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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

Fuel System 10.1 Fuel System Overview

10.1.1 Fuel System Schematic

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1. Frame mounted fuel filter water separator

2. Priming port

3. Shut-off valve

4. Pre-screen check ball

5. Fuel temperature sensor (in filter module)

6. Pre-screen filter

7. Pre-screen filter drain

8. Low Pressure Pump Outlet Pressure Sensor (LPPO)

9. Final fuel filter

10. Air vent check ball

11. Air bleed valve

12. Final fuel filter drain

13. High pressure flange throttle to doser block

14. Fuel cut-off valve

15. Fuel compensation pressure sensor

16. Electronic diesel dosing valve

17. Fuel doser line pressure sensor

18. Hydrocarbon fuel doser injector valve

19. Fuel Rail pressure sensor

20. Fuel injector

21. Fuel Rail

22. Pressure Control Valve (PCV)

23. Injector return regulator valve

24. High pressure fuel pump

25. Quantity Control Valve (QCV)

26. High pressure pump return

27. QCV regulator valve

28. Low pressure control valve

29. Low pressure limiting valve (16bar)

30. Low pressure fuel pump

31. Safety valve (0.2bar)

32. Fuel gallery

33. Shut-off valve

34. A. Fuel feed (suction side)

35. B. Low pressure side

36. C. High pressure side

37. D. Return fuel

38. E. Fuel drain (pre and final filter)

39. F. Air vent passage

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Fig 10.1, Fuel System Overview 10.1.2 Operation of the Fuel

Fig 10.1, Fuel System Overview

10.1.2 Operation of the Fuel System

The low pressure fuel pump is a gear pump that supplies fuel to the low pressure fuel 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 in the fuel filter module first passes into the fuel prefilter where debris particles greater than 100 microns are filtered out. A check ball, which is located at the fuel inlet of the fuel prefilter housing, 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 final filter. The final fuel filter filters out fine-grained contaminants greater than two microns.

Designed into the final filter element is a ventilation bore that allows trapped air to escape. For example, if air is trapped in the final filter element 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, 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 2400 bar (34,800 psi) and feeds it to the fuel rail. The fuel injectors are electronically actuated by the MCM and deliver a precise amount of fuel into each cylinder.

Low pressure fuel system

The low pressure fuel system consists of the following components:

• Fuel tank

• Fuel filter module in which fuel is cleaned in two stages

• Low pressure fuel pump delivers fuel from the fuel filter module to the high pressure fuel pump

• Low pressure supply lines deliver fuel from the fuel tank to the module

• Low pressure return lines return fuel from the filter module to the fuel tank

• Fuel temperature sensor

• Hydrocarbon (HC) fuel doser block

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• Hydrocarbon (HC) fuel doser injector valve

High pressure fuel system

The high pressure fuel system consists of the following components:

• Quantity control valve (QCV) delivers fuel to the high pressure fuel pump in precise quantities

• High pressure fuel pump compresses fuel up to 2400 bar (34,800 psi) and delivers it to the rail.

• Fuel Rail

• Pressure control valve (PCV) reduces the pressure in the fuel rail dependent on operating conditions of the engine.

• Rail pressure sensor

• High pressure fuel lines

• Fuel injectors

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10.2 Fuel System Draining Procedure

10.2.1 Draining the Fuel System Prior to Repairs

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. Remove the fuel tank fill caps to relieve pressure in the fuel tanks. Reinstall the fuel tank fill caps.

5. Using a 36mm 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.

6. Pull the cap and final filter (1) straight up and allow the fuel to drain back.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 7. After FIVE (5) minutes, the system will be drained

7. After FIVE (5) minutes, the system will be drained of fuel.

8. Install a new seal ring on to the final filter cap.

9. Install the final filter into the fuel filter module.

10. Torque the final filter cap to 25 to 30 N·m (19 to 22 lb·ft).

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10.3 Fuel System Priming

10.3.1 Priming the Fuel System

While servicing the fuel system, air can enter the system and will need to be purged. If the air in the system is not properly purged, a no-start condition, 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.

Detroit approved priming tools:

• DAVCO Shop Pro FXP 95

• DAVCO Shop Pro FXP

• ESOC® 350

• ESOC® 250E

Prime as follows:

1. Connect the Detroit® approved priming tool. Refer to the Original Equipment Manufacturer (OEM) instructions provided with the tool.

Note : If there is a need to stop the machine for any reason depress the STOP button.

2. Turn the priming tool ON.

3. Prime the fuel system for ONE (1) minute.

4. Turn the priming tool OFF and close the ball valve.

WARNING PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the

WARNING

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.

WARNINGPERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in

WARNING

ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well- ventilated area. Engine exhaust is toxic.

5. Start the engine and increase engine speed to 1500 rpm for ONE (1) minute.

6. Reduce engine speed and run at idle (600 rpm) for ONE (1) additional minute.

7. Disconnect the priming tool. Refer to OEM instructions.

Note : Starting difficulty may occur until a drive cycle has been completed to completely remove all remaining air from the fuel system.

8. Road test unit to purge all remaining air from the fuel system.

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10.4 Fuel Filters

10.4.1 Description and Operation of the Fuel Prefilter

Unfiltered fuel passes through the fuel inlet into the fuel prefilter. Fuel entering the prefilter pushes the prefilter check ball off its seat allowing flow through the prefilter element from inside to outside. The larger dirt particles (greater than 100m) remain in the prefilter element and the pre-filtered fuel flows through the fuel outlet to the low pressure pump. The prefilter check ball has the task of preventing fuel from draining out of the prefilter housing when the engine is stopped. When removing the prefilter element, a drain to the fuel accumulator is opened so the fuel can flow out of the fuel prefilter housing.

1. Pre-Filtered Fuel

2. Unfiltered Fuel

3. Prefilter Element

4. Check Ball

5. Fuel Inlet

1. Pre-Filtered Fuel 2. Unfiltered Fuel 3. Prefilter Element 4. Check Ball 5. Fuel Inlet

Fig 10.2, Fuel Prefilter

10.4.2 Removal of the Fuel Prefilter

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

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To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries. Refer to OEM procedures.

