Académique Documents
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Fuel System
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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. Remove the fuel tank fill caps to relieve pressure in the fuel tanks. Reinstall the fuel tank fill caps.
5. Using a 36mm socket, unscrew the final filter cap.
NOTICE
Do not tilt the final filter when removing it from the housing. Possible damage to the final
filter or stand pipe may occur.
6. Pull the cap and final filter (1) straight up and allow the fuel to drain back.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
WARNING
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
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.
5. Start the engine and increase engine speed to 1500 rpm for ONE (1) minute.
6. Reduce engine speed and run at idle (600 rpm) for ONE (1) additional minute.
7. 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.
8. Road test unit to purge all remaining air from the fuel system.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
1. Pre-Filtered Fuel
2. Unfiltered Fuel
3. Prefilter Element
4. Check Ball
5. Fuel Inlet
CAUTION
ELECTRICAL SHOCK
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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. Using a 36 mm socket, unscrew the prefilter cap.
5. Pull the cap and prefilter straight up and out of the fuel filter housing.
6. 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.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
3. Apply a thin coat of petroleum-based lithium grease to the prefilter cap seal ring (1).
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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. Using a 36mm socket, unscrew the final filter cap.
NOTICE
Do not tilt the final filter when removing it from the housing. Possible damage to the final
filter or stand pipe may occur.
5. Pull the cap and final filter (1) straight up and allow the fuel to drain back.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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. If necessary, remove the bumper end(s).
5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".
7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
8. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump
Lines".
9. Remove the chassis side fuel feed and return lines from the fuel filter module.
10. Disconnect the Pressure Control Valve (PCV) return line from the fuel filter module.
11. Disconnect the hydrocarbon doser block feed line from the fuel filter module.
12. Remove the three fuel filter module mounting bolts and remove the fuel filter module.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
1. Install the fuel filter module and the three mounting bolts securing the fuel filter module to the cylinder
block. Torque to 25 N·m (18 lb·ft).
2. Connect the pressure control valve (PCV) return line to the fuel filter module. Torque to 17 N·m (12 lb·ft).
3. Using new sealing washers, loosely install the Hydrocarbon (HC) doser block feed line to the fuel filter
module.
4. Position the HC doser block feed line in the 11 o'clock position (1) from vertical (2), as shown below.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
Note : Failure to brace the line while torquing can result in an improper installation position.
5. While holding the line in position, torque the banjo bolt at the fuel filter module to 25 N·m (18 lb·ft).
6. Install the chassis fuel feed and return lines on to the fuel filter module.
7. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump
Lines".
8. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".
9. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
10. If removed, install the bumper end(s).
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
11. Connect the batteries.
12. Prime the fuel system. Refer to section "Priming the Fuel System".
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
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Remove as follows:
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has
been shut down for a minimum of 10 minutes before servicing any component within the
high pressure circuit. Residual high fuel pressure may be present within the circuit.
1. 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.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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.
10. Using tool W936589003300, lift the fuel injector clamp and fuel injector from its seat in the cylinder head.
11. Inspect for the copper heat protection sleeve on the injector tip; if present, remove and discard. If the
copper sleeve is missing, use tool W936589033300 to extract it from the cylinder head and discard.
12. Cover the fuel injector hole in the cylinder head to keep out foreign material.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
NOTICE
Avoid cleaning (wire brushing etc.) the fuel injector tip spray holes to prevent damage and
plugging.
13. 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 copper heat protection sleeve
are considered one-use items and cannot be reused. Any time a fuel injector is removed,
the fuel injector bolt, two fuel injector O-ring seals and copper heat protection sleeve must
be replaced with new parts. Failure to replace the O-ring seals, heat protection sleeve and
bolt can result in leakage.
14. Inspect the fuel injector body for visible damage. Replace the fuel injector if damaged.
15. If the fuel injector is intended to be reused, remove and discard the two fuel injector O-rings and the copper
sleeve.
Install as follows:
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
1. Electrical Connector
2. Header With Calibration Codes
3. Injector Inlet O-ring
4. Injector Body O-ring
5. Fuel Return Port
6. Injector Tip
Note : Ensure excess fuel is removed from the top of the piston dome before fuel injector installation.
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 with fuel, change the engine oil and filter.
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, record the fuel injector calibration code, the injector
part number and note the cylinder location where it will be installed.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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14. If injectors were replaced because of a tip failure or leak, the EGR cooler must be cleaned. Refer to section
"Cleaning of the Exhaust Gas Recirculation System".
15. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
16. 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.
17. Connect the batteries.
WARNING
PRESSURIZED FUEL
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure
test.
18. If an injector cup was removed, fill and pressure test the cooling system; check for leaks. Refer to section
"Cooling System Fill Procedure".
19. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".
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1. Cylinder Head
2. Fuel Injector Cup
3. Fuel Injector Cup O-ring
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Remove as follows:
NOTICE
Take extra precautions when cleaning the fuel injector bores to ensure that debris does
not enter the fuel system. Do not use power tools to clean the fuel injector bores. Do not
use compressed air to blow out debris in the bores.
NOTICE
Engine coolant must be drained prior to fuel injector tube removal.
1. Drain the engine coolant. Refer to section "Cooling System Drain Procedure" .
2. Remove the fuel injectors. Refer to section "Removal of the Fuel Injector" .
Note : Tool W936589000700 must be fully engaged with the fuel injector cup to prevent damage to the tool and
the cup.
3. Install tool W936589000700 into fuel injector cup and align tool with slots in tube and turn counter
clockwise to remove.
4. Remove fuel injector cup; discard fuel injector cup O-ring in cylinder head.
5. Inspect the fuel injector cup for cracks or defects. If defective, replace fuel injector cup.
6. Clean fuel injector cup threads with a fine wire brush, being careful not to abrade the cylinder head to fuel
injector cup sealing surface.
7. Clean the fuel injector cup interior sealing surface; a chemical solvent maybe used for cleaning interior
sealing surface.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
2. Visually inspect the fuel injector cup copper washer land (1) for damage. If damage is found, replace the
fuel injector cup.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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
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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 batteries.
3. Open the hood.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
4. Remove the rocker cover. Refer to section "Removal of the Rocker Cover."
5. Remove the terminal nuts (2) on all four injectors.
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2. Install the fuel injector wiring harness locking tab into the rear of the camshaft housing.
3. Connect the fuel injector wiring harness 16-pin connector (4) to the engine wiring harness.
4. Connect the camshaft position sensor electrical connector (3).
5. Install the fuel injector terminal nuts (2) onto the injectors. Torque to 2 N·m (18 lb·in.).
6. Install the rocker cover. Refer to section "Installation of the Rocker Cover."
7. Close the hood.
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.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has
been shut down for a minimum of 10 minutes before servicing any component within the
high pressure circuit. Residual high fuel pressure may be present within the circuit.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
NOTICE
The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line
seals are one-time use components and MUST be replaced any time they are loosened or
removed.
1. Remove and discard the high pressure fuel injector lines. Refer to section "Removal of the High Pressure
Fuel Injector Lines".
2. Disconnect the electrical connectors at the rail pressure sensor (1) and the pressure control valve (2).
3. Disconnect the pressure control valve return line at the fuel rail.
4. Remove the two bolts securing the fuel rail to the cylinder head and remove the fuel rail from the engine.
NOTICE
The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line
seals are one-time-use components and MUST be replaced any time they are loosened or
removed.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
NOTICE
DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts
and fittings MUST be installed using hand tools.
1. Install the fuel rail (2) and the two fuel rail mounting bolts (1) on to the cylinder head. Hand-tighten the fuel
rail mounting bolts.
2. Connect the pressure control valve return line to the fuel rail. DO NOT torque the return line nut at this time.
3. Using tool W638589111500, install the high pressure fuel injector line seals (2) into the cylinder head (1).
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
4. Lubricate the inside of the new fuel injector line seals with a light coating of clean engine oil.
Note : The high pressure fuel injector lines must first be fastened onto the fuel rail and then onto the fuel injector
or leaks may occur.
Note : To install the high pressure line on cylinder #2, the high pressure line on cylinder #3 must be installed first.
5. Install the new high pressure fuel injector line (2) onto the fuel rail (3); hand-tighten the fuel injector line nut.
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6. Install the new high pressure fuel injector line onto the fuel injector; hand-tighten the fuel injector line nut.
7. Install the high pressure fuel rail feed line (1) to the fuel rail (3) and the high pressure fuel pump. Hand-
tighten the nuts.
8. Torque the fuel rail mounting bolts to 55 N·m (40 lb·ft).
9. Torque the pressure control valve return line nut to 30 N·m (22 lb·ft).
10. Using a commercially available 19mm fuel line socket, torque the high pressure fuel rail feed line nuts to 45
N·m (33 lb·ft).
