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SUBJECT DATE
Fuel in Coolant March 2011

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0084 EPA07/10 The procedures clarify the steps to take whether or not coolant is
Fuel in Coolant
DD Platform present in the amplifier return line and/or needle return line.

All information subject to change without notice. 3

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2 Fuel In Coolant

2 Fuel In Coolant

1. Pressurize the cooling system, per Original Equipment Manufacturer (OEM) specifications. Inspect for external leaks.
a. If leaks are found, repair as necessary.
b. If there are no leaks, Go to step 2.
2. Remove the amplifier fuel return line (1) and needle fuel return line (2) from the cylinder head with the cooling system
pressurized. Is coolant present in both the amplifier fuel return line and needle fuel return line?

a. If coolant is present in both or only the upper amplifier fuel return line, Go to step 6.
b. If coolant is present in only the needle fuel return line, Go to step 4.
c. If no coolant is present, Go to step 3.
3. Test the fuel cooler for leaks.
a. If the fuel cooler fails the leak test, replace the fuel cooler. Refer to section "Removal of the Fuel Cooler"
b. If no leaks are found, Go to step 5.
4. Remove the pressure from the cooling system. Remove all six fuel injectors and reinstall the injector hold-down crabs
with old injector bolts to hold the coolant cup plug in the cylinder head.

4 All information subject to change without notice.

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5. Pressurize the cooling system per OEM specifications. Inspect for leaks around the injector cups.
a. If leaks are found, clean the injector cups and replace all six injector cup O-rings. Refer to section "Removal of the
Fuel Injector Cup"
b. If no leaks are found, Go to step 6.
6. Remove the cylinder head. Pressure test the cylinder head using W470589012500 for DD13 or W470589002500 for DD15
or DD16.
a. If the cylinder head is leaking, replace or repair as necessary.
For the DD13: Refer to section "Removal of the DD13 Cylinder Head"
For the DD15 and DD16: Refer to section "Removal of the DD15 and DD16 Cylinder Head"
b. If no leaks are found, Go to step 3.

All information subject to change without notice. 5

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