
System".
8
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
6 20-14
4
Removal of the High Pressure Fuel Injector Lines - Three-Filter System
Remove as follows:
NOTICE: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time-use components and MUST be replaced any time they are loosened or removed.
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 13 TS-24 (http://ddcsnddc.freightliner.com/cps/rde/xbcr/ddcsn/13TS24.pdf) for the high pressure fuel line kit numbers to repair these
engines.
1. Remove the two high pressure fuel injector line seal mounting bolts (1) securing the high pressure fuel injector line seal
to the camshaft housing.
2. For the number six high pressure fuel injector line only, remove the Pressure Limiting Valve (PLV) return line banjo
bolt (1) and discard the sealing washers (2).
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
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4 Removal of the High Pressure Fuel Injector Lines - Three-Filter System
NOTE: Loosening high pressure injector lines from the rail first allows fuel to completely drain out, preventing oil
contamination.
3. Using J-48770 or equivalent, loosen the high pressure fuel injector line rail fitting nut (1) at the fuel rail.
4. Using J-48770 or equivalent, loosen the high pressure fuel injector line nut (1) at the camshaft housing.
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
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NOTE: The high pressure fuel injector line seal is a single-use item and cannot be reused.
5. Remove the high pressure fuel injector line and high pressure fuel injector line seal as an assembly from the engine.
6. Remove and discard the high pressure fuel injector line seal from the high pressure fuel injector line.
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
11
5 Installation of the High Pressure Fuel Injector Lines - Three-Filter System
5
Installation of the High Pressure Fuel Injector Lines - Three-Filter
System
Install 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: The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and hardware are
one-time use components and MUST be replaced any time they are loosened or removed.
NOTICE: Service kits have been released containing all of the necessary parts to replace the high pressure fuel
rail feed lines on EPA07/10 DD13, GHG14 DD13, EPA07/10 DD15/16, GHG14 DD15TC/DD16 and GHG14
DD15AT engines. Refer to TS letter 13 TS-24 (http://ddcsn-ddc.freightliner.com/cps/rde/xbcr/ddcsn/13TS24.pdf)
for the high pressure fuel line kit numbers to repair these engines.
NOTE: The high pressure fuel injector line seal is a single-use item and cannot be reused.
1. Lubricate the new high pressure fuel injector line O-ring with a light coat of clean diesel fuel.
2. Install the new high pressure fuel injector line seal on to the high pressure fuel injector line.
3. Install the high pressure fuel injector line and the new high pressure fuel injector line seal as an assembly onto the
engine. Tighten high pressure fuel injector line nut (1) hand-tight.
NOTICE: During tightening of the number six high pressure fuel injector line at the fuel rail, make sure the tool
does not bind against the Pressure Limiting Valve (PLV) banjo fitting. If the tool pushes against the banjo fitting,
reposition the tool on the high pressure fuel injector line rail fitting nut so that the specified tightening torque can
be accomplished without the tool binding against the PLV banjo fitting
4. Using J-48770 or equivalent, tighten the high pressure fuel injector line rail fitting nut to the fuel rail. Torque to 40
N·m (30 lb·ft).
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All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
6 20-14
5. For the number six high pressure fuel injector line only, install the PLV sealing washers (2) and PLV return line banjo
bolt (1). Torque to 30-32 N·m (22-24 lb·ft).
6. Using tool J-48770 or equivalent, torque the high pressure fuel injector line nut (1) to 40 N·m (30 lb·ft).
All information subject to change without notice.
6 20-14 Copyright © 2014 DETROIT DIESEL CORPORATION
13
5 Installation of the High Pressure Fuel Injector Lines - Three-Filter System
7. Install two high pressure fuel injector line seal mounting bolts (1). Torque to 15 N·m (11 lb·ft).
8. Prime the fuel system, Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter
System".
14
All information subject to change without notice.
Copyright © 2014 DETROIT DIESEL CORPORATION 6 20-14
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