1 EUROIV Fuel Manual (DDC-SVC-MAN-0182)

Two-Filter System

1.1 Fuel System Overview

1.1.1 Fuel System (With MCM Heat Exchanger) –Two-Filter System

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1. Fuel Tank
2. Fuel Supply from Tank
3. Pre-filter
4. Hand Primer
5. Low Pressure Fuel Pump
6. Fuel Bypass Valve
7. Water Coalescer / Final Filter
8. High Pressure Fuel Pump
9. Fuel Rail
10. High Pressure Fuel Injector Lines
11. Fuel Injectors
12. Needle Return Line
13. Needle Return Pressure Control Valve
14. Fuel Accumulator
15. Fuel Return Bypass
16. Gallery Bypass Valve
17. Pressure Relief Valve
18. Fuel Return from Amplifiers
19. Fuel Cooler
20. HC Doser Feed Line
21. High Pressure Fuel Flange
22. Fuel Cutoff Valve
23. Fuel Compensation Valve
24. HC Doser Valve
25. Water Coalescer/Final Filter Drain
26. Pressure Limiting Valve
27. Fuel Return from Pressure Limiting Valve
28. HC Doser Fuel Supply Pressure Control Valve (KM59 Gen1 ONLY)
29. Two-Stage Valve
30. Two-Stage Valve Return Flow
31. Fuel Return to Tank
32. Priming Port
33. Quantity Control Valve
34. Rail Pressure Sensor
35. Water Drain
36. Check Ball
37. Low Pressure Sensor
38. Fuel Temperature Sensor
39. Pre-filter Drain
40. MCM Heat Exchanger
41. Throttle Valve
42. Valve

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43. High Pressure Rail Supply Lines

Fig 1.1, Two-Filter Fuel System Overview (with MCM Heat Exchanger)

A. Fuel Feed (Suction Side)

B. Low Pressure Fuel
C. Return Fuel
D. Air Vent Passage
E. High Pressure Fuel

1.1.2 Fuel System (Without MCM Heat Exchanger) –Two-Filter System

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1. Fuel Tank
2. Fuel Supply from Tank
3. Pre-filter
4. Hand Primer
5. Low Pressure Fuel Pump
6. Fuel Bypass Valve
7. Water Coalescer / Final Filter
8. High Pressure Fuel Pump
9. Fuel Rail
10. High Pressure Fuel Injector Lines
11. Fuel Injectors
12. Needle Return Line
13. Needle Return Pressure Control Valve
14. Fuel Accumulator
15. Fuel Return Bypass
16. Gallery Bypass Valve
17. Pressure Relief Valve
18. Fuel Return from Amplifiers
19. Fuel Cooler
20. HC Doser Feed Line
21. High Pressure Fuel Flange
22. Fuel Cutoff Valve
23. Fuel Compensation Sensor
24. HC Doser Valve
25. Water Coalescer/Final Filter Drain
26. Pressure Limiting Valve
27. Fuel Return from Pressure Limiting Valve
28. HC Doser Fuel Supply Pressure Control Valve (KM59 Gen1 ONLY)
29. Two-Stage Valve
30. Two-Stage Valve Return Flow
31. Fuel Return to Tank
32. Priming Port
33. Quantity Control Valve
34. Rail Pressure Sensor
35. Water Drain
36. Check Ball
37. Low Pressure Sensor
38. Fuel Temperature Sensor
39. Pre-filter Drain
40. Throttle Valve
41. Valve
42. High Pressure Rail Supply Lines

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Fig 1.2, Two-Filter Fuel System Overview (without MCM Heat Exchanger)

A. Fuel Feed (Suction Side)

B. Low Pressure Fuel
C. Return Fuel
D. Air Vent Passage
E. High Pressure Fuel

1.1.3 Operation of the Fuel System

The low pressure fuel pump, which is a gear pump, 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 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 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 coalescer/final filter. The water in
the fuel is separated by the coalescer (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. The coalescer/final filter also filters out fine-
grained contaminants greater than 3 to 5 microns.
A supply fuel temperature sensor, located on the high pressure fuel flange, detects the current fuel temperature.
The MCM interprets this information and uses it for fuel mass calculations.

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Designed into the coalescer/final filter element is a ventilation bore that allows trapped air to escape. For example,
if air is trapped in the coalescer/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 900 bar (13,053 psi)
for KM59 GEN1 systems, and 1150 bar (16,679 psi) for KM63 GEN2 systems, 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 (44 psi) 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 (44 psi) relative to high pressure pump backflow pressure. The lubrication path is fully
open at 3.5 bar (51 psi).
• 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 (68 psi) relative to backpressure,
excess fuel is routed to the return path.
If the maximum rail pressure is exceeded, the pressure limiting valve opens and passes the excess fuel to the fuel
return. The KM59 GEN1 system opens at 1280 bar (18565 psi). The KM63 GEN2 system opens at 1500 bar
(21756 psi). If the system pressure drops below 3 bar (44 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 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 (248°F). 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.

1.1.4 Normal Fuel System Pressures

Service Tools Used in the Procedure

Tool Number Description
J-48876 Priming Port Fuel Pressure Test Gauge
W47058914910009 Filter Cap w/Test Port
DDDL 7.09 or newer

Normal fuel system pressures are listed in the table below. The fuel pressures can vary slightly due to different
chassis fuel line configurations, fuel temperatures, fuel filter condition, and fuel viscosity. All fuel pressures are
measured with the engine below 14% load and the fuel temperature above 22°C (72°F).
Note : Abnormal fuel pressure is when the fuel pressure is above or below the normal fuel pressure.

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Normal Fuel System Pressure Using (J-48876 Tool)

Port Engine 600 rpm Engine 1800 rpm
Priming Port (psi) 72 to 80 100 to 120

Normal Fuel System Pressure Using (W47058914910009 Tool)

Port Engine 600 rpm Engine 1800 rpm
Low Pressure Pump Inlet (LPPI) (in Hg) -4 to -8 -11 to -14

Normal Fuel System Pressures Using (DDDL)

Instruments Engine 600 rpm Engine 1800 rpm
LPPO Fuel Pressure (psi) 72 to 80 100 to 126

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1.2 Amplified Pressure Common Rail System

1.2.1 Fuel System -Two-Filter System

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1. High Pressure Fuel Pump

2. Low Pressure Fuel Pump
3. High Pressure Fuel Pump Inlet
4. High Pressure Fuel Pump Outlet
5. Low Pressure Fuel Pump Inlet
6. Low Pressure Fuel Pump Outlet
7. Water-in-Fuel Sensor
8. Priming Valve w/Dust cap
9. Fuel Filter Module
10. Fuel Rail Pressure Sensor
11. Fuel Injector
12. Fuel Rail
13. Fuel Return from Pressure Limiting Valve
14. Pressure Limiting Valve
15. Fuel Return from Fuel Injectors Amplifiers
16. Fuel Return from Fuel Injector Needle Valves
17. Low Pressure Fuel Sensor
18. Coalescer/Final Filter
19. Pressure Limiting Valve (PLV)
20. Needle Return Line
21. Needle Return Pressure Control Valve
22. Hand Primer Pump
23. Amplifier Return Line
24. Fuel Prefilter

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Fig 1.3, KM59 GEN1 Fuel System

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1. High Pressure Fuel Pump

2. Low Pressure Fuel Pump
3. High Pressure Fuel Pump Inlet
4. High Pressure Fuel Pump Outlet
5. Low Pressure Fuel Pump Outlet
6. Low Pressure Fuel Pump Inlet
7. Low Pressure Relief Valve
8. Water-in-Fuel Sensor
9. Priming Valve w/Dust cap
10. Fuel Filter Module
11. Fuel Rail Pressure Sensor
12. Fuel Injector
13. Fuel Rail
14. Fuel Return from Pressure Limiting Valve
15. Pressure Limiting Valve
16. Fuel Return from Fuel Injectors Amplifiers
17. Fuel Return from Fuel Injectors Needle Valves
18. Low Pressure Fuel Sensor
19. Coalescer/Final Filter
20. Amplifier Return Line
21. Needle Return Line
22. Needle Return Pressure Control Valve
23. Hand Primer Pump
24. PLV Return Line
25. Fuel Prefilter

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Fig 1.4, KM63 GEN2 Fuel System

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1.3 Fuel System Priming

1.3.1 Priming the Fuel System - KM63 GEN2 - Two-Filter 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.
The KM63 GEN2 fuel system requires higher priming pressures than previous fuel systems; it is important that
only Detroit® approved priming tools are used. The use of other priming tools may not properly prime the
lubrication circuit on the high pressure fuel pump, leading to severe damage to the pump and/or other fuel system
components. See Figure 1 for location of the High Pressure (HP) flange. See Figures 2 and 3 for identification
purposes.

Fig 1.5, Location of the HP Flange

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Fig 1.6, KM59 GEN1 HP Flange

Fig 1.7, KM63 GEN2 HP Flange

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Detroit approved priming tools for the KM63 GEN2 fuel system:
• DAVCO Shop Pro FXP 95
• 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 (leaks, forgot to connect hose, etc.), depress the
STOP button.
2. Turn the priming tool ON.
3. Prime the fuel system for TWO (2) minutes.

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

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.

4. With the priming tool still CONNECTED and PRIMING , start the engine and run at idle (600 rpm) for ONE
(1) minute.
5. Turn the priming tool OFF and close the ball valve.
6. Increase engine speed to 1500 rpm for ONE (1) additional minute.
7. Reduce engine speed to idle (600 rpm).
8. 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.
9. Take the unit for a 15-minute road test to purge all remaining air from the fuel system.

1.3.2 Priming the Fuel System - KM59 GEN1 - Two-Filter 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.
The KM59 GEN1 fuel system requires specific priming pressures to properly prime the lubrication circuit on the
high pressure pump. To prevent severe damage to the pump and/or other fuel system components, it is important
that only a Detroit approved priming tool is used. See Figure 1 for location of the high pressure flange. See
Figures 2 and 3 for identification purposes.

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Fig 1.8, Location of the HP Flange

Fig 1.9, KM59 GEN1 HP Flange

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Fig 1.10, KM63 GEN2 HP Flange

Detroit approved priming tools for the KM59 GEN1 fuel system:
• DAVCO Shop Pro FXP 95
• 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 (leaks, forgot to connect hose, etc.), depress the
STOP button.
2. Turn the priming tool ON.
3. Prime the fuel system for TWO (2) minutes.

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

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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.

4. With the priming tool still CONNECTED and PRIMING , start the engine and run at idle (600 rpm) for ONE
(1) minute.
5. Turn the priming tool OFF and close the ball valve.
6. Increase engine speed to 1500 rpm for ONE (1) additional minute.
7. Reduce engine speed to idle (600 rpm).
8. 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.
9. Take the unit for a 15-minute road test to purge all remaining air from the fuel system.

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1.4 Fuel System Draining Procedure

1.4.1 Draining the Fuel System Using J-48710 Prior to Repairs - Two-
Filter System

Service Tools Used in the Procedure

Tool Number Tool Description Tool Graphic

J-48710 Air Pressure Test Kit, Fuel System

Fuel System Tool Update Kit without an

W470589039100 MCM (Motor Control Module) cooler

Drain the fuel system as follows:

WARNING
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

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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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.

NOTICE
DO NOT remove the return line from the fuel filter module.

4. Remove the fuel feed line from the fuel filter module.
5. Remove the fuel tank fill caps.
6. Using W470589039100, install J-48710 fuel pressure test kit onto the fuel feed port at the fuel filter module.
Note : The high pressure side of the fuel system cannot be drained using air pressure, due to the fuel injectors
being in a closed state which will not return fuel to the return side of the fuel system.
7. Use regulator and adjust the system pressure to 483 kPa (70 psi).
8. After six minutes, the system will be drained of fuel.
9. Remove test equipment and install the fuel tank fill caps.

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1.5 Fuel Filter Module

1.5.1 Description and Operation of the Fuel Filter Module and Related
Parts –Two-Filter System
The fuel filter module is located on the left side of the cylinder block. The fuel filter module separates out water in
the fuel and filters out debris particles. The fuel filter module consists of the following components:
• Mechanical Drain Valve - used to remove water from the water drain bowl.
• Fuel Supply and Fuel Return Fittings - used to connect the fuel tank to the fuel filter module.
• Fuel Priming Valve - used for priming the fuel system when fuel is drained from the fuel system. The fuel
priming valve feeds fuel into the fuel filter module before the coalescer/final filter.
• Coolant Outlet Fitting - used for coolant to exit the fuel filter module after it has passed through the fuel
cooler.
• Low Pressure Sensor - used to sense fuel pressure in the low pressure circuit of the fuel system.
• Fuel prefilter - where large debris particles are removed from the fuel.
• Fuel coalescer/final filter - where water in the fuel is separated and small debris particles are removed from
the fuel.
• Hand Primer Pump - used to manually prime the fuel system when the engine is run out of fuel.
• Return from the Pressure Limiting Valve (PLV), Fuel Injector Needle and Amplifier - used for fuel returning
from the PLV, fuel injector needle and amplifier return circuits.
• Fuel Connection to Low Pressure Pump - used to send prefitered fuel to the low pressure pump.
• Return Connection from Low Pressure Pump - used to receive pressurized fuel from the low pressure
pump.
• Fuel Connection to High Pressure pump - used to send water-separated/final-filtered fuel to the high
pressure pump.
• Fuel Connection from the High Pressure pump - used to receive returned fuel from the high pressure pump.
• Pressure Relief Valve - (KM63 GEN2 ONLY) used to regulate the maximum fuel pressure of the low
pressure fuel circuit.
• Water-in-Fuel sensor - used to sense water levels in the water drain bowl.
• Water Drain Bowl - used to store water that has been separated from the fuel.

