1 1 20-13 SUBJECT DATE Installation of the Fuel Rail -Three-Filter System January 2013 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change Installation of the Fuel Rail - Three-Filter System Torque change in step 5a. DDC-SVC-MAN-0082 DD Platform Fuel System Torque Specifications -Two Filter System Torque changes for Fuel Rail Clamp & Water- In- Fuel Sensor. Installation of the Fuel Rail - Two-Filter System Torque change in step 5. DDC-SVC-MAN-0084 DD Platform Installation of the Water-in-Fuel Sensor-Two - Filter Fuel System Torque change in step 3. All information subject to change without notice. 3
2 Installation of the Fuel Rail - Three-Filter System 2 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 (10 lb ft). 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. 4 All information subject to change without notice. Copyright 2013 DETROIT DIESEL CORPORATION 1 20-13
3 Fuel System Torque Specifications Two Filter System The following table contains the torque specifications for the fuel system: Table 1. Component Metric Standard 90-Degree Coolant Fitting to Fuel Filter Module 4 to 5 N m 35 to 44 lb in. Allen Head Injector Harness Hold-Downs 10 N m 7 lb ft Coalescer/Final Filter Cap 55 to 60 N m 40 to 44 lb ft Coalescer/Final Filter Standpipe 6 to 8 N m 53 to 70 lb in. Coolant Line Clip to Fuel Filter Module 30 N m 22 lb ft Cylinder Head Fitting to Cylinder Head 55 to 60 N m 40 to 44 lb ft Doser Fuel Line (KM59 GEN1) 25 N m 18 lb ft Doser Fuel Line (KM63 GEN2) 15 N m 11 lb ft Fuel Compensation Pressure Sensor 11 N m 8 lb ft Fuel Cooler 12 to 13 N m 106 to 115 lb in. Fuel Feed Line Fitting 107 to 116 N m 79 to 85 lb ft Fuel Filter Module Housing Half (First Torque) 4.5 to 5.5 N m 40 to 49 lb in. Fuel Filter Module Housing Half (Second Torque) 11 to 13 N m 97 to 115 lb in. Fuel Filter Module to Cylinder Block 60 N m 44 lb ft Fuel Filter Module to Low Pressure Lines Bracket 30 N m 22 lb ft Fuel Injector Cup 50 N m 37 lb ft Fuel Injector Electrical Wiring Harness to Fuel Injector 1.5 N m 12 lb in. Fuel Injector Hold-Down Clamp 20 N m + 90 15 lb ft + 90 Fuel Rail Clamp 14 N m 120 lb in. Fuel Rail Pressure Sensor 65 to 70 N m 48 to 52 lb ft Fuel Return Line Fitting 107 to 116 N m 79 to 85 lb ft Fuel Temperature Sensor (KM59 GEN1) 20 to 23 N m 15 to 17 lb ft Fuel Temperature Sensor (KM63 GEN2) 35 N m 26 lb ft Gallery Bypass Valve 4 N m 35 lb in. Hand Primer 20 to 22 N m 15 to 16 lb ft HC Doser Fuel Supply Pressure Control Valve 30 to 33 N m 22 to 24 lb ft High Pressure Fuel Flange 30 N m 22 lb ft High Pressure Fuel Injector Line Seal 15 N m 11 lb ft High Pressure Fuel Injector Line to Fuel Injector 40 N m 30 lb ft High Pressure Fuel Injector Line to Fuel Rail 40 N m 30 lb ft High Pressure Fuel Line P-clips 15 N m 132 lb in. High Pressure Fuel Line Vibration Dampers 15 N m 132 lb in. High Pressure Fuel Pump Gear Nut 250 N m 184 lb ft High Pressure Fuel Pump Eyebrow 8 N m 72 lb in. High Pressure Fuel Pump Support Bracket to Cylinder Block 100 N m 74 lb ft High Pressure Fuel Pump Support Bracket to High Pressure Fuel Pump 30 N m 22 lb ft High Pressure Fuel Rail Feed Lines 40 N m 30 lb ft High Pressure Fuel Rail Feed Lines Mounting Bracket 15 N m 132 lb in. High Pressure Pump to Flywheel Housing 60 N m 44 lb ft Low Pressure Fuel Pump 8 N m 72 lb in. All information subject to change without notice. 5