3. Open the hood.

4. Using a 36 mm socket, unscrew the prefilter cap.

5. Pull the cap and prefilter straight up and out of the fuel filter housing.

6. Remove the prefilter (1) from the prefilter cap (2) by placing the filter on a solid surface and applying pressure on prefilter cap (2) at an angle.

and applying pressure on prefilter cap (2) at an angle. 7. Discard the prefilter. 8. Inspect

7. Discard the prefilter.

8. Inspect inside the housing for any large debris; clean housing as needed.

9. Discard the prefilter cap seal ring.

10.4.3 Installation of the Fuel Prefilter

1. Install a new prefilter cap seal ring (1) on to the prefilter cap.

2. Snap new prefilter into the prefilter cap.

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3. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal ring (1).

lithium grease to the prefilter cap seal ring (1). 4. Install the prefilter into the fuel

4. Install the prefilter into the fuel filter module.

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5. Torque prefilter cap to 25 to 30 N·m (19 to 22 lb·ft).

Note : If a filter service is being performed, replace all other filters before priming.

6. Once all required filters have been changed, prime the fuel system. Refer to section "Priming the Fuel System".

10.4.4 Description and Operation of the Fuel Final Filter

Pre-filtered fuel flows from the low pressure pump and passes through the final filter which has the task of filtering out small dirt particles (greater than 2m). The final filter element has fuel flowing from the outside of the element to the inside where it is then supplied to the high pressure fuel pump through an opening located near the top of the standpipe. The high position of the opening ensures that no unclean fuel can reach the high pressure fuel pump.

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1. Final Filter Element

2. Air Purge

3. Air Return to Tank

4. Filtered Fuel to High Pressure Pump

5. Inlet from Low Pressure Pump

Filter Element 2. Air Purge 3. Air Return to Tank 4. Filtered Fuel to High Pressure

Fig 10.3, Fuel Final Filter

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10.4.5 Removal of the Final Filter

Note : The fuel filter element may discolor over time. This is normal operation and the filter should not be replaced on that basis alone.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries. Refer to OEM procedures.

3. Open the hood.

4. Using a 36mm 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.

5. Pull the cap and final filter (1) straight up and allow the fuel to drain back.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 6. Discard the final filter. 7. Inspect inside the housing

6. Discard the final filter.

7. Inspect inside the housing for any large debris; clean housing as needed.

8. Discard the final filter cap seal ring.

10.4.6 Installation of the Final Filter

1. Install a new seal ring (1) on to final filter cap.

2. Snap a new final filter into the final filter cap.

3. Apply a light coat of Parker super O-lube or petroleum-based lithium grease to the final filter cap seal ring (1) and drain back port seal ring (2).

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 4. Install the final filter into the fuel filter module.

4. Install the final filter into the fuel filter module.

5. Torque the final filter cap to 25 to 30 N·m (19 to 22 lb·ft).

Note : If a filter service is being performed, replace all other filters before priming.

6. Once all required filters have been changed, prime the fuel system. Refer to section "Priming the Fuel System".

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10.5 Fuel Filter Module

10.5.1 Description and Operation of the Fuel Filter Module and Related Parts

The fuel filter module is located on the left side of the cylinder block behind the Motor Control module (MCM). The fuel is cleaned in two stages using a 100 micron prefilter and a two micron final filter. The fuel filter module consists of the following components:

• Fuel supply and fuel return fittings (1, 2) - used to connect the fuel tank to the fuel filter module.

• Low pressure sensor (6) - used to measure fuel pressure in the low pressure circuit of the fuel system.

• Fuel temperature sensor (3) - Used to measure the fuel temperature in the fuel filter module.

• Fuel prefilter (4) - where debris particles greater than 100m are removed from the fuel.

• Fuel final filter (5) - where debris particles greater than 2m are removed from the fuel.

• Return from the Pressure Control Valve (PCV) and Fuel Injector Needle (13) - used for fuel returning from the PCV and fuel injector needle return circuits.

• Fuel connection to low pressure pump (12) - used to send prefiltered fuel to the low pressure pump.

• Return connection from low pressure pump (11) - used to receive pressurized fuel from the low pressure pump.

• Fuel connection to high pressure pump (10) - used to send final-filtered fuel to the high pressure pump.

• Fuel connection from the high pressure pump (8) - used to receive returned fuel from the high pressure pump.

• Hydrocarbon (HC) doser block supply (9) - used to supply fuel to the HC doser block.

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1. Fuel Return Fitting

2. Fuel Supply Fitting

3. Fuel Temperature Sensor

4. Fuel Prefilter

5. Fuel Final Filter

6. Fuel Pressure Sensor

7. Priming Port

8. High Pressure Pump Return

9. HC Doser Supply

10. High Pressure Pump Supply

11. Low Pressure Pump Return

12. Low Pressure Pump Supply

13. Needle and Pressure Control Valve Return Line

Pump Supply 11. Low Pressure Pump Return 12. Low Pressure Pump Supply 13. Needle and Pressure

Fig 10.4, Fuel Filter Module

10.5.2 Removal of the Fuel Filter Module

WARNING PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle

WARNING

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

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1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. If necessary, remove the bumper end(s).

5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

8. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".

9. Remove the chassis side fuel feed and return lines from the fuel filter module.

10. Disconnect the Pressure Control Valve (PCV) return line from the fuel filter module.

11. Disconnect the hydrocarbon doser block feed line from the fuel filter module.

12. Remove the three fuel filter module mounting bolts and remove the fuel filter module.

fuel filter module mounting bolts and remove the fuel filter module. 10.5.3 Installation of the Fuel

10.5.3 Installation of the Fuel Filter Module

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

1. Install the fuel filter module and the three mounting bolts securing the fuel filter module to the cylinder block. Torque to 25 N·m (18 lb·ft).

module to the cylinder block. Torque to 25 N·m (18 lb·ft). 2. Connect the pressure control

2. Connect the pressure control valve (PCV) return line to the fuel filter module. Torque to 17 N·m (12 lb·ft).

3. Using new sealing washers, loosely install the Hydrocarbon (HC) doser block feed line to the fuel filter module.

4. Position the HC doser block feed line in the 11 o'clock position (1) from vertical (2), as shown below.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 Note : Failure to brace the line while torquing can

Note : Failure to brace the line while torquing can result in an improper installation position.

5. While holding the line in position, torque the banjo bolt at the fuel filter module to 25 N·m (18 lb·ft).

6. Install the chassis fuel feed and return lines on to the fuel filter module.

7. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump Lines".

8. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".

9. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

10. If removed, install the bumper end(s).

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

11. Connect the batteries.

12. Prime the fuel system. Refer to section "Priming the Fuel System".

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10.6 Fuel Injectors

10.6.1 Description and Operation of the Fuel Injector

The fuel injectors are secured to the cylinder head by means of a hold-down clamp, and located centrally between the valves of the respective cylinder. All injectors have a six-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 a fuel injector is replaced, this code must be recorded in the Motor Control Module (MCM) using DiagnosticLink .