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1. Mechanical Drain Valve

2. Fuel Supply Fitting
3. Fuel Priming Valve w/Dust Cap
4. Coolant Outlet Fitting
5. Low Pressure Fuel Sensor
6. Coalescer/Final filter
7. Hand Primer Pump
8. Fuel Prefilter
9. Return from PLV, Fuel Injector Needle and Amplifier
10. Needle Return Pressure Control Valve
11. Fuel Connection to High Pressure Pump
12. Return Connection from High Pressure Pump
13. Fuel Connection to Low Pressure Pump
14. Fuel Return Fitting
15. Fuel Connection from Low Pressure Pump
16. Water-in-Fuel Sensor
17. Water Drain Bowl

Fig 1.11, KM59 GEN1 Fuel Filter Module

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1. Mechanical Drain Valve

2. Fuel Supply Fitting
3. Fuel Priming Valve w/Dust Cap
4. Coolant Outlet Fitting
5. Low Pressure Fuel Sensor
6. Coalescer/Final filter
7. Hand Primer Pump
8. Fuel Prefilter
9. Return from PLV, Fuel Injector Needle and Amplifier
10. Needle Return Pressure Control Valve
11. Fuel Connection to High Pressure Pump
12. Return Connection from High Pressure Pump
13. Fuel Connection from Low Pressure Pump
14. Fuel Return Fitting
15. Fuel Connection to Low Pressure Pump
16. Low Pressure Relief Valve
17. Water-in-Fuel Sensor
18. Water Drain Bowl

Fig 1.12, KM63 GEN2 Fuel Filter Module

1.5.2 Removal of the Fuel Filter Module – Two-Filter System

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

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2. Disconnect the batteries. Refer to OEM procedures.

3. Open the hood.
4. If needed, remove the bumper. Refer to OEM procedures.
5. Drain cooling system. Refer to OEM procedures. Refer to section "Cooling System Drain Procedure"

WARNING
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.

6. Drain the fuel filter module by using shop air pressure. Refer to section "Draining the Fuel System Using J-48710 Prior to
Repairs - Two-Filter System" .

7. Remove the chassis fuel feed and return lines. Refer to OEM procedures.
8. Disconnect the electrical harness connectors from the water-in-fuel and the low pressure fuel sensors.
9. Disconnect the plastic clip holding the low pressure fuel sensor harness on to the fuel filter module.
10. Disconnect the low pressure fuel lines from the fuel filter module. Refer to section "Removal of the Low Pressure Fuel
Pump Lines - Two-Filter System" .

11. Disconnect the needle, amplifier, and pressure limiting valve return lines. Refer to section "Removal of the Needle,
Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System" .

12. Remove bolts securing coolant line clips to the fuel filter module and oil/coolant filter module.
13. Disconnect and remove the coolant line from the air compressor, fuel filter and oil/coolant filter module.
14. Inspect the coolant line for damage; replace if necessary.
15. Remove the five mounting bolts securing the fuel filter module to the cylinder block.
16. Remove the fuel filter module.
17. Remove and discard the fuel cooler rubber coupling from the engine block.

1.5.3 Disassembly of the Fuel Filter Module – Two Filter System

1. Remove the fuel cooler from the fuel filter module. Refer to section "Removal of the Fuel Cooler - Two Filter System" .
2. Remove the fuel prefilter from the fuel filter module. Refer to section "Removal of the Fuel Prefilter – Two Filter System" .
3. Remove the water coalescer/final filter from the fuel filter module. Refer to section "Removal of the Coalescer/Final
Filter – Two Filter System " .

4. Remove the prefilter drain back ball from the fuel filter module.
5. Remove the coalescer/final filter stand-pipe from the fuel filter module. Refer to section "Removal of the
Coalescer/Final Filter Stand Pipe - Two-Filter System" .

6. Remove the water drain bowl from the fuel filter module. Refer to section "Removal of the Water Drain Bowl – Two-Filter
System" .

7. Remove the hand primer from the fuel filter module. Refer to section "Removal of the Hand Primer – Two-Filter System" .
8. Remove the low pressure fuel sensor from the fuel filter module. Refer to section "Removal of the Low Pressure Fuel
Sensor – Two-Filter System" .

Note : KM59 GEN1 fuel filter module return lines are sourced to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are sourced to the module with a mounting plate attached to the
PLV return line.
9. For KM63 GEN2 only: Remove the pressure relief valve from the fuel filter module. Refer to section "Removal of
the Pressure Relief Valve -Two-Filter System" .

10. Remove the needle return pressure control valve from the fuel filter module. Refer to section "Removal of the
Needle Return Pressure Control Valve – Two-Filter System " .

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11. Remove the fuel feed line and fuel return line fittings from the fuel filter module. Discard the O-ring seal.
12. Remove the priming fitting from the fuel filter module. Discard the O-ring seal.
13. Remove the 90 degree coolant fitting from the side of the fuel filter module. Discard the O-ring seal.

1.5.4 Assembly of the Fuel Filter Module - Two Filter System

1. Install a new O-ring seal on to the 90-degree coolant fitting.
2. Lubricate the O-ring seal on the 90-degree coolant fitting with a light coat of clean coolant.
3. Install the 90-degree coolant fitting on to the side of the fuel filter module. Torque bolts to 4 to 5 N·m (35 to
44 lb·in.).
4. Install a new O-ring seal on to the priming fitting.
5. Install the priming fitting on to the fuel filter module. Torque to 21 to 24 N·m (15 to 18 lb·ft).
6. Install a new O-ring seal on to the fuel feed line and fuel return line fittings.
7. Lubricate the O-rings on the fittings with a light coat of clean diesel fuel.
8. Install the fuel feed line and fuel return line fittings on to the fuel filter module. Torque to 107 to 116 N·m (79
to 85 lb·ft).
9. Install the needle return pressure control valve on to the fuel filter module. Refer to section "Installation of the
Needle Return Pressure Control Valve – Two-Filter System" .

Note : KM59 GEN1 fuel filter module return lines are sourced to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are sourced to the module with a mounting plate attached to the
PLV return line.
10. For KM63 GEN2: Install the pressure relief valve on to the fuel filter module. Refer to section "Installation of the
Pressure Relief Valve – Two-Filter System " .

11. Install the low pressure fuel sensor on to the fuel filter module. Refer to section "Installation of the Low Pressure Fuel
Sensor -Two-Filter System" .

12. Install the hand primer on to the fuel filter module. Refer to section "Installation of the Hand Primer – Two-Filter System" .
13. Install the water drain bowl on to the fuel filter module. Refer to section "Installation of the Water Drain Bowl – Two-Filter
System" .

14. Install the coalescer/final filter stand-pipe on to the fuel filter module. Refer to section "Installation of the
Coalescer/Final Filter Stand Pipe - Two-Filter System" .

15. Install the prefilter drain back ball into the fuel filter module.
16. Install the water coalescer/final filter into the fuel filter module. Refer to section "Installation of the Coalescer/Final Filter
- Two-Filter System" .

17. Install the fuel prefilter into the fuel filter module. Refer to section "Installation of the Fuel Prefilter - Two-Filter System" .
18. Install the fuel cooler on to the fuel filter module. Refer to section "Installation of the Fuel Cooler – Two Filter System" .

1.5.5 Installation of the Fuel Filter Module – Two Filter System

1. Lightly lubricate the fuel cooler rubber coupling with clean engine coolant and install the coupling into the
cylinder block.
2. Install the fuel filter module and the five mounting bolts securing the fuel filter module to the cylinder block.
Torque to 60 N·m (44 lb·ft).
3. Install and connect the coolant line from the air compressor, fuel filter and oil/coolant filter module.
4. Install the mounting bolts securing coolant line clips to the fuel filter module and oil/coolant filter module.
Torque to 30 N·m (22 lb·ft).
5. Install the needle, amplifier, and pressure limiting valve return lines. Refer to section "Installation of the Needle,
Amplifier, and Pressure Limiting Valve Return Lines – Two-Filter System" .

6. Install the low pressure fuel lines. Refer to section "Installation of the Low Pressure Fuel Pump Lines – Two-Filter System" .
7. Connect the plastic clip holding the low pressure fuel sensor harness on to the fuel filter module.

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8. Connect the electrical harness connectors from the water-in-fuel and the low pressure fuel sensors.
9. Install the chassis fuel feed and return lines on to the fuel filter module. Refer to OEM procedures.
10. Fill the engine with coolant.
11. If removed, install the bumper. Refer to OEM procedures.
12. Connect the batteries. Refer to OEM procedures.
13. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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

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.

14. Start and run the engine.

1.5.6 Description and Operation of the Hand Primer- Two-Filter System

A fuel hand primer is incorporated into the fuel filter module. The hand primer can be used anytime the system is
run out of fuel. Average time to fill the module after running out of fuel is approximately two minutes or 120 pumps.
Fuel for the priming circuit is taken after the prefilter and is deposited before coalescer/final filter.

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1. Hand Primer

Fig 1.13, KM63 GEN2 shown, KM59 GEN1 similar Hand Primer.

1.5.7 Removal of the Hand Primer – Two-Filter System

1. Route the hand primer handle clockwise till it fully seats on the primer housing.
2. Remove the hand primer from the fuel filter module.

1.5.8 Inspection of the Hand Primer - Two- Filter System

1. Visually inspect the metal and plastic housing for damage. If damage is found, replace primer assembly.
Note : The illustration shown below is a Hand Primer.
2. Visually inspect the O-ring seals (1) and plunger (2) for damage. If damage is found, replace primer
assembly.

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1.5.9 Installation of the Hand Primer – Two-Filter System

1. Lubricate the hand primer O-rings with a light coat of clean diesel fuel.
2. Route the hand primer handle clockwise until it fully seats on the primer housing.
3. Install the hand primer on to the fuel filter module. Torque to 20 to 22 N·m (15 to 16 lb·ft).
4. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

1.5.10 Description and Operation of the Fuel Filter Module Housing

Half - Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
The fuel filter module housing half is located on the right side of the fuel filter module. The prefilter, prefilter check
ball, needle return pressure control valve, hand primer, hand primer valve and (pressure relief valve for KM63
GEN2 only) are located on the fuel filter module housing half. The gallery bypass valve and hand primer valves
are located behind the fuel filter module housing half.

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1. Fuel Filter Module Housing Half Mounting Bolts

2. Fuel Filter Module Housing Half
3. Fuel Filter Module Housing Half Gasket
4. Fuel Filter Module

Fig 1.14, Fuel Filter Module Housing Half

1.5.11 Removal of the Fuel Filter Module Housing Half – Two-Filter

System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.

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.

1. Steam clean the engine.

2. Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs - Two-Filter System" .
3. Remove the chassis fuel feed and return lines. Refer to OEM procedures.
4. Remove the low pressure fuel lines from the engine. Refer to section "Removal of the Low Pressure Fuel Pump Lines -
Two-Filter System" .

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5. Drain cooling system. Refer to OEM procedures.

6. Remove bolts securing coolant line clips to the fuel filter module and oil/coolant filter module.
7. Disconnect and remove the coolant line from the air compressor, fuel filter and oil/coolant filter module.
8. Remove the return line p-clip bolt securing the return lines to the mounting bracket.
9. Using J-48836 and J-48770, remove the needle and amplifier return lines from the rear of the cylinder head
and discard the sealing washers.
10. Remove the PLV return line from the fuel rail and discard sealing washers.
11. For KM63 GEN2, remove the two bolts securing the return lines to the fuel filter module. For KM59 GEN1,
remove the three banjo bolts securing the needle, amplifier and PLV from the fuel filter module and discard
the sealing washers.
12. For KM63 GEN2, remove the needle, amplifier and PLV lines from the fuel filter module and discard the O-
ring seals.
13. Remove the fuel filter module housing half mounting bolts (1) and remove housing half (2) from the fuel
filter module (4).
14. Remove and discard the fuel filter module housing half gasket (3).

1.5.12 Inspection of the Fuel Filter Module Housing Half – Two-Filter

System
1. Visually inspect the needle return pressure control valve housing threads (1) and the needle return
pressure control valve O-ring lands (2) for damage. If damage is found, replace the fuel filter module
housing half.
1.a The illustration shown below is a Needle Return Pressure Control Valve Housing.

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2. Visually inspect the prefilter check ball seat (1), prefilter cap housing threads (2), hand primer housing
threads (3), hand primer O-ring lands (4), prefilter O-ring lands (5) and prefilter cap O-ring land (6) for
damage. If damage is found, replace the fuel filter module housing half.
2.a The illustration shown below is a Prefilter and Hand Primer Housings.

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3. Visually inspect the fuel line bores (1), fuel line securing threads (2), return line sealing surface (3), return
line securing threads (4), hand primer valve bore (5) throttle valve (6), (KM63 GEN2) pressure relief valve
housing threads (7) and (KM63 GEN2) pressure relief valve bores (8) for damage. If damage is found,
replace the fuel filter module housing half.
3.a The illustration shown below is a KM59 GEN1 Fuel Filter Module Housing Half.

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3.b The illustration shown below is a KM63 GEN2 Fuel Filter Module Housing Half.

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1.5.13 Installation of the Fuel Filter Module Housing Half - Two-Filter

System
Install as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Install a new fuel filter module housing half gasket (3) on to the fuel filter module (4).
2. Install fuel filter module housing half (2) on to the fuel filter module (4) and install the fuel filter module
housing half mounting bolts (1).

3. Torque the fuel filter module housing half mounting bolts in the correct sequence from 1 thru 9 to 4.5-5.5
N·m (40-49 lb·in.) then to 11-13 N·m (97-115 lb·in.). Refer to illustrations below for correct torque sequence.
3.a The illustration shown below is a KM59 GEN1 fuel filter module housing half torque sequence.

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3.b The illustration shown below is a KM63 GEN2 fuel filter module housing half torque sequence.

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4. Using new sealing washers, install the needle and amplifier return line fittings to the cylinder head. Torque
to 55-60 N·m (40-44 lb·ft).
5. For KM63 GEN2: Lubricate new o-rings with a light coat of clean diesel fuel.
6. For KM63 GEN2: Install the needle, amplifier and PLV return lines on to the fuel filter module. For KM59
GEN1, install the return lines on to the fuel filter module with new sealing washers. Hand tighten the lines.
Do not torque at this time.
7. Install the needle and amplifier return lines on to the needle and amplifier return line fittings at the rear of
the cylinder head. Hand tighten the return lines. Do not torque at this time.
8. Install the PLV return line on to the fuel rail with new sealing washers. Hand tighten the line. Do not torque
at this time.
9. Install the return lines p-clip on to the mounting bracket. Torque to 15 N·m (11 lb·ft).
10. Using J-48836, torque the needle and amplifier return lines on to the needle and amplifier return line fittings
at the rear of the cylinder head to 25 N·m (18 lb·ft).
11. Torque the PLV line to the fuel rail to 30-33 N·m (22-24 lb·ft).
12. For KM63 GEN2: Install the two bolts securing the return lines to the fuel module. Torque to 30 N·m (22
lb·ft ). For KM59 GEN1: Torque the return lines to the fuel module to 30-33 N·m (22-24 lb·ft).
13. Install and connect the coolant line to the air compressor, fuel filter and oil/coolant filter module.
14. Fill the engine with coolant. Refer to OEM procedures.
15. Install the low pressure fuel lines on to the engine. Refer to section "Installation of the Low Pressure Fuel Pump Lines –
Two-Filter System" .

