High Pressure Diesel Fuel Feed to Injector 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 Injector 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 engine wiring harness bracket 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: 5193296
  14. Engine Coolant Air Bleed Hose(2)»Reposition

    15. Object ID: 5204431

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

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

    16. Object ID: 5206053
  16. Turbocharger Coolant Feed and Return Pipe Bolt(3)»Remove

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

    19. Object ID: 5204428
  19. Exhaust Gas Recirculation Outlet Pipe Bolt(1)»Remove[2x]

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

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

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

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

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

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

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

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

    36. Object ID: 5185361
  36. Turbocharger Heat Shield Bolt(1)»Remove[2x]
  37. Turbocharger Heat Shield Nut(2)»Remove

    38. Object ID: 5185371
  38. Turbocharger Heat Shield(1)»Reposition

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

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

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

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

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

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

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

    51. 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.

  51. Camshaft Housing Cover Insulator(1)»Remove

    52. Object ID: 5158567
  52. Loosen the high pressure diesel fuel feed pipe nuts (1) from the fuel injector and the fuel injection rail, as needed.

    53. Object ID: 5630549
  53. High Pressure Diesel Fuel Feed to Injector 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: 5630549
  1. High Pressure Diesel Fuel Feed to Injector Pipe(2)»Install NEW
  2. Hand tighten the high pressure diesel fuel feed to injector pipe fittings (1).

    3. Caution: Refer to Component Fastener Tightening Caution.

  3. Tighten the high pressure diesel fuel feed to injector pipe fittings (1). Fastener Specifications

    4. 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.

    Note: Ensure the camshaft housing cover insulator is properly seated.

  4. Camshaft Housing Cover Insulator(1)»Install

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

    8. Object ID: 5217574
  8. Charge Air Cooler Bracket(2)»Install

    9. Caution: Refer to Fastener Caution.

  9. Charge Air Cooler Bolt(1)»Install and tighten[5x]—Fastener Specifications

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

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

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

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

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

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

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

    20. Object ID: 5187895
  20. Upper Intake Manifold Bracket(2)»Install
  21. Upper Intake Manifold Brace Nut(1)»Install and tighten[3x]—Fastener Specifications

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

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

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

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

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

    29. Object ID: 5624867
  29. Engine Wiring Harness(4)»Reposition
  30. Wiring Harness Retainer(2)@Charge Air Cooler»Install[3x]
  31. Electrical Connector(3)@Charge Air Cooler»Connect[2x]
  32. Electrical Connector(1)@Nitrogen Oxides Sensor»Connect

    33. Object ID: 5628860
  33. Exhaust Gas Recirculation Cooler Inlet Pipe Gasket(3)»Install NEW
  34. Exhaust Gas Recirculation Pipe Seal(2)»Install NEW
  35. Exhaust Gas Recirculation Pipe(1)»Install

    36. Object ID: 5208251

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

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

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

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

    40. Object ID: 5208251

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

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

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

    43. Object ID: 5206053
  43. Install and tighten the turbocharger coolant feed and return pipe bolt (3).Fastener Specifications

    44. Object ID: 5204431

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

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

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

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

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

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

    52. Object ID: 5171779
  52. Oil Filler Cap»Remove
  53. Intake Manifold Cover(2)»Install
  54. Intake Manifold Cover Bolt(1)»Install and tighten—Fastener Specifications
  55. Oil Filler Cap»Install
  56. Plenum Front Panel Outer Reinforcement»Install—Plenum Front Panel Outer Reinforcement Removal and Installation
  57. Start the engine and check for exhaust leaks.
  58. Prime the fuel system and inspect for leaks. Fuel System Priming