DD Fuel System DDC SVC Man 0082

EPA07/10 DD PLATFORM WORKSHOP MANUAL - FUEL
TABLE OF CONTENTS
1 FUEL SYSTEM OVERVIEW

1.1 FUEL SYSTEM OVERVIEW .................................................................... 1- 3
1.2 AMPLIFIED PRESSURE COMMON RAIL SYSTEM ............................... 1- 8
2 FUEL SYSTEM PRIMING
2.1 AFTER FILTER CHANGE (USING ESOC 350 FUEL PRIMING PUMP) . 2- 3
2.2 AFTER FILTER CHANGE (USING J-47912 PRIMING CAN) .................. 2- 4
2.3 AFTER FILTER CHANGE (USING HAND PRIMER ON MODULE) ........ 2- 5
2.4 HIGH PRESSURE PUMP CHANGE OR COMPLETELY DRY SYSTEM
(USING J-47912 PRIMING CAN) ........................................................... 2- 6
2.5 PRIMING PORT PRESSURES ................................................................ 2- 8
3 FUEL SYSTEM DRAINING PROCEDURE
3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS ........ 3- 3
4 FUEL FILTER MODULE
4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE
AND RELATED PARTS ............................................................................ 4- 3
4.2 REMOVAL OF FUEL FILTER MODULE .................................................. 4- 5
4.3 DISASSEMBLY OF THE FUEL FILTER MODULE .................................. 4- 6
4.4 ASSEMBLY OF THE FUEL FILTER MODULE ........................................ 4- 7
4.5 INSTALLATION OF THE FUEL FILTER MODULE .................................. 4- 8
5 BYPASS VALVE
5.1 DESCRIPTION AND OPERATION OF THE BYPASS VALVE ................. 5- 3
5.2 REMOVAL OF BYPASS VALVE IN FUEL FILTER MODULE .................. 5- 4
5.3 INSPECTION OF THE BYPASS VALVE AND FUEL FILTER MODULE .. 5- 5
5.4 INSTALLATION OF BYPASS VALVE ....................................................... 5- 7
6 FUEL FILTERS
6.1 FUEL PREFILTER ................................................................................... 6- 3
6.2 WATER SEPARATOR/COALESCER ....................................................... 6- 6
6.3 FINAL FILTER .......................................................................................... 6-10
7 FUEL COOLER
7.1 DESCRIPTION AND OPERATION OF THE FUEL COOLER .................. 7- 3
7.2 REMOVAL OF THE FUEL COOLER ....................................................... 7- 4
7.3 INSTALLATION OF THE FUEL COOLER ................................................ 7- 5
8 LOW PRESSURE FUEL PUMP
8.1 DESCRIPTION AND OPERATION OF THE LOW PRESSURE FUEL
PUMP AND RELATED PARTS ................................................................ 8- 3
8.2 REMOVAL OF LOW PRESSURE FUEL PUMP ...................................... 8- 4
8.3 INSTALLATION OF LOW PRESSURE FUEL PUMP ............................... 8- 5
All information subject to change without notice.

DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION i
9 LOW PRESSURE FUEL LINES

LINES ....................................................................................................... 9- 3
9.2 REMOVAL OF LOW PRESSURE FUEL LINES ...................................... 9- 5
9.3 INSTALLATION OF LOW PRESSURE FUEL LINES ............................... 9- 6
10 NEEDLE, AMPLIFIER, AND PRESSURE LIMITING VALVE RETURN
LINES
10.1 DESCRIPTION AND OPERATION OF THE NEEDLE, AMPLIFIER, AND
PRESSURE LIMITING VALVE RETURN LINES ..................................... 10- 3
10.2 REMOVAL OF THE NEEDLE, AMPLIFIER, AND PRESSURE LIMITING
VALVE RETURN LINES ........................................................................... 10- 4
10.3 INSTALLATION OF THE NEEDLE, AMPLIFIER, AND PRESSURE
LIMITING VALVE RETURN LINES .......................................................... 10- 5
11 PRESSURE RELIEF VALVE
11.1 DESCRIPTION AND OPERATION OF THE PRESSURE RELIEF
VALVE ...................................................................................................... 11- 3
11.2 REMOVAL OF PRESSURE RELIEF VALVE ........................................... 11- 4
11.3 INSPECTION OF THE PRESSURE RELIEF VALVE AND HIGH
PRESSURE PUMP HOUSING ................................................................ 11- 5
11.4 INSTALLATION OF PRESSURE RELIEF VALVE .................................... 11- 7
12 HIGH PRESSURE FUEL PUMP
12.1 DESCRIPTION AND OPERATION OF THE HIGH PRESSURE FUEL
12.2 REMOVAL OF HIGH PRESSURE FUEL PUMP ...................................... 12- 6
12.3 INSTALLATION OF HIGH PRESSURE FUEL PUMP .............................. 12- 8
12.4 CHECKING FUEL PUMP TIMING ........................................................... 12-15
13 TWO STAGE VALVE
13.1 DESCRIPTION AND OPERATION OF THE TWO STAGE VALVE .......... 13- 3
13.2 REMOVAL OF TWO STAGE VALVE ....................................................... 13- 4
13.3 INSPECTION OF THE TWO STAGE VALVE AND HIGH PRESSURE
PUMP HOUSING ..................................................................................... 13- 6
13.4 INSTALLATION OF TWO STAGE VALVE ................................................ 13- 9
14 QUANTITY CONTROL VALVE
14.1 DESCRIPTION AND OPERATION OF THE QUANTITY CONTROL
VALVE ...................................................................................................... 14- 3
14.2 REMOVAL OF QUANTITY CONTROL VALVE ........................................ 14- 4
14.3 INSPECTION OF THE QUANTITY CONTROL VALVE AND HIGH
14.4 INSTALLATION OF QUANTITY CONTROL VALVE ................................ 14- 7
14.5 EPA07 RESETTING QUANTITY CONTROL VALVE ADAPTIVE
VALUES ................................................................................................... 14- 8
VALUES ................................................................................................... 14-10

ii DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION
15 HIGH PRESSURE FUEL INJECTOR LINES

INJECTOR LINES .................................................................................... 15- 3
15.2 REMOVAL OF HIGH PRESSURE FUEL INJECTOR LINES ................... 15- 4
15.3 INSTALLATION OF HIGH PRESSURE FUEL INJECTOR LINES ........... 15- 6
16 HIGH PRESSURE FUEL RAIL FEED LINES
16.1 REMOVAL OF HIGH PRESSURE FUEL RAIL FEED LINES .................. 16- 3
16.2 INSPECTION OF HIGH PRESSURE FUEL RAIL FEED LINES ............. 16- 4
16.3 INSTALLATION OF HIGH PRESSURE FUEL RAIL FEED LINES .......... 16- 5
17 FUEL RAIL
17.1 DESCRIPTION AND OPERATION OF THE FUEL RAIL AND RELATED
PARTS ...................................................................................................... 17- 3
17.2 REMOVAL OF THE FUEL RAIL ............................................................... 17- 4
17.3 INSPECTION OF THE FUEL RAIL .......................................................... 17- 5
17.4 INSTALLATION OF THE FUEL RAIL ....................................................... 17- 6
18 PRESSURE LIMITING VALVE
18.1 DESCRIPTION AND OPERATION OF THE PRESSURE LIMITING
VALVE ...................................................................................................... 18- 3
18.2 REMOVAL OF PRESSURE LIMITING VALVE ........................................ 18- 4
18.3 INSTALLATION OF PRESSURE LIMITING VALVE ................................. 18- 5
18.4 RESETTING THE PRESSURE LIMITING VALVE COUNTER ................ 18- 6
19 FUEL INJECTOR WIRING HARNESS
19.1 DESCRIPTION AND OPERATION OF TWO-PIECE FUEL INJECTOR
WIRING HARNESS ................................................................................. 19- 3
19.2 REMOVAL OF TWO-PIECE FUEL INJECTOR WIRING HARNESS ....... 19- 4
19.3 INSPECTION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS .. 19- 5
19.4 INSTALLATION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS 19- 6
19.5 DESCRIPTION AND OPERATION OF ONE-PIECE FUEL INJECTOR
WIRING HARNESS ................................................................................. 19- 7
19.6 REMOVAL OF ONE-PIECE FUEL INJECTOR WIRING HARNESS ....... 19- 8
19.7 INSPECTION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS ... 19- 9
19.8 INSTALLATION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS 19-10
20 FUEL INJECTORS
20.1 FUEL INJECTION WITH AMPLIFICATION .............................................. 20- 3
20.2 FUEL INJECTION WITHOUT AMPLIFICATION ...................................... 20- 5
20.3 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR ............... 20- 6
20.4 REMOVAL OF THE FUEL INJECTOR ..................................................... 20-10
20.5 INSTALLATION OF THE FUEL INJECTOR ............................................. 20-14
20.6 EPA07 THRESHOLD RESETTING AND LEARNING .............................. 20-18
20.7 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS
FUEL FROM COOLER AFTER FUEL INJECTORS FAILURE ................ 20-21

DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION iii
21 FUEL INJECTOR CUP

21.1 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR CUP ...... 21- 3
21.2 REMOVAL OF FUEL INJECTOR CUP .................................................... 21- 4
21.3 INSTALLATION OF FUEL INJECTOR CUP ............................................ 21- 5

iv DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION
1 FUEL SYSTEM OVERVIEW
Section Page
1.1 FUEL SYSTEM OVERVIEW .................................................................... 1- 3

1.2 AMPLIFIED PRESSURE COMMON RAIL SYSTEM ............................... 1- 8
1-2 DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION
1.1 FUEL SYSTEM OVERVIEW
The fuel supply ensures that the fuel required for combustion is available under all operating
conditions, in sufficient quantity, in the correct sequence, and at the required pressure. Fuel is
supplied to the APCRS from the fuel low pressure circuit. Fuel is then delivered to the individual
cylinders, supplied from the Amplified Pressure Common Rail System (APCRS).
The fuel low pressure circuit ensures that the fuel is cleaned and is provided in sufficient quantities
and at the required pressure to the APCRS.

DDC-SVC-MAN-0082 Copyright © 2010 DETROIT DIESEL CORPORATION 1-3
Figure 1-1 Version 5 System (with MCM Heat Exchanger)

Figure 1-2 Version 7 System (without MCM Heat Exchanger)

The low pressure fuel pump, which is a gear pump, supplies fuel to the fuel low pressure circuit.
When the engine is started, the fuel pump pulls fuel from the fuel tank and delivers it to the fuel
filter module. The fuel flows from the fuel filter module to the fuel heat exchanger (if equipped),
located on the Motor Control Module (MCM). The electronic components of the MCM are cooled
via the fuel heat exchanger (if equipped). The fuel in the fuel filter module first passes into the
fuel prefilter where large dirt particles greater than 100 micron are filtered out. A check ball which
is located at the fuel inlet of the fuel prefilter prevents emptying of the suction line to the fuel tank.
The fuel which has been cleaned by the fuel prefilter passes out of the fuel filter module to the low
pressure fuel pump. From there the fuel is delivered back into the fuel filter module and to the
water separator. The water in the fuel is separated by the water separator and begins to fall into
the water accumulator. If the water level in the water accumulator reaches its maximum level,
this will be detected by the water-in-fuel sensor. The MCM transmits an appropriate message
for illuminating the indicator lamp. At this point, the indicator lamp will inform the driver that
the separated water needs to be drained off. After leaving the water separator the fuel flows
through the final filter. Both the water separator and final filter elements filter out fine-grained
contaminants greater than 3 to 5 microns.
A supply fuel temperature sensor, located on the bottom of the fuel filter module, detects
the current fuel temperature. The MCM interrupts this information and uses it for fuel mass
calculations.
Designed into the water separator and final filter elements is a ventilation bore that allows
trapped air to escape. If air is trapped in the water separator or the final filter, for example, due
to replacement of a filter element, the trapped air will escape through the ventilation bore and
vent lines into the fuel accumulator. From there the air is then dissipated into the fuel tank.
Once all of the contaminants have been filtered out by the final filter, the fuel is delivered out
of the fuel filter module to the quantity control valve. The high pressure fuel pump pressurizes
the fuel up to 900 bar (13,053 psi) and feeds it to the fuel rail. The excess fuel from the quantity
control valve and high pressure fuel pump is routed past the two-stage valve. The excess fuel is
then routed to the fuel accumulator.
The two-stage valve has a number of tasks:
□ It closes at pressures in the low pressure circuit below 3 bar relative to high pressure
pump backflow pressure to ensure best filling under cranking speed where low pressure
pump flow is low.
□ It guarantees lubrication of the high pressure fuel pump components if the pressure in the
low pressure circuit is above 3 bar relative to high pressure pump backflow pressure. The
lubrication path is fully open at 3.5 bar.
□ It ensures that in overrun conditions the pressure at the inlet to the high pressure pump is
limited by opening of the backflow path. This function avoids pressures above burst
pressure level of the filter module. If the pressure at the high pressure pump inlet exceeds
4.7 bar relative to backpressure, excess fuel is routed to the return path.

If the maximum rail pressure is exceeded (leakage at 1075 bar, open at 1250 bar), the pressure
limiting valve opens and passes the excess fuel to the fuel return. If the system pressure drops
below 3 bar (43 psi) due to the opened pressure limiting valve, part of the excess fuel is taken
from the fuel return from the pressure limiting valve to be used for lubrication of the high pressure
fuel pump. The fuel taken for lubrication is fed through the emergency lubrication line and the
regulator to the fuel high pressure pump. The head pressure required to do this is generated by the
throttle valve which is located upstream of the fuel accumulator. The excess and warmed fuel
from the amplifier circuits of each individual fuel injector is routed through a passage within the
cylinder head. This fuel is fed via the amplifier fuel return line through the fuel cooler, throttle, and
finally a regulator. This fuel is fed to the fuel filter module in front of the prefilter. The fuel cooler
serves to lower the temperature of the fuel to about 120°C. The throttle valve in the amplifier fuel
return line dampens pressure peaks which occur during activation of the fuel injector amplifiers.
The excess fuel for the fuel injector needle valves is also routed through a bore in the cylinder
head. The fuel return from the fuel injector needle valves flows through a regulator and into the
fuel accumulator. The regulator has the task of regulating back pressure of about 1 bar (14.5 psi)
relative to back pressure while the engine is running. The fuel accumulator is part of the returned
fuel, and delivers fuel directly upstream of the fuel prefilter in the fuel low pressure circuit.
The fuel quantity is determined by the throttle valve and the regulator in the fuel return bypass.
This returned fuel leads to a lower suction load for the low pressure fuel pump. The remaining
fuel from the fuel accumulator is led back to the fuel tank. The assembly valve in the fuel
return prevents fuel leaking out when disassembling the fuel line between the fuel tank and
the fuel filter module.