16. Install the chassis fuel feed and return lines. Refer to OEM procedures.
17. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.6 Fuel Filtration and Fuel Tank Cleaning

1.6.1 Fuel Filtration and Fuel Tank Cleaning (After a High Pressure
Fuel Pump Failure)

.. Refer to section "Metal in the Fuel System – Two-Filter Fuel System"

.. Refer to section "Metal in the Fuel System – Three-Filter Fuel System"

IMPORTANT: Always follow Environmental Protection Agency (EPA) and local regulations when disposing of
contaminated fuel.
Clean 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.
4. Is the vehicle equipped with frame-mounted fuel/water separator(s)?
4.a Yes; Go to step 5.
4.b No; install a frame-mounted fuel/water separator and then Go to step 11.
5. Remove the frame-mounted fuel/water separator(s) from the system.
6. Remove and discard the filter element. Thoroughly clean the filter housing.
7. Install a new frame-mounted filter element into the housing.
8. Disconnect the fuel supply line from the frame-mounted fuel/water separator to the engine fuel filter
module, and flush the line with clean diesel fuel.
9. If removed from the vehicle, install the frame-mounted fuel/water separator(s) onto the vehicle and leave
the fuel lines disconnected.
10. Install the fuel supply line from the frame-mounted fuel/water separator to the new engine fuel filter module.
11. If connected, disconnect the chassis return line from the engine fuel filter module.
12. If connected, disconnect the chassis supply line from the frame-mounted fuel/water separator.
13. Connect the Davco Shop Pro95 (or equivalent primer with 7 micron filter) to the fuel/water separator inlet
line from the chassis and return line from the engine fuel module and back flush separately, each with one
gallon of clean fuel back to the tank.
14. Drain or pump all of the fuel from the tank(s) into a suitable clean storage container. Where possible, use
the Davco Shop Pro95 (or equivalent primer with 7 micron filter) to pump the fuel from the tank to the
storage container to filter/separate the metal debris.
15. Remove the tank(s) from the vehicle. Refer to the Original Equipment Manufacturer (OEM) procedures.
16. Thoroughly steam clean the inside of the tank(s) until all water leaving the drain hole looks clean.
17. Install a magnetic drain plug (Grainger part number 5044121) and cap any other open outlets.
Note : It may not be possible to remove all of the metal debris from the tanks, especially if they are baffled-style
tanks. This procedure should remove most of the metal and any remaining metal particles will be caught in the
fuel filters.

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18. Put two gallons of clean diesel fuel in the tank, and install the cap. Slosh the diesel around in the tank
making sure it reaches all interior surfaces. This should collect most of any remaining contaminants in the
tank.
19. Drain this fuel from the tank into a suitable container. Dispose of this contaminated fuel in an appropriate
manner.
20. Remove, clean, and reinstall the magnetic drain plug in the fuel tank.
21. Install the fuel tank(s) on the vehicle. Refer to the OEM procedures.
22. Using the Davco Shop Pro95 (or equivalent primer with 7 micron filter), filter the fuel again while filling the
vehicle fuel tanks from the storage tank.

CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
23. Connect the batteries.
24. If all repairs are complete, prime the fuel system and check for fuel leaks.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

25. Close the hood.

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1.7 Gallery Bypass Valve

1.7.1 Description and Operation of the Gallery Bypass Valve – Two-
Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
The gallery bypass valve is incorporated into the fuel filter module. The gallery bypass valve creates a restriction
for the fuel accumulator. It is designed to regulate the amount of fresh fuel that is used from the fuel tank
compared to the amount of fuel that is used from the fuel accumulator. This valve opens between 0.2 to 0.3 bar
(2.9 to 4.3 psi).

Fig 1.15, KM59 GEN1 Gallery Bypass Valve

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Fig 1.16, KM63 GEN2 Gallery Bypass Valve

1.7.2 Removal of the Gallery Bypass Valve – Two-Filter System

1. Remove the fuel filter module housing half. Refer to section "Removal of the Fuel Filter Module Housing Half – Two-Filter
System" .

2. Remove and discard the gallery bypass valve (2) and hand primer outlet valve (1) from the fuel filter
module.

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3. Remove and discard the hand primer inlet valve (1) from the fuel filter module housing half.

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1.7.3 Installation of the Gallery Bypass Valve – Two-Filter System

Install as follows:

NOTICE
Hand primer valves MUST be installed with springs facing outwards.

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Lubricate the new hand primer valves and new Gallery bypass valve O-rings with a light coat of clean diesel
fuel.
2. Install a new hand primer valve (1) on to the fuel filter module housing half.

3. Install the new gallery bypass valve (2) and the new hand primer valve (1) on to the fuel filter module. For
KM63 GEN2, torque the gallery bypass valve (2) to 4 N·m (35 lb·in.).

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4. Install the fuel filter module housing half. Refer to section "Installation of the Fuel Filter Module Housing Half - Two-Filter
System" .

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1.8 Fuel Filters

1.8.1 Description and Operation of the Fuel Prefilter - Two-Filter
System
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
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. Check Ball
4. Fuel Inlet
5. Fuel Outlet
6. Prefilter Element

Fig 1.17, Fuel Prefilter

1.8.2 Removal of the Fuel Prefilter – Two Filter System

Remove as follows:
1. Using a 36 mm socket, unscrew the prefilter cap.

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2. Pull the cap and prefilter straight up and out of the fuel filter housing.
3. 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.

4. Discard the prefilter.

5. Inspect inside the housing for any large debris; clean housing as needed.
6. Discard the prefilter cap seal ring.

1.8.3 Installation of the Fuel Prefilter – Two Filter System

Note : If a filter service is being performed, replace all other filters before priming.
1. Install a new prefilter cap seal ring on to the prefilter cap.
2. Snap new prefilter into the prefilter cap.
3. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal ring and the prefilter seals (1).

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4. Install the prefilter into the fuel filter module.

5. Turn the cap counterclockwise until a click sound is made, then turn clockwise and hand tighten.
6. Torque prefilter cap to 55 to 60 N·m (41 to 44 lb·ft).
7. Once all required filters have been changed, prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

1.8.4 Description and Operation of the Coalescer/Final Filter - Two-

Filter System
The coalescer/final filter element consists of many layers and has the task of separating the water contained in the
fuel and filtering small dirt particles. The coalescer/final filter element has fuel flowing from outside to inside. The
special construction ensures that small water droplets either remain in the coalescer/final filter 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 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.
Water level in the water bowl is detected by using a Water-In-Fuel (WIF) 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. The ventilation bore also guarantees full
use of the coalescer/final filter element. When removing the coalescer/final filter 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.
The smallest dirt particles are filtered out at a very high separation rate by the coalescer/final filter element. The
cleaned fuel is 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 or water can reach the high pressure fuel pump.

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1. Mechanical Drain Valve

2. Water Bowl
3. Coolant Connection
4. Separated Water
5. Filtered Fuel
6. Air Purge
7. Coalescer/Final Element
8. Fuel In (from feed pump)
9. Water-In-Fuel (WIF) Sensor

Fig 1.18, Coalescer/Final Filter

1.8.5 Removal of the Coalescer/Final Filter – Two Filter System

Remove the water coalescer/final filter as follows:

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NOTICE
Do not tilt the water coalescer/final filter when removing it from the housing. Possible
damage to the water coalescer/final filter or stand pipe may occur.

1. Using a 36mm socket, unscrew the water coalescer/final filter cap.

2. Pull the cap and water coalescer/final filter straight up and allow the fuel to drain back.
3. Remove the water coalescer/final filter (2) from the water coalescer/final filter cap (1) by placing the filter on
a solid surface with the drain back plug location at 12 o'clock (3) and applying pressure on the water
coalescer/final filter cap at an angle.

4. Discard the water coalescer/final filter.

5. Inspect inside the housing for any large debris; clean housing as needed.
6. Discard water coalescer/final filter cap seal ring.

1.8.6 Installation of the Coalescer/Final Filter - Two-Filter System

Install the water coalescer/final filter as follows:
Note : If a fuel filter service is being performed, replace all other fuel filters before priming the fuel system.
1. Install a new seal ring on to water coalescer/final filter cap.
2. Snap a new water coalescer/final filter into the water coalescer/final filter cap.
3. Apply a light coat of Parker super O-lube or petroleum-based lithium grease to the water coalescer/final
filter cap seal ring and drain back plug seal ring (C).Apply a heavy coat of Parker super O-lube or
petroleum-based lithium grease to the upper (A) and lower seals (B) on the water coalescer/final filter.

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The illustration below shows the proper amount of lubricant to use on the upper and lower seals.

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4. Install the water coalescer/final filter into the fuel filter module.
Note : Viewing the fuel filter module from the top, the drain back port is located at 10 o'clock.
5. Turn the water coalescer/final filter cap counterclockwise until the drain back plug has located the
drain back port. Apply light pressure to the top of the water coalescer/final filter cap to seat the drain back
plug into the drain back port, hand tighten the filter cap by turning the cap clockwise.
6. Torque water coalescer/final filter cap to 55 to 60 N·m (41 to 44 lb·ft).
7. Once all required filters have been changed, prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

1.8.7 Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter

System
1. Open the mechanical drain valve on the fuel filter module to drain the fuel filter module.
2. Remove the water Coalescer/Final Filter from the fuel filter module. Refer to section "Removal of the Coalescer/Final
Filter – Two Filter System " .

3. Remove the three bolts securing the stand pipe to the fuel filter module.
4. Pulling straight up on the stand pipe, remove the stand pipe from the fuel filter module.
5. Remove and discard the O-ring seals from the stand-pipe.

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6. Remove any debris from the fuel filter module.

1.8.8 Installation of the Coalescer/Final Filter Stand Pipe - Two-Filter

System
Install as follows:

NOTICE
Do not over tighten the mechanical drain valve. Failure to properly tighten the mechanical
drain valve may cause damage to the mechanical drain valve and housing.

1. Close the mechanical water drain valve.

2. Install new O-rings on to the stand pipe.
3. Lubricate the O-rings on the stand pipe with a light coat of clean diesel fuel.
4. Install the stand pipe in to the fuel module, so the drain back port (1) is located at 10 o'clock.

5. Install the three stand pipe mounting bolts. Torque to 6-8 N·m (53-70 lb·in).
6. Install the coalescer/final filter. Refer to section "Installation of the Coalescer/Final Filter - Two-Filter System" .
7. Once all required filters have been changed, prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.9 Water Drain Bowl

1.9.1 Removal of the Water Drain Bowl – Two-Filter System
1. Open the mechanical drain valve on the fuel filter module to drain the fuel filter module.
2. Remove the water drain bowl mounting bolts.
3. Remove the water drain bowl from the fuel filter module.
4. Remove and discard the water drain bowl O-ring.

1.9.2 Installation of the Water Drain Bowl – Two-Filter System

Install as follows:

NOTICE
Do not over tighten the mechanical drain valve. Failure to properly tighten the mechanical
drain valve may cause damage to the mechanical drain valve and housing.

1. Close the mechanical water drain valve.

Note : If installing a new water drain bowl, transfer the drain hose and install the drain hose clamp.
2. Clean the sealing area around the fuel filter module and water drain bowl.
3. Install a new water drain bowl O-ring on to the water drain bowl.
4. Lubricate the water drain bowl O-ring with a light coat of clean diesel fuel.
5. Install the water drain bowl on to the fuel filter module.
6. Install the water drain bowl mounting bolts. Torque the water drain bowl mounting bolts to 20 to 22 N·m (15
to 16 lb·ft).

NOTICE
Ensure MCM is not contaminated with diesel fuel.

7. Prime the fuel system.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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

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.

8. Start the engine and check for leaks.

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1.10 Fuel Cooler

1.10.1 Description and Operation of the Fuel Cooler - Two Filter
System
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

2. Coolant Outlet from Fuel Filter Module
3. Fuel Outlet
4. Fuel Cooling Ducts
5. Coolant Outlet
6. Coolant Inlet
7. Fuel Cooler
8. Fuel Inlet

Fig 1.19, KM63 GEN2 Shown, KM59 GEN1 Similar

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1.10.2 Removal of the Fuel Cooler - Two Filter System

1. Remove the fuel filter module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System" .
2. Remove the bolts securing the fuel cooler to the fuel filter module.
3. Remove and discard the fuel cooler gaskets from the fuel filter module.

1.10.3 Inspection of the Fuel Cooler – Two-Filter System

1. Visually inspect the fuel cooler for leaks, damage or corrosion. If leaks, damage or corrosion are found,
replace the fuel cooler.

1.10.4 Installation of the Fuel Cooler – Two Filter System

1. Lubricate the new fuel cooler gaskets (4) with a light coat of clean diesel fuel.
2. Install the new fuel cooler gaskets (4) in to their correct locations on the fuel filter module (5).
3. Install the fuel cooler (2) on to the fuel filter module (5). Torque the six bolts (1) to 12 to 13 N·m (106 to 115
lb·in).

4. Install the fuel filter module (5). Refer to section "Installation of the Fuel Filter Module – Two Filter System" .

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1.11 Fuel Cooler Delete Bypass Plate

1.11.1 Description and Operation of the Fuel Cooler Delete Bypass
Plate - Two Filter System

The fuel cooler bypass plate is located behind the fuel filter module. The fuel cooler bypass plate replaces the fuel
cooler starting in production as of May 2, 2014. The fuel cooler bypass plate receives fuel from the fuel injector
amplifiers to the fuel filter module and directs flow back to the inlet of the low pressure pump.

1. Fuel Filter Module

2. Fuel Outlet
3. Fuel Cooler Rubber Coupling
4. Fuel Coolant Delete Bypass Plate
5. Fuel Supply
6. A = Fuel Flow

Fig 1.20, KM63 GEN2 Shown, KM59 GEN1 Similar

1.11.2 Removal of the Fuel Cooler Delete Bypass Plate - Two Filter
System

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WARNING
PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.

Remove as follows:
1. Remove the fuel filter module (5). Refer to section "Removal of the Fuel Filter Module – Two-Filter System" .

