No.

: 02 TS - 51
December 12, 2002

TO: All Distributors and Their Branches US and Canada

ATTN.: Service Managers

FROM: Chris Lemanski

SUBJECT: S60 Fuel Line Repair Procedure

When removing and replacing Series 60 fuel lines the starter does not need to be removed in
order to complete the repair. DDC has performed this repair at several repair facilities and it
can be achieved in an hour or less utilizing the procedure detailed below.

The following procedure has been found to be easy to perform and places the fuel line going to
the head in a less congested area of the engine compartment.

Re routing procedure
1) Verifying the leak has come from the fuel hose going to the head

2) Park the vehicle, apply the parking brakes, and then chock the tires

3) It may help if you turn the wheels to the right before shutting off the engine in truck
applications in order to gain better access to the fuel line.

4) Disconnect the fuel line that goes to the cylinder head at both ends.

5) Cut the failed line in two between the clips and pull the hose out of the clips. There is no
need to remove the old clips

6) Install the new hose

Suggested replacement hose for zero filter group BAHP0410 (wire reinforced)
Suggested replacement hose for two filter group BAHP0267 (wire reinforced)
Plastic coated clip for the above hoses (if needed) 02362448
Optional dual tie strap 23532144

Route the new hose outside of the starter, free of rub conditions. The fuel line must be
routed free of twists and with some slack between clamping points. You may need to
slightly rotate adapter fittings on the fuel pump or fuel filter to aid the routing.

Detroit Diesel Corporation 13400 Outer Drive, West / Detroit, Michigan 48239-4001 / Telephone: 313-592-5000
DA 1 DaimlerChrysler Powersystems
 -2-

Caution: To avoid injury from fire, ensure that fuel lines are not in contact with battery
cables in a vehicle, vessel or piece of equipment. Contact with battery cables could
produce an electrical arc and act as an ignition source for a potential fire.

The fuel line may NOT be attached directly to electrical wires/bundles/terminals. The dual
clamp pictured above may be used to secure the fuel line to non-electrical lines only.

Depending upon the chassis you may use available stand offs/bolt holes and clip the fuel
line securely at certain points. Tie strap the fuel hose appropriately to prevent it from
rubbing on other objects.

7) Start the engine and let it run to allow air in the fuel system to e bled out and verify there are
no leaks.

8) Remove the chocks

Chris Lemanski
Technical Service