The injectors inject fuel under high pressure into the cylinders. The injection timing, injection period, and the injection variants are established by the MCM, dependent on the operating condition of the engine. There is a solenoid valve in the fuel injector which triggers the injector process when it is commanded by the Motor Control Module (MCM).The very short response times of the solenoid valve, within a few microseconds, allow up to five injections per cycle.

1. Electrical Connector

2. Header With Calibration Codes

3. Injector Inlet O-ring

4. Injector Body O-ring

5. Fuel Return Port

6. Injector Tip

2. Header With Calibration Codes 3. Injector Inlet O-ring 4. Injector Body O-ring 5. Fuel Return

Fig 10.5, Fuel Injector

10.6.2 Removal of the Fuel Injector

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Service Tools Used in the Procedure

Tool Number

Tool Name

Tool Graphic

W936589003300

Injector Puller

W936589003300 Injector Puller

W936589013300

Injector Seal Installer

W936589013300 Injector Seal Installer

W936589033300

Tool Kit

W936589033300 Tool Kit
Name Tool Graphic W936589003300 Injector Puller W936589013300 Injector Seal Installer W936589033300 Tool Kit

Remove as follows:

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1. Electrical Connector

2. Header With Calibration Codes

3. Injector Inlet O-ring

4. Injector Body O-ring

5. Fuel Return Port

6. Injector Tip

2. Header With Calibration Codes 3. Injector Inlet O-ring 4. Injector Body O-ring 5. Fuel Return

Fig 10.6, Fuel Injector

WARNING PERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin,

WARNING

PERSONAL INJURY

To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

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3. Open the hood.

WARNING FIRE HAZARD Do not power wash or steam clean the engine bay in the

WARNING

FIRE HAZARD

Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage.

4. Steam clean the engine.

5. Remove the rocker cover. Refer to section "Removal of the Rocker Cover".

6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

7. Disconnect the fuel injector electrical wiring harness from the fuel injectors and position aside. Refer to section "Removal of the Fuel Injector Wiring Harness".

8. Remove the high pressure fuel injector feed lines. Refer to section "Removal of the High Pressure Fuel Injector Lines".

9. Remove the fuel injector hold-down bolt (1). Discard bolt.

Remove the fuel injector hold-down bolt (1). Discard bolt. 10. Using tool W936589003300, lift the fuel

10. Using tool W936589003300, lift the fuel injector clamp and fuel injector from its seat in the cylinder head.

11. Inspect for the copper heat protection sleeve on the injector tip; if present, remove and discard. If the copper sleeve is missing, use tool W936589033300 to extract it from the cylinder head and discard.

12. Cover the fuel injector hole in the cylinder head to keep out foreign material.

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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 copper heat protection sleeve

are considered one-use items and cannot be reused. Any time a fuel injector is removed,

the fuel injector bolt, two fuel injector O-ring seals and copper heat protection sleeve must

be replaced with new parts. Failure to replace the O-ring seals, heat protection sleeve 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 two fuel injector O-rings and the copper sleeve.

10.6.3 Installation of the Fuel Injector

Service Tools Used in the Procedure

Tool Number

Tool Name

Tool Graphic

W936589003300

Injector Puller

W936589003300 Injector Puller

W936589013300

Injector Seal Installer

W936589013300 Injector Seal Installer

W936589033300

Tool Kit

W936589033300 Tool Kit
Name Tool Graphic W936589003300 Injector Puller W936589013300 Injector Seal Installer W936589033300 Tool Kit

Install as follows:

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1. Electrical Connector

2. Header With Calibration Codes

3. Injector Inlet O-ring

4. Injector Body O-ring

5. Fuel Return Port

6. Injector Tip

2. Header With Calibration Codes 3. Injector Inlet O-ring 4. Injector Body O-ring 5. Fuel Return

Fig 10.7, Fuel Injector

Note : Ensure excess fuel is removed from the top of the piston dome before fuel injector installation.

1.

If the fuel system is contaminated:

Drain the fuel tanks and refill with clean fuel.

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 with fuel, change the engine oil and filter.

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 or remanufactured fuel injectors are being used, record the fuel injector calibration code, the injector part number and note the cylinder location where it will be installed.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 6. Remove the fuel injector nozzle tip protector. 7. Apply

6. Remove the fuel injector nozzle tip protector.

7. Apply a thin coat of acid-free grease or clean engine oil to the fuel injector seal rings and then use W936589013300 (Fuel Injector O-ring Installer) to install them into the fuel injector. Make sure they are properly seated.

8. Using tool W936589033300, install the copper heat protection sleeve on the fuel injector tip.

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 the high pressure fuel injector feed lines. Refer to section "Installation of the High Pressure Fuel Injector Lines".

11. Torque the fuel injector hold-down bolt to 25 N·m (18 lb·ft) + 90 degree torque turn.

12. Install the fuel injector wiring harness. Refer to section "Installation of the Fuel Injector Wiring Harness".

13. Input the fuel injector calibration codes and injector part number that were recorded earlier into DiagnosticLink using the service routine.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 14. If injectors were replaced because of a tip failure

14. If injectors were replaced because of a tip failure or leak, the EGR cooler must be cleaned. Refer to section "Cleaning of the Exhaust Gas Recirculation System".

15. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

16. Install the rocker cover. Refer to section "Installation of the Rocker Cover".

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

17. Connect the batteries.

WARNING PRESSURIZED FUEL To avoid injury to eye or face, wear a face shield or

WARNING

PRESSURIZED FUEL

To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.

18. If an injector cup was removed, fill and pressure test the cooling system; check for leaks. Refer to section "Cooling System Fill Procedure".

19. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".

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10.7 Fuel Injector Cup

10.7.1 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 a fuel injector cup O-ring installed in the cylinder head to create a water and fuel tight seal.

1. Cylinder Head

2. Fuel Injector Cup

3. Fuel Injector Cup O-ring

1. Cylinder Head 2. Fuel Injector Cup 3. Fuel Injector Cup O-ring

Fig 10.8, Fuel Injector Cup and Related Parts

10.7.2 Removal of the Fuel Injector Cup

Service Tools Used in the Procedure

Tool Number

Tool Name and Engine

Tool Graphic

W936589000700

Injector Cup Remover/Installer

Tools Used in the Procedure Tool Number Tool Name and Engine Tool Graphic W936589000700 Injector Cup

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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 blow out debris in the bores.

NOTICE

Engine coolant must be drained prior to fuel injector tube removal.