1.2 AMPLIFIED PRESSURE COMMON RAIL SYSTEM
The high pressure circuit of the APCRS consists of the following components:
□ Fuel High Pressure Pump
□ Rail
□ Pressure Limiting Valve
□ Rail Pressure Sensor
□ Quantity Control Valve
□ Fuel injector (cylinder 1)
□ Fuel Injector (cylinder 6)

1. MCM Heat Exchanger 13. Regulator

2. Priming Port 14. High Pressure Fuel Pump
3. Fuel Prefilter 15. Low Pressure Fuel Pump
4. Fuel Filter Module 16. Amplifier Return Line (External to Module)
5. Hand Primer Pump B146. Fuel Rail Pressure Sensor
6. Water Separator B150. Water-in-Fuel Sensor
7. Final Filter A. Low Pressure Fuel Pump Outlet
8. Fuel Return from Pressure Limiting Valve B. Low Pressure Fuel Pump Inlet
9. Fuel Rail C. High Pressure Fuel Pump Outlet
10. Fuel Return from Injectors Amplifiers D. High Pressure Fuel Pump Inlet
11. Pressure Limiting Valve E. High Pressure Fuel Pump Emergency Lubrication Line
12. Fuel Return for fuel injector Needle Valves
Figure 1-3 V5 Fuel System

1. Water-in-Fuel Sensor 12. Pressure Limiting Valve

2. Priming Port 13. Fuel Return from Injectors Amplifiers
3. Fuel Prefilter 14. Fuel Return for Fuel Injector Needle Valves
4. Fuel Filter Module 15. Regulator
5. Hand Primer Pump 16. High Pressure Fuel Pump
6. Water Separator 17. Low Pressure Fuel Pump

7. Final Filter 18. High Pressure Fuel Pump Inlet
8. Fuel Return from Pressure Limiting Valve 19. High Pressure Fuel Pump Outlet
9. Fuel Rail 20. Low Pressure Fuel Pump Inlet
10. Fuel Rail Pressure Sensor 21. Low Pressure Fuel Pump Outlet
11. Fuel Injector
Figure 1-4 V7 Fuel System

2 FUEL SYSTEM PRIMING
Section Page
2.1 AFTER FILTER CHANGE (USING ESOC 350 FUEL PRIMING PUMP) . 2- 3
2.2 AFTER FILTER CHANGE (USING J-47912 PRIMING CAN) .................. 2- 4
2.3 AFTER FILTER CHANGE (USING HAND PRIMER ON MODULE) ........ 2- 5
(USING J-47912 PRIMING CAN) ........................................................... 2- 6
2.5 PRIMING PORT PRESSURES ................................................................ 2- 8
2.1 AFTER FILTER CHANGE (USING ESOC 350 FUEL PRIMING PUMP)
The ESOC® 350 fuel priming pump is used to properly prime the fuel system after a repair or
fuel filter replacement on a DD13 or DD15 engine.
When a high pressure fuel pump is replaced on a DD15/DD13 engine, the fuel system must be
primed for 2 minutes at 70 psi to properly prime the lubrication circuit on the pump. The tool uses
shop air pressure (120 psi) to prime the fuel system at 70 psi. The fuel system will prime quicker
after a normal filter change, however a full two minute prime cycle will allow for quick, easy start
up and less potential damage to the starter.
To use the ESOC® 350 fuel priming unit, follow this procedure:
1. Connect air supply (min. 120 psig).
2. Press “STOP” button once.
3. Open ball valve.
4. Fill the unit with approximately two gallons of clean ultra-low sulfur diesel fuel by
pouring the fuel into the fill box on the top of the machine. Ensure that the ball valve is
open when pouring the fuel into the fuel fill box.
5. Close the ball valve when the fuel tank is full.
6. Connect the priming port adaptor on the end of the hose to the priming adaptor on the
engine.
7. Depress the “start” button on the machine and watch the gauge. The gauge should rise up
to around 90 psig. a. If there is a need to stop the machine for any reason (leaks, forgot
to connect the hose, etc.), depress the red “Stop” button.
8. The machine will prime at 70 psi until the unit is almost out of fuel (it is designed to shut
off before pumping air in to the system); allow the machine to turn off on its own. There
will be a sound of air pressure relieving when the prime cycle is complete.
9. Disconnect the priming hose and start the engine.
NOTE:
To refill the holding tank without pouring fuel into the filler box, the priming hose may
be connected with the machine off and the engine running. This will use engine fuel
pressure to refill the holding tank. Disconnect the machine when the holding tank fuel
level reaches the top of the gauge.
NOTICE:
Leaving the hose connected with the engine running will cause
the holding tank to overfill.
10. Allow the engine to run until any remaining air in the system is purged.

2.2 AFTER FILTER CHANGE (USING J-47912 PRIMING CAN)
2.2 AFTER FILTER CHANGE (USING J-47912 PRIMING CAN)
During service of the fuel system air can be introduced, and the system will need to be purged. If
the air in the system is not properly purged, longer than normal crank times or electronic service
codes related to unstable rail pressure may occur. If a service code is set after work is performed
on the fuel system, clear the codes and retest the system.
Proceed as follows:
1. Ensure priming canister is ¾ full (approximately 9 liters) of fuel.
2. Install fuel priming canister to the priming port on the fuel filter module.
3. Ensure priming canister shutoff valve is closed.
4. Pressurize priming canister to maximum pressure.
5. Open shutoff valve and allow system to fill for 60 seconds.
6. Close shutoff valve.
7. Check for fuel leaks, repair as necessary.
8. Crank engine for no more than 20 seconds.
9. If the engine starts, go to step 12.
10. If engine does not start, allow for a 60-second cool-down and repeat steps 4-8. The
starting cycle can be repeated up to three times.
11. If engine still fails to start:
[a] Use DDDL to check for fault codes. Repair as necessary.
[b] Repeat steps 4 through 9.
12. Remove priming canister from filter module.
13. Allow engine to reach operating temperature 140°F (60°C).
14. Increase engine speed to 1800 RPM for three minutes.
15. Reduce RPM and check for fuel leaks or service codes. Repair or clear if necessary.

2.3 AFTER FILTER CHANGE (USING HAND PRIMER ON MODULE)
Proceed as follows:
1. Operate hand primer until resistance is felt.
2. Check for leaks, repair as necessary.
3. Crank engine for no more than 20 seconds.
4. If engine starts, 7.
5. If engine does not start, allow for a 60-second cool-down and repeat step 3. The starting
cycle can be repeated up to three times.
6. If engine still fails to start:
[a] Use DDDL to check for fault codes, repair as necessary.
[b] Repeat steps 2 through step 3.
7. Start the engine with the accelerator pedal in the idle position. Monitor the oil pressure
gauge or indicator lamp. Keep the engine running at a idling speed until a stable oil
pressure reading of 14 psi (97 kPa) or more is maintained for one minute. Check for leaks.
8. Allow the engine to reach operating temperature of 60°C (140°F).
NOTICE:
Increasing engine speed above idle before oil pressure has
stabilized may cause severe engine damage.
9. Increase engine speed to 1800 rpm for three minutes.

10. Return the engine to idle and allow to idle for approximately one minute, then shut down
the engine.
11. Check for leaks.

2.4 HIGH PRESSURE PUMP CHANGE OR COMPLETELY DRY SYSTEM (USING J-47912 PRIMING CAN)

(USING J-47912 PRIMING CAN)
Proceed as follows:
1. Ensure priming canister is ¾ full (approximately 9 liters) of fuel.
2. Install fuel priming tool to the priming port on the fuel filter module.
3. Ensure priming canister shutoff valve is closed.
4. Pressurize priming canister to maximum pressure.
5. Open shutoff valve and allow system to fill for 2 1/2 minutes.
7. Check for fuel system leaks.
NOTE:
Check canister fuel level and fill, as necessary.
8. Repressurize priming canister to maximum pressure.

9. Open shutoff valve. Pressure in the priming canister will drop.
10. As the system is filling, continue to pump the priming canister for one minute minimum.
This process may take an additional 5 – 15 pumps of the priming canister.
NOTE:
If using an electric priming pump, ensure the pump is capable of producing 70 psi.

12. Crank engine for 20 seconds.
13. If engine starts, go to step 16.
14. If engine does not start, allow for a 60 second cool down and repeat step 8 through step 10
15. If engine still fails to start, use DDDL to check for fault codes, repair as necessary. Begin
process again with step 1.
pressure reading of 14 psi (97 kPa) or more is maintained for one minute. Check for leaks.
Allow the engine to reach operating temperature of 60°C (140°F).

NOTICE:
stabilized may cause severe engine damage. Increase engine
speed to 1800 rpm for three minutes. Return the engine to idle
and allow to idle for approximately one minute, then shut down
the engine. Check for leaks.
17. Remove priming canister.

2.5 PRIMING PORT PRESSURES
2.5 PRIMING PORT PRESSURES
Priming port pressures are as follows:
Priming Port (J-48876) Pressures

Check for Stuck Open
Normal Check for Fuel
RPM Replace Filter Pressure Relief Valve for
Pressures Aeration
Low Pressure Pump
600 RPM 70-115 PSI >115 PSI <60 PSI <20 PSI
1800 RPM 100-150 PSI >150 PSI <80 PSI <20 PSI

3 FUEL SYSTEM DRAINING PROCEDURE
Section Page
3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS ........ 3- 3

3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS
Drain system as follows:

1. Remove the fuel feed line from the fuel filter module.
2. Install J-48710 fuel pressure test kit onto the fuel feed line at the module.
3. Do NOT remove the return line from the module.
4. Use regulator and adjust the system pressure to 50 psi.
5. After one to two minutes the system should be drained of fuel.
6. Remove test equipment.

3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS

4 FUEL FILTER MODULE
Section Page
4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE

AND RELATED PARTS ............................................................................ 4- 3
4.2 REMOVAL OF FUEL FILTER MODULE .................................................. 4- 5
4.3 DISASSEMBLY OF THE FUEL FILTER MODULE .................................. 4- 6
4.4 ASSEMBLY OF THE FUEL FILTER MODULE ........................................ 4- 7
4.5 INSTALLATION OF THE FUEL FILTER MODULE .................................. 4- 8
4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE AND

RELATED PARTS
The fuel filter module is located on the left side of the crankcase. The fuel filter module separates
out water in the fuel and filters out dirt particles in two stages. The fuel filter module consists of
the following components:
□ Fuel prefilter where large dirt particles are removed from the fuel.
□ Water separator with water collector through where water in the fuel is separated.
□ Final filter where small dirt particles are removed from the fuel.
□ The fuel accumulator gathers fuel from all return lines and passes it through a bypass valve
to either the fuel prefilter or to the fuel tank.
□ The hand-operated primer pump allows for priming the system when a filter is changed or
when the fuel system is run dry.
□ The fuel priming valve can also be used after replacing a fuel filter or when the fuel
system is run dry.
□ Assembly valves which prevents fuel from escaping when disassembling the fuel lines
between the fuel tank and the fuel filter module.
1. Water-in-Fuel Sensor 7. Return from PLV, fuel injector 13. Fuel Connection from LP Pump
Needle and Amplifier
2. Fuel Priming Valve 8. Emergency Lubrication 14. Amplifier Bracket
Connection for HP Pump
3. Assembly Valves 9. Fuel Connection to HP Pump 15. Supply Fuel Temperature Sensor
4. Hand Primer Pump 10. Fuel Accumulator 16. Fuel Prefilter
5. Water Separator 11. Return Connection from HP 17. Mechanical Drain Valve
Pump
6. Final Filter 12. Fuel Connection to LP Pump
Figure 4-1 Fuel Filter Module

4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE AND RELATED PARTS
4.1.1 Fuel Hand Primer
A fuel hand primer is incorporated into the center section of the fuel filter module. The hand
primer can be used anytime the system is run out of fuel or after a fuel filter change. Average
time to fill the module after a filter change is approximately 3 minutes or 200 to 300 pumps. Fuel
for the priming circuit is taken after the prefilter and is deposited between the water separator
and final filter.
4.1.2 Fuel Priming Valve
A fuel priming valve is also incorporated into the fuel filter module. This port can be used to
prime the fuel system in the event of an engine running out of fuel or after a fuel filter change.
The fuel priming valve feeds fuel into the fuel filter module after the water separator, but before
the final filter. The design of the fuel priming valve is the same as current production.
4.1.3 Supply Fuel Temperature Sensor
The Supply Fuel Temperature Sensor is located on the left side of the crankcase on the fuel filter
module. The MCM2 detects the current temperature of the fuel via the fuel temperature sensor.
There is an NTC resistor inside the Supply Fuel Temperature Sensor. NTC stands for "Negative
Temperature Coefficient" and means that the electrical resistance falls as the temperature increases.

4.2 REMOVAL OF FUEL FILTER MODULE
Remove as follows:
1. Drain cooling system. Refer to OEM procedures.
2. Drain the fuel filter module by using shop air pressure. Refer to section 3.1.
3. Remove the chassis fuel feed and return lines. Refer to OEM procedures.
4. Disconnect and remove the coolant lines from the front and bottom of the fuel filter
module.
5. Disconnect the electrical harness connectors from the water-in-fuel and from the fuel
temperature sensors.
6. Disconnect the low pressure fuel lines from the fuel filter module. Refer to section 9.2
7. Disconnect the needle, amplifier, and pressure limiting valve return lines. Refer to section
10.2.
8. Unclip the electrical harness from the amplifier return line bracket.
9. Remove the four bolts securing the fuel filter module to the cylinder block
10. Remove fuel filter module.
11. Remove the fuel cooler rubber coupling from the engine block and discard.

4.3 DISASSEMBLY OF THE FUEL FILTER MODULE
4.3 DISASSEMBLY OF THE FUEL FILTER MODULE
Disassemble as follows:
1. Remove the fuel cooler from the fuel filter module. Refer to section 7.2.
2. Remove the three filter covers using a 36 mm socket.
3. Pull the covers and filters straight up and out of the fuel filter module.
4. Remove the filters from the covers by applying a lateral force to the bottom of the filters.
The filter will unsnap from the cover. Discard the filters.
5. Remove the seal rings from the covers and discard seal.
6. Inspect the fuel filter module for cracks or damage ; replace if necessary.
7. Inspect fuel filter sensors; replace if necessary.
8. Inspect the fuel cooler for wear or damage; replace if necessary.
9. Inspect the fuel filter housing and cooler for debris and clean if necessary.

