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SUBJECT DATE
High Pressure Fuel System - Leak Test - Two Filter System October 2012

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

EPA10/
High Pressure Fuel
DDC-SVC-MAN-0084 GHG14 DD This is a new section.
System - Leak Test
Platform

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2 High Pressure Fuel System - Leak Test – Two-Filter System

2 High Pressure Fuel System - Leak Test – Two-Filter System

High pressure fuel system leaks can cause a variety of problems including fault codes, difficulty starting, fuel in oil, rough
running, low power, and several other issues. If there is a suspected leak in the high pressure fuel system, follow these steps
to find the leak.

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.

To avoid injury from fire caused by heated diesel-fuel vapors:

• Keep those people who are not directly involved in servicing away from the engine.
• Stop the engine immediately if a fuel leak is detected.
• Do not smoke or allow open flames when working on an operating engine.
• Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).
• To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during operation.

NOTE: KM59 GEN1 fuel filter module return lines are secured to the module with banjo bolts.

NOTE: KM63 GEN2 fuel filter module return lines are secured to the module with a mounting plate attached to the
PLV return line.

1. Steam clean the entire fuel system prior to inspecting for leaks. If there are obvious external leaks, repair the leak(s).
Go to step 2.

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: 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.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.

2. Start engine and allow it to reach operating temperature 60°C (140°F).

3. Perform a Rail Pressure Bleed-Off (RPBO) Test. Refer to section "Fuel Injection System (FIS) Leak Detection - Rail
Pressure Bleed off" . Was the bleed-off time less than 35 seconds?
a. Yes; Go to step 4.
b. No; return to original troubleshooting.
4. Inspect the high pressure pump to rail feed fittings at the rail and the pump (2) for leakage. KM63 GEN2 shown, KM59
GEN1 similar. Are any leaks found? Are the line fittings loose?
a. Yes; replace the lines (1). Refer to section "Removal of the High Pressure Fuel Injector Lines" .
b. No; Go to step 5.

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5. Inspect fuel injector fuel line rail connections (1) for external leaks. Are leaks found or are there any loose lines?
a. Yes; torque the fuel line rail connections, start the engine and recheck. If leaks are still found, replace the lines.
Refer to section "Removal of the High Pressure Fuel Injector Lines" .
b. No; Go to step 6.

6. Inspect the fuel rail pressure sensor (3) for leakage. Is the sensor leaking or is it loose?
a. Yes; torque the fuel rail pressure sensor, start the engine and recheck. If leaks are still found, replace the fuel rail
pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
b. No; Go to step 7.

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2 High Pressure Fuel System - Leak Test – Two-Filter System

7. Inspect Pressure Limiting Valve (PLV) (2) for leakage. Is the PLV leaking externally or is it loose?
a. Yes; torque the PLV, start the engine and recheck. If leaks are still found, replace the Pressure Limiting Valve
(PLV). Refer to section "Removal of the Pressure Relief Valve -Two-Filter System" .
b. No; Go to step 8.

8. Inspect the high pressure fuel pump for external leaks at the pressure relief valve/two-stage valve (1), low pressure
pump (2), Quantity Control Valve (QCV) (3), high pressure pump elements (4) and high pressure pump element
fittings (5) (KM59 GEN1). Are there any leaks coming from the high pressure pump?
a. Yes; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-
Filter System" .
b. No; Go to step 9.
c. KM59 GEN1 High Pressure Fuel Pump shown below:

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d. KM63 GEN2 High Pressure Fuel Pump shown below:

NOTE: It will take a few minutes for the dye in the test bottle to make its way into the high pressure system and
up to the fuel injectors.

9. Install fuel test bottle kit (J-48708). Fill one container with ultra-low sulfur diesel fuel and add fuel dye to the fuel in
the bottle per the fuel dye manufacturer’s recommendation. Connect the hoses to the fitting on the top of the cap. This
will isolate the engine from the chassis fuel system.
10. Prime the fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel Priming Pump" .
11. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" . Install tool (W470589009800) Cam Gear
Cover onto the rear of the cam frame.

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WARNING: HOT OIL

To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.

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: 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.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.

12. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine at 950 rpm.
Using the black light, inspect the fuel injectors and fuel lines for signs of leakage. Are there any leaks coming from any
of the fuel injectors (1) or lines (2)?

a. Yes; replace any leaking fuel injector(s) or replace any leaking fuel line(s).
b. No; Go to step 13.
13. Using the black light, inspect the entire high pressure system for leaks. Repair as necessary. If no leaks are found, Go to
step 14.
14. Perform amplifier/needle return flow test and measurements. Refer to section "High Amplifier Return Flow Test - Two
Fuel Filter System" .
a. If the amplifier/needle return flow test passes, Go to step 15.
b. If the amplifier/needle return flow test fails, repair as necessary.
15. Cap the rail at all six injector feed connections using J-48704 injector rail caps and attempt to start the engine. Does the
ASL001 Rail Pressure reach AS098 Desired Rail Pressure?
a. Yes; Go to step 16.

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b. No; replace high pressure fuel pump. Refer to section "Installation of the High Pressure Fuel Pump – Two Filter
System" .
16. Does the rail pressure bleed down under a 100 bar in less than five minutes?
a. Yes; replace the High Pressure Fuel Pump and contact the Customer Support Center (800-445-1980).
b. No; contact the Customer Support Center (800-445-1980). Be prepared to provide the FSIC log files and
completed troubleshooting.

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