1. Drain the engine coolant. Refer to section "Cooling System Drain Procedure" .

2. Remove the fuel injectors. Refer to section "Removal of the Fuel Injector" .

Note : Tool W936589000700 must be fully engaged with the fuel injector cup to prevent damage to the tool and the cup.

3. Install tool W936589000700 into fuel injector cup and align tool with slots in tube and turn counter clockwise to remove.

4. Remove fuel injector cup; discard fuel injector cup O-ring in cylinder head.

5. Inspect the fuel injector cup for cracks or defects. If defective, replace fuel injector cup.

6. Clean fuel injector cup threads with a fine wire brush, being careful not to abrade the cylinder head to fuel injector cup sealing surface.

7. Clean the fuel injector cup interior sealing surface; a chemical solvent maybe used for cleaning interior sealing surface.

10.7.3 Inspection of the Fuel Injector Cup

1. Visually inspect the fuel injector cup tip (3), fuel injector cup threads (4), fuel injector cup index slots (1) and fuel injector cup O-ring land (2) for damage. If damage is found, replace the fuel injector cup.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) Fig 10.9, Fuel Injector Cup 2. Visually inspect the fuel

Fig 10.9, Fuel Injector Cup

2. Visually inspect the fuel injector cup copper washer land (1) for damage. If damage is found, replace the fuel injector cup.

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 Fig 10.10, Fuel Injector Cup Copper Washer Land 10.7.4 Installation

Fig 10.10, Fuel Injector Cup Copper Washer Land

10.7.4 Installation of the Fuel Injector Cup

Service Tools Used in the Procedure

Tool Number

Tool Name and Engine

Tool Graphic

W936589000700

Injector Cup Remover/Installer

Tool Graphic W936589000700 Injector Cup Remover/Installer Install as follows: Note : Take extra precautions when

Install as follows:

Note : Take extra precautions when cleaning fuel injector bores to ensure debris does not enter fuel system. Do not use power tools to clean fuel injector bores, use a suitable hand brush and a rag. Do not use compressed air

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to blow out debris in the bores.

1. Clean fuel injector bore. Use a suitable hand brush to remove debris.

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 threads of fuel injector cup and cup sealing surface with a high temperature, nickel-based, anti-seize lubricant.

4. Install fuel injector cup onto tool W936589000700 and install into cylinder head bore.

5. Torque fuel injector cup to 55 N·m (40 lb·ft).

6. Release torque by rotating injector cup counterclockwise.

7. Torque fuel injector cup to 55 N·m (40 lb·ft).

8. Install fuel injector. Refer to section "Installation of the Fuel Injector" .

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10

10.8 Fuel Injector Wiring Harness

10.8.1 Description of the Fuel Injector Wiring Harness

One 16-pin fuel injector harness connector acts as the interface between the four fuel injectors and the 120-pin MCM connector.

1. Fuel Injector Wiring Harness

2. Wiring Terminals to Injectors

3. Camshaft Position (CMP) Sensor Electrical Connector

4. Fuel Injector Harness Electrical Connector

to Injectors 3. Camshaft Position (CMP) Sensor Electrical Connector 4. Fuel Injector Harness Electrical Connector

Fig 10.11, DD5 Fuel Injector Wiring Harness Location

10.8.2 Removal of the Fuel Injector Wiring Harness

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect batteries.

3. Open the hood.

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4. Remove the rocker cover. Refer to section "Removal of the Rocker Cover."

5. Remove the terminal nuts (2) on all four injectors.

5. Remove the terminal nuts (2) on all four injectors. 6. Disconnect the camshaft position sensor

6. Disconnect the camshaft position sensor electrical connector (3).

7. Disconnect the fuel injector wiring harness 16-pin connector (4) from the engine wiring harness.

8. Remove the fuel injector wiring harness (1) from the camshaft housing by pulling up on the tab as indicated on the harness.

10.8.3 Installation of the Fuel Injector Wiring Harness

1. Install the fuel injector wiring harness into the camshaft housing.

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 2. Install the fuel injector wiring harness locking tab into

2. Install the fuel injector wiring harness locking tab into the rear of the camshaft housing.

3. Connect the fuel injector wiring harness 16-pin connector (4) to the engine wiring harness.

4. Connect the camshaft position sensor electrical connector (3).

5. Install the fuel injector terminal nuts (2) onto the injectors. Torque to 2 N·m (18 lb·in.).

6. Install the rocker cover. Refer to section "Installation of the Rocker Cover."

7. Close the hood.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

8. Connect the batteries.

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10.9 Fuel Rail

10.9.1 Description and Operation of the Fuel Rail and Related Parts

The fuel rail incorporates the fuel rail pressure sensor and the pressure control valve. The high pressure fuel pump pressurizes the fuel and sends it to the fuel rail through a high pressure rail supply line. The fuel then goes from the rail through the individual high pressure fuel injector lines to each fuel injector.

1. High Pressure Pump

2. Low Pressure Pump

3. High Pressure Fuel Line from Pump to Rail

4. High Pressure Fuel Lines from Rail to Fuel Injector

5. Fuel Rail

Pump 3. High Pressure Fuel Line from Pump to Rail 4. High Pressure Fuel Lines from

Fig 10.12, Fuel Rail and Related Parts

10.9.2 Removal of the Fuel Rail

WARNING PERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin,

WARNING

PERSONAL INJURY

To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit.

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10

NOTICE

The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line

seals are one-time use components and MUST be replaced any time they are loosened or

removed.

1. Remove and discard the high pressure fuel injector lines. Refer to section "Removal of the High Pressure Fuel Injector Lines".

2. Disconnect the electrical connectors at the rail pressure sensor (1) and the pressure control valve (2).

rail pressure sensor (1) and the pressure control valve (2). 3. Disconnect the pressure control valve

3. Disconnect the pressure control valve return line at the fuel rail.

4. Remove the two bolts securing the fuel rail to the cylinder head and remove the fuel rail from the engine.

10.9.3 Installation of the Fuel Rail

NOTICE

The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line

seals are one-time-use components and MUST be replaced any time they are loosened or

removed.

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NOTICE

DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts

and fittings MUST be installed using hand tools.

