High Pressure Diesel Fuel Feed to Rail Pipe Replacement
Single Use Fasteners and Components
  • Exhaust Gas Recirculation Cooler Inlet Pipe Gasket
  • Exhaust Gas Recirculation Pipe Seal
  • High Pressure Diesel Fuel Feed to Rail Pipe

Warning: Refer to Diesel/Gasoline Vapors Warning.

Warning: Refer to Safety Glasses Warning.

Removal Procedure
  1. Turn OFF the engine for 30 seconds before proceeding. This will purge the fuel pressure from the complete fuel system.
  2. Plenum Front Panel Outer Reinforcement»Remove—Plenum Front Panel Outer Reinforcement Removal and Installation

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

    7. Object ID: 5150211
  7. Air Cleaner Outlet Front Duct Clamp(1)»Loosen[2x]
  8. Air Cleaner Outlet Front Duct(2)»Remove

    9. Object ID: 5150241
  9. Air Cleaner Outlet Duct Clamp(1)»Loosen
  10. Air Cleaner Outlet Duct(2)»Remove

    11. Object ID: 5170071
  11. Remove the 3 rear engine wiring harness channel nuts (1).
  12. Position the rear engine wiring harness channel (2) out of the way.

    13. Object ID: 5193255
  13. Engine Coolant Outlet Pipe Bracket Bolt(1)»Remove

    14. Object ID: 5204431

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  14. Remove the 2 exhaust gas recirculation cooler bolts (1).

    15. Object ID: 5206053
  15. Remove the turbocharger coolant feed pipe bolt (3) and position the turbocharger coolant feed pipe (2) out of the way.

    16. Object ID: 5204427
  16. Remove the turbocharger coolant return hose clip (1) and position the turbocharger coolant return hose out of the way.
  17. Remove the exhaust gas recirculation pipe bolt (2).

    18. Object ID: 5204428
  18. Remove the 2 exhaust gas recirculation pipe bolts (1).

    19. Object ID: 5628860
  19. Exhaust Gas Recirculation Pipe(1)»Remove
  20. Exhaust Gas Recirculation Pipe Seal(2)»Remove and DISCARD
  21. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Remove and DISCARD

    22. Object ID: 5624867
  22. Electrical Connector(1)@Nitrogen Oxides Sensor»Disconnect
  23. Wiring Harness Retainer(2)@Charge Air Cooler»Remove[3x]
  24. Electrical Connector(3)@Charge Air Cooler»Disconnect[2x]
  25. Engine Wiring Harness(4)»Position aside

    26. Object ID: 5216906
  26. Wiring Harness Retainer(4)@Charge Air Cooler»Remove

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

    29. Object ID: 5211389
  29. Charge Air Cooler Inlet Air Hose Clamp(1)»Loosen until disengaged[2x]
  30. Charge Air Cooler Inlet Air Hose(2)»Remove

    31. Object ID: 5217133
  31. Charge Air Cooler Bolt(1)»Remove[4x]

    32. Object ID: 5217156
  32. Reposition charge air cooler (1) with coolant hoses attached.

    33. Object ID: 5187895
  33. Upper Intake Manifold Brace Nut(1)»Remove[3x]
    34. Reposition the upper intake manifold bracket (2) with the nitrogen oxides sensor.
    Object ID: 5185361
  34. Turbocharger Heat Shield Bolt(1)»Remove[2x]
  35. Turbocharger Heat Shield Nut(2)»Remove

    36. Object ID: 5185371
  36. Reposition the turbocharger heat shield (1) with the exhaust gas recirculation temperature sensor attached.

    37. Object ID: 5219691
  37. Release the retaining spring (1).
  38. Intake Manifold Resonator(2)»Remove

    39. Object ID: 5138644
  39. Turbocharger Bracket Bolt(1)»Remove

    40. Object ID: 5499646
  40. Engine Wiring Harness Bracket Nut(1)»Remove[2x]
  41. Engine Wiring Harness Bracket(3)»Reposition

    42. Object ID: 5217555
  42. Oil Filler Tube Support Stud(1)»Remove

    43. Object ID: 5499644
  43. Engine Coolant Air Bleed Hose Clip(1)»Remove

    44. Object ID: 5217574
  44. Charge Air Cooler Bolt(1)»Remove[5x]
  45. Charge Air Cooler Bracket(2)»Remove

    46. Object ID: 5149255
  46. Reposition harness and hoses, and connect electrical connectors as needed.
  47. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Remove
  48. Exhaust Gas Recirculation Pipe Bracket(5)»Remove

    49. Object ID: 5135087

    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.