2. Remove the bolts (1) securing the fuel cooler delete bypass plate (2) to the fuel filter module.
3. Remove and discard the fuel cooler delete bypass plate gaskets (4) from the fuel filter module.

1.11.3 Inspection of the Fuel Cooler Delete Bypass Plate - Two-Filter

System
1. Visually inspect the fuel cooler delete bypass plate for damage or corrosion. If damage or corrosion is
found, replace the fuel cooler bypass plate.

1.11.4 Installation of the Fuel Cooler Delete Bypass Plate - Two Filter
System
1. Lubricate the new fuel cooler delete bypass plate gaskets (4) with a light coat of clean diesel fuel.

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Note : New mounting bolts have self-tapping threads.

Note : When installing the fuel cooler delete bypass plate on to the fuel filter module, un-threaded holes (1) will be
tapped with new threads when new bolts are installed.
2. Install the new fuel cooler delete bypass plate gaskets (4) in to their correct locations on the fuel filter
module (5). See figure above.

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3. Install the fuel cooler delete bypass plate (2) on to the fuel filter module (5). Torque the new mounting bolts
(1) between 12 and 13 N·m (106 and 115 lb·in.).

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4. Install the fuel filter module. Refer to section "Installation of the Fuel Filter Module – Two Filter System" .

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1.12 Low Pressure Fuel Pump

1.12.1 Description and Operation of the Low Pressure Fuel Pump and
Related Parts - Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
Note : KM59 GEN1 high pressure fuel pump is equipped with a two-stage valve and a low pressure relief valve.
Note : KM63 GEN2 high pressure fuel pump is equipped with a two-stage valve.
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
4. Low Pressure Fuel Pump Gasket

Fig 1.21, KM59 GEN1 Low Pressure Fuel Pump

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1. Low Pressure Fuel Pump

2. Drive Coupler
3. High Pressure Fuel Pump
4. Low Pressure Fuel Pump Gasket(s)

Fig 1.22, KM63 GEN2 Low Pressure Fuel Pump

1.12.2 Removal of the Low Pressure Fuel Pump - Two-Filter System

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

WARNING
PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before
removing any component.

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 needed, remove the bumper. Refer to OEM procedures.
5. If needed, remove the splash shield. Refer to OEM procedures.

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.

6. Steam clean engine and housing on high pressure fuel pump.

7. Drain the cooling system. Refer to section "Cooling System Drain Procedure" .
8. For a vehicle with a short (less than 120 inches) Bumper-to-Back-of-Cab (BBC), remove the cold boost
pipe. Refer to section "Removal of the Composite Cold Boost Pipe (Charge Air Pipe)" .
9. For a vehicle with a short (less than 120 inches) Bumper-to-Back-of-Cab (BBC), remove the fuel filter
module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System" .
10. Disconnect the low pressure fuel lines from the high pressure flange. Refer to section "Removal of the Low Pressure
Fuel Pump Lines - Two-Filter System" .

11. Disconnect the quantity control valve electrical connector.

12. Disconnect the plastic clip from the high pressure fuel pump mounting bracket.
13. Remove the coolant line from the cylinder block and air compressor.
14. Remove the bolts attaching the low pressure fuel pump to the high pressure fuel pump.
15. Remove and discard the low pressure pump gasket(s) from the high-pressure fuel pump.
16. Clean the housing around the high pressure fuel pump.
17. Inspect the low pressure fuel pump, drive key, drive coupler and driven key. Refer to section "Inspection of the Low
Pressure Fuel Pump - Two-Filter System " .

1.12.3 Inspection of the Low Pressure Fuel Pump - Two-Filter System

Inspect as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Remove the low pressure fuel pump from the high pressure fuel pump. Refer to section "Removal of the Low
Pressure Fuel Pump - Two-Filter System" .

2. Visually inspect the drive key (1) on the high pressure fuel pump for damage. If damage is found, replace
the high pressure fuel pump.
2.a The illustration shown below is a KM59 GEN1 Low Pressure Fuel Pump Drive Key.

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2.b The illustration shown below is a KM63 GEN2 Low Pressure Fuel Pump Drive Key.

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3. Visually inspect the drive coupler (1) and driven key (2) for damage. If damage is found, replace the high
pressure fuel pump.
3.a The illustration shown below is a KM59 GEN1 Low Pressure Fuel Pump Coupling.

3.b The illustration shown below is a KM63 GEN2 Low Pressure Fuel Pump Coupling.

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Note : For KM63 GEN2 only, the low pressure fuel pump MUST be replaced every time the fuel pump is
disassembled for inspection. The purpose of inspecting the KM63 GEN2 low pressure fuel pump is to verify the
fuel pump has failed.
4. For KM63 GEN2, remove the low pressure fuel pump housing half bolt (1).
4.a The illustration shown below is a Low Pressure Fuel Pump Housing Half Bolt.

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5. Remove the low pressure fuel pump housing half from the low pressure fuel pump housing.
6. Visually inspect the low pressure fuel pump housing half (1), 1ow pressure fuel pump housing (2) and low
pressure fuel pump gears (3) for damage. If damage is found, replace the low pressure fuel pump. For
KM59 GEN1, if no damage is found, install the low pressure fuel pump housing half back on to the low
pressure fuel pump housing. For KM63 GEN2, if no damage is found, replace the low pressure fuel pump.
6.a The illustration shown below is a KM59 GEN1 Low Pressure Fuel Pump Half.

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6.b The illustration shown below is a KM63 GEN2 Low Pressure Fuel Pump Half.

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7. Install the low pressure fuel pump on to the high pressure fuel pump. Refer to section "Installation of the Low
Pressure Fuel Pump - Two-Filter System" .

1.12.4 Installation of the Low Pressure Fuel Pump - Two-Filter System

1. Install a new low pressure fuel pump gasket(s) on to the high pressure fuel pump.
2. Install the drive coupler on to the drive key.
3. Install the low pressure fuel pump on to high pressure pump. Torque bolts to 8 N·m (72 lb·in).
4. Connect the quantity control valve electrical connector.
5. Install the air compressor inlet coolant line to the side of the cylinder block.
6. If removed, install the fuel filter module. Refer to section "Installation of the Fuel Filter Module – Two Filter System" .
7. If removed, install the cold boost pipe. Refer to section "Installation of the Composite Cold Boost Pipe (Charge Air Pipe)" .

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.
9. Fill the cooling system. Refer to section "Cooling System Fill Procedure" .
10. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System" .
Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System" .
11. If removed, install the splash shield. Refer to OEM procedures.
12. If removed, install the bumper. Refer to OEM procedures.
13. Close the hood.

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1.13 Low Pressure Fuel Pump Lines

1.13.1 Description and Operation of Low Pressure Fuel Pump Lines -
Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.

[Link] KM59 GEN1 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.
• The high pressure pump inlet line (1) is used to supply low pressure (water separated) final filtered fuel to
the high pressure fuel pump.
• The high pressure pump outlet line (2) is used to send low pressure return fuel from the high pressure fuel
pump to the fuel filter module.
• The low pressure pump inlet line (3) is used to supply prefiltered fuel to the low pressure pump.
• The low pressure pump outlet line (4) is used to send low pressure fuel from the low pressure pump to the
fuel filter module.

1. High Pressure Pump Inlet Line

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

Fig 1.23, KM59 GEN1 Low Pressure Fuel Pump Lines

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[Link] KM63 GEN2 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.
• The high pressure pump inlet line (1) is used to supply low pressure (water separated) final filtered fuel to
the high pressure fuel pump.
• The high pressure pump outlet line (2) is used to send low pressure return fuel from the high pressure fuel
pump to the fuel filter module.
• The low pressure pump outlet line (3) is used to send low pressure fuel from the low pressure pump to the
fuel filter module.
• The low pressure pump inlet line (4) is used to supply prefiltered fuel to the low pressure pump.

1. High Pressure Pump Inlet Line

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

Fig 1.24, KM63 GEN2 Low Pressure Pump Lines

1.13.2 Removal of the Low Pressure Fuel Pump Lines - Two-Filter

System

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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.

1. Steam clean the engine.

2. Drain the fuel filter module by using shop air pressure. Refer to section "Draining the Fuel System Using J-48710 Prior to
Repairs - Two-Filter System" .

3. Remove the high pressure pump inlet and outlet lines from the fuel filter module and the high pressure
flange.
4. Remove the two bolts holding the wiring harness bracket to the fuel filter module and the low pressure lines
and set aside the wiring harness bracket.
5. Disconnect the plastic clip holding the quantity control valve harness from the low pressure flange.
6. Remove the low pressure fuel pump inlet and outlet lines from the fuel filter module and the high pressure
fuel pump.
7. Remove and discard all O-rings.

1.13.3 Inspection of the Low Pressure Fuel Pump Lines - Two-Filter

System
Inspect as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Visually inspect the low pressure fuel pump lines for damage at the O-ring lands (1), flexible lines (2),
sealing rings (3) and rigid lines (4). If damage is found, replace the damaged low pressure fuel line.
1.a The illustration shown below is a KM59 GEN1 Low Pressure Fuel Pump Lines.

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1.b The illustration shown below is a KM63 GEN2 Low Pressure Fuel Pump Lines.

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1.13.4 Installation of the Low Pressure Fuel Pump Lines – Two-Filter

System
1. Lubricate the new O-rings with a light coat of clean diesel fuel.
2. Install new O-rings on to the high pressure pump inlet and outlet lines and the low pressure fuel pump inlet
and outlet lines.
3. Install the low pressure fuel pump inlet and outlet lines on to the fuel filter module and the high pressure
fuel pump. Torque to 30 N·m (22 lb·ft).
4. Re-install the wiring harness bracket on to the fuel filter module and low pressure lines. Torque to 30 N·m
(22 lb·ft).
5. Install the high pressure pump inlet and outlet lines on to the fuel filter module and the high pressure flange.
Torque to 30 N·m (22 lb·ft).
6. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.14 Needle, Amplifier and Pressure Limiting Valve Return

Lines
1.14.1 Description and Operation of the Needle, Amplifier, and
Pressure Limiting Valve Return Lines – Two-Filter System
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

2. Fuel Filter Module
3. Fuel Rail
4. Fuel Return from Pressure Limiting Valve
5. Fuel Return from Injector Amplifiers
6. Fuel Return for Fuel Injector Needle Valves

Fig 1.25, KM59 GEN1

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1. High Pressure Fuel Pump

2. Fuel Filter Module
3. Fuel Rail
4. Fuel Return from Pressure Limiting Valve
5. Fuel Return from Injector Amplifiers
6. Fuel Return for Fuel Injector Needle Valves

Fig 1.26, KM63 GEN2

1.14.2 Removal of the Needle, Amplifier, and Pressure Limiting Valve

(PLV) Return Lines – Two-Filter System
Remove as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Remove the return line p-clip bolt securing the return lines to the mounting bracket.
2. Remove the return line p-clip from the engine.
3. Using J-48836 to hold the cylinder head fitting, remove the needle return line from the cylinder head fitting
using J-48770.

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4. Remove the PLV return line from the fuel rail and discard sealing washers.
5. Using J-48836 to hold the cylinder head fitting, remove the amplifier return line from the cylinder head fitting
using J-48770.
6. For KM63 GEN2: Remove the two bolts securing the return lines to the fuel filter module. For all others:
Remove the three banjo bolts securing the needle, amplifier and PLV from the fuel filter module.
7. For KM63 GEN2: Remove the needle, amplifier and PLV from the fuel filter module and discard the O-ring
seals.
8. Remove the needle, amplifier and PLV return lines from the engine.
9. Remove both cylinder head fittings from the cylinder head and discard the sealing washers.

1.14.3 Inspection of the Needle, Amplifier, Pressure Limiting Valve

Return Lines – Two-Filter System
1. Visually inspect the needle, amplifier and pressure limiting valve return lines for damage at the cylinder
head fitting sealing surface (1), return line nuts (2), washer sealing surface (3), rigid return lines (4), flexible
return lines (5) and O-ring lands (KM63 GEN2) (6). If damage is found, replace the damaged return line.
1.a The following figure shows the KM59 GEN 1 system.

1.b The following figure shows the KM63 GEN 2 system.

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1.14.4 Installation of the Needle, Amplifier, and Pressure Limiting Valve

Return Lines – Two-Filter System
Install as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Using new sealing washers, install both cylinder head fittings at the rear of the cylinder head. Torque to 55
to 60 N·m (40 to 44 lb·ft).
2. For KM63 GEN2: Lubricate new O-rings with a light coat of clean diesel fuel and install them on to the
needle, amplifier and PLV return lines.
3. Install the needle, amplifier and PLV return lines on to the engine.
4. For KM63 GEN2: Install the needle, amplifier and PLV return lines on to the fuel filter module.
5. Install the needle and amplifier return lines on to the cylinder head fittings at the rear of the cylinder head.
Hand-tighten the return lines. Do not torque at this time.
6. Install the PLV return line on to the fuel rail with new sealing washers. Hand-tighten the line. Do not torque
at this time.
7. For KM59 GEN1: Install the return lines on to the fuel filter module with new sealing washers. Hand-tighten
the lines. Do not torque at this time.
8. Install the return lines p-clip on to the return lines.
9. Install the return lines p-clip on to the mounting bracket. Torque to 15 N·m (11 lb·ft).
10. Using J-48770, torque the needle and amplifier return lines on to the cylinder head fittings at the rear of the
cylinder head to 25 N·m (18 lb·ft).
11. Torque the PLV line to the fuel rail to 30 to 33 N·m (22 to 24 lb·ft).

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NOTICE
For KM59 GEN1 only, when tightening to the specified torque, ensure the amplifier return
line to the fuel filter module does not come in to contact with the intake manifold.

12. For KM63 GEN2: Install the two bolts securing the return lines to the fuel module. Torque to 30 N·m (22
lb·ft ).
For KM59 GEN1: Torque the return lines to the fuel module to 30 to 33 N·m (22 to 24 lb·ft).
13. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.15 Needle Return Pressure Control Valve

1.15.1 Description and Operation of the Needle Control Pressure Valve
– Two-Filter System
The needle control pressure valve is located on the fuel filter module next to the needle return line. Fuel returning
from fuel injector needle valves flows to the needle control pressure control valve. The needle control pressure
valve has the task of regulating back pressure to the injector needle valves. The opening pressure of the valve is
1 bar (14.5 psi) relative to the back pressure while the engine is running.

