High Pressure Diesel Fuel Sensor Replacement

Removal Procedure

Danger: High Pressure Lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 1600 Bar (23,200 psi). Use extreme caution when inspecting for high pressure leaks. Fuel under this amount of pressure can penetrate skin causing personal injury, or death. Wear safety goggles and adequate clothing when servicing this fuel system.

  1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
  2. Oil Filler Cap»Remove

    3. Object ID: 5171779
  3. Intake Manifold Cover Bolt(1)»Remove
  4. Intake Manifold Cover(2)»Remove
  5. Install the oil filler cap after removal of the intake manifold cover to prevent debris from falling into the engine.

    6. Object ID: 5211335
  6. Charge Air Cooler Outlet Air Hose Clamp (1)»Loosen until disengaged[2x]
  7. Charge Air Cooler Outlet Air Hose(2)»Remove

    8. Object ID: 5149834

    Danger: The noise cancelling foam component MUST be replaced if it has been exposed to engine fluids. Failure to replace the noise canceling foam component that has been exposed to engine fluids may result in an engine fire resulting in catastrophic engine damage, and possible injury or death.

  8. Disconnect the high pressure diesel fuel sensor electrical connector.
  9. High Pressure Diesel Fuel Sensor(1)»Remove
Cleaning and Inspection Procedure - Required

    Object ID: 5854825
  1. Inspect the charge air cooler outlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler outlet air hose (2). Clean the interior of the hose, and allow to completely dry. Ensure any oil residue is removed from the hose internal interface surfaces.
    2. Inspect the interior of the charge air cooler outlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler outlet air hose clamps (1). Replace the charge air cooler outlet air hose (2) if damage is found or the clamp components are missing.

Installation Procedure


    Object ID: 5149834

    Caution: Refer to Component Fastener Tightening Caution.

  1. High Pressure Diesel Fuel Sensor(1)»Install and tighten—Fastener Specifications
  2. Connect the high pressure diesel fuel sensor electrical connector.

    3. Object ID: 5211335
  3. Charge Air Cooler Outlet Air Hose(2)»Install

    4. Caution: Refer to Fastener Caution.

  4. Charge Air Cooler Outlet Air Hose Clamp (1)»Tighten[2x]—Fastener Specifications

    5. Object ID: 5171779
  5. Oil Filler Cap»Remove
  6. Intake Manifold Cover(2)»Install
  7. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  8. Oil Filler Cap»Install
  9. Prime the fuel system and inspect for leaks. Fuel System Priming