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SUBJECT DATE
Amplifier Return Flow Test – Two-Filter Fuel System November 2012

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

EPA10/ Amplifier Return Flow

DDC-SVC-MAN-0084 GHG14 DD Test – Two-Filter Fuel This is a new section.
Platform System

All information subject to change without notice. 3

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2 Amplifier Return Flow Test - Two-Filter Fuel System

2 Amplifier Return Flow Test - Two-Filter Fuel System

Test as follows:
1. Install the W470589209100 Fuel Flow/Aeration Test Adaptors. Refer to Tool Letter 12 TL-7 for the injector amplifier
and needle return flow test adaptors installation.
2. Prime fuel system using ESOC 350. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump -
Two-Filter System" for fuel system priming.

WARNING: ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.

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.

NOTE: When measuring amplifier return flow, the needle return line MUST be removed from the fuel module and
put into a separate container to equalize pressure in the fuel gallery in the cylinder head. Only the amplifier return
fuel is measured.

3. Start engine and allow it to run at base idle.

4. Measure and record the amplifier return flow from the clear return line (J-48708-2) to the J-48708-1 container.
5. The maximum allowable amplifier return rate at idle is 15 liters per hour (250 mL per minute).
a. If the fuel return flow rate is within specifications, the system passed. Return system to original condition. Refer
to section "Verify Repairs".
b. If the fuel return flow rate is out of specification, Go to step 6.
6. Using DDDL 7.09 or higher, read the “Idle Speed Balance Values” parameters under “Instrumentation” section for all
six cylinders. Refer to section "Checking the Idle Speed Balance". Did the Idle Speed Balance (ISB) test identify a bad
injector?
a. Yes; replace bad injector. Refer to section "Removal of the Fuel Injector - Two-Filter System". After replacing
the fuel injector, repeat the amplifier return flow test; Go to step 5.
b. No; Go to step 7.

NOTE: The system may contain residual high pressure when engine is turned off. Allow the residual pressure to
bleed off for ten minutes.

7. Turn engine OFF and wait ten minutes.

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.

8. Disconnect the #1 fuel injector high pressure line.

9. Install J-48704 rail plug on to the fuel rail and torque to 40 N·m (30 lb·ft).

4 All information subject to change without notice.

Copyright © 2012 DETROIT DIESEL CORPORATION 11 05-12
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WARNING: ENGINE EXHAUST

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.

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.

10. Start engine and allow it to run at base idle.

11. Measure the amplifier flow from the clear return line (J-48708-2) to the container (J-48708-1) during a one minute time
frame and note the flow rate in the following chart.
12. Repeat steps 7 through 11 for the remaining injectors, one at the time.

All information subject to change without notice. 5

11 05-12 Copyright © 2012 DETROIT DIESEL CORPORATION
2 Amplifier Return Flow Test - Two-Filter Fuel System

Table 1.
Amplifier Leakage Rate Worksheet
Total Leakage Rate mL per minute
(from step 4)
Capped Cylinder Leakage Rate Was a drop of more than 50mL (1.7 ounces)
compared to the Total Leakage Rate noted?
Cylinder #1 mL per minute YES NO
Cylinder #2 mL per minute YES NO
Cylinder #3 mL per minute YES NO
Cylinder #4 mL per minute YES NO
Cylinder #5 mL per minute YES NO
Cylinder #6 mL per minute YES NO

13. Replace any fuel injector causing a drop of more than 50 mL (1.7 ounces) compared to the “Total Leakage Rate” value.
Refer to section "Removal of the Fuel Injector - Two-Filter System". After replacing the fuel injector, recheck the
system; Go to step 4.

6 All information subject to change without notice.

Copyright © 2012 DETROIT DIESEL CORPORATION 11 05-12