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Fuel Injection System Low Pressure Leak Test, Potential Fuel Leak
Points, Alternative Contrast Spray Method for Determining a Leak
November 2012
Path, Alternative Fuel Dye Method for Determining a Leak Path –
Two-Filter Fuel Systems
Table 1.
Service Tools Used in the Procedure
Tool Number Description
J-48710 Air Pressure Test, Fuel System
DDDL 7.09 or later
Test as follows:
1. With the engine OFF, apply the parking brake, chock the wheels and perform any other applicable safety steps.
2. Remove the fuel tank fill caps.
3. Remove the fuel feed line from the fuel filter module.
12. Click the “FIS Low Pressure Leak Test” tab in DDDL.
13. Using J-48710 tool, pressurize the fuel system to 517 kPa (75 psi) for four minutes.
14. Close the ball valve and disconnect the air supply from J-48710 tool.
NOTE: The fuel compensation pressure will increase after the “Start” button has been pressed.
NOTE: The fuel compensation pressure sensor reads in absolute pressure, therefore the pressure should read
about 100 kPa (14.5 psi) (depending on elevation) more than the fuel pressure gauge on the J-48710 tool. The
fuel compensation sensor will read close to 620 kPa (90 psi) of pressure when the J-48710 tool is reading 517
kPa (75 psi).
16. Once the test is complete, review the DDDL log file test results.
17. Did the fuel system pass the FIS Low Pressure Leak Test?
a. Yes; slowly remove the J-48710 cap tool from the fuel filter module. Remove the J-48710 tool from the fuel filter
module. Install the fuel feed line and return line on to the fuel filter module. Return to the initial diagnostics that
directed you to the FIS Low Pressure Leak Test.
b. No; Go to step 18.
Torque all fuel system fittings; Refer to section "Fuel System Torque Specifications –Two Filter System" .
1. Pressure Limiting Valve (PLV) Return Line Sealing 3. Return Line Nuts
Washers
2. Cylinder Head Fittings Sealing Washers
Figure 1. Return Lines
NOTE: Do not remove the fuel filter module from the engine to check for leaks on the engine side of the fuel filter
module. The use of a mirror can be helpful in locating leaks.
1. Two-Stage Valve and Low Pressure Relief Valve O-rings 4. Pumping Element O-rings
2. Low Pressure Pump O-ring 5. Pumping Element fitting
3. Quantity Control Valve O-ring
Figure 10. KM59 GEN1 High Pressure Fuel Pump
1. Fuel Injector O-rings Location 2. High Pressure Fuel Injector Line O-ring Location
Figure 14. Fuel Injector and Fuel Line O-ring Locations
NOTE: Contrast spray will change color when the fuel leak contacts the spray.
Table 2.
Service Tools Used in the Procedure
Tool Number Description
J-48710 Air Pressure Test, Fuel System
J-48708 Fuel Flow
W470589009800 Cam Gear Cover DD13/DD15
NOTE: It will take a few minutes for the dye in the test bottle to make its way into the high pressure fuel system
and up to the fuel injectors.
2. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" and install tool W470589009800 Cam Gear
Cover onto the rear of the cam frame.
3. Start the engine and allow it to reach an operating temperature of 60°C (140°F).
4. Run the engine at 900 rpm.
5. Using a black light, inspect the fuel injector O-rings (1) and high pressure fuel injector line O-rings (2) for signs of
leakage. Are any leaks coming from the fuel injectors or high pressure injector lines?
a. Yes; replace the leaking fuel injector O-rings or leaking high pressure injector line(s).
b. No; Go to step 6.
6. Using a black light, inspect the entire high pressure system for leaks. Repair as necessary. If no leaks are found, re-
pressurize the system with tool J-48710 and inspect the fuel filter module, low pressure fuel lines and low pressure fuel
pump for leaks. Repair as necessary.