1. Install the fuel rail (2) and the two fuel rail mounting bolts (1) on to the cylinder head. Hand-tighten the fuel rail mounting bolts.

cylinder head. Hand-tighten the fuel rail mounting bolts. 2. Connect the pressure control valve return line

2. Connect the pressure control valve return line to the fuel rail. DO NOT torque the return line nut at this time.

3. Using tool W638589111500, install the high pressure fuel injector line seals (2) into the cylinder head (1).

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 4. Lubricate the inside of the new fuel injector line

4. Lubricate the inside of the new fuel injector line seals with a light coating of clean engine oil.

Note : The high pressure fuel injector lines must first be fastened onto the fuel rail and then onto the fuel injector or leaks may occur.

Note : To install the high pressure line on cylinder #2, the high pressure line on cylinder #3 must be installed first.

5. Install the new high pressure fuel injector line (2) onto the fuel rail (3); hand-tighten the fuel injector line nut.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 6. Install the new high pressure fuel injector line onto

6. Install the new high pressure fuel injector line onto the fuel injector; hand-tighten the fuel injector line nut.

7. Install the high pressure fuel rail feed line (1) to the fuel rail (3) and the high pressure fuel pump. Hand- tighten the nuts.

8. Torque the fuel rail mounting bolts to 55 N·m (40 lb·ft).

9. Torque the pressure control valve return line nut to 30 N·m (22 lb·ft).

10. Using a commercially available 19mm fuel line socket, torque the high pressure fuel rail feed line nuts to 45 N·m (33 lb·ft).

11. Tighten the high pressure fuel injector line nut to the fuel rail. Torque to 45 N·m (33 lb·ft).

12. Using a commercially available 19mm fuel line socket, torque the high pressure fuel injector line nut to the fuel injector to 45 N·m (33 lb·ft).

13. Connect the electrical connectors on the rail pressure sensor (1) and the pressure control valve (2).

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 14. Install the air compressor resonator. Refer to section

14. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

15. Connect the batteries.

16. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".

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10.10 Low Pressure Fuel Pump

10.10.1 Description and Operation of the Low Pressure Fuel Pump and

Related Parts

The low pressure fuel pump is mounted on the high pressure fuel pump. The low pressure fuel pump pulls fuel from the fuel tank to supply fuel to the high pressure fuel pump. The low pressure fuel pump is a gear pump. The low pressure fuel pump is driven by a drive coupler that is connected to high pressure fuel pump camshaft. The fuel is suctioned due to the rotational movement of both low pressure fuel pump gear-wheels and the design of the pump chamber.

1. Low Pressure Fuel Pump

2. Drive Coupler

3. High Pressure Fuel Pump

1. Low Pressure Fuel Pump 2. Drive Coupler 3. High Pressure Fuel Pump

Fig 10.13, Low Pressure Fuel Pump

10.10.2 Removal of the Low Pressure Fuel Pump

WARNING PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle

WARNING

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

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10

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

5. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

6. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

7. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".

8. Remove the three bolts (1) attaching the low pressure pump to the high pressure pump.

attaching the low pressure pump to the high pressure pump. 9. Remove the low pressure pump

9. Remove the low pressure pump from the high pressure pump.

10.10.3 Inspection of the Low Pressure Fuel Pump

1. Remove the low pressure fuel pump from the high pressure fuel pump. Refer to section "Removal of the Low Pressure Fuel Pump".

2. Visually inspect the drive plate (1) on the high pressure fuel pump for damage. If damage is found, replace the high pressure fuel pump.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 3. Visually inspect the drive coupler (2) and driven key

3. Visually inspect the drive coupler (2) and driven key for damage. If damage is found, replace the high pressure fuel pump (3).

inspect the drive coupler (2) and driven key for damage. If damage is found, replace the

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

10

4. Remove the low pressure fuel pump housing half from the low pressure fuel pump housing.

5. Visually inspect the low pressure fuel pump housing half, 1ow pressure fuel pump housing and low pressure fuel pump gears for damage. If damage is found, replace the low pressure fuel pump.

10.10.4 Installation of the Low Pressure Fuel Pump

1. If the low pressure fuel pump is being reused, clean mounting surface of low pressure fuel pump and O-ring groove.

2. If the low pressure fuel pump is being reused, install a new O-ring mounting seal and lubrication port seal onto the low pressure fuel pump.

3. Install the low pressure fuel pump and three mounting bolts (1). Torque to 17 N·m (12 lb·ft).

and three mounting bolts (1). Torque to 17 N·m (12 lb·ft). 4. Install the low pressure

4. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump Lines".

5. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".

6. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

7. Connect the batteries.

8. Prime the fuel system. Refer to section "Priming the Fuel System".

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10.11 Low Pressure Fuel Pump Lines

10.11.1 Description and Operation of Low Pressure Fuel Pump Lines

There are four low pressure fuel lines on the engine. The low pressure fuel lines run from the fuel pump to the fuel filter module.

1. Low Pressure Pump Inlet Line

2. Low Pressure Pump Outlet Line

3. High Pressure Pump Inlet Line

4. High Pressure Pump Outlet Line

Pump Inlet Line 2. Low Pressure Pump Outlet Line 3. High Pressure Pump Inlet Line 4.

Fig 10.14, Low Pressure Fuel Pump Lines

10.11.2 Removal of the Low Pressure Fuel Pump Lines

WARNING PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle

WARNING

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

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10

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

5. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator"

6. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

7. Remove the high pressure pump supply and return lines (2) from the fuel filter module to the high pressure pump and discard the sealing rings.

to the high pressure pump and discard the sealing rings. 8. Remove the low pressure pump

8. Remove the low pressure pump supply and return lines (1) from the fuel filter module to the low pressure pump and discard the sealing rings.

10.11.3 Inspection of the Low Pressure Fuel Pump Lines

1. Visually inspect the low pressure fuel pump lines for damage at the O-ring lands (1) and flexible lines (2). If damage is found, replace the damaged low pressure fuel line.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10.11.4 Installation of the Low Pressure Fuel Pump Lines 1.

10.11.4 Installation of the Low Pressure Fuel Pump Lines

1. Install new sealing rings on the low and high pressure pump supply and return lines.

2. Install the low pressure pump supply and return lines (1) from the fuel filter module to the low pressure pump. Torque the bolts to 17 N·m (12 lb·ft).

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 3. Install the high pressure pump supply and return lines

3. Install the high pressure pump supply and return lines (2) from the fuel filter module to the high pressure pump. Torque the bolts to 17 N·m (12 lb·ft).

4. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".

5. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

6. Connect the batteries.

7. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".

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10.12 High Pressure Fuel Injector Lines

10.12.1

Description and Operation of the High Pressure Fuel Injector

Lines

The high pressure fuel pump pressurizes the fuel and sends it to the fuel rail through a high pressure rail supply line. The fuel then goes from the rail through the individual high pressure fuel injector lines to each fuel injector.

