DD15 Engine

Section 35.9 Fuel Rail

Section 35.9
Fuel Rail

The fuel rail incorporates the fuel pressure sensor and pressure limiting valve. The fuel rail attaches to the camshaft frame with brackets. The Fuel Rail Pressure Sensor is installed at the front of the rail. ‪

Section 35.9.1
Removal of the Fuel Rail

Remove as follows:‪

  1. Steam clean the engine.
  2. Disconnect the batteries.
  3. Drain the fuel system.
  4. 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.

  5. Remove injector feed tubes with tool J-48770.
    Click to see this graphic in a separate window
    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.‪

  6. Remove high pressure fuel lines from the high pressure pump and fuel rail.
  7. Remove injector feed tube bracket.
  8. Remove bolts and clamps connecting the fuel rail to the camshaft frame and remove fuel rail.
  9. Inspect the bolts for damage and wear; replace as necessary.
  10. Inspect the fuel rail for damage and wear; replace as necessary.
  11. Inspect the fuel feed tubes for damage and wear; replace as necessary.
  12. Inspect the rocker arm frame sealing for damage; replace as necessary.

Section 35.9.2
Installation of the Fuel Rail

Install as follows:‪

  1. Install fuel rail to camshaft frame with three clamps and six bolts. Torque bolts to 10 N·m (7.376 lb·ft).
  2. Remove covers from injector feed tubes.
  3. Using tool J-48770, install injector feed tubes to fuel rail and the injectors. Torque to 40 N·m. (29.5 lb·ft).
  4. Install high pressure fuel lines to the fuel rail and high pressure pump with tool J-48770. Torque lines to 40 N·m (29.5 lb·ft).
  5. Install pressure limiting valve fuel return line to the fuel filter module and fuel rail with tool J-48770. Torque to banjo bolt 35 N·m (25.8 lb·ft).
  6. Install pressure limiting valve. Refer to "35.9.6 Installation/Replacement of Pressure Limiting Valve" , “Installation/Replacement of Pressure Limiting Valve.”
  7. Install and connect Fuel Rail Pressure Sensor to the Engine Harness. Refer to "35.9.4 Installation of the Fuel Rail Sensor" , “Installation of the Fuel Rail Pressure Sensor.”
  8. Install bracket to the high pressure fuel lines.
  9. Connect the batteries.
    warning

    ENGINE EXHAUST

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

  10. Prime the fuel system, start the engine and check for leaks. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

Section 35.9.3
Removal of the Fuel Rail Pressure Sensor

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 1. Fuel Rail Pressure Sensor‪

 3. Injector‪

 2. Fuel Rail‪

 4. Pressure Limiting Valve‪

The Fuel Rail Pressure Sensor is mounted on the front end of the fuel rail. ‪

Remove as follows:‪

warning

PRESSURIZED FUEL

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

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. Remove connector.
  2. Place a small container below the Fuel Rail Pressure Sensor to catch escaping fuel.
  3. Remove the Fuel Rail Pressure Sensor using the appropriate wrench on the hex end of the Fuel Rail Pressure Sensor and unscrew the sensor from the fuel rail.

Section 35.9.4
Installation of the Fuel Rail Sensor

Install as follows:‪

  1. Install the Fuel Rail Pressure Sensor using the appropriate wrench on the hex end of the Fuel Rail Pressure Sensor and screw the sensor to the fuel rail; torque to 70 N·m (52 ft·lb).
  2. Install the sensor connector.
  3. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”

Section 35.9.5
Removal of Pressure limiting Valve

Click to see this graphic in a separate window

 1. Fuel Rail Pressure Sensor‪

 3. Injector‪

 2. Fuel Rail‪

 4. Pressure Limiting Valve‪

Remove as follows:‪

warning

PRESSURIZED FUEL

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

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. Place a small container below the Pressure Limiting Valve to catch escaping fuel.
  2. Clean the Pressure Limiting Valve and surrounding area.
  3. Using a socket and a ratchet, remove the Pressure Limiting Valve from the rear end of the Fuel Rail.

Section 35.9.6
Installation/Replacement of Pressure Limiting Valve

Install or replace as follows:‪

  1. Lubricate the threads and O-ring of the new Pressure Limiting Valve with clean fuel.
  2. Install the Pressure Limiting Valve and torque to 95-105 N·m (70-77 ft·lb).
  3. Prime fuel system using fuel priming valve or hand primer. Refer to "6.5 Fuel System Priming" , “Fuel System Priming.”
  4. Reset Pressure Limiting Valve counter, refer to "6.3 Resetting the Pressure Limiting Valve Counter" , “Resetting the Pressure Limiting Valve Counter.” Start the engine. Check for leaks.


DD15 Fuel System Technician's Guide - DDC-SVC-MAN-0037
Generated on 10-13-2008

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