  49. Camshaft Housing Cover Insulator(1)»Remove
  50. Front Wheelhouse Liner-Left Side»Remove—Front Wheelhouse Liner Replacement

    51. Object ID: 5153904
  51. Fuel Feed Pipe Clip Bolt(1)»Remove

    52. Object ID: 5153945
  52. Fuel Pump Fuel Feed Hose(1)»Reposition

    53. Object ID: 5154341
  53. Diesel Fuel Separator Bracket Bolt(1)»Remove

    54. Object ID: 5154342
  54. Diesel Fuel Separator(1)»Reposition

    55. Object ID: 5156838
  55. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel pump.

    56. Object ID: 5156840
  56. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).

    57. Object ID: 5156855
  57. Remove the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1).
  58. Unclip the fuel injector fuel return pipe retainer (2).

    59. Object ID: 5156867
  59. Disconnect the 2 high pressure diesel fuel feed to rail pipe fittings (1) from the high pressure diesel fuel injection rail.

    60. Object ID: 5628961

    Note: Do NOT reuse the high pressure diesel fuel feed pipes.

  60. High Pressure Diesel Fuel Feed to Rail Pipe(2)»Remove and DISCARD
Cleaning and Inspection Procedure - Required

    Object ID: 5854827
  1. Inspect the charge air cooler inlet air hose (2):
    1. Use dish soap and water to clean the inside of the charge air cooler inlet 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 inlet air hose (2) for tears or delamination. Replace the hose if damage is found.
    3. Inspect the charge air cooler inlet air hose clamps (1). Replace the charge air cooler inlet air hose (2) if damage is found or the clamp components are missing.

    Object ID: 5854825
  2. 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: 5628961
  1. High Pressure Diesel Fuel Feed to Rail Pipe(2)»Install NEW
  2. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel injection rail.

    3. Object ID: 5156855

    Caution: Refer to Fastener Caution.

  3. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications
  4. Attach the fuel injector fuel return pipe retainer (2).

    5. Object ID: 5156840
  5. Install the 2 high pressure diesel fuel feed to rail pipe bracket bolts (1) and tighten. Fastener Specifications

    6. Object ID: 5156838
  6. Hand tighten the 2 high pressure diesel fuel feed to rail pipe fittings (1) to the high pressure diesel fuel pump.

    7. Caution: Refer to Component Fastener Tightening Caution.

  7. Tighten the high pressure diesel fuel feed to rail pipe fittings to both the high pressure diesel fuel pump and the high pressure diesel fuel injection rail. Fastener Specifications

    8. Object ID: 5154342
  8. Diesel Fuel Separator(1)»Install

    9. Object ID: 5154341
  9. Diesel Fuel Separator Bracket Bolt(1)»Install and tighten—Fastener Specifications

    10. Object ID: 5153945
  10. Fuel Pump Fuel Feed Hose(1)»Install

    11. Object ID: 5153904
  11. Fuel Feed Pipe Clip Bolt(1)»Install and tighten—Fastener Specifications
  12. Front Wheelhouse Liner-Left Side(3)»Install—Front Wheelhouse Liner Replacement

    13. Object ID: 5135087

    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.

  13. Camshaft Housing Cover Insulator(1)»Install

    14. Object ID: 5149255
  14. Exhaust Gas Recirculation Pipe Bracket(5)»Install
  15. Exhaust Gas Recirculation Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications
  16. Reposition harness and hoses, and connect electrical connectors as needed.