1. High Pressure Pump

2. Low Pressure Pump

3. High Pressure Fuel Lines from Pump to Rail

4. High Pressure Fuel Lines from Rail to Fuel Injector

5. Fuel Rail

Pump 3. High Pressure Fuel Lines from Pump to Rail 4. High Pressure Fuel Lines from

10.12.2 Removal of the High Pressure Fuel Injector Lines

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10

Service Tools Used in the Procedure

 

Tool Number

Tool Name

Tool Graphic

W936589043300

Puller

W936589043300 Puller

W936589033302

Impact Extractor

W936589033302 Impact Extractor

Remove as follows:

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

WARNINGFIRE HAZARD Do not power wash or steam clean the engine bay in the area

FIRE HAZARD

Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage.

4. Steam clean the engine.

5. Remove the air compressor resonator. Refer to section " Removal of the Air Compressor Resonator ".

Note : Removal of the high pressure rail feed line is only required if removing the high pressure fuel injector line on cylinder #2 or cylinder #3.

WARNINGPERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin, ensure

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.

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NOTICE

The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line

seals are one-time use components and MUST be replaced any time they are loosened or

removed.

6. Remove the high pressure rail feed line (1). Refer to section " Removal of the High Pressure Rail Feed Line ".

" Removal of the High Pressure Rail Feed Line ". Note : To remove the high

Note : To remove the high pressure fuel injector line on cylinder #3, the high pressure fuel injector line on cylinder #2 must be removed first.

7. Using a commercially available 19mm fuel line socket, remove and discard the high pressure fuel injector lines (2).

8. Using puller W936589043300 and impact extractor W936589033302, remove the high pressure fuel injector line seals (2) from the cylinder head (1) and discard. See graphic below.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 10.12.3 Installation of the High Pressure Fuel Injector Lines Service

10.12.3 Installation of the High Pressure Fuel Injector Lines

Service Tools Used in the Procedure

Tool Number

Tool Name

Tool Graphic

W638589111500

Injector Seal Installer

Tool Name Tool Graphic W638589111500 Injector Seal Installer Install as follows: 1. Using Injector Seal Installer

Install as follows:

1. Using Injector Seal Installer tool W638589111500, install the high pressure fuel injector line seals (2) into the cylinder head (1).

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 2. Lubricate the inside of the new fuel injector line

2. Lubricate the inside of the new fuel injector line seals with a light coating of clean engine oil.

3. Loosen the fuel rail clamp bolts.

Note : The high pressure fuel injector lines must first be fastened onto the fuel rail and then onto the fuel injector or leaks may occur.

Note : To install the high pressure line on cylinder #2, the high pressure line on cylinder #3 must be installed first.

4. Install the new high pressure fuel injector line (2) onto the fuel rail (3); hand-tighten the fuel injector line nut.

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 5. Install the new high pressure fuel injector line (2)

5. Install the new high pressure fuel injector line (2) onto the fuel injector; hand-tighten the fuel injector line nut.

6. If removed, install the high pressure rail feed line (1). Refer to section “Installation of the High Pressure Rail Feed Line”.

7. Torque the fuel rail clamp bolts to 55 N·m (40 lb·ft).

8. Tighten the high pressure fuel injector line nut to the fuel rail (3). Torque to 45 N·m (33 lb·ft).

9. Using a commercially available 19mm fuel line socket, torque the high pressure fuel injector line nut to the fuel injector to 45 N·m (33 lb·ft).

10. Install the air compressor resonator. Refer to section “Installation of the Air Compressor Resonator”.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

11. Connect the batteries.

12. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".

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10.13 High Pressure Fuel Pump

10.13.1 Description and Operation of the High Pressure Fuel Pump

and Related Parts

10.13.2 Removal of the High Pressure Fuel Pump

WARNING PERSONAL INJURY Diesel engine exhaust and some of its constituents are known to the

WARNING

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.

WARNINGPERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle is

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

WARNING ENGINE EXHAUST To avoid injury from inhaling engine exhaust, always operate the engine in

WARNING

ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well- ventilated area. Engine exhaust is toxic.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

WARNING FIRE HAZARD Do not power wash or steam clean the engine bay in the

WARNING

FIRE HAZARD

Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage.

4. Steam clean the high pressure fuel pump and the surrounding area.

5. If necessary, remove the driver's side bumper end.

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10

6. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

7. Position the engine at No. 1 Top Dead Center (TDC) on the compression stroke. Refer to section "Camshaft Timing Verification".

8. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

9. Remove the Motor Control module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

10. Remove the high pressure fuel rail feed line from the high pressure pump to the fuel rail. Refer to section "Removal of the High Pressure Fuel Rail Feed Line".

11. Remove low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".

12. Remove the hydrocarbon fuel doser block feed line. Refer to section "Removal of the Hydrocarbon Fuel Doser Block Feed Line".

13. Remove the pressure control valve return line. Refer to section "Removal of the Pressure Control Valve Return Line."

14. Disconnect the quantity control valve (QCV) electrical harness connector.

15. Remove the two mounting bolts securing the front of the high pressure fuel pump to the cylinder block bracket.

16. If necessary, disconnect and position aside the air compressor discharge line.

17. Remove the three bolts attaching the high pressure fuel pump to the timing case.

attaching the high pressure fuel pump to the timing case. 18. Remove the high pressure fuel

18. Remove the high pressure fuel pump from the timing case.

19. If the high pressure fuel pump is being reused, remove and discard the high pressure fuel pump O-ring seals.

10.13.3 Installation of the High Pressure Fuel Pump

1. Ensure the engine is at No. 1 Top Dead Center (TDC) on the compression stroke. Refer to section “Camshaft Timing Verification”.

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2. If a new or remanufactured high pressure fuel pump is being installed, install the high pressure fuel pump drive gear on to the high pressure fuel pump. Refer to section "Installation of the High Pressure Fuel Pump Drive Gear”.

3. If the high pressure fuel pump is being reused, clean mounting surface of the high pressure fuel pump and O-ring groove.

4. If the high pressure fuel pump is being reused, install a new O-ring mounting seal and lubrication port seal on to the high pressure fuel pump.

5. Lightly lubricate the high pressure fuel pump O-ring mounting seals with clean engine oil.

Note : The high pressure fuel pump should slide into the timing case without binding. The mounting bolt holes on the high pressure fuel pump housing should align closely with the mounting holes on the timing case.