Fig 1.27, Needle Control Pressure Valve

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Fig 1.28, Location of the Needle Control Pressure Valve (KM63 GEN2 shown, KM59 GEN1 similar)

1.15.2 Removal of the Needle Return Pressure Control Valve – Two-

Filter System

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.

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 needle return pressure control valve (1) and discard the O-ring seals. In the figure below,
KM63 GEN2 is shown; KM59 GEN1 is similar.

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1.15.3 Inspection of the Needle Return Pressure Control Valve – Two-

Filter System
Inspect as follows:

NOTICE
Do NOT use compressed air as it may lodge particles in the filter housing passages.

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
1. Inspect the fuel filter module housing bore for any debris. If debris is present, use a vacuum to remove it
from the filter housing. In the figure below, KM63 GEN2 is shown; KM59 GEN1 is similar.

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2. Visually inspect the needle return pressure control valve ports to ensure no damage is present. If damage
is found, replace the valve.

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3. Remove the c-clip from the valve housing and remove the needle valve.

4. Inspect the valve housing bore/seat and needle valve for damage and debris. If damage is found, replace
the needle return pressure control valve assemble. If debris is found, clean the debris from the valve
housing bore/seat and needle valve.

1.15.4 Installation of the Needle Return Pressure Control Valve – Two-

Filter System
1. Lubricate the O-ring and the threads with a light coat of clean diesel fuel and install the new O-ring on to
the needle return pressure control valve. In the figure below, KM63 GEN2 is shown; KM59 GEN1 is similar.

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2. Install the needle pressure control valve (1) in the fuel filter module and torque to 41 to 46 N·m (30 to 34
lb·ft).

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

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

3. Test for leaks by priming fuel system. Start the engine.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.16 Pressure Relief Valve

1.16.1 Description and Operation of the Pressure Relief Valve - Two-
Filter System

For KM59 GEN1 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).

Fig 1.29, KM59 GEN1 Pressure Relief Valve Location on High Pressure Fuel Pump

For KM63 GEN2 A pressure relief valve (1) is incorporated into the fuel filter module. If the system pressure is too

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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 15 bar
absolute (217 psi).

Fig 1.30, KM63 GEN2 Pressure Relief Valve Location on the Fuel Filter Module

1.16.2 Removal of the Pressure Relief Valve -Two-Filter System

Remove as follows:

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.

1. Steam clean the fuel filter module and high pressure fuel pump.
2. Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs - Two-Filter System"
3. Remove the pressure relief valve (1).
4. Remove and discard the O-ring seals on the pressure relief valve.
4.a The illustration shown below is a KM59 GEN1.

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4.b The illustration shown below is a KM63 GEN2.

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1.16.3 Inspection of the Pressure Relief Valve - Two-Filter System

Inspect as follows:
Note : KM59 GEN1 pressure relief valve is located on the high pressure fuel pump.
Note : KM63 GEN2 pressure relief valve is located on the fuel filter module.
1. Inspect the pressure relief valve housing bore (1) for any debris. If debris is present use a vacuum to
remove the debris from the pressure relief valve housing bore. (Do NOT use compressed air as it may
lodge particles in the housing passages).
1.a The illustration shown below is a KM59 GEN1 Pressure Relief Valve Housing Bore.

1.b The illustration shown below is a KM63 GEN2 Pressure Relief Valve Housing Bore.

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2. Visually inspect the pressure relief valve ports (1), threads (2), and O-rings (3) to ensure no damage is
present. If damage is found replace the pressure relief valve.
2.a The illustration shown below is a KM59 GEN1 Pressure Relief Valve.

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2.b The illustration shown below is a KM63 GEN2 Pressure Relief Valve.

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3. Inspect the valve piston for damage and for being stuck (1); for KM59 GEN1 the valve piston (2) should be
approximately 1.6 mm (0.06 inch) flush from the end of the valve and approximately 14 mm (0.55 inch) from
the end of the valve for KM63 GEN2. If there is damage to the valve piston or if the valve piston is stuck in
the bore, replace the pressure relief valve.
3.a The illustration shown below is a KM59 GEN1 Pressure Relief Valve stuck valve piston and seated
valve piston.

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3.b The illustration shown below is a KM63 GEN2 Pressure Relief Valve stuck valve piston and seated
valve piston.

4. Using a small screwdriver, depress the valve piston in the pressure relief valve. The valve piston should
smoothly slide in and return to the seated position shown below. If the piston sticks, replace the pressure
relief valve. If no trouble is found with the pressure relief valve, immediately reinstall the pressure relief
valve. Refer to section "Installation of the Pressure Relief Valve – Two-Filter System " .
4.a The illustration shown below is a KM59 GEN1 Depressing Valve Piston.

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4.b The illustration show below is a KM63 GEN2 Depressing Valve Piston.

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1.16.4 Installation of the Pressure Relief Valve – Two-Filter System

Install as follows:
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Install new o-rings on to the pressure relief valve.
2. Lubricate the O-ring and the threads with a light coat of clean diesel fuel.
3. For KM 59 GEN1: Thread the pressure relief valve into the high pressure fuel pump and torque to 32 N·m
(25 lb·ft). For KM63 GEN2: Thread the pressure relief valve into the fuel filter module and torque to 41-46
N·m (30-34 lb·ft).

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

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.

4. Test for leaks by priming fuel system. Start the engine.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.17 High Pressure Fuel Pump

1.17.1 Description and Operation of the High Pressure Fuel Pump and
Related Parts – Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
Excess fuel in the high pressure fuel circuit passes through the fuel return line, to the pressure limiting valve and
two fuel return lines (located in cylinder head) from the injectors back into the low pressure fuel circuit.
High Pressure Fuel Pump
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 degrees. With this configuration, two pressure strokes occur for one camshaft revolution of 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 rising compression pressure and the fuel in is
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. The high
pressure fuel pump rotates 1.5 times crankshaft speed.

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1. Intake Valve
2. High Pressure Connection
3. High Pressure Valve
4. High Pressure Pump Elements
5. High Pressure Piston
6. Compression Spring
7. Roller Tappet
8. Camshaft

Fig 1.31, KM59 GEN1 High Pressure Fuel Pump shown, KM63 GEN2 High Pressure Fuel Pump Similar

The low pressure fuel pump suctions fuel through the fuel prefilter, and pumps it back to the fuel filter module
coalescer/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) for KM59 GEN1 and 1300
bar (18,854 psi) for KM63 GEN2. Fuel moves from the high pressure fuel feed lines to the fuel rail, then to the
high pressure fuel injector lines to the fuel 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.

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1. Low Pressure Pump Outlet

2. Low Pressure Pump Inlet
3. High Pressure Pump Inlet
4. Quantity Control Valve
5. High Pressure Pump Fittings
6. Two-Stage Valve (KUeV)
7. High Pressure Pump Outlet

Fig 1.32, KM59 GEN1 High Pressure Fuel Pump

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1. Low Pressure Inlet

2. Low Pressure Pump
3. Low Pressure Outlet
4. Bypass
5. Quantity Control Valve {Fuel Metering Unit (FMU)}
6. Fuel Inlet from Filter (to High Pressure Pump)
7. Pump to the High Pressure Rail
8. Fuel Return
9. Two-stage Valve (KUeV)

Fig 1.33, KM63 GEN2 High Pressure Fuel Pump

Bypass and Quantity Control Valves

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) for the KM59 GEN1 and 0.09 to 0.21 bar (1.3 to 3.0 psi) for the KM63 GEN2.
Located on the high pressure fuel pump is the quantity control valve. 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.

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1. Bypass Valve
2. Quantity Control Valve

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Fig 1.34, KM59 GEN1 Bypass and Quantity Control Valve

1. Bypass Valve
2. Quantity Control Valve

Fig 1.35, KM63 GEN2 Bypass and Quantity Control Valve

1.17.2 Removal of the High Pressure Fuel Pump – Two-Filter System

1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety
steps.
2. Disconnect the batteries. Refer to OEM procedures.
3. Open the hood.
4. If needed, remove the bumper. Refer to OEM procedures.
5. If needed, remove the splash shield. Refer to OEM procedures.
6. Remove the air filter housing. Refer to OEM procedure.
7. Remove the cold boost pipe. Refer to section "Removal of the Cold Boost Pipe (Charge Air Pipe)" .
8. Remove the two bolts from the inspection cover on the bottom of the flywheel housing.
9. Install an engine barring tool (J-46392 or W904589046300 ) to the flywheel housing (1).

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Note : When the flywheel dot is aligned with the edge of the pointer, the engine is at TDC.
10. Rotate the flywheel until the dot located on the inside tooth (2) of the flywheel is aligned with the edge of
pointer (3).
11. Remove the Crankshaft Position (CKP) sensor.
Note : The crankshaft locking tool (W470589001500) MUST sit flush with the flywheel housing to be correctly
installed.
Note : If the crankshaft locking tool (W470589001500) does not sit flush with the flywheel housing, slowly rotate
engine using barring tool until the tool is flush with the flywheel housing.
12. Install the crankshaft locking tool (W470589001500) into the CKP hole.
13. Remove the fuel filter module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System" .

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NOTICE
The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware
are one-time-use components and MUST be replaced any time they are removed.

14. Remove the high pressure fuel rail feed lines from the high pressure pump to the fuel rail. Refer to section
"Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System" .

15. Remove the high pressure fuel flange from the high pressure fuel pump. Refer to section "Removal of the High
Pressure Fuel Flange - Two-Filter System"

16. Disconnect the quantity control valve electrical harness connector.

17. Disconnect the plastic clip from the high pressure fuel pump mounting bracket.
18. Remove the coolant line from the cylinder block and air compressor.
19. Remove the high pressure fuel pump mounting bracket.
20. Remove the four bolts attaching the high pressure fuel pump to the cylinder block (KM59 GEN1 shown,
KM63 GEN2 similar).

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21. Remove the high pressure fuel pump from the cylinder block.
22. Remove and discard the high pressure fuel pump O-ring seal.
23. If the high pressure fuel pump is being replaced, remove the high pressure fuel pump drive gear. Refer to
section "Removal of the High Pressure Fuel Pump Drive Gear -Two-Filter System" Refer to section "Removal of the High
Pressure Fuel Pump Drive Gear -Two-Filter System".

1.17.3 Inspection of the High Pressure Fuel Pump – Two-Filter System

Inspect as follows:
Note : KM59 GEN1 high pressure fuel pump is equipped with a two-stage valve and a low pressure relief valve.
Note : KM63 GEN2 high pressure fuel pump is equipped with a two-stage valve.
1. Visually inspect the high pressure fuel pump for leaks at the two-stage valve (10), pressure relief valve
(KM59 GEN1) (13), low pressure fuel pump (1), and Quantity Control Valve (QCV) (3). If leaks are found,
replace the gasket on the leaking component.

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2. Visually inspect the pumping elements (7), pumping element fittings (6) and bypass (2) for leaks. If leaks
are found, replace the high pressure fuel pump.
3. Visually inspect the high pressure fuel pump for damage at the high pressure fuel flange threads (4), high
pressure fuel rail feed lines sealing surface (5), high pressure fuel flange sealing surface (9), low pressure
fuel lines threads (11) and low pressure fuel lines sealing surface (12). If damage is found, replace the high
pressure fuel pump.
4. Visually inspect the high pressure fuel pump gear (8) for damage. If damage is found, replace the high
pressure fuel pump gear.
4.a KM59 GEN1 high pressure fuel pump shown below.

4.b KM63 GEN2 high pressure fuel pump shown below.

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5. Install the high-pressure fuel pump into the high-pressure pump holding device tool (W470589014000).
Check the torque on the high pressure fuel pump gear nut (1). Torque to 250 N·m (184 lb·ft).

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6. Visually inspect the high pressure fuel pump weep hole (1) for fuel. If fuel is found, replace the high
pressure fuel pump.

1.17.4 Installation of the High Pressure Fuel Pump – Two Filter System
Install as follows:
Note : KM59 GEN1 high pressure fuel pump is equipped with a two-stage valve and a low pressure relief valve.
Note : KM63 GEN2 high pressure fuel pump is equipped with a two-stage valve.
1. Ensure flywheel is positioned at Top Dead Center (TDC) and crankshaft locking tool (W470589001500) is
installed.
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 -
Two-Filter System" .

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3. If the high pressure fuel pump is being reused, clean mounting surface of high pressure fuel pump and O-
ring groove.
4. If the high pressure fuel pump is being reused, install a new O-ring seal on to the high pressure fuel pump.
5. Lightly lubricate the high pressure fuel pump O-ring seal with clean engine oil.
6. Clean and inspect the flywheel housing bore for any burrs or other sharp edges; remove as necessary.
Note : The high pressure fuel pump should slide into the flywheel housing without binding. The mounting bolt
holes on the high pressure fuel pump housing should align closely with the mounting holes on the flywheel
housing.
Note : If 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 the timing mark is at the 12 o'clock position and the engine is at
number one cylinder TDC.
7. Install the high pressure fuel pump to the cylinder block (KM59 GEN1 shown, KM63 GEN2 similar).

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NOTICE
Ensure the correct bolt length is used when installing the high pressure pump. 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
size is M10 X 35 mm (1.37 in.).

8. Install the four mounting bolts securing the high pressure pump to the cylinder block. Torque to 60 N·m (44
lb·ft).
9. Install the coolant line on to the cylinder block and air compressor.
10. 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).
11. Install the two bolts securing the high pressure fuel pump bracket to the cylinder block. Torque to 100 N·m
(74 lb·ft).
12. Connect the plastic clip on to the high pressure fuel pump mounting bracket.
13. Connect the quantity control valve electrical harness connector.
14. Install the high pressure fuel flange on to the high pressure fuel pump. Refer to section "Installation of the High
Pressure Fuel Flange – Two-Filter System"

NOTICE
The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware
are one-time-use components and MUST be replaced any time they are removed.

15. Install the two new high-pressure lines on to the high pressure pump and the fuel rail. Refer to section
"Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System"

NOTICE
When installing the Fuel Filter Module, do not attempt to prime or start the engine.

16. Install the fuel filter module. Refer to section "Installation of the Fuel Filter Module – Two Filter System"
17. Remove the crankshaft locking tool (W470589001500) from the CKP hole.
18. Install the Crankshaft Position (CKP) sensor.
19. Remove the engine barring tool (J-46392 or W904589046300) from the flywheel housing.
20. Install the inspection cover on the bottom of the flywheel housing. Torque to 30 N·m (22 lb·ft).
21. Install the cold boost pipe. Refer to section "Installation of the Cold Boost Pipe (Charge Air Pipe)" .
22. Install the air filter housing assembly. Refer to OEM procedure.
23. If removed, install the splash shield. Refer to OEM procedures.
24. If removed, install the bumper. Refer to OEM procedures.
25. Connect the batteries. Refer to OEM procedures.
26. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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

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.