4.4 ASSEMBLY OF THE FUEL FILTER MODULE
Assemble as follows:
1. Install new seal rings onto the fuel filter caps and coat with clean engine oil.
2. Install the filters into the fuel filter caps by snapping the filter into the cap.
NOTE:
The prefilter has slots and the tabs should align with the slot in the fuel filter cap.
3. Install filters and caps into fuel filter module

4. Turn the cap counter clockwise until a clicking sound is made and then turn the cap
clockwise and hand tighten.
5. Torque prefilter cap to 15-20 N·m (11-18 lb·ft).
6. Torque water separator and fuel filter caps to 50-60 N·m (37-44 lb·ft).
7. Install fuel cooler into fuel filter module. Refer to section 7.3.

4.5 INSTALLATION OF THE FUEL FILTER MODULE
4.5 INSTALLATION OF THE FUEL FILTER MODULE
Install as follows:
1. Lightly lubricate the fuel cooler rubber coupling with engine oil and install them into the
engine block.
2. Install the fuel filter module.
3. Install the four bolts securing the fuel filter module to the cylinder block. Torque to 60
N·m (44 lb·ft).
4. Clip the electrical harness to the amplifier return line bracket.
5. Install the low pressure fuel lines. Refer to section 9.3
6. Install the Needle, Amplifier, and Pressure Limiting Valve Return Lines refer to section
10.3.
7. Connect electrical harness connectors to the water-in-fuel and the fuel temperature sensors.
8. Connect the coolant lines to the front and bottom of the fuel filter module.
9. Install the chassis fuel feed and return lines. Refer to OEM procedures.
10. Fill the engine with coolant.
11. Prime fuel system. Refer to section 2.1.

5 BYPASS VALVE
Section Page
5.1 DESCRIPTION AND OPERATION OF THE BYPASS VALVE ................. 5- 3

5.2 REMOVAL OF BYPASS VALVE IN FUEL FILTER MODULE .................. 5- 4
5.3 INSPECTION OF THE BYPASS VALVE AND FUEL FILTER MODULE .. 5- 5
5.4 INSTALLATION OF BYPASS VALVE ....................................................... 5- 7
5.1 DESCRIPTION AND OPERATION OF THE BYPASS VALVE
A bypass valve is incorporated into the fuel filter module. The bypass valve in the module creates
a restriction for the fuel accumulator. It is designed to regulate the amount of fresh fuel that it uses
from the fuel tank compared to the amount of fuel that it uses from the fuel accumulator.
Figure 5-1 Bypass Valve

5.2 REMOVAL OF BYPASS VALVE IN FUEL FILTER MODULE
5.2 REMOVAL OF BYPASS VALVE IN FUEL FILTER MODULE
Remove as follows:
1. Steam clean the engine.
2. Drain the fuel filter module by removing one of the fuel filters or by using the water
in fuel drain.
3. Remove the bypass valve (1).

5.3 INSPECTION OF THE BYPASS VALVE AND FUEL FILTER MODULE
Inspect as follows:
1. Inspect the fuel filter module housing bore (1) for any debris. If debris is present use a
vacuum remove it from the filter housing (Do NOT use compressed air as it may lodge
particles in the filter housing passages).
2. Visually inspect the bypass valve threads (2), ports and O-ring (1) to ensure no damage is
present. If damage is found, replace the valve.

5.3 INSPECTION OF THE BYPASS VALVE AND FUEL FILTER MODULE
3. Inspect the valve piston for damage and for being stuck. Using a small screwdriver,
depress the piston in the valve. The piston should smoothly slide in and return to the end
of the valve. If the piston sticks or has damage, replace the valve.

5.4 INSTALLATION OF BYPASS VALVE
Install as follows:
1. Lubricate the O-ring and the threads with a light coat of clean diesel fuel.
2. Thread the valve into the high pressure fuel pump and torque to 40 N·m (30 lb·ft).
3. Test for leaks by priming fuel system. Refer to section 2.1, and then starting the engine.

5.4 INSTALLATION OF BYPASS VALVE

6 FUEL FILTERS
Section Page
6.1 FUEL PREFILTER ................................................................................... 6- 3

6.2 WATER SEPARATOR/COALESCER ....................................................... 6- 6
6.3 FINAL FILTER .......................................................................................... 6-10
6.1 FUEL PREFILTER
Unfiltered fuel passes through the fuel inlet into the fuel prefilter. Fuel entering the prefilter
pushes the check ball off its seat allowing flow through the filter element from inside to outside.
The larger dirt particles remain in the filter element and the precleaned fuel flows through the fuel
outlet to the low pressure pump. The check ball has the task of preventing fuel from draining
out of the fuel inlet circuit when the engine is stopped. If the fuel flow is blocked, the prefilter
can be bypassed via the opened bypass valve located at the top of the filter. When removing
the filter element a drain to the fuel accumulator is opened so the fuel can flow out of the fuel
prefilter housing.
1. Filter Element 5. Fuel Inlet

2. Check Ball D. Unfiltered Fuel
3. Bypass Valve E. Prefiltered Fuel
4. Fuel Outlet
Figure 6-1 Fuel Prefilter

6.1 FUEL PREFILTER
6.1.1 Removal of Fuel Prefilter
Remove prefilter as follows:

1. Using a 36 mm socket, unscrew the prefilter cap.
NOTICE:
Do not tilt the prefilter when removing it from the housing.
Possible damage to the prefilter or stand pipe may occur.
2. Pull the cap and prefilter straight up and out of the fuel filter housing.
3. Remove the prefilter from the prefilter cap and discard.
4. Discard the prefilter cap seal ring.
6.1.2 Installation of Fuel Prefilter
Install as follows:
NOTE:
If a filter service is being performed, replace all other filters before priming.
1. Install a new prefilter cap seal ring (2).

2. Snap new prefilter (4) into the prefilter cap (1).
NOTE:
The prefilter should snap into the cap in two positions. The tabs (5) should align with
the slot in the prefilter cap (3).
3. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal ring.
4. Apply a thin coat of petroleum-based lithium grease to the inside and outside of the
prefilter bottom seal.
5. Install the prefilter into the fuel filter module.
6. Turn the cap counterclockwise until a “click” sound is made, then turn clockwise and
hand tighten.

7. Torque prefilter cap to 15-20 N·m (11-15 lb·ft).

8. Once all required filters have been changed, prime the fuel system. Refer to section 2.1.2.
pressure reading of 14 psi (97 kPa) or more is maintained for one minute.
NOTICE:

the engine.

6.2 WATER SEPARATOR/COALESCER
The water separator element consists of many layers and has the task of separating out the water
contained in the fuel. The water separator element has fuel flowing from inside to the outside.
The special construction ensures that small water droplets either remain in the water separator
element or bind themselves to already retained water droplets. Small dirt particles are also filtered
out due to the construction.
In order to ensure that the water droplets can sink downwards into the water bowl, it is essential
that the flow rate of the fuel is reduced. This is achieved purely by the design of the housing.
The flow rate of the fuel is increased again due to the shape of the housing as it flows to the final
filter element. Water level in the water bowl is detected by using a water-in-fuel sensor. If the
Motor Control Module (MCM) detects excessive water in the water bowl it will transmit an
appropriate message to illuminate an indicator lamp.

The driver will need to drain the water using the mechanical drain valve. An air purge/ventilation
bore, located above the water separator element, serves to divert the trapped air in the water
separator and routes it to fuel collector where it can be returned via the fuel return line to the
fuel tank. The ventilation bore also guarantees full use of the water separator element. When
removing the water separator element the mechanical drain valve to the fuel transfer bore/fuel
accumulator is opened so that fuel can flow out of the water separator housing.
1. Water Bowl 4. Air Purge 7. Coolant Connection

2. Fuel In (from feed pump) 5. Fuel Transfer Bore 8. Supply Fuel Temperature Sensor
3. Water Separator (Coalescer) 6. Final Filter Element 9. Mechanical Drain Valve
Element
Figure 6-2 Water Separator/Coalescer

6.2.1 Removal of the Water Separator/Coalescer
Remove the water separator/coalescer as follows:

1. Using a 36 mm socket, unscrew the water separator/coalescer cap.
NOTICE:
Do not tilt the coalescer when removing it from the housing.
Possible damage to the coalescer or stand pipe may occur.
2. Pull the cap and water separator/coalescer straight up and allow the fuel to drain back.
3. Remove the water separator/coalescer (1) from the water separator/coalescer cap (2) by
placing the filter on a solid surface and apply pressure on the water separator/coalescer
cap at an angle.
4. Discard the filter.

5. Inspect inside the housing for any large debris and clean it out if needed.
6. Discard water separator/coalescer cap seal ring.
6.2.2 Installation of Water Separator/Coalescer
Install as follows:
1. Install a new water separator/coalescer cap seal ring.
2. Snap a new water separator/coalescer into the water separator/coalescer cap.

3. Apply a light coat of petroleum-based lithium grease (supplied with filter kit) to the water
separator/coalescer cap seal ring and to the lower seal (1) on the water separator/coalescer
filter.
4. Install the water separator/coalescer into the fuel filter module.

hand tighten.
6. Torque the water separator/coalescer cap to 55-60 N·m (40-44 lb·ft).
NOTE:

9. Check for leaks.
NOTICE:

the engine.

6.3 FINAL FILTER
6.3 FINAL FILTER
The final filter element consists of many layers. Fuel flow through the filter element is from the
outside to inside. The smallest dirt particles are filtered out at a very high separation rate by
the final filter element. Just like the prefilter and water separator, the final filter housing has a
ventilation bore. This ventilation bore allows full use of the filter media. When removing the final
filter element a drain bore to the fuel accumulator is opened so the fuel can flow out of the fuel
filter housing. The cleaned fuel is supplied to the fuel high pressure pump through an overflow
bore in the inner dome. The high position of the overflow bore in the inner dome ensures that the
no unclean fuel can reach the fuel high pressure pump.
1. Water Bowl 5. Fuel Transfer Bore 7. Coolant Connection

2. Fuel In (from feed pump) 4. Air Purge 8. Supply Fuel Temperature Sensor
3. Water Separator (Coalescer) 6. Final Filter Element 9. Mechanical Drain Valve
Element
Figure 6-3 Final Filter

6.3.1 Removal of Final Filter
Remove the final filter as follows:

1. Using a 36-mm socket, unscrew the final filter cap.
NOTICE:
Do not tilt the final filter when removing it from the housing.
Possible damage to the final filter or stand pipe may occur.
2. Pull the cap and final filter straight up and allow the fuel to drain back.
3. Remove the final filter (2) from the final filter cap (1) by placing the filter on a solid
surface and apply pressure on the final filter cap at an angle.
4. Discard the filter.

5. Inspect inside the housing for any large debris and clean if needed.
6. Discard final filter cap seal ring.
6.3.2 Installation of the Final Filter
Install the final filter as follows:

1. Install a new final filter cap seal ring.
2. Snap new final filter into the final filter cap.

6.3 FINAL FILTER
3. Apply a light coat of petroleum-based lithium grease (supplied with filter kit) to the cap
seal ring (1) and to the lower seal on the final filter.
4. Install the final filter into the fuel filter module.

hand tighten.
6. Torque final filter cap to 55-60 N·m (40-44 lb·ft).
NOTE:

9. Check for leaks.
NOTICE:

the engine.

7 FUEL COOLER
Section Page
7.1 DESCRIPTION AND OPERATION OF THE FUEL COOLER .................. 7- 3

7.2 REMOVAL OF THE FUEL COOLER ....................................................... 7- 4
7.3 INSTALLATION OF THE FUEL COOLER ................................................ 7- 5
7.1 DESCRIPTION AND OPERATION OF THE FUEL COOLER
The fuel cooler is located behind the fuel filter module. The fuel cooler cools the warmed
fuel which comes from the fuel injector amplifiers to the fuel filter module. The fuel cooler is
designed as a shell cooler. The warmed fuel from the fuel injector amplifiers flows via the fuel
inlet through the fuel cooling ducts to the fuel outlet. The cooled fuel then passes from there to
the fuel filter housing and mixes with the colder fuel from the low pressure pump. The fuel cooler
is supplied coolant through a passage in the block. Coolant exits the fuel cooler and enters the
fuel filter module through an internal passage. From there the coolant exits the fuel filter module
and returns to the oil/coolant module.
1. Fuel Filter Module 6. Fuel Inlet

2. Fuel Cooler 7. Fuel Outlet
3. Coolant Outlet for Fuel Filter Module 8. Fuel Cooling Ducts
4. Coolant Inlet A. Fuel Circuit
5. Coolant Outlet B. Cooling Circuit
Figure 7-1 Fuel Cooler and Related Parts

7.2 REMOVAL OF THE FUEL COOLER
7.2 REMOVAL OF THE FUEL COOLER
Remove as follows:
NOTE:
For EVO Bus applications you must remove the radiator and cooling fan assemblies for
access. Refer to OEM procedures.
Disassemble as follows:
1. Remove the fuel filter module. Refer to section 4.2.
2. Remove the four bolts securing the fuel cooler to the fuel filter module.
3. Inspect the fuel cooler for damage and replace, if necessary.

7.3 INSTALLATION OF THE FUEL COOLER
Install as follows:
1. Install new seal rings onto the fuel filter cooler and coat with clean diesel fuel.
2. Install the fuel cooler to the fuel filter module. Torque the four bolts to 30 N·m (22 lb·ft).
3. Install the fuel filter module. Refer to section 4.5.