    17. Object ID: 5217574
  17. Charge Air Cooler Bracket(2)»Install
  18. Charge Air Cooler Bolt(1)»Install[5x]—Fastener Specifications

    19. Object ID: 5499644
  19. Engine Coolant Air Bleed Hose Clip(1)»Install

    20. Object ID: 5217555
  20. Oil Filler Tube Support Stud(1)»Install—Fastener Specifications

    21. Object ID: 5499646
  21. Engine Wiring Harness Bracket(3)»Install
  22. Engine Wiring Harness Bracket Nut(1)»Install and tighten[2x]—Fastener Specifications

    23. Object ID: 5138644
  23. Turbocharger Bracket Bolt(1)»Install and tighten—Fastener Specifications

    24. Object ID: 5219691
  24. Intake Manifold Resonator(2)»Install
  25. Engage the retaining spring (1).

    26. Object ID: 5185371
  26. Turbocharger Heat Shield(1)»Install

    27. Object ID: 5185361
  27. Turbocharger Heat Shield Nut(2)»Install and tighten—Fastener Specifications
  28. Turbocharger Heat Shield Bolt(1)»Install and tighten[2x]—Fastener Specifications

    29. Object ID: 5187895
  29. Install the upper intake manifold bracket (2) with nitrogen oxides sensor attached.
  30. Upper Intake Manifold Brace Nut(1)»Install and tighten[3x]—Fastener Specifications

    31. Object ID: 5217156
  31. Charge Air Cooler(1)»Install

    32. Object ID: 5217133
  32. Charge Air Cooler Bolt(1)»Install[4x]—Fastener Specifications

    33. Object ID: 5211389
  33. Charge Air Cooler Inlet Air Hose(2)»Install
  34. Charge Air Cooler Inlet Air Hose Clamp(1)»Tighten[2x]—Fastener Specifications

    35. Object ID: 5211335
  35. Charge Air Cooler Outlet Air Hose(2)»Install
  36. Charge Air Cooler Outlet Air Hose Clamp (1)»Tighten[2x]—Fastener Specifications

    37. Object ID: 5216906
  37. Wiring Harness Retainer(4)@Charge Air Cooler»Install

    38. Object ID: 5624867
  38. Engine Wiring Harness(4)»Reposition
  39. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
  40. Electrical Connector(3)@Charge Air Cooler»Connect[2x]
  41. Electrical Connector(1)@Nitrogen Oxides Sensor»Connect

    42. Object ID: 5628860
  42. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Install NEW
  43. Exhaust Gas Recirculation Pipe Seal(2)»Install NEW
  44. Exhaust Gas Recirculation Pipe(1)»Install

    45. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  45. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Install and hand tighten[2x]

    46. Object ID: 5204427
  46. Install and hand tighten the exhaust gas recirculation outlet pipe bolt (2).
  47. Install the turbocharger coolant return hose clip (1).

    48. Object ID: 5204431
  48. Install and hand tighten the 2 exhaust gas recirculation pipe bolts (1).

    49. Object ID: 5208251

    Note: Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  49. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Tighten in sequence[2x]—Fastener Specifications

    50. Object ID: 5204427
  50. Exhaust Gas Recirculation Outlet Pipe Bolt(2)»Tighten in sequence[2x]—Fastener Specifications
  51. Install the turbocharger coolant return hose clip (1).

    52. Object ID: 5206053
  52. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Install and tighten—Fastener Specifications

    53. Object ID: 5204431

    Note: Support the exhaust gas recirculation pipe when loosening/tightening the bolts to ensure the pipe is not deformed.

  53. Exhaust Gas Recirculation Cooler Bolt(1)»Tighten in sequence[2x]—Fastener Specifications.

    54. Object ID: 5193255
  54. Engine Coolant Outlet Pipe Bracket Bolt(1)»Install and tighten—Fastener Specifications

    55. Object ID: 5170071
  55. Install the rear engine wiring harness channel (2).
  56. Install the 3 rear engine wiring harness channel nuts (1) and tighten. Fastener Specifications

    57. Object ID: 5150241
  57. Air Cleaner Outlet Duct(2)»Install
  58. Air Cleaner Outlet Duct Clamp(1)»Tighten—Fastener Specifications

    59. Object ID: 5150211
  59. Air Cleaner Outlet Front Duct(2)»Install
  60. Air Cleaner Outlet Front Duct Clamp(1)»Tighten[2x]—Fastener Specifications

    61. Object ID: 5171779
  61. Oil Filler Cap»Remove
  62. Intake Manifold Cover(2)»Install
  63. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  64. Oil Filler Cap»Install
  65. Plenum Front Panel Outer Reinforcement»Install—Plenum Front Panel Outer Reinforcement Removal and Installation
  66. Prime the fuel system and inspect for leaks. Fuel System Priming
  67. Check for exhaust leak.