27. Start and run the engine.

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

1.17.5 Removal of the High Pressure Fuel Pump Camshaft Oil Seal -
Two-Filter System
ISSUE
The old production High Pressure Fuel Pump (HPFP) camshaft oil seal can fail causing an oil leak at the weep
hole location on the HPFP. The old production seal can wear into the HPFP camshaft creating a groove that may
allow oil to pass. This groove does not mean the HPFP has failed. A new design service seal has been created to
service the old production HPFP. The service seal will not groove the HPFP camshaft and changes the seal point
on the HPFP camshaft away from any possible groove. High Pressure Fuel Pumps affected are located on
EPA07/10 and GHG14 DD13/15/16 engines, built before engine serial number 201835 with three-filter and KM59
(GEN1) two-filter systems and engines built before ESN 205055 with KM63 (GEN2) two-filter systems.
For engines built after these engine serial numbers, a newly designed seal has been implemented into production
that will not groove the camshaft. Engines built with a newly designed production HPFP camshaft seal are not
serviceable (see required action).

Old Production Seal1. Steel Ring New Service Seal New Production Seal

Note : Refer to TS letter 15 TS-6Rev for testing procedures and warranty claim process information.
1. Shut off the engine, apply the parking brake, chock the wheels and perform any other applicable safety
steps.
2. Remove the high pressure fuel pump from the engine. Refer to section "Removal of the High Pressure Fuel Pump –
Two-Filter System" .

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3. Remove the high pressure fuel pump drive gear from the high pressure fuel pump. Refer to section "Removal of
the High Pressure Fuel Pump Drive Gear -Two-Filter System" .

4. If equipped with a key, remove the high pressure fuel pump key from the high pressure fuel pump
camshaft. If equipped with a pin, Refer to section "Removal of the High Pressure Fuel Pump Locating Pin - Two-Filter System"
.
5. Install the high pressure fuel pump camshaft oil seal protector tool (1) on to the high pressure fuel pump.

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6. Position the camshaft oil seal removal tool (W470589055903) over the high pressure fuel pump camshaft
until it has made contact with the camshaft oil seal. Once the camshaft oil seal removal tool
(W470589055903) has made contact with the oil seal, press the removal tool firmly against the camshaft oil
seal and rotate the tool clockwise by hand until the removal tool has completely screwed into the camshaft
oil seal.

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7. Remove the camshaft oil seal by holding the camshaft oil seal removal tool (1) and turning the camshaft oil
seal removal tool bolt (2)

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8. Remove the camshaft oil seal from the camshaft oil seal removal tool (W470589055903).

1.17.6 Installation of the High Pressure Fuel Pump Camshaft Oil Seal -
Two-Filter System
ISSUE
The old production High Pressure Fuel Pump (HPFP) camshaft oil seal can fail causing an oil leak at the weep
hole location on the HPFP. The old production seal can wear into the HPFP camshaft creating a groove that may
allow oil to pass. This groove does not mean the HPFP has failed. A new design service seal has been created to
service the old production HPFP. The service seal will not groove the HPFP camshaft and changes the seal point
on the HPFP camshaft away from any possible groove. High Pressure Fuel Pumps affected are located on
EPA07/10 and GHG14 DD13/15/16 engines, built before engine serial number 201835 with three-filter and KM59
(GEN1) two-filter systems and engines built before ESN 205055 with KM63 (GEN2) two-filter systems.
For engines built after these engine serial numbers, a newly designed seal has been implemented into production
that will not groove the camshaft. Engines built with a newly designed production HPFP camshaft seal are not
serviceable (see required action).

Old Production Seal1. Steel Ring New Service Seal New Production Seal

Note : Refer to TS letter 15 TS-6Rev for testing procedures and warranty claim process information.
Install as follows:
1. Clean the face of the camshaft fuel seal, camshaft and the outside sealing area of the camshaft oil seal
inside the high pressure pump.

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2. Install the camshaft sleeve tool (W470589055902) on to the camshaft.

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3. Lightly coat the camshaft sleeve tool (W470589055902) with clean diesel fuel.

4. Place the new service camshaft oil seal onto the camshaft sleeve tool (W470589055902) with the FLAT
side of the seal facing outwards.
5. Using the camshaft oil seal installer tool (W470589055901), by hand, slide the camshaft oil seal inwards
until the camshaft oil seal presses against the high pressure fuel pump.
Note : When installing the camshaft seal onto the high pressure fuel pump, the camshaft oil seal installer tool
MUST make contact with the high pressure fuel pump to seat the camshaft oil seal properly.
6. Remove the camshaft sleeve tool (W470589055902) from the camshaft.
7. Using a dead blow hammer, lightly tap the camshaft seal installer tool (W470589055901) until the tool
makes contact with the high pressure fuel pump.
8. Inspect the camshaft oil seal, camshaft and high pressure fuel pump for damage.
Note : Setting the locating pin depth is critical; follow the pin installation instructions closely.
9. If equipped with the key, install the high pressure fuel pump key onto the camshaft. If equipped with a pin,
Refer to section "Installation of the High Pressure Fuel Pump Locating Pin -Two-Filter System" .

10. Install the high pressure fuel pump drive gear from the high pressure fuel pump. Refer to section "Installation of
the High Pressure Fuel Pump Drive Gear - Two-Filter System" .

11. Install the high pressure fuel pump onto the engine. Refer to section "Installation of the High Pressure Fuel Pump – Two
Filter System " .

1.17.7 Removal of the High Pressure Fuel Pump Locating Pin - Two-
Filter System

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1. Remove the high pressure fuel pump from the engine. Refer to section "Removal of the High Pressure Fuel Pump –
Two-Filter System" .

2. Remove the high pressure fuel pump drive gear from the high pressure fuel pump. Refer to section "Removal of
the High Pressure Fuel Pump Drive Gear -Two-Filter System" .

3. Apply tape around the locating pin on the camshaft.

4. Place a wood protector over the camshaft threads. Using diagonal pliers remove the locating pin from the
high pressure fuel pump. If the pin cannot be removed using diagonal pliers follow steps 5 thru 7 to remove
the pin using a drill bit.
Note : Steps 5 thru 7 are only to be done if the locating pin was not able to be removed using diagonal pliers.
5. Tape a clean shop towel around the camshaft covering the camshaft oil seal.
6. Support the camshaft by placing a wood block under the camshaft.
7. Using a 3.5mm (9/64 in.) drill bit, drill the center of the locating pin and remove the pin from the camshaft.

1.17.8 Installation of the High Pressure Fuel Pump Locating Pin -Two-
Filter System
1. Clean any debris or engine oil from the locating pin hole and camshaft.
2. Remove the clean shop towel and tape from around the camshaft.

NOTICE
When pressing in the locating pin, the depth measurement MUST be taken on the side of
the pin closest to the threaded area on the camshaft.

3. Using a minimum press-in force of 80N·m (59 lb·ft), press the new locating pin to a depth of 2.3 to 2.7mm
(0.090 to 0.106in.).
4. 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 - Two-Filter System" .

5. Install the high pressure fuel pump on to the engine. Refer to section "Installation of the high pressure fuel
pump-two-filter system Refer to section "Installation of the High Pressure Fuel Pump – Two Filter System "

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1.18 High Pressure Fuel Flange

1.18.1 Description and Operation of the High Pressure Fuel Flange -
Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
The high pressure fuel flange is located on the high pressure fuel pump. The high pressure fuel flange is used to
regulate fuel to the hydrocardon doser block. The high pressure fuel pump inlet and high pressure fuel pump
outlet fuel lines connect to the high pressure fuel flange. Located on the high pressure fuel flange is the fuel
temperature sensor. The fuel temperature sensor reads absolute fuel temperature in the fuel system.

1.18.2 Removal of the High Pressure Fuel Flange - Two-Filter System

Remove as follows:
1. Clean the housing on the high pressure fuel pump.
2. Remove the two bolts (5) holding the high pressure pump inlet (1) and outlet (6) fuel lines to the high
pressure fuel flange (2).
3. Remove high pressure pump inlet (1) and outlet (6) fuel lines from the high pressure fuel flange (2) and
discard the O-rings; see above graphic.
4. Disconnect the fuel temperature sensor connector (3); remove the fuel temperature sensor wiring harness
from the high pressure fuel flange (2) and position aside the wiring harness; see above graphic.
5. Remove three bolts (4) securing the high pressure fuel flange (2) to high pressure pump and discard
gasket; see above graphic.

1.18.3 Inspection of the High Pressure Flange - Two-Filter System

Inspect as follows:
1. Visually inspect the high pressure flange fuel line bores (3), high pressure flange fuel line mounting threads
(1) and high pressure flange fuel temperature sensor threads (2) for damage. If damage is found, replace
the high pressure flange.
2. Visually inspect the high pressure flange gaskets (1) and the high pressure flange back plate (2) for
damage or leakage. If damage or leakage is found, replace the high pressure flange.

1.18.4 Installation of the High Pressure Fuel Flange – Two-Filter

Install as follows:
1. Clean the high pressure flange surface and mating fuel pump surface.
2. Install the high pressure fuel flange (2) onto the high pressure pump. Torque to 30 N·m (22 lb·ft).
3. Connect the fuel temperature sensor connector (3) and install the fuel temperature sensor wiring harness
on to the high pressure fuel flange; see above graphic.
4. Install new O-rings on to the high pressure pump inlet (1) and outlet (6) fuel lines; see above graphic.
5. Install the high pressure pump inlet (1) and outlet (6) fuel lines. Torque to 30 N·m (22 lb·ft); see above
graphic.
6. Test for leaks by priming fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.19 Two Stage Valve

1.19.1 Description and Operation of the Two Stage Valve - Two-Filter
System

1.19.2 Removal of the Two-Stage Valve for Two-Filter System

Service Tools Used in the Procedure

Tool Number Tool Name and Engine Tool Graphic

Remove as follows:

NOTICE
Do not use compressed air to clean the two-stage valve or housing bore of the two-stage
valve.

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Clean the housing on the high pressure fuel pump.
2. For KM59 GEN1: Remove the high pressure flange from the high pressure fuel pump; refer to the fuel
manual, high pressure fuel flange, Refer to section "Removal of the High Pressure Fuel Flange - Two-Filter System" . For
KM63 GEN2: Remove the Low pressure pump fuel lines from the high pressure fuel pump; refer to the fuel
manual, low pressure fuel pump lines, Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System"
.
3. Remove the two-stage valve (1) from the high pressure fuel pump.
4. Remove and discard the o-ring seals from the two-stage valve.
4.a The illustration shown below is a KM59 GEN1 two-stage valve location.
4.b The illustration shown below is a KM63 GEN2 two-stage valve location.

1.19.3 Inspection of the Two-Stage Valve – Two- Filter System

Inspect as follows:

NOTICE
Do not use compressed air to remove debris from high pressure pump housing. Doing so
may lodge particles in high pressure fuel pump housing passages.

1. Inspect the two-stage valve housing bore on the high pressure fuel pump for any debris. If debris is
present, use a vacuum to remove debris from the bore housing. Do not use compressed air, as it may
lodge particles in to the high pressure fuel pump passages.
1.a The illustration shown below is KM59 GEN1 two-stage housing bore; KM63 GEN2 two-stage housing
bore is similar.
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 two-stage valve.
2.a The illustration shown below is KM59 GEN1 Two-stage valve.

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2.b The illustration shown below is KM63 GEN2 Two-stage valve.

3. Inspect the valve piston for damage and for being stuck (1); For KM59 GEN1 the valve piston (2) should be
near flush with the end of the valve housing, For KM63 GEN2 the valve piston (2) should be seated against
the C-clip (3). If there is damage to the valve piston or if the valve piston is stuck in the bore (1), replace the
two-stage valve.
3.a The illustration shown below is KM59 GEN1 Two-stage valve stuck valve piston and seated valve
piston.
3.b The illustration shown below is KM63 GEN2 Two-stage valve stuck valve piston and seated valve
piston.
4. Using a small screwdriver, depress the valve piston in the two-stage valve. The valve piston should
smoothly slide in and return to the seated position shown below. If the valve piston sticks, replace the two-
stage valve. If no trouble is found with the valve piston, immediately reinstall the two-stage valve. Refer to
section "Installation of the Two-Stage Valve – Two Filter System"

4.a The illustration shown below is a KM59 GEN1 Depressing Valve Piston.
4.b The illustration shown below is a KM63 GEN2 Depressing Valve Piston.

1.19.4 Installation of the Two-Stage Valve – Two Filter System

Service Tools Used in the Procedure

Tool Number Tool Name and Engine Tool Graphic

Install as follows:
Note : KM59 GEN1 high pressure fuel pump is equipped with a two-stage valve and a low pressure relief valve.
Note : KM63 GEN2 high pressure fuel pump is equipped with a two-stage valve.
1. Install new o-ring seals on to the two-stage valve.
2. Lubricate the o-ring seals and threads with clean diesel fuel.
3. Install the two-stage valve (1) on to the high pressure fuel pump. Torque to 26 N·m (20 lb·ft).
3.a The illustration shown below is a KM59 GEN1 two-stage valve location.
3.b The illustration shown below is a KM63 GEN2 two-stage valve location.
Note : KM59 GEN1 Verify there is no plastic line plugs on the high pressure flange before installing on to the high
pressure fuel pump.
Note : KM63 GEN2 Verify there is no plastic line plugs on the low pressure fuel lines before installing on to the
high pressure fuel pump.
4. For KM59 GEN1 Install the high pressure flange on to the high pressure fuel pump. Refer to the fuel
manual, high pressure fuel flange, Refer to section "Installation of the High Pressure Fuel Flange – Two-Filter System" . For
KM63 GEN2 Install the Low pressure pump fuel lines on to the high pressure fuel pump; refer to the fuel
manual, low pressure fuel pump lines, Refer to section "Installation of the Low Pressure Fuel Pump Lines – Two-Filter
System" .

CAUTION
Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer,
birth defects, and other reproductive harm.
5. Check for leaks by priming fuel system. Then start the engine.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.20 Quantity Control Valve

1.20.1 Description and Operation of the Quantity Control Valve - Two-
Filter System

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.