7.3 INSTALLATION OF THE FUEL COOLER

8 LOW PRESSURE FUEL PUMP
Section Page

8.2 REMOVAL OF LOW PRESSURE FUEL PUMP ...................................... 8- 4
8.3 INSTALLATION OF LOW PRESSURE FUEL PUMP ............................... 8- 5

PUMP AND RELATED PARTS
The low pressure pump is mounted on the high pressure fuel pump. The low pressure pump pulls
fuel from the fuel tank through the fuel heat exchanger for the MCM.
The low pressure pump is designed as a gear pump and is driven, if equipped, by the high pressure
fuel pump. As soon as the engine starts and runs, the right gearwheel in the low pressure pump is
driven by the drive plate on the high pressure fuel pump camshaft. The fuel is suctioned due to
the rotational movement of both gearwheels and the design of the pump chamber.
1. Pressure Relief Valve For Low Pressure Pump (UeV) 7. Pump to the High Pressure Rail Fittings
2. Low Pressure Pump 8. Lubrication Fuel
3. Low Pressure Inlet 9. Two-stage Valve (KUeV)
4. Bypass 10. Fuel Return
5. Quantity Control Valve Fuel Metering Unit (FMU) 11. Low Pressure Outlet
6. Fuel Inlet from Filter (to High Pressure Pump)
Figure 8-1 Low Pressure Fuel Pump

8.2 REMOVAL OF LOW PRESSURE FUEL PUMP
8.2 REMOVAL OF LOW PRESSURE FUEL PUMP
Remove as follows:
2. Disconnect the battery cable(s) from the battery(s).
3. Drain cooling system. Refer to OEM procedures.
4. Drain the fuel. Refer to section 3.1.
5. Disconnect the needle return fuel line from the high pressure pump flange.
6. Disconnect the fuel doser supply line from the high pressure pump flange.
7. Remove the three bolts and remove the high pressure pump flange.
8. Remove the three bolts and remove the low pressure pump flange.
9. Remove the three bolts attaching the low pressure fuel pump to the high pressure fuel
pump.
10. Remove the O-ring from the high-pressure fuel pump.
11. Clean housing around the high pressure fuel pump.
12. Inspect the drive coupling on the high pressure fuel pump, replace high pressure fuel
pump if coupling damaged.

8.3 INSTALLATION OF LOW PRESSURE FUEL PUMP
Install as follows:
1. Install low pressure pump to the high pressure pump with new O-rings and torque bolts
to 8 N·m (6 lb·ft).
2. Install needle return fuel line from the fuel filter module to the high pressure pump.
[a] Fuel doser supply line for low pressure pump to 45 N·m (33 lb·ft).
[b] Fuel needle return fuel line for low pressure pump to 45 N·m (33 lb·ft).
3. Install new gasket, bolts and high pressure pump flange. Torque to 30 N·m (22 lb·ft).
4. Install new gasket, bolts and low pressure pump flange. Torque to 30 N·m (22 lb·ft).
5. Connect batteries.

8.3 INSTALLATION OF LOW PRESSURE FUEL PUMP

9 LOW PRESSURE FUEL LINES
Section Page

LINES ....................................................................................................... 9- 3
9.2 REMOVAL OF LOW PRESSURE FUEL LINES ...................................... 9- 5
9.3 INSTALLATION OF LOW PRESSURE FUEL LINES ............................... 9- 6

LINES
There are five low pressure lines on EPA07 engines. Four low pressure lines run from the two fuel
pumps to the fuel filter module, and the emergency fuel pump lubrication line.
1. Emergency Pump Lubrication Line 4. Low Pressure Pump Inlet

2. High Pressure Pump Inlet 5. Low Pressure Pump Outlet
3. High Pressure Pump Outlet 6. MCM Cooler Lines
Figure 9-1 V5 Low Pressure Pump Lines

9.1 DESCRIPTION AND OPERATION OF THE LOW PRESSURE FUEL LINES
There are four low pressure lines on EPA10 engines. Four low pressure lines run from the two
fuel pumps to the fuel filter module, and the emergency fuel pump lubrication line.
1. High Pressure Pump Inlet 3. Low Pressure Pump Inlet

2. High Pressure Pump Outlet 4. Low Pressure Pump Outlet
Figure 9-2 V7 Low Pressure Pump Lines

9.2 REMOVAL OF LOW PRESSURE FUEL LINES
Removal of low pressure fuel lines

2. Disconnect the battery cable(s) from the battery(s).
3. Drain the fuel filter module.
4. Remove the emergency lubrication line (if equipped) from the fuel filter module and
the high pressure flange.
5. Remove the high pressure pump inlet line from the fuel filter module and the high pressure
flange.
6. Remove the high pressure pump outlet line from the fuel filter module and the high
pressure flange.
7. On V5 systems only, remove the banjo bolt from the low pressure fuel pump inlet line
and discard both sealing washers.
8. Remove the low pressure fuel pump inlet line from the fuel filter module and the low
pressure flange.
9. Remove the low pressure fuel pump outlet line from the fuel filter module and the low
pressure flange.

9.3 INSTALLATION OF LOW PRESSURE FUEL LINES
9.3 INSTALLATION OF LOW PRESSURE FUEL LINES
Installation of low pressure fuel lines

1. Install the low pressure fuel pump outlet line and torque to 45 N·m (33 lb·ft).
2. Install the low pressure fuel pump inlet line and torque to 45 N·m (33 lb·ft). On V5 systems
only, install the banjo bolt with new sealing washers and torque to 20 N·m (15 lb·ft).
3. Install the high pressure pump outlet line and torque to 30 N·m (22 lb·ft).
4. Install the high pressure pump inlet line and torque to 30 N·m (22 lb·ft).
5. Install the emergency lubrication line and torque to 23 N·m (17 lb·ft).
6. Connect the battery cable(s) to the battery(s).

10 NEEDLE, AMPLIFIER, AND PRESSURE LIMITING
VALVE RETURN LINES
Section Page

PRESSURE LIMITING VALVE RETURN LINES ..................................... 10- 3
VALVE RETURN LINES ........................................................................... 10- 4
LIMITING VALVE RETURN LINES .......................................................... 10- 5

PRESSURE LIMITING VALVE RETURN LINES
Fuel passages in the cylinder head provide a fuel return path from the injectors for the excess
fuel via the needle and amplifier circuits. Fuel return lines connect to the cylinder head and lead
to the fuel filter module. If the pressure limiting valve opens, fuel returns to the module via the
pressure limiting valve return line.
1. High Pressure Fuel Pump 4. Fuel Return from Pressure Limiting Valve
2. Fuel Filter Module 5. Fuel Return from Injector Amplifiers
3. Fuel Rail 6. Fuel Return for Fuel Injector Needle Valves
Figure 10-1 V7 Needle, Amplifier, and Pressure Limiting Valve Return Lines

10.2 REMOVAL OF THE NEEDLE, AMPLIFIER, AND PRESSURE LIMITING VALVE RETURN LINES

VALVE RETURN LINES
Remove as follows:
1. Remove P-clips from the fuel line retainer bracket.
2. Remove the fuel line retaining bracket from the intake manifold.
3. Using J-48836 and J-48770, remove the needle return line from the rear of the cylinder
head.
4. Remove the needle return line from the fuel filter module and the high pressure flange.
5. Remove the Pressure Limiting Valve (PLV) return line from the fuel rail.
6. Remove the Pressure Limiting Valve (PLV) return line from the fuel filter module.
7. Using J-48836 and J-48770, remove the amplifier return line from the rear of the cylinder
head.
8. Remove the amplifier return line from the fuel filter module.


LIMITING VALVE RETURN LINES
Install as follows:
1. Install the amplifier and needle return line fittings to the cylinder head, Using J-48770,
torque M18x1.5 to 55-60 N·m (40-44 lb·ft) M16x1.5 to 45-50 N·m (33-37 lb·ft).
2. Install the amplifier return line from the fitting on the rear of the cylinder head, using new
washers, to the fuel filter module.
[a] Use J-48770 and J-48836 to torque the line fitting to the fitting in the cylinder head;
torque to 23-25 N·m (17-19 lb·ft).
[b] Use an appropriate tool to hold the fitting on the fuel filter module; torque to 28-30
N·m (21-22 lb·ft).
3. Install the Pressure Limiting Valve (PLV) return line from the fuel rail to the fuel filter
module. Use an appropriate tool; torque to 28-30 N·m (21-22 lb·ft). Torque the banjo
bolt to 30-32 N·m (22-24 lb·ft).
4. Install the needle return line to the cylinder head, the fuel filter module and the high
pressure flange.
[a] Use J-48770 and J-48836 to torque the line fitting to the fitting in the cylinder head;
torque to 23-25 N·m (17-19 lb·ft).
[b] Use an appropriate tool to hold the fitting on the fuel filter module and to the high
pressure flange; torque to 28-30 N·m (17-19 lb·ft).
[c] Torque check valve to 50-55 N·m (37-41 lb·ft).
5. Install the fuel line retaining bracket from the intake manifold.
6. Install all the P-clips removed from the bracket.

10.3 INSTALLATION OF THE NEEDLE, AMPLIFIER, AND PRESSURE LIMITING VALVE RETURN LINES

11 PRESSURE RELIEF VALVE
Section Page
11.1 DESCRIPTION AND OPERATION OF THE PRESSURE RELIEF

VALVE ...................................................................................................... 11- 3
11.2 REMOVAL OF PRESSURE RELIEF VALVE ........................................... 11- 4
11.4 INSTALLATION OF PRESSURE RELIEF VALVE .................................... 11- 7
11.1 DESCRIPTION AND OPERATION OF THE PRESSURE RELIEF VALVE
A pressure relief valve (1) is incorporated into the high pressure fuel pump. If the system pressure
is too high, the pressure relief valve will open allowing the fuel pressure side to be connected
to the fuel suction side. This will prevent further build-up of fuel pressure. The pressure relief
valve (UeV) is designed to open at 13 bar absolute (189 psi).
Figure 11-1 Pressure Relief Valve Location on High Pressure Fuel Pump

11.2 REMOVAL OF PRESSURE RELIEF VALVE
11.2 REMOVAL OF PRESSURE RELIEF VALVE
Remove as follows:
NOTE:
Do not use compressed air.
1. Steam clean the engine and high pressure fuel pump.

2. Drain the fuel filter module by removing one of the fuel filters or by using the water
in fuel drain.
3. Remove the pressure relief valve.


PRESSURE PUMP HOUSING
Inspect as follows:
1. Inspect the high pressure pump housing bore (1) for any debris. If debris is present use a
vacuum remove it from the pump housing. (Do NOT use compressed air as it may lodge
particles in the pump housing passages).
2. Visually inspect the pressure relief valve ports (1), threads (2), and O-ring (3) to ensure
no damage is present. If damage is found replace valve.

11.3 INSPECTION OF THE PRESSURE RELIEF VALVE AND HIGH PRESSURE PUMP HOUSING
3. Inspect the valve piston for damage and for being stuck; the piston should be near flush
with the end of the valve housing. If there is damage to the piston or if the piston is
stuck in the bore, replace the valve.
4. Using a small screwdriver, depress the piston in the valve. The piston should smoothly
slide in and return to the end of the valve. The piston should stop approximately 1/16”
(near-flush) from the end of the valve (2). If the piston sticks (1), replace the valve. If no
trouble is found with the valve, immediately reinstall. Refer to section 11.4.

11.4 INSTALLATION OF PRESSURE RELIEF VALVE
Install as follows:
1. Lubricate the O-ring and the threads with a light coat of clean diesel fuel.
2. Thread the valve into the high pressure fuel pump and torque to 32 N·m (25 lb·ft).
3. Test for leaks by priming fuel system. Refer to section 2.1, and then start the engine.

11.4 INSTALLATION OF PRESSURE RELIEF VALVE

12 HIGH PRESSURE FUEL PUMP
Section Page

12.2 REMOVAL OF HIGH PRESSURE FUEL PUMP ...................................... 12- 6
12.3 INSTALLATION OF HIGH PRESSURE FUEL PUMP .............................. 12- 8
12.4 CHECKING FUEL PUMP TIMING ........................................................... 12-15

PUMP AND RELATED PARTS
Excess fuel in the fuel high pressure circuit passes through the fuel return line, to the fuel
return line pressure limiting valve and two fuel return lines of the injectors back into the fuel
low pressure circuit.
The camshaft for the high pressure fuel pump is driven by the pinion gear drive. The fuel
is compressed by two high pressure pistons and feeds the high pressure connection and
corresponding high pressure lines to the rail. The two roller tappets on the double cams of the
camshaft are pressed together by two push springs which are offset by 90°. With this configuration,
two pressure strokes occur for one camshaft revolution for each high pressure piston. If the high
pressure piston is in a downward movement, the fuel can flow over the corresponding intake
valve into the clearance volume of the high pressure piston. If the high pressure piston now
changes to an upward movement, the corresponding intake valve is closed by the compression
pressure rising and the fuel in compressed until the high pressure valve opens a transfer duct
between the high pressure compartment and the corresponding high pressure connection. The
highly compressed fuel can now flow into the rail. If the high pressure piston again changes to a
downward movement, the transfer duct is closed again by the spring-loaded high pressure valve
and new fuel can flow through the opened intake valve into the clearance volume.
1. Intake Valve 5. High Pressure Piston

2. High Pressure Connection 6. Compression Spring
3. High Pressure Valve 7. Roller Tappet
4. High Pressure Pump Elements 8. Camshaft
Figure 12-1 High Pressure Fuel Pump

12.1 DESCRIPTION AND OPERATION OF THE HIGH PRESSURE FUEL PUMP AND RELATED PARTS
The low pressure fuel pump suctions fuel through the fuel prefilter, and pumps it back to the fuel
filter module coalescer/water separator and then through the final filter. After filtering, fuel moves
through the quantity control valve into the high pressure fuel pump. The high pressure fuel pump
plungers increase fuel pressure up to 900 bar (13,053 psi). Fuel moves from the high pressure
delivery pipes to the fuel rail, feed pipes, and injectors. The two-stage valve diverts some fuel
for use as fuel pump crankcase lubricant. Fuel not used by the quantity control valve and high
pressure fuel pump is routed past the two-stage valve and diverted back to the fuel filter module.
1. Low Pressure Pump Outlet 5. High Pressure Pump Fittings

2. Low Pressure Pump Inlet 6. Two-Stage Valve
3. High Pressure Pump Inlet 7. High Pressure Pump Outlet
4. Quantity Control Valve
Figure 12-2 Fuel Flow – Low and High Pressure Fuel Pumps

12.1.1 Bypass Valve
Located within the plate between the low and high pressure fuel pump is a bypass valve (1) that
allows fuel to bypass the stopped gearwheels and continue to the fuel pressure side. This valve
opens between 0.15 to 0.25 bar (2.2 to 3.6 psi).
1. Bypass Valve 2. Quantity Control Valve

12.2 REMOVAL OF HIGH PRESSURE FUEL PUMP
12.2 REMOVAL OF HIGH PRESSURE FUEL PUMP
Remove as follows:
1. Disconnect the batteries.
2. Drain the fuel system. Refer to section 3.1.
3. Remove the two bolts from the inspection cover on the bottom of the flywheel housing.
4. Install an engine barring tool (J-46392) to the flywheel housing (3).
5. Rotate the flywheel until the dot located on the inside tooth (2) of the flywheel is aligned
with the edge of pointer (1). The engine should now be at TDC for cylinder one.
6. Remove the crankshaft position sensor.