Note : If the high pressure fuel pump binds when being installed or if there is misalignment in the mounting bolt holes, remove the high pressure fuel pump and verify that the timing mark is at the 12 o'clock position and the engine is positioned at number one cylinder TDC.

NOTICE

DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts

and fittings MUST be installed using hand tools.

6. Install the high pressure fuel pump and three mounting bolts into the timing case. Hand-tighten the mounting bolts.

bolts into the timing case. Hand-tighten the mounting bolts. 7. Install the two mounting bolts securing

7. Install the two mounting bolts securing the front of the high pressure pump to the cylinder block bracket. Torque to 25 N·m (18 lb·ft).

8. Torque the three mounting bolts securing the high pressure pump to the timing case to 50 N·m (37 lb·ft).

9. Connect the QCV electrical harness connector.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)

10

10. If removed, connect the air compressor discharge line to the air compressor.

11. Install the pressure control valve return line. Refer to section "Installation of the Pressure Control Valve (PCV) Return Line".

12. Install the high pressure fuel rail feed line from the high pressure pump to the fuel rail. Refer to section "Installation of the High Pressure Fuel Rail Feed Line".

13. Install the hydrocarbon fuel doser block feed line. Refer to section "Installation of the Hydrocarbon Fuel Doser Block Feed Line".

14. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump Lines".

15. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".

16. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

17. Connect the batteries.

18. Prime the fuel system. Refer to section “Priming the Fuel System”.

10.13.4 Removal of the High Pressure Fuel Pump Drive Gear

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Service Tools Used in the Procedure

Tool Number

Tool Description

Tool Graphic

W470589084000

HP pump holding fixture

W470589084000 HP pump holding fixture

W936589053300

Drive gear puller

W936589053300 Drive gear puller

W936589003100

HP Pump adaptor and locking tooth

W936589003100 HP Pump adaptor and locking tooth

Note : To ensure proper alignment between the locking tooth and the HP drive gear leave the bolts holding the locking tooth finger-tight until the high pressure pump has been installed into the holding fixture.

1. Clamp holding fixture (W47058984000) into a vise and attach pump adaptor and locking tooth

(W936589003100).

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10

GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 2. Install the high pressure fuel pump into the high

2. Install the high pressure fuel pump into the high pressure pump holding-device tool (W470589084000) and tighten the locking tooth (W936589003100).

pump into the high pressure pump holding-device tool (W470589084000) and tighten the locking tooth (W936589003100). 62

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3. Loosen, but do not remove, the high pressure fuel pump drive gear nut (1).

not remove, the high pressure fuel pump drive gear nut (1). 4. Using the drive gear

4. Using the drive gear puller tool (W936589053300), unfasten the high pressure pump drive gear from the high pressure fuel pump camshaft.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 5. Remove the high pressure pump drive gear nut and

5. Remove the high pressure pump drive gear nut and the drive gear from the high pressure fuel pump.

10 5. Remove the high pressure pump drive gear nut and the drive gear from the

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6. Inspect the dowel pin for wear or damage and replace pin if necessary.

7. Remove the high pressure fuel pump from the high pressure pump holding-device tool (W470589084000).

10.13.5 Installation of the High Pressure Fuel Pump Drive Gear

Service Tools Used in the Procedure

Tool Number

Tool Description

Tool Graphic

W470589084000

HP pump holding fixture

W470589084000 HP pump holding fixture

W936589053300

Drive gear puller

W936589053300 Drive gear puller

W936589003100

HP Pump adaptor and locking tooth

W936589003100 HP Pump adaptor and locking tooth

1. Install the high pressure fuel pump onto the high pressure pump holding-device tool (W470589084000) using adaptor plate and locking tooth tool (W936589003100).

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 2. Using a suitable degreaser, clean any oil or grease

2. Using a suitable degreaser, clean any oil or grease from the high pressure pump shaft and mating surface on the high pressure pump drive gear.

3. Install the high pressure fuel pump drive gear onto the high pressure fuel pump camshaft.

4. If removed, install the high pressure pump timing plate to the high pressure pump drive gear. Torque to 25 N·m (18 lb·ft).

5. Install the high pressure fuel pump drive gear nut (1) onto the high pressure fuel pump. Torque the drive gear nut to 125 N·m (92 lb·ft).

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 6. Remove the locking tooth (W936589003100). 7. Using a non-marring

6. Remove the locking tooth (W936589003100).

7. Using a non-marring strap wrench, rotate the drive gear until the hash mark (1) is at the 12 o'clock position in line with the pumping elements.

rotate the drive gear until the hash mark (1) is at the 12 o'clock position in

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10.14 High Pressure Fuel Rail Feed Line

10.14.1

Description and Operation of the High Pressure Fuel Rail Feed

Line

The high pressure fuel pump pressurizes the fuel and sends it to the fuel rail through a high pressure fuel rail supply line. The fuel then goes from the rail through the individual high pressure fuel injector lines to each fuel injector.

1. High Pressure Pump

2. Low Pressure Pump

3. High Pressure Fuel Line from Pump to Rail

4. High Pressure Fuel Lines from Rail to Fuel Injector

5. Fuel Rail

Pump 3. High Pressure Fuel Line from Pump to Rail 4. High Pressure Fuel Lines from

Fig 10.15, The High Pressure Fuel Rail Feed Line

10.14.2 Removal of the High Pressure Fuel Rail Feed Line

Remove as follows:

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WARNINGPERSONAL INJURY To prevent the escape of high pressure fuel that can penetrate skin, ensure

PERSONAL INJURY

To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has been shut down for a minimum of 10 minutes before servicing any component within the high pressure circuit. Residual high fuel pressure may be present within the circuit.

NOTICE

The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line

seals are one-time use components and MUST be replaced any time they are loosened or

removed.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

WARNINGFIRE HAZARD Do not power wash or steam clean the engine bay in the area

FIRE HAZARD

Do not power wash or steam clean the engine bay in the area of vehicle electrical components, unless specified by vehicle manuals or service literature. Power washing/steam cleaning can permanently damage these components, which could result in fire, personal injury, or property damage.

4. Steam clean the engine.

5. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator" .

6. Using a commercially available 19mm fuel line socket, loosen the high pressure rail feed line (1) at the fuel rail (3) and at the high pressure fuel pump (4).

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 7. Loosen but do not remove the fuel rail mounting

7. Loosen but do not remove the fuel rail mounting bolts (2).

8. Remove and discard the high pressure fuel rail feed line.

10.14.3 Installation of the High Pressure Fuel Rail Feed Line

Install as follows:

NOTICE

The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line

seals are one-time use components and MUST be replaced any time they are loosened or

removed.