1.20.2 Removal of the Quantity Control Valve - Two-Filter System

Remove as follows:

NOTICE
Do not over-tighten the mechanical water drain valve. Failure to properly tighten the water
drain valve may cause damage to the water drain valve and housing.

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. If needed, remove the bumper. Refer to OEM procedures.
5. If needed remove the splash shield. Refer to OEM procedures.
6. Steam clean engine and housing on high pressure fuel pump.
7. Drain the fuel system. Refer to section "Draining the Fuel System Using J-48710 Prior to Repairs - Two-Filter System" .
8. For a vehicle with a short (less than 120 inches) Bumper-to-Back-of-Cab (BBC), remove the cold boost
pipe. Refer to section "Removal of the Composite Cold Boost Pipe (Charge Air Pipe)" .
9. Remove the low pressure pump lines and high pressure pump inlet and outlet lines from the fuel filter
module and high pressure flange. Refer to section "Removal of the Low Pressure Fuel Pump Lines - Two-Filter System" .
10. Drain the coolant from the engine. Refer to section "Cooling System Drain Procedure" .
11. Remove the air compressor inlet coolant line (1) from the side of the cylinder block.
12. Disconnect electrical connector from the Quantity Control Valve (QCV).
13. For a vehicle with a short (less than 120 inches) Bumper-to-Back-of-Cab (BBC), remove the fuel filter
module. Refer to section "Removal of the Fuel Filter Module – Two-Filter System" .
14. Remove the high pressure fuel pump support bracket (2) from high pressure fuel pump and cylinder block.
15. Remove the bolts attaching QCV (3) to high pressure fuel pump.
16. Remove QCV from the high pressure fuel pump.
17. Remove and discard the O-ring seals from the QCV. Ensure that both O-rings are removed from the high
pressure fuel pump housing.

1.20.3 Inspection of the Quantity Control Valve and High Pressure

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Pump Housing – Two-Filter System

NOTICE
Do not use compressed air to remove debris from high pressure pump housing. Doing so
may lodge particles in pump housing passages.

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
1.a Figure below illustrates KM59 GEN1 shown, KM63 GEN2 similar.
2. Inspect Quantity Control Valve (QCV) 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 QCV. If no trouble is found with the
QCV, immediately reinstall.

1.20.4 Installation of the Quantity Control Valve - Two-Filter System

1. Install new O-ring seals on to the Quantity Control Valve (QCV).
2. Lubricate the new O-ring seals on the quantity control valve with clean diesel fuel.
3. Install the QCV (3). Torque bolts to 8 N·m (6 lb·ft).
4. Connect the QCV electrical connector.
5. If removed, install the fuel filter module. Refer to section "Installation of the Fuel Filter Module – Two Filter System" .
6. Install the high pressure fuel pump support bracket (2) on to the high pressure fuel pump and cylinder
block. Torque to 30 N·m (22 lb·ft) on pump side; 100 N·m (74 lb·ft) on cylinder block side.
7. Install the air compressor inlet coolant line (1) on to the side of the cylinder block.
8. Fill the engine with coolant to the correct level.
9. Install the low pressure pump lines and high pressure pump inlet and outlet lines on to the fuel filter module
and high pressure flange. Refer to section "Installation of the Low Pressure Fuel Pump Lines – Two-Filter System" .
10. If removed, install the cold boost pipe. Refer to section "Installation of the Composite Cold Boost Pipe (Charge Air Pipe)" .
11. If removed, install the bumper. Refer to OEM procedures.
12. If removed, install the splash shield. Refer to OEM procedures.

CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
13. Reconnect battery power to the engine. Refer to OEM procedures.
14. Prime fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.21 High Pressure Fuel Injector Lines

1.21.1 Description and Operation of the High Pressure Fuel Injector
Lines - Two-Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
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.

1.21.2 Removal of the High Pressure Fuel Injector Lines - Two-Filter

System
Remove as follows:

NOTICE
For DD15/16 engines: If removing the high pressure fuel line from fuel injector number
one, remove the intake manifold temperature sensor. Refer to section "Removal of the
Intake Manifold Air Temperature Sensor".

NOTICE
For DD13 engines: If removing the high pressure fuel line from fuel injector number four,
remove the intake manifold temperature sensor. Refer to section "Removal of the Intake
Manifold Air Temperature Sensor".

NOTICE
If removing the high pressure fuel line from fuel injector number six, remove the pressure
limiting valve return line banjo bolt and the rear high pressure fuel feed line P-clip.

NOTICE
The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and
hardware are one-time use components and MUST be replaced any time they are loosened
or removed.

NOTICE
Service kits have been released containing all of the necessary parts to replace the high
pressure fuel rail feed lines on EPA07/10 DD13, GHG14 DD13, EPA07/10 DD15/16, GHG14
DD15TC/DD16 and GHG14 DD15AT engines. Refer to TS letter 13 TS-24 for the high
pressure fuel line kit numbers to repair these engines.

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1. Remove the two fuel injector seal mounting bolts (1) securing the high pressure fuel injector line seal to the
camshaft housing.
Note : Loosening high pressure injector lines from the rail first allows fuel to completely drain out, preventing oil
contamination.
2. Loosen the high pressure fuel line nut (1) at the fuel rail.
3. Loosen the high pressure fuel injector line nut (1) at the camshaft housing.
Note : The high pressure fuel injector line seal is a single-use item and cannot be reused.
4. Remove the high pressure fuel injector line and high pressure fuel injector line seal as an assembly from
the engine.
5. Remove and discard the high pressure injector line seal from the high pressure fuel injector line.

1.21.3 Inspection of the High Pressure Fuel Injector Lines- Two-Filter

System
1. Visually inspect the high pressure fuel injector lines for damage at the fuel injector line bend (1), fuel
injector line hex (2), fuel injector line tube threads (3), fuel injector line sealing surface (4) and fuel injector
line rail fitting nut threads (5). If damage is found, replace the high pressure fuel injector line.

1.21.4 Installation of the High Pressure Fuel Injector Lines - Two-Filter

System
Install as follows:

NOTICE
For DD15/16 engines: If the high pressure fuel line from fuel injector number one was
removed, reinstall the intake manifold temperature sensor. Refer to section "Installation of
the Intake Manifold Air Temperature Sensor".

NOTICE
For DD13 engines: If the high pressure fuel line from fuel injector number one was
removed, reinstall the intake manifold temperature sensor. Refer to section "Installation of
the Intake Manifold Air Temperature Sensor".

NOTICE
If the high pressure fuel line from fuel injector number six was removed, install the
pressure limiting valve return line banjo bolt and a high pressure fuel feed line service kit.

NOTICE
The high pressure fuel rail feed lines, P-clips, vibration dampers, mounting bracket and
hardware are one-time-use components and MUST be replaced any time they are
loosened or removed

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NOTICE
Service kits have been released containing all of the necessary parts to replace the high
pressure fuel rail feed lines on EPA07/10 DD13, GHG14 DD13, EPA07/10 DD15/16, GHG14
DD15TC/DD16 and GHG14 DD15AT engines. Refer to TS letter 13 TS-24 for the high
pressure fuel line kit numbers to repair these engines

Note : The high pressure fuel injector line seal is a single-use item and cannot be reused.
1. Lubricate the new high pressure fuel injector line O-ring with a light coat of clean diesel fuel.
2. Install the new high pressure fuel injector line seal on to the high pressure fuel injector line.
3. Install the high pressure fuel injector line and the new high pressure fuel injector line seal as an assembly
onto the engine. Hand-tighten the high pressure fuel injector line nut (1).
4. Tighten the high pressure fuel injector line nut to the fuel rail. Torque to 40 N·m (30 lb·ft).
5. Using tool J-48770, torque the high pressure fuel injector line nut (1) to 40 N·m (30 lb·ft).
6. Install two high pressure fuel injector line seal mounting bolts (1). Torque to 15 N·m (11 lb·ft).
7. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.22 High Pressure Fuel Rail Feed Lines

1.22.1 Description and Operation of the High Pressure Fuel Rail Feed
Lines and Related Parts - Two-Filter System

NOTICE
The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and
hardware are one-time use components and MUST be replaced any time they are
removed.

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
• Return lines P-clip mounting bolt is used to secure the return lines P-clip to the mounting bracket. This is a
reusable bolt.
• Return lines P-clip is used to secure the return lines to the mounting bracket. This is a reusable P-clip.
• Mounting bracket is used to secure the high pressure fuel rail feed lines and return lines to rear rail clamp.
This is a one-time-use component.
• High pressure fuel rail feed lines are used to transfer high pressure fuel from the high pressure fuel pump to
the fuel rail. This is a one-time-use component.
• Vibration dampers are used to lower the vibration in the high pressure fuel rail feed lines. This is a one-
time-use component.
• Mounting bracket bolts are used to secure the mounting bracket to the rear rail clamp. This is a one-time
use component.
• P-clips are used to lower vibration and secure the high pressure fuel rail feed lines to the mounting bracket.
This is a one-time-use component.

1.22.2 Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter
System
Remove as follows:

NOTICE
The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and
hardware are one-time use components and MUST be replaced any time they are removed
or loosened. Refer to TS letter 16TS-9 for the high pressure fuel line kit numbers.

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. If necessary, remove the bumper. Refer to the Original Equipment Manufacturer (OEM) procedures.
5. If necessary for access, remove the air cleaner. Refer to the (OEM) procedures.
Note : Do not discard the return lines P-clip and bolt. They will be reused on the installation of the high pressure
fuel rail feed lines.
6. Remove the return lines P-clip bolt (1) from the mounting bracket (2) and save for re-use. See graphics
below.

KM59 GEN1 with Bolted Vibration Dampers

KM59 GEN1 with Permanent Vibration Dampers

KM63 GEN2 with Permanent Vibration Dampers

7. Remove and discard the two P-clip bolts from the mounting bracket.
Note : For KM59 GEN1: When removing the high pressure fuel rail feed lines, hold the high pressure pump fitting
with a 24mm wrench.
8. Remove and discard the high pressure fuel rail feed lines (3), P-clips (5), and vibration dampers as an
assembly from the fuel rail and high pressure fuel pump. See graphic above.
9. Remove and discard the mounting bracket bolts (4) from the fuel rail clamp and discard the mounting
bracket (2). See graphic above.

1.22.3 Inspection of the High Pressure Fuel Rail Feed Lines – Two
Filter System
Inspect as follows:

NOTICE
Failure to follow these instructions will result in catastrophic damage to the engine and
will not be covered under warranty.

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
1. Inspect and verify the mounting bracket (2) and its attaching bolts (4), the two P-clips (5), and the high
pressure fuel feed lines (3) with two vibration dampers are not missing or loose. Do not attempt to loosen,
tighten or otherwise disturb any of the parts.

KM59 GEN1 with Bolted Vibration Dampers

KM59 GEN1 with Permanent Vibration Dampers

KM63 GEN2 with Permanent Vibration Dampers

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1.22.4 Installation of the High Pressure Fuel Rail Feed Lines - Two-
Filter System
Install as follows:

NOTICE
The high pressure fuel rail feed lines, vibration dampers, P-clips, mounting bracket and
hardware are one-time use components and MUST be replaced any time they are removed
or loosened. Refer to TS letter 16TS-9 for the high pressure fuel line kit numbers.

Note : DO NOT install bolts and fittings using power tools. All bolts and fittings MUST be installed using hand
tools.
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate.

1. Clean the sealing area inside the high pressure fuel pump outlet fittings 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 new mounting bracket (2) and two new mounting bracket bolts (4) to the fuel rail clamp. Hand-
tighten the mounting bracket bolts all the way until the bracket and bolts are flush. Do not torque at this
time.

KM59 GEN1 with Bolted Vibration Dampers

KM59 GEN1 with Permanent Vibration Dampers

KM63 GEN2 with Permanent Vibration Dampers

4. Install both of the new P-clips, one each, onto the high pressure fuel rail feed lines; see graphic below.
Note : DO NOT use new high pressure fuel rail feed lines that do not have new vibration dampers installed.
5. Position the rear high pressure fuel rail feed line into the fuel rail and the high pressure fuel pump. Do not
start the threads of the fuel line nuts at this point.
6. Position the front high pressure fuel rail feed line into the fuel rail and the high pressure fuel pump. Do not
start the threads of the fuel line nuts at this point.

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MUST

7. Ensure the rear high pressure fuel rail feed line is in place so that the P-clip mounting hole lines up with the
bracket nut. No excessive force should be applied to components in the high pressure fuel rail feed lines kit
while assembling them loosely.
8. Install the new rear P-clip bolt hand tight. Do not torque at this time.
9. Hand-tighten the rear high pressure fuel rail feed line starting with the rail side nut first, and then the nut at
the high pressure fuel pump.

10. Using fuel line socket W314589010300 or a commercially available 19mm fuel line socket, torque the rear
high pressure fuel rail feed line nuts to 40 N·m (30 lb·ft) starting with the rail side nut first, and then the nut
at the high pressure fuel pump. Using a paint pen, draw a paint line on the torqued fuel line nut and the
adjacent metal, as shown in the photograph above.
11. Ensure the front high pressure fuel rail feed line is in place so that the P-clip mounting hole lines up with the
bracket nut. No excessive force should be applied to any components in the high pressure fuel rail feed
lines kit when loosely assembling them.
12. Install the new front P-clip bolt hand tight. Do not torque at this time.
13. Hand-tighten the front high pressure fuel rail feed line starting with the rail side nut first, and then the nut at
the high pressure fuel pump.
14. Using fuel line socket W314589010300 or a commercially available 19mm fuel line socket, torque the front
high pressure fuel rail feed line nuts to 40 N·m (30 lb·ft) starting with the rail side nut first, and then the nut
at the high pressure fuel pump. Using a paint pen, draw a paint line on the torqued fuel line nut and the
adjacent metal, as shown in the photograph above.