7. Install Crankshaft Locking tool (W470589001500) into the CKP hole. The tool should sit
flush to the flywheel housing, if not, slowly rotate engine using baring tool until the tool is
flush with the flywheel housing.
8. Remove the W470589001500 tool from the CKP hole.
9. Remove the following fuel lines from the fuel filter module:
[a] Needle return fuel line Refer to section 10.2.
[b] Pressure Limiting Valve (PLV) fuel line Refer to section 10.2.
[c] Amplifier return fuel line Refer to section 10.2.
10. Disconnect the needle return fuel line from the high pressure pump flange.
11. Disconnect the fuel doser supply line from the high pressure pump flange.
12. Remove the three bolts and remove the high pressure pump flange.

13. Remove the three bolts and remove the low pressure pump flange.
14. Disconnect the quantity control valve electrical harness connector. Disconnect the plastic
clip from the high pressure fuel flange.
15. Remove the high pressure fuel pump mounting bracket.
16. Using HP Pressure Offset Wrench tool (J-48770), remove the high pressure fuel lines from
the high pressure fuel pump to the fuel rail.
17. Remove the four bolts attaching the high pressure fuel pump to the cylinder block.
18. Remove the pump from the block.

12.3 INSTALLATION OF HIGH PRESSURE FUEL PUMP
Install as follows:
1. Ensure flywheel is positioned at top dead center (TDC) on cylinder number one.
2. Inspect the high pressure fuel pump:
[a] If the fuel pump drive gear is installed from the factory, go to step 11.
[b] If the fuel pump drive is being replaced (or new) or exchanged from the old pump,
go to step 3.
3. Remove the O-ring from the pump flange.
4. Install the high pressure fuel pump into the High Pressure Pump Holding Device tool
(W470589014000) then remove locking tooth from the tool.
5. Install the half-moon key (1) onto the fuel pump shaft using a brass hammer.
6. Install the fuel pump drive onto the fuel pump shaft.

7. Prior to installing the nut, mark the gear with paint (1) to show the location of the key way.
Figure 12-3 EPA07 Fuel Pump Driven Gear
1. 2.
Figure 12-4 EPA07 Fuel Pump Driven Gear
8. Install the nut and locking tooth for tool (W470589014000). Using High Pressure Fuel
Pump Nut Socket tool (J-48669), torque the nut to 250 N·m (184 lb·ft).

9. Remove the locking tooth from the tool and install the eyebrow plate over the gear.
Position eyebrow plate to align hash mark on plate to paint mark on gear.
Figure 12-5 EPA07 Fuel Pump Eyebrow Plate
Figure 12-6 EPA10 Fuel Pump Eyebrow Plate
10. Install three eyebrow mounting bolts:

[a] For EPA07 engines, torque the three bolts to 30 N·m (22 lb·ft).
[b] For EPA10 engines, torque the three bolts to 8 N·m (6 lb·ft).

11. Using a non-marring strap wrench, rotate the gear until the hash mark is at the 12 o'clock
position (1) and lined up with the dot on the housing.
Figure 12-7 EPA07 Fuel Pump Eyebrow Plate Aligned with Dot
1. 2.
Figure 12-8 EPA10 Fuel Pump Eyebrow Plate Aligned with Dot
12. Remove strap from pump.

13. Clean mounting surface of fuel pump and O-ring groove. If a new fuel pump is being
installed go to step 16.

14. Remove the fuel pump from the tool and install a new O-ring.
15. Lubricate new O-ring lightly with clean engine oil.
16. Clean the flywheel housing bore. Inspect for burrs or other sharp edges.

17. Install the high pressure fuel pump to the cylinder block.
NOTE:
The pump should slide into the flywheel housing without binding. The bolt hole on the
pump housing should align very close with the mounting hole on the flywheel housing.
NOTE:
If the high pressure pump binds when being installed or if there is misalignment in the
bolt holes, remove the pump and verify the timing mark is at the 12 o'clock position
and the engine is at TDC; and reinstall.

NOTICE:
Ensure the correct bolt length is used when the high pressure
pump is installed. If an incorrect bolt length (long) is used the
cup plugs installed in the cylinder block can be pushed out into
the gear train causing severe damage to the gear train. The
correct bolt length is M10X35 mm (1.37 in.).
18. Install the four bolts securing the high pressure pump to the engine block and torque to
60 N·m (44 lb·ft).
19. Loosely install the high pressure pump bracket, and install the two nuts securing the high
pressure fuel pump to the bracket; torque to 30 N·m (22 lb·ft).
20. Install the two bolts securing the high pressure fuel pump bracket to the cylinder block
and torque to 100 N·m (74 lb·ft).
21. Connect the quantity control valve connector.
22. Using a new gasket, install the high pressure pump flange onto the high pressure pump.
Torque to 30 N·m (22 lb·ft).
23. Using a new gasket, install the low pressure pump flange onto the high pressure pump.
Torque to 30 N·m (22 lb·ft).
24. Install the fuel supply line to doser block assembly. Torque to 25 N·m (18 lb·ft).
25. Install two high pressure lines from the high pressure pump to the fuel rail. Refer to section
16.3.
26. Prime the fuel system. Refer to section 2.1.
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always
operate the engine in a well-ventilated area. Engine
exhaust is toxic.
27. Start and run the engine.

28. When the engine has reached operating temperature 140° F (60° C), observe pump for any
performance problems or leaks.

12.4 CHECKING FUEL PUMP TIMING
Observe the following:
NOTICE:
This procedure can only be performed if the flywheel housing is
equipped with a fuel pump gear inspection cover (1).
Time the fuel pump as follows:

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other
applicable safety steps.
2. Disconnect the battery power.
3. Install engine barring tool J-46392 to flywheel housing (3).

4. Rotate the flywheel until the dot (3) that is located inside the tooth is aligned with edge
of pointer (2).
5. Install the crankshaft locking tool (W470589001500) into the crankshaft position sensor
hole until the tool engages the flywheel.
NOTE:
Cylinder No. 1 must be positioned on the firing stroke. Removal of the rocker cover is
necessary to determine correct positioning.

6. Remove rocker cover and ensure cylinder No. 1 is at top dead center (TDC) in the firing
position.
[a] If cylinder No. 1 is not at TDC firing position, remove crankshaft locking tool
(W470589001500). Rotate the crankshaft one more revolution (360°) and position
timing mark. Install the crankshaft locking tool (W470589001500).
7. Remove the fuel pump gear inspection cover (1) located on flywheel housing.
NOTE:
All new pumps (factory or service installed) will be timed with the “T” mark at the 12
o'clock position when the crankshaft is at TDC #1.
8. Using a telescoping mirror or looking in from the rear of the engine under the cab, look at
the high pressure fuel pump eyebrow timing plate. Compare the eyebrow timing plate
to the #3 idler gear. The radius of the eyebrow timing plate and the idler gear should
not intersect.

[a] If there is an intersection of the radius or the “T” timing mark is not at the 12 o'clock
position, remove the pump and inspect for gear train damage. If the gear train is not
damaged, install the pump and time correctly.
[b] If the “T” timing mark is at the 12 o'clock position, and the radius of the eyebrow
timing plate and the idler gear do not intersect, the pump is correctly timed.

13 TWO STAGE VALVE
Section Page
13.1 DESCRIPTION AND OPERATION OF THE TWO STAGE VALVE .......... 13- 3
13.2 REMOVAL OF TWO STAGE VALVE ....................................................... 13- 4
PUMP HOUSING ..................................................................................... 13- 6
13.4 INSTALLATION OF TWO STAGE VALVE ................................................ 13- 9
13.1 DESCRIPTION AND OPERATION OF THE TWO STAGE VALVE
Internal to the high pressure fuel pump is a two-stage valve. The excess fuel from the quantity
control valve and high pressure fuel pump is routed past the two-stage valve.
The two-stage valve has a number of tasks:
□ It is closed at pressures in the low pressure circuit below 3 bar relative to the high pressure
pump backflow pressure. This will ensure best filling for the pumping elements under
cranking speed where low pressure pump flow is low.
□ It guarantees lubrication of the high pressure fuel pump components if the pressure in the
low pressure circuit is above 3 bar relative to high pressure pump backflow pressure. The
lubrication path is fully open at 3.5 bar.
□ It ensures that in overrun conditions the pressure at the inlet to the high pressure pump is
limited by opening of the backflow path. This function avoids pressures above burst
pressure level of the filter module. If the pressure at the high pressure pump inlet exceeds
4.7 bar relative to backpressure, excess fuel is routed to the return path.
Figure 13-1 Two-Stage Valve

13.2 REMOVAL OF TWO STAGE VALVE
13.2 REMOVAL OF TWO STAGE VALVE
Remove as follows:
NOTE:
1. Clean the housing on the high pressure fuel pump.

2. Remove the high pressure flange from the high pressure fuel pump and discard the gasket.
3. Remove the needle return line (2) from the high pressure flange.
4. Remove the doser supply line (1) from the high pressure flange.
5. Remove the three bolts (3) that secure the high pressure flange to the high pressure fuel
pump and discard the gasket.

6. Remove the two-stage valve from the high pressure fuel pump (1).

13.3 INSPECTION OF THE TWO STAGE VALVE AND HIGH PRESSURE PUMP HOUSING

PUMP HOUSING
Inspect as follows:
NOTICE:
Do Not use compressed air.
1. Inspect the high pressure pump housing bore for any debris. If debris is present use a
vacuum remove it from the pump housing. Do not use compressed air, as it may lodge
particles in the pump housing passages.

2. Inspect the two-stage valve ports (1), threads (2), and O-rings (3) to ensure no damage is
present. If damage is found, replace the valve.
3. Inspect the valve piston for damage and for being stuck; the piston should be near flush
(2) with the end of the valve housing. If there is damage to the piston or if the piston
is stuck in the bore (1), replace the valve.
4. Using a small screwdriver, depress the piston in the housing. The piston should smoothly
slide in and return flush to the end of the valve as shown in the picture. If the piston

13.3 INSPECTION OF THE TWO STAGE VALVE AND HIGH PRESSURE PUMP HOUSING
sticks, replace the valve. If no trouble is found with the valve immediately reinstall.
Refer to section 13.4.

13.4 INSTALLATION OF TWO STAGE VALVE
Install as follows:
1. Lubricate replacement two stage valve O-ring and threads with clean diesel fuel. Insure
that the O-ring is not cut, damaged, or twisted.
2. Install the two stage valve (1). Torque to 26 N·m (20 lb·ft).
NOTE:
Verify that there are no plastic line plugs on the high pressure flange before installing it
onto the fuel pump.

13.4 INSTALLATION OF TWO STAGE VALVE
3. Install new gasket and torque high pressure flange bolts (3) on the high pressure fuel
pump to 30 N·m (22 lb·ft).
4. Install needle return line to high pressure manifold and torque to 25 N·m (18 lb·ft).
5. Install doser supply line to high pressure manifold and to 25 N·m (18 lb·ft).
Diesel engine exhaust and some of its constituents are

known to the State of California to cause cancer, birth
defects, and other reproductive harm.
□ Always start and operate an engine in a well ventilated
area.
□ If operating an engine in an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper with the exhaust system or
emission control system.
6. Test for leaks by priming fuel system. Refer to section 2.1, and then starting the engine.

14 QUANTITY CONTROL VALVE
Section Page
14.1 DESCRIPTION AND OPERATION OF THE QUANTITY CONTROL

VALVE ...................................................................................................... 14- 3
14.2 REMOVAL OF QUANTITY CONTROL VALVE ........................................ 14- 4
14.4 INSTALLATION OF QUANTITY CONTROL VALVE ................................ 14- 7
VALUES ................................................................................................... 14- 8
VALUES ................................................................................................... 14-10
14.1 DESCRIPTION AND OPERATION OF THE QUANTITY CONTROL VALVE
The quantity control valve is located on the high pressure fuel pump. The quantity control valve
has the following tasks:
□ Regulation of the fuel feed to the high pressure fuel pump
□ Regulation of the rail pressure
The MCM actuates the coil of the quantity control valve using a pulse width modulated signal.
The magnetic field of the coil influences the position of the float needle and thus the fuel flow in
the quantity control valve. At engine off the float needle is pushed back by the valve spring and
the fuel flow is interrupted.
1. Float Needle 4. Valve Spring

2. Quantity Control Valve 5. High Pressure Pump
3. Coil
Figure 14-1 Quantity Control Valve

14.2 REMOVAL OF QUANTITY CONTROL VALVE
14.2 REMOVAL OF QUANTITY CONTROL VALVE
Remove as follows:
1. Steam clean engine and housing on high pressure fuel pump.
2. Drain fuel filter module by removing one of the fuel filters or by using the water in fuel
drain.
3. Remove needle return line (2) from high pressure flange.
4. Remove doser supply line (1) from high pressure flange.
5. Remove 3 bolts (3) that secure high pressure flange to high pressure fuel pump. Discard
gasket.
6. Disconnect electrical connector from quantity control valve.

7. Remove bracket from high pressure fuel pump to block.
8. Remove three bolts attaching quantity control valve to high pressure pump.
9. Remove quantity control valve, ensure that both O-rings are removed from pump housing.
Remove three bolts attaching quantity control valve to high pressure pump.


PRESSURE PUMP HOUSING
Inspect as follows:
NOTICE:
1. Using a mirror (1), inspect high pressure pump housing bore (2) for any debris. If debris is
present, use a vacuum to remove from pump housing. Doing so may lodge particles in
pump housing passages.
2. Inspect quantity control valve for debris, check ports and O-rings (in circled area in the
illustration) to ensure damage is not present. If damage or debris is found, replace quantity

14.3 INSPECTION OF THE QUANTITY CONTROL VALVE AND HIGH PRESSURE PUMP HOUSING
control valve. If no trouble is found with the valve immediately reinstall. Refer to section
14.4.

14.4 INSTALLATION OF QUANTITY CONTROL VALVE
Install as follows:
1. Lubricate the O-ring seal on the new quantity control valve with clean diesel fuel.
2. Install new quantity control valve; torque three attaching bolts to 8 N·m (6 lb·ft).
3. Connect electrical connector for quantity control valve.
4. Install bracket from high pressure fuel pump to block. Torque to 30 N·m (22 lb·ft) on
pump side; 100 N·m (74 lb·ft) on block side.
NOTE:
Verify that there are no plastic line plugs on the high pressure flange before installing it
onto the fuel pump.
5. Install new gasket; torque high pressure manifold bolts on high pressure fuel pump to
30 N·m (22 lb·ft).
6. Install needle return line to high pressure manifold; torque to 25 N·m (18 lb·ft).
7. Install doser supply line to high pressure manifold; torque to 25 N·m (18 lb·ft).