11. Tighten the high pressure fuel injector line nut to the fuel rail. Torque to 45 N·m (33 lb·ft).
12. Using a commercially available 19mm fuel line socket, torque the high pressure fuel injector line nut to the
fuel injector to 45 N·m (33 lb·ft).
13. Connect the electrical connectors on the rail pressure sensor (1) and the pressure control valve (2).
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
14. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
15. Connect the batteries.
16. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
5. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".
6. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
7. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump
Lines".
8. Remove the three bolts (1) attaching the low pressure pump to the high pressure pump.
9. Remove the low pressure pump from the high pressure pump.
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3. Visually inspect the drive coupler (2) and driven key for damage. If damage is found, replace the high
pressure fuel pump (3).
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4. Remove the low pressure fuel pump housing half from the low pressure fuel pump housing.
5. Visually inspect the low pressure fuel pump housing half, 1ow pressure fuel pump housing and low
pressure fuel pump gears for damage. If damage is found, replace the low pressure fuel pump.
4. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump
Lines".
5. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".
6. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
7. Connect the batteries.
8. Prime the fuel system. Refer to section "Priming the Fuel System".
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
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. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
5. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator"
6. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
7. Remove the high pressure pump supply and return lines (2) from the fuel filter module to the high pressure
pump and discard the sealing rings.
8. Remove the low pressure pump supply and return lines (1) from the fuel filter module to the low pressure
pump and discard the sealing rings.
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3. Install the high pressure pump supply and return lines (2) from the fuel filter module to the high pressure
pump. Torque the bolts to 17 N·m (12 lb·ft).
4. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".
5. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
6. Connect the batteries.
7. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".
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Remove 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.
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.
WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has
been shut down for a minimum of 10 minutes before servicing any component within the
high pressure circuit. Residual high fuel pressure may be present within the circuit.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
NOTICE
The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line
seals are one-time use components and MUST be replaced any time they are loosened or
removed.
6. Remove the high pressure rail feed line (1). Refer to section " Removal of the High Pressure Rail Feed Line
".
Note : To remove the high pressure fuel injector line on cylinder #3, the high pressure fuel injector line on cylinder
#2 must be removed first.
7. Using a commercially available 19mm fuel line socket, remove and discard the high pressure fuel injector
lines (2).
8. Using puller W936589043300 and impact extractor W936589033302, remove the high pressure fuel
injector line seals (2) from the cylinder head (1) and discard. See graphic below.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
Install as follows:
1. Using Injector Seal Installer tool W638589111500, install the high pressure fuel injector line seals (2) into
the cylinder head (1).
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2. Lubricate the inside of the new fuel injector line seals with a light coating of clean engine oil.
3. Loosen the fuel rail clamp bolts.
Note : The high pressure fuel injector lines must first be fastened onto the fuel rail and then onto the fuel injector
or leaks may occur.
Note : To install the high pressure line on cylinder #2, the high pressure line on cylinder #3 must be installed first.
4. Install the new high pressure fuel injector line (2) onto the fuel rail (3); hand-tighten the fuel injector line nut.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
5. Install the new high pressure fuel injector line (2) onto the fuel injector; hand-tighten the fuel injector line
nut.
6. If removed, install the high pressure rail feed line (1). Refer to section “Installation of the High Pressure Rail
Feed Line”.
7. Torque the fuel rail clamp bolts to 55 N·m (40 lb·ft).
8. Tighten the high pressure fuel injector line nut to the fuel rail (3). Torque to 45 N·m (33 lb·ft).
9. Using a commercially available 19mm fuel line socket, torque the high pressure fuel injector line nut to the
fuel injector to 45 N·m (33 lb·ft).
10. Install the air compressor resonator. Refer to section “Installation of the Air Compressor Resonator”.
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
11. Connect the batteries.
12. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System".
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WARNING
PERSONAL INJURY
Diesel engine exhaust and some of its constituents are known to the State of California to
cause cancer, birth defects, and other reproductive harm.
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.
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.
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.
4. Steam clean the high pressure fuel pump and the surrounding area.
5. If necessary, remove the driver's side bumper end.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
6. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
7. Position the engine at No. 1 Top Dead Center (TDC) on the compression stroke. Refer to section
"Camshaft Timing Verification".
8. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".
9. Remove the Motor Control module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
10. Remove the high pressure fuel rail feed line from the high pressure pump to the fuel rail. Refer to section
"Removal of the High Pressure Fuel Rail Feed Line".
11. Remove low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".
12. Remove the hydrocarbon fuel doser block feed line. Refer to section "Removal of the Hydrocarbon Fuel
Doser Block Feed Line".