15. Torque the two new high pressure fuel rail feed line P-clip bolts to 14 N·m (124 lb·in.). Using a paint pen,
draw a paint line on the torqued bolt head and the adjacent metal, as shown in the notice after step 9.
16. Using a deep well socket for clearance, torque the two new mounting bracket bolts to 14 N·m (124 lb·in.).
Using a paint pen, draw a paint line on the torqued bolt head and the adjacent metal, as shown in the
notice after step 9.
17. Install the bolt for the amplification, needle, and pressure limiting valve return line triple-clip (1). Torque to
14 N·m (124 lb·in.). Using a paint pen, draw a paint line on the torqued bolt head and the adjacent metal, as
shown in the notice after step 9.
18. Inspect all components of the high pressure fuel rail feed line kit to make sure all fittings and fasteners have
been properly installed, torqued and marked with a paint pen. Have the lead hand or supervisor review the
installation and sign off on the repair order to ensure that all components were properly torqued and
painted.
19. If removed for clearance, install the air cleaner. Refer to the Original Equipment Manufacturer (OEM)
procedures.

CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
20. Connect the batteries.
21. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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22. Perform the Rail Pressure Bleed-Off test using DiagnosticLink to verify that there are no leaks.
23. If there are leaks, find the leak and repair, as necessary.
24. Refer to the Original Equipment Manufacturer (OEM) procedures.
25. Close the hood.

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1.23 Fuel Rail

1.23.1 Description and Operation of the Fuel Rail and Related Parts -
Two-Filter System
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.

[Link] 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.

1.23.2 Removal of the Fuel Rail - Two-Filter System

1. Steam clean the engine.
2. Disconnect the batteries.
3. Disconnect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2) and intake
temperature sensor (1).
4. Remove and discard the high pressure fuel rail feed lines from the high pressure pump to the fuel rail. Refer
to section "Removal of the High Pressure Fuel Rail Feed Lines - Two-Filter System"

5. Remove the high pressure fuel injector feed lines with tool J-48770 and discard the high pressure fuel
injector line seals. Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System" .
6. Remove pressure limiting valve (PLV) return line from fuel rail and discard the sealing washers. Refer to
section "Removal of the Needle, Amplifier, and Pressure Limiting Valve (PLV) Return Lines – Two-Filter System" .

7. Remove the fuel rail clamp bolts (1) and fuel rail clamps (2) from the camshaft housing (3) and remove the
fuel rail (4) from the engine, discard the fuel rail clamp bolts.

1.23.3 Inspection of the Fuel Rail - Two-Filter System

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.

1.23.4 Installation of the Fuel Rail – Two-Filter System

NOTICE
Fuel rail clamps MUST be installed with arrows pointing upwards. (See Item 5 in figure
below).

Note : The rear fuel rail clamp has mounting holes for the high pressure fuel lines mounting bracket.
Install as follows:

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NOTICE
Fuel rail clamp bolts are single-use items and cannot be re-used

1. Install the fuel rail (4) on to the camshaft housing (3). With the arrows pointing upwards (5), install the three
fuel rail clamps (2) and six new fuel rail clamp bolts (1) on to the camshaft housing (3). Hand-tighten the
fuel rail clamp bolts.
2. Using tool J-48770, install the high pressure fuel injector lines on to the fuel rail and fuel injectors with new
high pressure fuel injector line seals. Refer to section "Installation of the High Pressure Fuel Injector Lines - Two-Filter
System" . Hand-tighten the high pressure fuel injector lines.

3. Install Pressure Limiting Valve (PLV) return line with new sealing washers on to the fuel rail. Refer to section
"Installation of the Needle, Amplifier, and Pressure Limiting Valve Return Lines – Two-Filter System" .

4. Torque the high pressure fuel injector lines to 40 N·m (30 lb·ft).
5. Torque the fuel rail clamps bolts to 14 N·m (120 lb·in.).

NOTICE
The high pressure fuel rail feed lines, vibration dampers, mounting bracket and hardware
are one-time use components and MUST be replaced any time they are removed.

6. Install the new high pressure fuel rail feed lines on to the high pressure pump and fuel rail. Refer to section
"Installation of the High Pressure Fuel Rail Feed Lines - Two-Filter System" .

7. Connect the electrical connectors on the fuel injector harness (3), fuel rail pressure sensor (2), and intake
temperature sensor (1).
8. Connect the batteries.
9. Prime the fuel system.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

10. Start the engine and check for leaks.

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1.24 Pressure Limiting Valve

1.24.1 Description and Operation of the Pressure Limiting Valve - Two-
Filter System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
The pressure limiting valve is a safety device which limits the maximum rail pressure in the injection system to
approximately 1280-1380 bar for KM59 GEN1, and approximately 1500-1600 bar for KM63 GEN2 Fuel Systems.
If the current rail pressure exceeds the maximum rail pressure, a push spring is compressed by a pressure plate
within the valve and a connection is opened at the same time to the cutoff bore, allowing fuel to flow into the return
relieving rail pressure.

1.24.2 Removal of the Pressure Limiting Valve - Two-Filter System

Remove as follows:
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.

1.24.3 Inspection of the Pressure Limiting Valve – Two-Filter System

Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
Pressure Limiting Valve (PLV) return line.
Inspect 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 Pressure Limiting Valve (PLV) Change.
4. The dialog box that appears shows the current PLV counter.
5. Is the current PLV counter greater than 50 counts?
5.a Yes; replace the PLV.
5.b No; Go to step 6.
6. Remove the PLV from the fuel rail. Refer to section "Removal of the Pressure Limiting Valve - Two-Filter System" .
7. Visually inspect the PLV for debris. If debris is found, replace the PLV and clean all debris from the fuel
system.
8. Using a mirror, check the part number of the PLV, as different generations of the PLV will appear identical.
If the PLV is incorrect for the engine serial number per the parts catalog, replace the PLV with a new
correct PLV.
9. Install the PLV into fuel rail. Refer to section "Installation of the Pressure Limiting Valve - Two-Filter System" .

1.24.4 Installation of the Pressure Limiting Valve - Two-Filter System

Install as follows:
Note : If installing a new PLV, there may be a protection disk on the tip of the PLV or in the bag with the PLV. This
disk is only to protect the edge biting surface during shipping and should be discarded.
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).

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3. Prime fuel system.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

4. Reset pressure limiting valve counter using DDDL 7.X. Refer to section "Resetting the Pressure Limiting Valve Counter -
Two-Filter System" .

5. Start the engine. Check for leaks.

6. Reset the pressure limiting valve counter. Refer to section "Resetting the Pressure Limiting Valve Counter - Two-Filter
System" .

1.24.5 Resetting the Pressure Limiting Valve Counter - Two-Filter

System
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.

NOTICE
Only reset the counter if the PLV is being replaced.

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 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.
5. Click the button Reset Learned Data to clear the counter.

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1.25 Fuel Injector Wiring Harness

1.25.1 Description and Operation of the Two-Piece Fuel Injector Wiring
Harness - Two-Filter System
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.

1.25.2 Removal of the Two-Piece Fuel Injector Wiring Harness - Two-

Filter System
Remove as follows:
1. Disconnect batteries. Refer to proper OEM procedures.
2. Remove the rocker cover. Refer to section "Removal of the 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 camshaft housing.
7. Remove spring clips holding the appropriate injector harness connector to camshaft frame.
8. Remove injector wiring harness.

1.25.3 Inspection of the Two-Piece Fuel Injector Wiring Harness - Two-

Filter System
Inspect and clean as follows:
1. Clean the injector harness in clean fuel oil.
2. Blow dry with compressed air.
3. Check the injector harness for damage. Replace as necessary.

1.25.4 Installation of the Two-Piece Fuel Injector Wiring Harness -

Two-Filter System
Install as follows:
1. Lightly lubricate the outer seal (1) prior to installing the new injector harnesses with clean engine oil.
2. Install injector harness and tighten the allen head mounting screws to 10 N·m (7 lb·ft).

NOTICE
Effective with engine s/n HDE0053776 built on October 11, 2010; The terminals on the
injector harness for the engine brake solenoid now have a protective plastic cover (1). If
installing a new harness with the protective terminal cover on an older engine that has a
protective cover on the engine brake solenoid (2), it will be necessary to first remove the
existing protective cover from the engine solenoid (3). The protective cover slides off the
engine brake solenoid.

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NOTICE
The protective cover on the injector harness is not removable. Attempting to remove the
protective cover from the terminal nut will result in damage to the injector harness.

3. Install electrical contacts to injector and tighten to 1.9 N·m (17 lb·in).
4. Connect engine brake solenoid terminals and torque to 1.5 N·m (1 lb·ft).
5. Install spring clips holding injector harness connector to camshaft frame.
6. Connect 14-pin injector harness connectors.
7. Install the rocker cover. Refer to section "Installation of the Rocker Cover" .
8. Connect batteries. Refer to OEM procedures.

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1.26 Fuel Injectors

1.26.1 Fuel Injection with Amplification - Two-Filter System

[Link] 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.

[Link] 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.

[Link] 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.
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.

1.26.2 Fuel Injection without Amplification - Two-Filter System

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

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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.

1.26.3 Description and Operation of the Fuel Injector - Two-Filter

System
Note : KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.
Note : KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.
The fuel injectors are secured 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 a fuel injector is replaced, then this code must be recorded in the
Motor Control Module (MCM) 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).
In the case of injection with amplification the injection pressure of up to: For KM59 GEN1 2,200 bar, For KM63
GEN2 2,500 bar is generated in the fuel injector.
Use of an amplifier within a fuel injector offers the following advantages:
• The leak fuel 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 and the amplifier solenoid valve either at other times or simultaneously.

1.26.4 Removal of the Fuel Injector - Two-Filter System

Remove as follows:
Note : If replacing fuel injectors, due to a no start condition after a repair, also replace the fuel rail and all high
pressure fuel lines.
1. Shut off the engine and apply the parking brake, chock the wheels, disconnect vehicle battery power, and
perform any other applicable safety steps.
2. Steam clean the engine.
3. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" .
4. Disconnect the 14-pin fuel injector harness connector from the camshaft housing.
5. Disconnect the fuel injector electrical wiring harness from the fuel injectors. Refer to section "Removal of the Two-
Piece Fuel Injector Wiring Harness - Two-Filter System" .

6. Remove the spring clip holding the fuel injector electrical wiring harness connector to the camshaft frame.
Remove the fuel injector electrical wiring harness.
7. Remove the high pressure fuel injector feed lines. Refer to section "Removal of the High Pressure Fuel Injector Lines -
Two-Filter System" .

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

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11. 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.

12. 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 a 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.

13. Inspect the fuel injector body for visible damage. Replace the fuel injector if damaged.
14. If the fuel injector is intended to be reused, remove and discard the three fuel injector O-rings and the
copper washer.

1.26.5 Installation of the Fuel Injector - Two-Filter System

Install as follows:
Note : Ensure excess fuel is removed from the top of the piston dome before fuel injector installation.
Note : If replacing fuel injectors, due to a no start condition after a repair, also replace the fuel rail and all high
pressure fuel lines.
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, 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 or remanufactured fuel injectors are being used, write down the new (2) or remanufactured (1) fuel
injector's calibration code, the injector part number and note the cylinder location where it will be installed.
6. Remove the fuel injector nozzle tip protector.

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NOTICE
The older-style copper washer must be installed with the recess (1) facing the fuel
injector body. Incorrect installation can cause combustion gasses to enter the fuel
system.

7. Install a new copper washer with the recess facing UP (1) toward the fuel injector and the flat side of the
washer facing DOWN. The new-style copper washer (2) is flat on both sides and does not need to be
installed with a specific side up or down.
8. Apply a thin coat of acid-free grease or clean engine oil to the fuel injector seal rings and then use J-48837
(Fuel Injector O-ring Installer) to 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 the high pressure fuel injector feed lines. Refer to section "Installation of the High Pressure Fuel Injector Lines -
Two-Filter System" .

11. Torque the fuel injector hold-down bolt to 20 N·m (15 lb·ft) + 90 degree torque turn.
12. Insert the 14–pin connector from the fuel injector harness into the hole in the cam frame and install
electrical connections and Allen head hold-down bolts before torquing.
13. Install the spring clip onto the 14–pin connector.
14. Torque all of the fuel injector connections to 1.9 N·m (17 lb·in.).
15. Torque all of the Allen head fuel injector harness hold-down bolts to 10 N·m (7 lb·ft).
16. Input the fuel injector calibration codes and injector part number that were recorded earlier into
DiagnosticLink using the service routine.
17. If injectors were replaced because of a tip failure or leak, the EGR cooler must be cleaned.
• For DD13: Refer to section "Cleaning of the DD13 Exhaust Gas Recirculation System" .
• For DD15 and DD16: Refer to section "Cleaning of the Turbo Compound DD15 and DD16 Exhaust Gas Recirculation Systems" .
18. 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.
19. Connect batteries.
20. If an injector cup was removed, fill and pressure test the cooling system; check for leaks. Refer to section
"Cooling System Fill Procedure" .

21. Prime the fuel system. Verify repair.

Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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1.27 Fuel Injector Cup

1.27.1 Description and Operation of the Fuel Injector Cup - Two-Filter
System
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.

1.27.2 Removal of the Fuel Injector Cup - Two-Filter System

1. Euro V info to come.

1.27.3 Inspection of the Fuel Injector Cup – Two-Filter System

1. Visually inspect the fuel injector cup tip (1), fuel injector cup threads (2), fuel injector cup index slots (3) and
fuel injector cup O-ring land (4) for damage. If damage is found, replace the fuel injector cup.
1.a The illustration shown below is a 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.
2.a The illustration shown below is a Fuel Injector Cup Copper Washer Land.

1.27.4 Installation of the Fuel Injector Cup - Two-Filter System

Service Tools Used in the Procedure

Tool Number Tool Name and Engine Tool Graphic

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
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 J-47388A or W470589000700 and install into cylinder head bore.
5. Torque fuel injector cup to 70 N·m (52 lb·ft).
6. Release torque by rotating injector cup counter clockwise.
7. Torque fuel injector cup to 70 N·m (52 lb·ft).
8. Install fuel injector. Refer to section "Installation of the Fuel Injector - Two-Filter System" .
9. Install fuel injector harness.
Refer to section "Installation of the One-Piece Fuel Injector Wiring Harness - Two-Filter System" .
Refer to section "Installation of the Two-Piece Fuel Injector Wiring Harness - Two-Filter System" .
10. Install rocker cover. Refer to section "Installation of the Rocker Cover" .
11. Fill and pressure test the cooling system; check for leaks. Refer to section "Cooling System Fill Procedure" .
12. Prime the fuel system.
Refer to section "Priming the Fuel System - KM59 GEN1 - Two-Filter System"

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Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System"

13. If necessary, install the bumper end(s). Refer to the Original Equipment Manufacturer (OEM) procedures.

CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
14. Connect the batteries.
15. Close hood.

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