9. Reset the quantity control valve adaptive values. Refer to section 14.5.

14.5 EPA07 RESETTING QUANTITY CONTROL VALVE ADAPTIVE VALUES
This procedure will allow a technician to retrieve and clear the Quantity Control Valve adaptive
values. The stored values should be reset ONLY when a Quantity Control Valve replacement has
occurred.
Reset as follows:
1. Install and connect DDDL 7.X.
2. Click on the Actions menu located at the top of the screen.

3. Select Fuel System and then Replace Quantity Control Valve.
4. The dialog box that appears shows the current quantity control valve adaptive values,
and the ability to reset the values.
NOTE:
Only reset the values if the quantity control valve is being replaced.
5. The dialog box that appears shows the current quantity control valve adaptive values,
and the ability to reset the values.
NOTE:
6. Click the button “Reset Learned Data” to clear the counter.

This procedure will allow a technician to retrieve and clear the Quantity Control Valve adaptive
values. The stored values should be reset ONLY when a Quantity Control Valve replacement has
occurred.
Reset as follows:
2. Click on the “Service Routines work window.”
3. Select the “FIS Fuel Quantity Control Valve” tab.

4. The screen will open to the FMU Stick Test. Select the FMU Adaptation tab located at
the bottom of the screen.
NOTE:
5. Press the “Reset” button to clear the Quantity Control Valve adaptation values after the
Quantity Control Valve has been replaced.


15 HIGH PRESSURE FUEL INJECTOR LINES
Section Page

INJECTOR LINES .................................................................................... 15- 3
15.2 REMOVAL OF HIGH PRESSURE FUEL INJECTOR LINES ................... 15- 4
15.3 INSTALLATION OF HIGH PRESSURE FUEL INJECTOR LINES ........... 15- 6

INJECTOR LINES
The high pressure fuel pump pressurizes the fuel and sends it to the two high pressure lines
and then to the fuel rail. The fuel then goes from the rail through the individual high pressure
lines to each fuel injector.
1. High Pressure Pump 4. Fuel Rail

2. Low Pressure Pump 5. High Pressure Fuel Lines from Pump to Rail
3. High Pressure Fuel Lines from Rail to Fuel Injector .
Figure 15-1 High Pressure Fuel Injector Lines

15.2 REMOVAL OF HIGH PRESSURE FUEL INJECTOR LINES
15.2 REMOVAL OF HIGH PRESSURE FUEL INJECTOR LINES
Remove as follows:
NOTICE:
If removing high pressure fuel line at fuel injector number one,
remove the Intake Manifold Temperature Sensor.
NOTICE:
If removing high pressure fuel line at fuel injector number six,
remove the Pressure Limiting Valve return line banjo bolt and
the rear high pressure pump feed line P-clip.
1. Loosen two bolts (1) from the camframe housing to fuel injector seal.

2. Loosen the fuel line nut (1) at the fuel rail.
3. Loosen the fuel injector feed line nut (1) at the camframe housing.

15.3 INSTALLATION OF HIGH PRESSURE FUEL INJECTOR LINES
Install as follows:
1. Using tool J-48770, install the fuel injector feed line nut to the camframe housing. Torque
to 40 N·m (30 lb·ft).
2. Install the fuel line nut to the fuel rail. Torque to 40 N·m (30 lb·ft).

3. Install two bolts to the camframe housing to fuel injector seal. Torque to 15 N·m (11 lb·ft).


16 HIGH PRESSURE FUEL RAIL FEED LINES
Section Page
16.1 REMOVAL OF HIGH PRESSURE FUEL RAIL FEED LINES .................. 16- 3
16.2 INSPECTION OF HIGH PRESSURE FUEL RAIL FEED LINES ............. 16- 4
16.3 INSTALLATION OF HIGH PRESSURE FUEL RAIL FEED LINES .......... 16- 5
16.1 REMOVAL OF HIGH PRESSURE FUEL RAIL FEED LINES
Remove as follows:
PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles
when conducting a pressure test.
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. Disconnect batteries.
2. Remove the fuel line retaining bracket by removing the two bolts.
3. Remove the three P-clips that retain the fuel lines to the bracket.
4. Using tool J-48770, remove the front high pressure pump line at the fuel rail and fuel pump.
5. Using tool J-48770, remove the rear high pressure pump line at the fuel rail and fuel pump.
6. Clean the line using compressed solvent and compressed shop air.

16.2 INSPECTION OF HIGH PRESSURE FUEL RAIL FEED LINES
16.2 INSPECTION OF HIGH PRESSURE FUEL RAIL FEED LINES
Inspect as follows:
1. Inspect and verify that dampeners are in their proper location.
2. Inspect the lines for cracks, kinks, or any other sign of damage. Replace as necessary.
3. Inspect sealing area of nipple for damage.

16.3 INSTALLATION OF HIGH PRESSURE FUEL RAIL FEED LINES
Install as follows:
1. Install the rear high pressure fuel line to the fuel rail and the high pressure fuel pump.
Hand tighten the nuts.
2. Using tool J-48770, torque to 40 N·m (30 lb·ft).
3. Install the front high pressure fuel line to the fuel rail and the high pressure fuel pump.
Hand tighten the nuts.
4. Using tool J-48770, torque to 40 N·m (30 lb·ft).
5. Install the fuel line retaining bracket. Torque to 10 N·m (8 lb·ft).
6. Install three P-clips that retain the fuel lines to the bracket. Torque to 10 N·m (8 lb·ft).
7. If new high pressure feed lines are being installed, transfer the dampeners.
9. Perform the Rail Pressure Bleed Off Test to verify that there are no leaks. Refer to section .
10. If there are leaks, find the leak and repair, as necessary.

16.3 INSTALLATION OF HIGH PRESSURE FUEL RAIL FEED LINES

17 FUEL RAIL
Section Page

PARTS ...................................................................................................... 17- 3
17.2 REMOVAL OF THE FUEL RAIL ............................................................... 17- 4
17.3 INSPECTION OF THE FUEL RAIL .......................................................... 17- 5
17.4 INSTALLATION OF THE FUEL RAIL ....................................................... 17- 6

PARTS
The fuel rail incorporates the fuel rail pressure sensor and pressure limiting valve. The fuel rail
attaches to the side of the camshaft housing with brackets.
17.1.1 Fuel Rail Pressure Sensor
The fuel rail pressure sensor uses a sensor element and a hybrid element. As pressure increases
the sensor membrane will distort. There are four pressure-dependent resistances (strain measuring
resistors) on the sensor membrane. Its bridge circuit is supplied with voltage by an electronic
analysis system which also serves for signal amplification and signal correction. The electronic
analysis system itself is supplied a 5 V DC voltage by the MCM. The resistors in the sensor
membrane are arranged in a way that when deforming the sensor membrane two resistors will
contract and two resistors will expand. Contracting and expanding changes the electrical
resistance and in turn has effects upon the measurement voltage, which is being applied to the
electronic analysis system. The electronic analysis system amplifies the measurement voltage,
compensating for possible temperature fluctuations or balancing out possible manufacturing
tolerances and passes the cleaned measurement voltage to MCM.
1. Fuel Rail Pressure Sensor 3. Fuel Injector

2. Fuel Rail 4. Pressure Limiting Valve
Figure 17-1 Fuel Rail

17.2 REMOVAL OF THE FUEL RAIL
17.2 REMOVAL OF THE FUEL RAIL
Remove as follows:
3. Disconnect the fuel rail pressure sensor connector.
NOTE:
When removing the fuel rail feed tubes, cover the ends to ensure debris does not enter
the tubes.
4. Remove fuel injector feed tubes with tool J-48770. Refer to section 15.2.
PERSONAL INJURY
5. Remove high pressure fuel lines from the high pressure pump and fuel rail. Refer to section
16.1.
6. Remove pressure limiting valve (PLV) line from fuel rail. Refer to section 10.2.
7. Remove bolts and clamps connecting the fuel rail to the camshaft housing and remove
fuel rail.

17.3 INSPECTION OF THE FUEL RAIL
Inspect as follows:
1. Inspect the bolts for damage and wear; replace as necessary.
2. Inspect the fuel rail for damage and wear; replace as necessary.
3. Inspect the fuel feed tubes for damage and wear; replace as necessary.
4. Inspect the rocker arm frame sealing for damage; replace as necessary.

17.4 INSTALLATION OF THE FUEL RAIL
17.4 INSTALLATION OF THE FUEL RAIL
Install as follows:
1. Install fuel rail to camshaft frame with three clamps and six bolts; hand-tighten bolts.
2. Using tool J-48770, install fuel injector feed tubes to fuel rail and the injectors;
hand-tighten fuel injector feed tubes.
3. Install high pressure fuel lines to the fuel rail and high pressure pump with tool J-48770
and hand-tighten.
4. Install pressure limiting valve fuel return line to the fuel filter module and fuel rail with
tool J-48770 and hand-tighten.
5. Torque the following in this sequence:
[a] fuel rail clamp bolts to 10 N·m (7 lb·ft).
[b] injector feed tubes to 40 N·m. (30 lb·ft).
[c] high pressure pump to rail lines to 40 N·m (30 lb·ft).
[d] pressure limiting valve banjo bolt to 35 N·m (26 lb·ft).
6. If removed, install fuel rail pressure sensor; torque to 65-70 N·m (48-52 lb·ft) and then
install connector.
7. If removed, install PLV and torque to 100 N·m (74 lb·ft).
8. Install bracket to the high pressure fuel lines.
9. Install the fuel line retaining bracket. Torque to 10 N·m (8 lb·ft).
10. Install three P-clips that retain the fuel lines to the bracket. Torque to 10 N·m (8 lb·ft).
11. Connect the batteries.
ENGINE EXHAUST
exhaust is toxic.

13. Start the engine and check for leaks.

18 PRESSURE LIMITING VALVE
Section Page
18.1 DESCRIPTION AND OPERATION OF THE PRESSURE LIMITING

VALVE ...................................................................................................... 18- 3
18.2 REMOVAL OF PRESSURE LIMITING VALVE ........................................ 18- 4
18.3 INSTALLATION OF PRESSURE LIMITING VALVE ................................. 18- 5
18.4 RESETTING THE PRESSURE LIMITING VALVE COUNTER ................ 18- 6
18.1 DESCRIPTION AND OPERATION OF THE PRESSURE LIMITING VALVE
The pressure limiting valve is a safety element which limits the maximum rail pressure in the
injection system to about 1280-1380 bar. If the current rail pressure exceeds the maximum rail
pressure of about 1280-1380 bar, the push spring is pressed together by the pressure plate. A
connection is opened at the same time to the cutoff bore, and the excess fuel flows into the return.
1. Fuel Rail Pressure Sensor 3. Fuel Injector

2. Fuel Rail 4. Pressure Limiting Valve
Figure 18-1 Pressure Limiting Valve

18.2 REMOVAL OF PRESSURE LIMITING VALVE
18.2 REMOVAL OF PRESSURE LIMITING VALVE
Remove as follows:
PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles
when conducting a pressure test.
PERSONAL INJURY
1. Place a small container below the pressure limiting valve to catch escaping fuel.
2. Clean the pressure limiting valve and surrounding area.
3. Remove the pressure limiting valve from the rear end of the fuel rail.

18.3 INSTALLATION OF PRESSURE LIMITING VALVE
Install or replace as follows:

1. Lubricate the threads and O-ring of the pressure limiting valve with clean fuel.
2. Install the pressure limiting valve and torque to 95-105 N·m (70-77 lb·ft).
4. Reset pressure limiting valve counter using DDDL 7.X. Refer to section 18.4.
5. Start the engine. Check for leaks.
6. To reset the pressure limiting valve counter, refer to section 18.4.

18.4 RESETTING THE PRESSURE LIMITING VALVE COUNTER
18.4 RESETTING THE PRESSURE LIMITING VALVE COUNTER
This procedure will allow a technician to retrieve and clear the Pressure Limiting Valve (PLV)
counter. The PLV counter should be reset ONLY during a PLV replacement. If the PLV counter
has reached a value of 50 or greater, the PLV should be replaced and the counter reset.
2. Click on the “Actions” menu located at the top of the screen.
3. Select “Fuel System” and then “Pressure Limiting Valve (PLV) Change.”
4. The dialog box that appears shows the current Pressure Limiting Valve counter, and the
ability to reset the counter.
NOTE:
Only reset the counter if the PLV is being replaced.
5. Click the button “Reset Learned Data” to clear the counter.

19 FUEL INJECTOR WIRING HARNESS
Section Page

WIRING HARNESS ................................................................................. 19- 3
19.2 REMOVAL OF TWO-PIECE FUEL INJECTOR WIRING HARNESS ....... 19- 4
19.3 INSPECTION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS .. 19- 5
19.4 INSTALLATION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS 19- 6
WIRING HARNESS ................................................................................. 19- 7
19.6 REMOVAL OF ONE-PIECE FUEL INJECTOR WIRING HARNESS ....... 19- 8
19.7 INSPECTION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS ... 19- 9
19.8 INSTALLATION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS 19-10

WIRING HARNESS
One 14-pin fuel injector harness connectors act as the interface between the six fuel injectors, two
engine brake solenoids, and the 120-pin MCM connector. The rocker cover bolts maintain torque
and sealing integrity on the rocker cover seal.
1. Camshaft Housing 4. O-ring (2 qty.)

2. Engine Brake Solenoid Wiring Terminals (4 qty.) 5. 14-Pin Injector Harness
3. Engine Brake Solenoid (2 qty.) 6. Wiring Terminals to Injectors (24 qty.)
7. Bolt
Figure 19-1 Two-Piece Fuel Injector Wiring Harness

19.2 REMOVAL OF TWO-PIECE FUEL INJECTOR WIRING HARNESS
19.2 REMOVAL OF TWO-PIECE FUEL INJECTOR WIRING HARNESS
Remove as follows:
1. Disconnect batteries. Refer to proper OEM procedures.
2. Remove rocker cover.
3. Disconnect 14-pin injector harness connectors.
4. Disconnect electrical contacts at the injectors.
5. Disconnect two wiring terminals going to the appropriate engine brake solenoid.
6. Remove the bolts attaching the fuel injector wiring harness to the camframe housing.
7. Remove spring clips holding the appropriate injector harness connector to camshaft frame.
8. Remove injector wiring harness.