13. Remove the pressure control valve return line. Refer to section "Removal of the Pressure Control Valve
Return Line."
14. Disconnect the quantity control valve (QCV) electrical harness connector.
15. Remove the two mounting bolts securing the front of the high pressure fuel pump to the cylinder block
bracket.
16. If necessary, disconnect and position aside the air compressor discharge line.
17. Remove the three bolts attaching the high pressure fuel pump to the timing case.
18. Remove the high pressure fuel pump from the timing case.
19. If the high pressure fuel pump is being reused, remove and discard the high pressure fuel pump O-ring
seals.
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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”.
3. If the high pressure fuel pump is being reused, clean mounting surface of the high pressure fuel pump and
O-ring groove.
4. If the high pressure fuel pump is being reused, install a new O-ring mounting seal and lubrication port seal
on to the high pressure fuel pump.
5. Lightly lubricate the high pressure fuel pump O-ring mounting seals with clean engine oil.
Note : The high pressure fuel pump should slide into the timing case without binding. The mounting bolt holes on
the high pressure fuel pump housing should align closely with the mounting holes on the timing case.
Note : If the 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 that the timing mark is at the 12 o'clock position and the
engine is positioned at number one cylinder TDC.
NOTICE
DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts
and fittings MUST be installed using hand tools.
6. Install the high pressure fuel pump and three mounting bolts into the timing case. Hand-tighten the
mounting bolts.
7. Install the two mounting bolts securing the front of the high pressure pump to the cylinder block bracket.
Torque to 25 N·m (18 lb·ft).
8. Torque the three mounting bolts securing the high pressure pump to the timing case to 50 N·m (37 lb·ft).
9. Connect the QCV electrical harness connector.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
10. If removed, connect the air compressor discharge line to the air compressor.
11. Install the pressure control valve return line. Refer to section "Installation of the Pressure Control Valve
(PCV) Return Line".
12. Install the high pressure fuel rail feed line from the high pressure pump to the fuel rail. Refer to section
"Installation of the High Pressure Fuel Rail Feed Line".
13. Install the hydrocarbon fuel doser block feed line. Refer to section "Installation of the Hydrocarbon Fuel
Doser Block Feed Line".
14. Install the low pressure fuel pump lines. Refer to section "Installation of the Low Pressure Fuel Pump
Lines".
15. Install the Motor Control Module (MCM). Refer to section "Installation of the Motor Control Module".
16. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator".
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
17. Connect the batteries.
18. Prime the fuel system. Refer to section “Priming the Fuel System”.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
Note : To ensure proper alignment between the locking tooth and the HP drive gear leave the bolts holding the
locking tooth finger-tight until the high pressure pump has been installed into the holding fixture.
1. Clamp holding fixture (W47058984000) into a vise and attach pump adaptor and locking tooth
(W936589003100).
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
2. Install the high pressure fuel pump into the high pressure pump holding-device tool (W470589084000) and
tighten the locking tooth (W936589003100).
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
3. Loosen, but do not remove, the high pressure fuel pump drive gear nut (1).
4. Using the drive gear puller tool (W936589053300), unfasten the high pressure pump drive gear from the
high pressure fuel pump camshaft.
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5. Remove the high pressure pump drive gear nut and the drive gear from the high pressure fuel pump.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
6. Inspect the dowel pin for wear or damage and replace pin if necessary.
7. Remove the high pressure fuel pump from the high pressure pump holding-device tool (W470589084000).
1. Install the high pressure fuel pump onto the high pressure pump holding-device tool (W470589084000)
using adaptor plate and locking tooth tool (W936589003100).
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2. Using a suitable degreaser, clean any oil or grease from the high pressure pump shaft and mating surface
on the high pressure pump drive gear.
3. Install the high pressure fuel pump drive gear onto the high pressure fuel pump camshaft.
4. If removed, install the high pressure pump timing plate to the high pressure pump drive gear. Torque to 25
N·m (18 lb·ft).
5. Install the high pressure fuel pump drive gear nut (1) onto the high pressure fuel pump. Torque the drive
gear nut to 125 N·m (92 lb·ft).
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
WARNING
PERSONAL INJURY
To prevent the escape of high pressure fuel that can penetrate skin, ensure the engine has
been shut down for a minimum of 10 minutes before servicing any component within the
high pressure circuit. Residual high fuel pressure may be present within the circuit.
NOTICE
The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line
seals are one-time use components and MUST be replaced any time they are loosened or
removed.
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.
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.