NOTICE

DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts

and fittings MUST be installed using hand tools.

1. Clean the sealing area inside the high pressure fuel pump fitting using a clean lint free cloth.

2. Clean the sealing area inside the high pressure fuel rail using a clean lint free cloth.

3. Install the high pressure fuel rail feed line (1) to the fuel rail (3) and the high pressure fuel pump (4). Hand- tighten the nuts.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 4. Torque the fuel rail mounting bolts (2) to 55

4. Torque the fuel rail mounting bolts (2) to 55 N·m (41 lb·ft).

5. Using a commercially available 19mm fuel line socket, torque the high pressure fuel rail feed line nuts to 45 N·m (33 lb·ft).

6. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator" .

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

7. Connect the batteries.

8. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System" .

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10.15 Needle and Pressure Control Valve Return Line

10.15.1 Description and Operation of the Needle and Pressure Control

Valve Return Line

A passage in the cylinder head provides a fuel return path for excess fuel supplied to the injector's needle circuit. The needle return line (4) connects to the cylinder head and contains a 6 bar pressure regulating valve where it meets with the Pressure Control Valve (PCV) return line (3). If the pressure control valve opens, fuel returns to the module (1) via the pressure control valve return line (3).

1. Fuel Filter Module

2. Fuel Rail

3. Pressure Control Valve Return Line

4. Needle Return Line

5. High Pressure Fuel Pump

1. Fuel Filter Module 2. Fuel Rail 3. Pressure Control Valve Return Line 4. Needle Return

10.15.2

Removal of the Needle and Pressure Control Valve Return

Line

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WARNING PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle

WARNING

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. If necessary, remove the driver's side bumper end.

5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

8. Remove low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".

9. Remove the hydrocarbon fuel doser block feed line. Refer to section "Removal of the Hydrocarbon Fuel Doser Block Feed Line".

10. Disconnect the quantity control valve electrical harness connector.

11. Disconnect the Pressure Control Valve (PCV) return line at the fuel rail.

12. Remove the banjo bolt (1) from the PCV return line at the pressure regulator and discard sealing washers.

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 13. Remove the bolt securing the PCV return line at

13. Remove the bolt securing the PCV return line at the fuel filter module.

14. Remove the clamp bolt securing the PCV return line to the air intake manifold and remove the PCV return line.

15. If necessary, remove the bolt securing the needle return line to the cylinder head and remove the needle return line.

10.15.3 Installation of the Needle and Pressure Control Valve Return Line

1. If removed, install the needle return line and torque the bolt to 25 N·m (18 lb·ft).

2. Install the Pressure Control Valve (PCV) return line on to the fuel rail. Hand-tighten the return line nut.

3. Install the PCV return line banjo bolt (1) with new sealing washers to the pressure regulator. Torque to 25 N·m (18 lb·ft).

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 4. Install the PCV return line to the fuel filter

4. Install the PCV return line to the fuel filter module. Torque to 17 N·m (12 lb·ft).

5. Install the clamp and bolt securing the PCV return line to the air intake manifold. Torque to 25 N·m (18 lb·ft).

6. Torque the PCV return line to the fuel rail to 30 N·m (22 lb·ft).

7. Connect the quantity control valve electrical harness connector.

8. Install the hydrocarbon fuel doser block feed line. Refer to section "Installation of the Hydrocarbon Fuel Doser Block Feed Line". Follow the procedure to completion.

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10.16 Quantity Control Valve

10.16.1 Description and Operation of the Quantity Control Valve

The Quantity Control Valve (QCV) is located on the high pressure fuel pump. The quantity control valve:

The Motor Control Module (MCM) actuates the coil of the QCV 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. Quantity Control Valve

2. High Pressure Fuel Pump

1. Quantity Control Valve 2. High Pressure Fuel Pump

Fig 10.16, Quantity Control Valve

10.16.2 Removal of the Quantity Control Valve

WARNING PERSONAL INJURY To avoid injury before starting and running the engine, ensure the vehicle

WARNING

PERSONAL INJURY

To avoid injury before starting and running the engine, ensure the vehicle is parked on a level surface, parking brake is set, and the wheels are blocked.

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.

CAUTION

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ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

2. Disconnect the batteries.

3. Open the hood.

4. If necessary, remove the bumper end(s).

5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".

6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".

7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section "Removal of the Motor Control Module".

8. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".

9. Remove the pressure control valve return line. Refer to section "Removal of the Pressure Control Valve Return Line."

10. Disconnect the hydrocarbon doser block feed line at the fuel filter module.

11. Disconnect the quantity control valve electrical harness connector.

12. Remove the two bolts securing the Quantity Control Valve (QCV) (1) to the high pressure fuel pump (2).

Control Valve (QCV) (1) to the high pressure fuel pump (2). 13. Remove the QCV. 10.16.3

13. Remove the QCV.

10.16.3 Inspection of the Quantity Control Valve and High Pressure Pump Housing

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NOTICE

Do not use compressed air to remove debris from the high pressure pump housing. Doing

so may lodge particles in the pump housing passages.

1. Using a mirror, inspect the high pressure pump housing bore (1) for any debris. If debris is present, use a vacuum to remove from pump housing.

debris is present, use a vacuum to remove from pump housing. 2. Inspect the Quantity Control

2. Inspect the Quantity Control Valve (QCV) for debris; check ports and O-rings (1) to ensure damage is not present. If damage or debris is found, replace the QCV. If no trouble is found with the QCV, immediately reinstall.

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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10.16.4 Installation of the Quantity Control Valve 1. Install new

10.16.4 Installation of the Quantity Control Valve

1. Install new O-ring seals on to the Quantity Control Valve (QCV).

2. Lubricate the new O-ring seals on the QCV with clean diesel fuel.

3. Install the QCV (1) into the high pressure fuel pump (2). Torque bolts to 6 N·m (4 lb·ft).

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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10 4. Connect the QCV electrical connector. 5. Connect the hydrocarbon

4. Connect the QCV electrical connector.

5. Connect the hydrocarbon fuel doser block feed line at the fuel filter module. Refer to section "Installation of the Hydrocarbon Fuel Doser Block Feed Line".

6. Install the pressure control valve return line. Refer to section "Installation of the Pressure Control Valve Return Line."

7. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump Lines".

8. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".

9. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".

10. If removed, install the bumper end(s).

CAUTION

ELECTRICAL SHOCK

To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch studs are at battery voltage.

11. Connect the batteries.

12. Prime the fuel system. Refer to section "Priming the Fuel System".

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