19.3 INSPECTION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS
Inspect and clean as follows:

1. Clean the injector harness in clean fuel oil.
EYE INJURY
To avoid injury from flying debris when using compressed
air, wear adequate eye protection (face shield or safety
goggles) and do not exceed 276 kPa (40 psi) air pressure.
2. Blow dry with compressed air.

3. Check the injector harness for damage. Replace as necessary.

19.4 INSTALLATION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS
19.4 INSTALLATION OF TWO-PIECE FUEL INJECTOR WIRING HARNESS
Install as follows:
1. Install injector harness and tighten the Allen head mounting screws to 10 N·m (7 lb·ft).
2. Install electrical contacts to injector and tighten to 1.5 N·m (1 lb·ft).
3. Connect engine brake solenoid terminals and torque to 1.5 N·m (1 lb·ft).
4. Install spring clips holding injector harness connector to camshaft frame.
5. Connect 14-pin injector harness connectors.
6. Install rocker cover.
7. Connect batteries. Refer to OEM procedures.


WIRING HARNESS
The one-piece fuel injector wiring harness connectors act as the interface between the six fuel
injectors, two engine brake solenoids and the 120-pin MCM connector. The one-piece fuel
injector wiring harness is made of a plastic material with an elastomer seal. The harness is located
between the rocker cover and the camshaft housing. The rocker cover bolts maintain torque and
sealing integrity on the rocker cover seal and intermediate cam housing seal.
1. Camshaft Housing 5. One-Piece Fuel Injector Wiring Harness

2. Elastomer Seal 6. Wiring Terminals to Engine Brake Solenoids (4 qty.)
3. Engine Brake Solenoid (2 qty.) 7. Wiring Terminals to Injectors (24 qty.)
4. Injector (6 qty.) 8 14-Pin Injector Harness Connectors
Figure 19-2 Two Piece Fuel Injector Wiring Harness

19.6 REMOVAL OF ONE-PIECE FUEL INJECTOR WIRING HARNESS
19.6 REMOVAL OF ONE-PIECE FUEL INJECTOR WIRING HARNESS
Remove as follows:
3. Remove the rocker cover. Refer to section .
4. Disconnect both 14-pin injector harness connectors.
5. Disconnect the 24 electrical terminals at the fuel injectors.
6. Disconnect two wiring terminals at each engine brake solenoid.
7. Loosen the Allen screws holding the one-piece fuel injector wiring harness to the camshaft
housing. Remove the wiring harness.

19.7 INSPECTION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS
Inspect and clean as follows:

1. Clean one-piece fuel injector wiring harness in clean fuel oil.
EYE INJURY
goggles) and do not exceed 276 kPa (40 psi) air pressure.
2. Blow dry with compressed air.

3. Check the one-piece fuel injector wiring harness and seal for damage. Replace as
necessary.

19.8 INSTALLATION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS
19.8 INSTALLATION OF ONE-PIECE FUEL INJECTOR WIRING HARNESS
Install as follows:
1. Install seal into groove in one-piece fuel injector wiring harness.
2. Install one-piece fuel injector wiring harness on camshaft housing. Torque Allen bolts
to 10 N·m (7 lb·ft).
3. Install electrical terminals to injectors and torque to 1.5 N·m (1 lb·ft).
4. Connect engine brake solenoid terminals and torque to 1.5 N·m (1 lb·ft).
5. Install the rocker cover. Refer to section .
6. Connect both 14-pin injector harness connectors.
ENGINE EXHAUST
exhaust is toxic.
7. Connect the batteries.

8. Start the engine and check for leaks.

20 FUEL INJECTORS
Section Page
20.1 FUEL INJECTION WITH AMPLIFICATION .............................................. 20- 3

20.2 FUEL INJECTION WITHOUT AMPLIFICATION ...................................... 20- 5
20.3 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR ............... 20- 6
20.4 REMOVAL OF THE FUEL INJECTOR ..................................................... 20-10
20.5 INSTALLATION OF THE FUEL INJECTOR ............................................. 20-14
20.6 EPA07 THRESHOLD RESETTING AND LEARNING .............................. 20-18
20.1 FUEL INJECTION WITH AMPLIFICATION
Use of an amplifier within an fuel injector offers the following advantages:

□ The leak oil losses in the high pressure area are reduced.
□ The pressure load of the high pressure pump, the fuel rail, and the high pressure lines is
reduced since only a few components have high pressure applied to them.
□ During injection with amplification the injection process is determined by actuation of
the needle solenoid valve (6) and the amplifier solenoid valve either at other times or
simultaneously.
Actuation of the amplifier solenoid valve before actuation of the needle solenoid valve (Square)
The amplifier solenoid valve is actuated before the needle solenoid valve. The rail pressure
applied below the amplifier is routed to the fuel injector return passage inside the fuel injector.
This difference in pressure allows the amplifier to move. The fuel within the amplifier circuit is
compressed by the amplifier piston up to a higher fuel pressure level (red). If the MCM actuates
the needle solenoid valve the fuel pressure in the control compartment above the fuel injector
needle is allowed to escape through the fuel injector needle return. The fuel injector needle is then
lifted due to the rail pressure being greater that the needle spring pressure.
The fuel is injected with the fuel pressure increased by the amplifier into the respective cylinder.
The level of the fuel pressure is dependent on the point in time of the initial actuation of the
amplifier control module. If the MCM deactivates the amplifier control module, the pressure in the
control compartment under the amplifier builds up and the amplifier returns to its starting position.
If the MCM deactivates the needle solenoid valve, the pressure in the control compartment above
the fuel injector needle builds up again. The fuel injector needle is returned to its seat with the aid
of the spring and fuel system pressure. At this point the injection process stops.
Actuation of the amplifier solenoid valve parallel to actuation of the needle solenoid valve
(Ramp)
The amplifier solenoid valve and the needle solenoid valve are actuated at the same time by
the MCM. The rail pressure applied below the amplifier is routed to the fuel injector return
passage inside the fuel injector. This difference in pressure allows the amplifier to move. The
fuel injector needle is lifted first by the rail pressure. Next, the fuel within the amplifier circuit
is compressed by the amplifier piston up to a higher fuel pressure level (red). Thus, during the
complete injection phase the fuel pressure increases. If the MCM deactivates the amplifier control
module, the pressure in the control compartment under the amplifier builds up and the amplifier
returns to its starting position. The amplifier goes back into its starting position. If the MCM
deactivates the needle solenoid valve, the pressure in the control compartment above the fuel
injector needle builds up again. The fuel injector needle is pressed onto its seat with the aid
of the spring and the injection process stops.
Actuation of the amplifier solenoid valve after actuation of the needle solenoid valve (Boot)
The MCM actuates the needle solenoid valve to allow the fuel pressure in the control compartment
above the fuel injector needle to escape through the fuel injector needle return. The fuel injector
needle is then lifted due to the rail pressure being greater than the needle spring pressure. The fuel
is then injected at the prescribed rail pressure.

20.1 FUEL INJECTION WITH AMPLIFICATION
After the beginning injection, the rail pressure applied below the amplifier is routed to the fuel
injector return passage inside the fuel injector. The fuel within the amplifier circuit is compressed
by the amplifier piston up to a higher fuel pressure level (red). If the MCM deactivates the
amplifier solenoid valve, the pressure in the control compartment under the amplifier builds up
and the amplifier returns to its starting position. If the MCM deactivates the needle solenoid valve,
the pressure in the control compartment above the fuel injector needle builds up again. The fuel
injector needle is pressed onto its seat with the aid of the spring and the injection process stops.
1. Amplifier Solenoid Valve 5. Check Valve

2. Return Spring 6. Needle Solenoid Valve
3. High Pressure Feed 7. Spring
4. Amplifier Piston 8. Fuel injector Needle
Figure 20-1 Fuel Injection with Amplification

20.2 FUEL INJECTION WITHOUT AMPLIFICATION
The amplifier solenoid valve is not actuated during this process. The fuel internal to the fuel
injector is at rail pressure above and below the amplifier piston.
The compressed fuel from the rail enters the fuel injector needle through the center of the amplifier
and through the check valve at the bottom of the amplifier. If the MCM actuates the needle
solenoid valve then the fuel pressure in the control compartment above the fuel injector needle is
allowed to escape through the fuel injector needle return. The fuel injector needle is then lifted
due to the rail pressure being greater than the needle spring pressure combined with the reduction
of pressure in the control department. The fuel is injected at the specified rail pressure into the
respective cylinder. If the MCM deactivates the needle solenoid valve, the pressure in the control
compartment above the fuel injector needle builds up again. The fuel injector needle is returned to
its seat with the aid of the spring and fuel system pressure. At this point the injection process stops.
1. Amplifier Solenoid Valve 5. Check Valve

2. Return Spring 6. Needle Solenoid Valve
3. High Pressure Feed 7. Spring
4. Amplifier Piston 8. Fuel injector Needle
Figure 20-2 Fuel Injection without Amplification

20.3 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR
The fuel injectors are fixed by means of a hold down clamp inside the camshaft housing and
located centrally between the valves of the respective cylinder. All injectors have a 6-digit code,
the fuel injector quantity compensation coding, which is located on the upper side of the fuel
injector. This code describes the quantity characterization of the respective fuel injector. If an
fuel injector is replaced then this code must be reported to the Motor Control Module (MCM2)
using DDDL 7.X.
The injectors have the task of injecting the fuel under high pressure into the cylinders. The
injection timing, injection period, and the injection variants (e.g. with or without amplification)
are established by the MCM.
The injectors are fitted with an amplifier circuit. This allows for two modes of injection: without
amplification and with amplification.

In the case of injection without amplification the injection pressure is determined by the rail
pressure (about 900 bar).
1. Electrical Connector 6. Spring

2. Amplifier Solenoid Valve 7. Fuel Injector Needle
3. High Pressure Feed 8. Amplification Chamber
4. Amplifier Piston 9. Return Spring
5. Needle Solenoid Valve
Figure 20-3 Fuel Injector

In the case of injection with amplification the injection pressure of up to 2100 bar is generated in
the fuel injector.
Use of an amplifier within an fuel injector offers the following advantages:

□ The leak oil losses in the high pressure area are reduced.

□ The pressure load of the high pressure pump, the fuel rail, and the high pressure lines is
reduced since only a few components have high pressure applied to them.
A. (Square) Actuation of the amplifier solenoid valve before actuation of the needle solenoid valve
B. (Ramp) Actuation of the amplifier solenoid valve parallel to actuation of the needle solenoid valve
C. (Boot) Actuation of the amplifier solenoid valve after actuation of the needle solenoid valve
(p). Injection pressure
(t). Time
□ During injection with amplification the injection process is determined by actuation

of the needle solenoid valve and the amplifier solenoid valve either at other times or
simultaneously.

20.4 REMOVAL OF THE FUEL INJECTOR
Remove as follows:
PERSONAL INJURY
1. Shut off engine and apply the parking brake, chock the wheels, disconnect vehicle battery
power, and perform any other applicable safety steps.
3. Remove the rocker cover. Refer to section .

goggles) and do not exceed 40 psi (276 kPa) air pressure.
4. Disconnect 14-pin fuel injector harness connector from the camframe housing.
5. Disconnect the fuel injector electrical wiring harness from the fuel injectors.
Refer to section 19.2.
6. Remove spring clip holding the fuel injector electrical wiring harness connector to the
camshaft frame. Remove the fuel injector electrical wiring harness.

PERSONAL INJURY
7. Loosen the bolts in the camframe housing to the fuel injector feed line seal.
8. Remove high pressure fuel injector feed lines. Refer to section 15.2.

9. Remove the fuel injector hold down bolt (1). Discard bolt.
10. Using tool J-47391 (1), lift the fuel injector clamp and fuel injector (2) from its seat in
the cylinder head.
11. Remove clamps from fuel injector and install a tip protector onto the fuel injector nozzle.

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 bolt and the fuel
injector copper washer are considered one-use items and cannot
be reused. Any time an fuel injector is removed, the fuel injector
bolt, three fuel injector O-ring seals and copper washer must
be replaced with new parts. Failure to replace the O-ring seals
copper washer 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 three fuel injector
O-rings and the copper washer.

20.5 INSTALLATION OF THE FUEL INJECTOR
Install as follows:
NOTE:
Ensure excess fuel is removed from the top of the piston dome before fuel injector
installation.
1. If the fuel system is contaminated:

[a] Drain the fuel tanks and refill with clean fuel.
[b] Clean the fuel water/separator and replace the fuel filters.
2. If the coolant system is contaminated with fuel, flush and reverse flush the system.
3. If the oil system is contaminated, change the engine oil and filters.
NOTICE:
The fuel injector tube bore should be cleaned and inspected
for damage or leakage of coolant before installation of the fuel
injector.
4. Check to make sure the fuel injector tube bore is thoroughly clean.
5. If new injectors are being used, write down the fuel injector's calibration code and note the
cylinder location where it will be installed.

6. Remove fuel injector nozzle tip protector.
NOTICE:
The copper washer must be installed with recess (1) facing
fuel injector body. Incorrect installation can cause combustion
gasses to enter the fuel system.
7. Install a new copper washer with recess facing UP (1) toward the fuel injector and the
flat side of the washer facing DOWN (2).
8. Using J-48837 (fuel injector O-ring installer), apply a thin coat of acid free grease or clean
engine oil to the fuel injector seal rings and then install them in the fuel injector nut ring
grooves. Make sure they are properly seated.
9. 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.
NOTE:
If the high pressure lines leak after installation, the lines need to be replaced.
10. Install high pressure line to the injectors and fuel rail; finger tighten the cap nuts.
11. Torque the fuel injector hold-down bolt to 20 N·m (15 lb·ft) + 90 degrees.
12. Using J-48770, torque the high pressure lines to the fuel injector to 40 N·m (29 lb·ft).

13. Torque bolts securing fuel injector feed line seal (1) to 15 N·m (11 lb·ft).
14. Insert the 14–pin connector of the fuel injector harness into the hole in the cam frame and
install electrical connections and Allen head hold-down bolts before torquing.
15. Install the spring clip onto the 14–pin connector.
16. Torque all of the fuel injector connections to 1.5 N·m (12 lb·in.).
17. Torque all of the Allen head fuel injector harness hold-down bolts to 10 N·m (7 lb·ft).
18. Input the fuel injector calibration codes that were recorded earlier into DDDL using the
service routine.

19. Install rocker cover. Refer to section .

20. Connect batteries. Verify repair.
21. If more than one fuel injector was changed, reset the leak detection threshold for the high
pressure fuel system. Refer to section 20.6.