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7. Loosen but do not remove the fuel rail mounting bolts (2).
8. Remove and discard the high pressure fuel rail feed line.
NOTICE
The high pressure fuel rail feed line, high pressure fuel injector lines and fuel injector line
seals are one-time use components and MUST be replaced any time they are loosened or
removed.
NOTICE
DO NOT install any high pressure fuel line bolts and fittings using power tools. All bolts
and fittings MUST be installed using hand tools.
1. Clean the sealing area inside the high pressure fuel pump fitting 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 high pressure fuel rail feed line (1) to the fuel rail (3) and the high pressure fuel pump (4). Hand-
tighten the nuts.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
4. Torque the fuel rail mounting bolts (2) to 55 N·m (41 lb·ft).
5. Using a commercially available 19mm fuel line socket, torque the high pressure fuel rail feed line nuts to 45
N·m (33 lb·ft).
6. Install the air compressor resonator. Refer to section "Installation of the Air Compressor Resonator" .
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
7. Connect the batteries.
8. Prime the fuel system. Verify repair. Refer to section "Priming the Fuel System" .
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A passage in the cylinder head provides a fuel return path for excess fuel supplied to the injector's needle circuit.
The needle return line (4) connects to the cylinder head and contains a 6 bar pressure regulating valve where it
meets with the Pressure Control Valve (PCV) return line (3). If the pressure control valve opens, fuel returns to the
module (1) via the pressure control valve return line (3).
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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.
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. If necessary, remove the driver's side bumper end.
5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".
7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
8. Remove low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump Lines".
9. Remove the hydrocarbon fuel doser block feed line. Refer to section "Removal of the Hydrocarbon Fuel
Doser Block Feed Line".
10. Disconnect the quantity control valve electrical harness connector.
11. Disconnect the Pressure Control Valve (PCV) return line at the fuel rail.
12. Remove the banjo bolt (1) from the PCV return line at the pressure regulator and discard sealing washers.
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13. Remove the bolt securing the PCV return line at the fuel filter module.
14. Remove the clamp bolt securing the PCV return line to the air intake manifold and remove the PCV return
line.
15. If necessary, remove the bolt securing the needle return line to the cylinder head and remove the needle
return line.
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
4. Install the PCV return line to the fuel filter module. Torque to 17 N·m (12 lb·ft).
5. Install the clamp and bolt securing the PCV return line to the air intake manifold. Torque to 25 N·m (18
lb·ft).
6. Torque the PCV return line to the fuel rail to 30 N·m (22 lb·ft).
7. Connect the quantity control valve electrical harness connector.
8. Install the hydrocarbon fuel doser block feed line. Refer to section "Installation of the Hydrocarbon Fuel
Doser Block Feed Line". Follow the procedure to completion.
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The Motor Control Module (MCM) actuates the coil of the QCV 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.
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.
CAUTION
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10 GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194)
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 necessary, remove the bumper end(s).
5. Drain the fuel system. Refer to section "Draining the Fuel System Prior to Repair".
6. Remove the air compressor resonator. Refer to section "Removal of the Air Compressor Resonator".
7. Remove the Motor Control Module (MCM) and position the 120-pin connector to the side. Refer to section
"Removal of the Motor Control Module".
8. Remove the low pressure fuel pump lines. Refer to section "Removal of the Low Pressure Fuel Pump
Lines".
9. Remove the pressure control valve return line. Refer to section "Removal of the Pressure Control Valve
Return Line."
10. Disconnect the hydrocarbon doser block feed line at the fuel filter module.
11. Disconnect the quantity control valve electrical harness connector.
12. Remove the two bolts securing the Quantity Control Valve (QCV) (1) to the high pressure fuel pump (2).
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NOTICE
Do not use compressed air to remove debris from the high pressure pump housing. Doing
so may lodge particles in the pump housing passages.
1. Using a mirror, inspect the high pressure pump housing bore (1) for any debris. If debris is present, use a
vacuum to remove from pump housing.
2. Inspect the Quantity Control Valve (QCV) for debris; check ports and O-rings (1) to ensure damage is not
present. If damage or debris is found, replace the QCV. If no trouble is found with the QCV, immediately
reinstall.
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GHG17 Medium Duty Workshop (DDC-SVC-MAN-0194) 10
CAUTION
ELECTRICAL SHOCK
To avoid injury from electrical shock, use care when connecting battery cables. The magnetic switch
studs are at battery voltage.
11. Connect the batteries.
12. Prime the fuel system. Refer to section "Priming the Fuel System".
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