3 Fuel System Torque Specifications Two Filter System Component Metric Standard Low Pressure Fuel Pump Housing Half 7 to 8 N m 62 to 70 lb in. Low Pressure Fuel Lines 30 N m 22 lb ft Low Pressure Fuel Sensor 21 to 24 N m 15 to 18 lb ft Low Pressure Fuel Sensor Protective Bracket 10 N m 7 lb ft Needle Return Pressure Control Valve 41 to 46 N m 30 to 34 lb ft Prefilter Cap 55 to 60 N m 40 to 44 lb ft Pressure Limiting Valve 95 to 105 N m 70 to 77 lb ft Pressure Limiting Valve Return Line to Fuel Rail 30 to 33 N m 22 to 24 lb ft Pressure Relief Valve (KM59 GEN1) 32 N m 25 lb ft Pressure Relief Valve (KM63 GEN2) 41 to 46 N m 30 to 34 lb ft Priming Port Fitting 21 to 24 N m 15 to 18 lb ft Quantity Control Valve (QCV) 8 N m 6 lb ft Return lines P-clip 15 N m 132 lb in. Return Lines to Cylinder Head Fitting 25 N m 18 lb ft Return lines to Fuel Filter Module (KM59 GEN1) 30 to 33 N m 22 to 24 lb ft Return lines to Fuel Filter Module (KM63 GEN2) 30 N m 22 lb ft Two-Stage Valve 26 N m 20 lb ft Water Drain Bowl 20 to 22 N m 15 to 16 lb ft Water-In-Fuel (WIF) Sensor 5 N m 44 lb in. Wiring Harness Bracket from Fuel Filter Module to Low Pressure Lines 30 N m 22 lb ft 6 All information subject to change without notice. Copyright 2013 DETROIT DIESEL CORPORATION 1 20-13
4 Installation of the Fuel Rail Two-Filter System NOTICE: Fuel rail clamps MUST be installed with arrows pointing upwards. NOTE: The rear fuel rail clamp has mounting holes for the high pressure fuel lines mounting bracket. Install as follows: 1. Install the fuel rail (4) on to the camshaft housing (3). With the arrows pointing upwards install the three fuel rail clamps (2) and six fuel rail clamp bolts (1) on to the camshaft housing (3). Hand-tighten the fuel rail clamp bolts. 2. Using tool J-48770, install the high pressure fuel injector lines on to the fuel rail and fuel injectors. Refer to section "Installation of the High Pressure Fuel Injector Lines - Two-Filter System". Hand-tighten the high pressure fuel injector lines. 3. Install Pressure Limiting Valve (PLV) return line with new sealing washers on to the fuel rail. Refer to section "Installation of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines Two-Filter System". 4. Torque the high pressure fuel injector lines to 40 N m (30 lb ft). 5. Torque the fuel rail clamps bolts to 14 N m (120 lb in.). 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. 6. Install the new high pressure fuel rail feed lines on to the high pressure pump and fuel rail. Refer to section "Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System". 7. Connect 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. 7
4 Installation of the Fuel Rail Two-Filter System 8. Connect the batteries. 9. Prime the fuel system. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-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. 10. Start the engine and check for leaks. 8 All information subject to change without notice. Copyright 2013 DETROIT DIESEL CORPORATION 1 20-13
5 Installation of the Water-in-Fuel Sensor - Two - Filter Fuel System Install as follows: 1. Install a new o-ring seal (3) on to the WIF sensor (4). 2. Lubricate the o-ring seal on the WIF sensor with clean diesel fuel. 3. Install the WIF sensor (4) on to the fuel filter module (2). Torque to 5 N m (44 lb in.). 4. Connect the electrical connector (6) on to the WIF sensor (4). 5. Prime the fuel system. All information subject to change without notice. 9