20.6 EPA07 THRESHOLD RESETTING AND LEARNING
When more than one fuel injector or a high pressure pump is replaced, a relearn of the threshold
must occur.
Reset the threshold as follows:
1. Turn ignition ON (key ON, engine OFF).
2. While in the “Leak Detection” screen, click the “Reset Learned Data” button.
NOTE:
This will clear the “HP Learned Leak Value” and “HP Learned Leak Counter.”
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
□ Always start and operate an engine in a well ventilated
area.
□ If operating an engine in an enclosed area, vent the
exhaust to the outside.
□ Do not modify or tamper with the exhaust system or
emission control system.
3. Start engine and monitor “Coolant Temperature” and “Fuel Temperature.” Both dialog
boxes will turn green when temperature conditions are met.
[a] Coolant temperature must be between 70°C (158°F) and 100°C (212°F).
[b] Fuel temperature must be between 35°C (95°F) and 89°C (192°F).
4. When temperature entry conditions are met, increase engine speed above idle using the
throttle pedal for a minimum of five minutes. Ensure the “Engine State” parameter in the

screen indicates “Torque Demand.” You can use the free running timer located at the
bottom right of the screen to monitor the time above idle.
5. When the five minute time is reached, decrease engine speed to idle.
NOTE:
Do not allow the engine to stay at idle for more than five minutes or the test will need to
be repeated.
6. Turn ignition OFF (key OFF, engine OFF).

7. Allow system to bleed down for approximately 10 seconds.
8. Turn ignition ON (key ON, engine OFF).
9. Reconnect to the MCM and CPC.
10. Read the value for “HP Leak Actual Value.”
[a] If the value is between 0.500 and 1.800, the system leakage is acceptable.
[b] If the value is less than 0.500 or greater than 1.800, the system leakage is unacceptable
and should be checked.

11. At this point “HP Learned Leak Counter” or “HP Leak Counter” should increase by
one (1).
[a] If the “HP Learned Leak Counter” did not increase but the “HP Leak Counter” did,
the leakage in the system is above the threshold. Repair the system and rerun the test.
[b] If the “HP Learned Leak Counter” and the “HP Leak Counter” did not increment,
entry conditions were not met. Go to step 3.
[c] If the “HP Learned Leak Counter” did increase, complete the relearn process one
more time. If the second learn test also passes, release the truck to the customer. The
remaining eight “learns” will be completed on the road. Go to step 3.


FUEL FROM COOLER AFTER FUEL INJECTORS FAILURE
Inspect as follows:
1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube

2. Hose 11. Banjo Bolt 20. Gasket
3. Coolant Crossover Pipe 12. Bolt 21. Bolt
4. Bolt 13. Bolt 22. Venturi
5. Support 14. Outlet Nipple 23. Mixer Pipe
6. Coolant Connecting Tube 15. Seal 24. Seal Ring

7. Exhaust Gas Connecting Tube 16. Exhaust Gas Recirculation 25. Bolt
Cooler Water Manifold Assembly
8. Gasket 17. Clamps 26. Lifting Bracket Mounting Bolt
9. Seal Ring 18. Hot Pipe 27. Front Lifting Bracket
Figure 20-4 EPA10 DD13 EGR Cooler Water Manifold and Related Parts

20.7 DD13 EGR COOLER CLEANING PROCEDURE TO REMOVE EXCESS FUEL FROM COOLER AFTER
FUEL INJECTORS FAILURE
1. Clamp 10. Banjo Union 19. Exhaust Gas Crossover Tube /

Lifting Eye
2. Hose 11. Banjo Bolt 20. Gasket
3. Coolant Crossover Pipe 12. Bolt 21. Bolt
4. Bolt 13. Bolt 22. Venturi
5. Support 14. Outlet Nipple 23. Mixer Pipe
6. Coolant Connecting Tube 15. Seal 24. Seal Ring

7. Exhaust Gas Connecting Tube 16. Exhaust Gas Recirculation 25. Bolt
Cooler Water Manifold Assembly
8. Gasket 17. Clamps 26. Bolt
9. Seal Ring 18. Hot Pipe
Figure 20-5 EPA10 DD13 EGR Cooler Water Manifold and Related Parts

NOTICE:
This procedure must be followed after replacing a fuel injector
due to any failure that could cause high DOC temperature
codes, excessive fuel, oil, or coolant to enter the exhaust
system. Failure to perform this procedure could cause severe
engine damage.
Check as follows:
1. Remove the marmon clamps (2) and EGR hot pipe (3) and inspect for any signs of liquid
or moisture. The EGR hot pipe (exhaust pipe) and EGR cooler inlet (1) should have
a black dry soot residue inside.
[a] If liquid or moisture is present in the pipe, go to the next step.
[b] If there is no sign of liquid or moisture in the pipe or EGR cooler (1), install the
hot pipe. No further action is required.

2. Remove the mixer pipe (1) from the cold boost pipe (2).
3. Remove the exhaust gas crossover tube (2) and venturi (6).
4. Place a towel over the outlet of the EGR cooler and retain it with a zip tie.


5. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in
the EGR cooler to clear any excess fuel, soot, and carbon.
6. After performing the cleaning procedure, refer to section to install the:
[a] Mixer pipe.
[b] Exhaust gas crossover tube/lifting eye (EPA07 engines) and exhaust gas crossover
tube (EPA10 engines).
[c] Venturi.
7. If the cooler has an excessive amount of buildup that cannot be removed, replace the
EGR cooler. Refer to section .
This procedure must be followed after replacing a fuel injector due to any failure that could cause
excessive fuel, oil, or coolant to enter the exhaust system. Failure to perform this procedure
could cause severe engine damage.
Check as follows:
1. Remove the EGR cooler exhaust pipe and inspect for any signs of liquid or moisture. The
hot EGR pipe should have a black dry soot residue inside.
[b] If there is no sign of liquid or moisture in the pipe, install the EGR cooler hot pipe.
No further action is required.
2. Remove the EGR mixer pipe from the cold boost pipe.
3. Remove the exhaust gas crossover tube/lifting eye and venturi.
5. Using a rubber tipped blow gun, blow compressed shop air into the individual tubes in
EGR cooler.


FUEL FROM COOLER AFTER FUEL INJECTORS FAILURE
Inspect as follows:
1. Venturi 9. Connecting Tube 17. Metal Seal

2. Bolt 10.Seal Ring 18. Hot Pipe
3. Gasket 11. Banjo Union 19. Water Manifold
4. Bolt 12. Banjo Bolt 20. Support
5. Exhaust Gas Crossover Tube 13. Exhaust Gas Cooler 21. Clamp
6. Bolt 14. Strap 22. Hose
7. Lifting Bracket 15. Shim 23. Mixer Pipe

8. Connecting Tube 16. Clamp 24. Coolant Delivery Pipe
25. Seal Ring
Figure 20-6 EPA10 DD15 EGR Cooler and Related Parts

1. Venturi 9. Banjo Union 17. Water Manifold

2. Bolt 10. Banjo Bolt 18. Support
3. Gasket 11. Exhaust Gas Cooler 19. Clamp
4. Bolt 12. Strap 20. Hose
5. Exhaust Gas Crossover Tube/Lifting 13. Shim 21. Mixer Pipe
Eye
6. Connecting Tube 14. Clamp 22. Coolant Delivery Pipe
7. Connecting Tube 15. Metal Seal 23. Seal Ring
8. Seal Ring 16. Hot Pipe
Figure 20-7 EPA07 DD15 EGR Cooler and Related Parts

NOTICE:
This procedure must be followed after replacing a fuel injector
due to any failure that could cause high DOC temperature
codes, excessive fuel, oil, or coolant to enter the exhaust
system. Failure to perform this procedure could cause severe
engine damage.
1. Remove the clamps (2), exhaust pipe (4) and gaskets (3) from the EGR cooler (1) and
inspect and inspect for any signs of liquid or moisture. The EGR hot pipe and EGR cooler
inlet should have a black dry soot residue inside.
[b] If there is no sign of liquid or moisture in the pipe, install the EGR cooler hot pipe.
No further action is required. Refer to section .
2. Remove the mixer pipe (4) from the cold boost pipe (1). Refer to section .

3. Remove the exhaust gas crossover tube/lifting eye (2) and venturi (3).

5. Using a rubber tipped blow gun blow compressed shop air into the individual tubes in
6. After performing the cleaning procedure, refer to section to install the:
[a] Mixer pipe.
[b] Exhaust gas crossover tube/lifting eye (EPA07 engines) and exhaust gas crossover
tube (EPA10 engines).
[c] Venturi.
EGR cooler. Refer to section .


21 FUEL INJECTOR CUP
Section Page
21.1 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR CUP ...... 21- 3
21.2 REMOVAL OF FUEL INJECTOR CUP .................................................... 21- 4
21.3 INSTALLATION OF FUEL INJECTOR CUP ............................................ 21- 5
21.1 DESCRIPTION AND OPERATION OF THE FUEL INJECTOR CUP
The fuel injector cup prevents coolant from contaminating the fuel injector while maintaining
maximum cooling of the fuel injector. The fuel injector cup is a stainless steel tube screwed
into the cylinder head. There is an O-ring installed in the cylinder head to create a water and
fuel tight seal.
1. Cylinder Head 3. Fuel Injector Cup

2. O-ring 4. O-ring Sealing Location
Figure 21-1 Fuel Injector Cup and Related Parts

21.2 REMOVAL OF FUEL INJECTOR CUP
21.2 REMOVAL OF FUEL INJECTOR CUP
Remove as follows:
NOTICE
Take extra precautions when cleaning the fuel injector bores
to ensure that debris does not enter the fuel system. Do not
use power tools to clean the fuel injector bores. Do not use
compressed air to blowout debris in the bores.
NOTICE:
Engine coolant must be drained prior to fuel injector tube
removal.
1. Drain the engine coolant.

2. Remove fuel injector harness. Refer to section .
3. Remove the fuel injectors. Refer to section 20.4.
4. Install tool J-47388 into fuel injector cup and align tool with slots in tube and turn counter
clockwise to remove.
NOTE:
Tool J-47388 must be fully engaged with the fuel injector cup to prevent damage to
the tool and the cup.
5. Remove fuel injector cup; discard fuel injector cup O-ring in cylinder head.
6. Inspect the fuel injector cup for cracks or defects. If defective replace fuel injector cup.
7. Clean fuel injector cup threads with a fine wire brush, being careful not to abrade the
cylinder head to fuel injector cup sealing surface.
8. Clean the fuel injector cup interior sealing surface, a chemical solvent maybe used for
cleaning interior sealing surface.

21.3 INSTALLATION OF FUEL INJECTOR CUP
Install as follows:
1. Clean the fuel injector bore of debris.
NOTICE
Take extra precautions when cleaning the fuel injector bores to
ensure that debris does not enter the fuel system. Do not use
power tools to clean the fuel injector bores, use J–47375 hand
brush and a rag. Do not use compressed air to blowout debris
in the bores.
NOTE:
Replace fuel injector cup O-ring with a new O-ring when fuel injector cup is removed or
replaced.
2. Install O-ring in cylinder head, a small amount of silicone based O-ring lubrication will
aid in the installation.
3. Coat the threads of the fuel injector cup and cup sealing surface with a high temperature
nickel based anti-seize lubricant.
4. Install fuel injector cup onto tool J–47388 and install into cylinder head bore.
5. Torque fuel injector cup to 50 N·m (37 lb·ft).
6. Release torque approximately 180 degrees.
7. Torque fuel injector cup to 50 N·m (37 lb·ft). If cylinder head has been removed ensure
edge cup is flush with the fire deck.
8. Install fuel injector. Refer to section 20.5.
9. Install fuel injector harness. Refer to section .
10. Install rocker cover. Refer to section .
11. Fill and pressure test the cooling system; check for leaks.


DD Fuel System DDC SVC Man 0082

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EPA07/10 DD PLATFORM WORKSHOP MANUAL - FUEL

1 FUEL SYSTEM OVERVIEW

All information subject to change without notice.

9 LOW PRESSURE FUEL LINES

All information subject to change without notice.

15 HIGH PRESSURE FUEL INJECTOR LINES

All information subject to change without notice.

21 FUEL INJECTOR CUP

All information subject to change without notice.

1.1 FUEL SYSTEM OVERVIEW .................................................................... 1- 3

1.1 FUEL SYSTEM OVERVIEW

All information subject to change without notice.

Figure 1-1 Version 5 System (with MCM Heat Exchanger)

All information subject to change without notice.

Figure 1-2 Version 7 System (without MCM Heat Exchanger)

All information subject to change without notice.

All information subject to change without notice.

All information subject to change without notice.

1.2 AMPLIFIED PRESSURE COMMON RAIL SYSTEM

All information subject to change without notice.

1. MCM Heat Exchanger 13. Regulator

Figure 1-3 V5 Fuel System

All information subject to change without notice.

1. Water-in-Fuel Sensor 12. Pressure Limiting Valve

6. Water Separator 17. Low Pressure Fuel Pump

Figure 1-4 V7 Fuel System

All information subject to change without notice.

All information subject to change without notice.

2.2 AFTER FILTER CHANGE (USING J-47912 PRIMING CAN)

All information subject to change without notice.

2.3 AFTER FILTER CHANGE (USING HAND PRIMER ON MODULE)

9. Increase engine speed to 1800 rpm for three minutes.

All information subject to change without notice.

2.4 HIGH PRESSURE PUMP CHANGE OR COMPLETELY DRY SYSTEM

8. Repressurize priming canister to maximum pressure.

11. Close shutoff valve.

All information subject to change without notice.

17. Remove priming canister.

All information subject to change without notice.

2.5 PRIMING PORT PRESSURES

Priming port pressures are as follows:

Priming Port (J-48876) Pressures

All information subject to change without notice.

3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS ........ 3- 3

3.1 DRAINING FUEL SYSTEM USING J-48710 PRIOR TO REPAIRS

Drain system as follows:

All information subject to change without notice.

All information subject to change without notice.

4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE

4.1 DESCRIPTION AND OPERATION OF THE FUEL FILTER MODULE AND

Figure 4-1 Fuel Filter Module

All information subject to change without notice.

4.1.1 Fuel Hand Primer

4.1.2 Fuel Priming Valve

4.1.3 Supply Fuel Temperature Sensor

All information subject to change without notice.

4.2 REMOVAL OF FUEL FILTER MODULE

All information subject to change without notice.

4.3 DISASSEMBLY OF THE FUEL FILTER MODULE

All information subject to change without notice.

4.4 ASSEMBLY OF THE FUEL FILTER MODULE

3. Install filters and caps into fuel filter module

All information subject to change without notice.