1067-12.pdf - fuel injection system low pressure leak test
TRANSCRIPT
1067-12.pdf - Fuel Injection System Low Pressure Leak Test,
Potential Fuel LeakSUBJECT DATE
Fuel Injection System Low Pressure Leak Test, Potential Fuel Leak Points, Alternative Contrast Spray Method for Determining a Leak Path, Alternative Fuel Dye Method for Determining a Leak Path –
Two-Filter Fuel Systems
DDC-SVC-MAN-0084 EPA10
Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
New procedure
System
Determining a Leak Path – Two-Filter System
Alternative Fuel Dye Method for Determining a Leak Path – Two-Filter
System
10 67-12
All information subject to change without notice. 3 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
Table 1. Service Tools Used in the Procedure
Tool Number Description
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.
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
4. Install J-48710 tool (1) on to the fuel filter module.
5. Connect an air supply to J-48710 tool. 6. Pressurize the fuel system to 345 kPa (50 psi) for six minutes. 7. Close the ball valve on J-48710 tool. 8. Remove the return line from the fuel filter module and install J-48710 cap tool (1) on the fuel filter module return line
fitting.
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
4 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
9. Install the fuel tank fill caps. 10. Ignition ON, engine OFF, connect to the MCM using DDDL. 11. Click the “service routines” tab in DDDL.
12. Click the “FIS Low Pressure Leak Test” tab in DDDL.
10 67-12
All information subject to change without notice. 5 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
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).
15. Press the “Start” button on DDDL.
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
6 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
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.
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
18. Connect an air supply to the J-48710 tool. 19. Open the ball valve and pressurize the fuel system to 517 kPa (75 psi). 20. Using a soapy solution, spray connectors, fittings and hoses shown in the Potential Fuel Leak Points. Was a leak found?
a. Yes; repair as necessary. Repeat the FIS Low Pressure Leak Test to verify the repair. b. No; contact the Detroit™ Customer Support Center at (800) 445-1980.
10 67-12
All information subject to change without notice. 7 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
3 Potential Fuel Leak Points - Two-Filter Fuel System
Torque all fuel system fittings; Refer to section "Fuel System Torque Specifications –Two Filter System" .
1. Pressure Limiting Valve (PLV) Return Line Sealing Washers
2. Cylinder Head Fittings Sealing Washers
3. Return Line Nuts
Figure 1. Return Lines
3 Potential Fuel Leak Points - Two-Filter Fuel System
8 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Water Drain Bowl O-ring 2. Fuel Feed Line Fitting O-ring 3. Priming Port Fitting O-ring 4. Low Pressure Fuel Sensor O-ring 5. Coalescer/Final Filter Cap O-ring 6. Hand Primer O-rings 7. Pre-Filter Cap O-ring
8. Return Lines Sealing Washers 9. Needle Return Pressure Control Valve O-rings
10. Water-In-Fuel (WIF) O-ring 11. Low Pressure Fuel Lines O-rings 12. Fuel Return Line Fitting O-ring 13. Water Drain Valve O-rings
Figure 2. KM59 GEN1 Fuel Filter Module
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All information subject to change without notice. 9 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. Water Drain Bowl O-ring 2. Fuel Feed Line Fitting O-ring 3. Priming Port Fitting O-ring 4. Low Pressure Fuel Sensor O-ring 5. Coalescer/Final Filter Cap O-ring 6. Hand Primer O-rings 7. Pre-Filter Cap O-ring
8. Return Lines O-rings 9. Needle Return Pressure Control Valve O-rings
10. Water-In-Fuel (WIF) O-ring 11. Low Pressure Fuel Lines O-rings 12. Fuel Return Line Fitting O-ring 13. Water Drain Valve O-rings 14. Pressure Relief Valve O-rings
Figure 3. KM63 GEN2 Fuel Filter Module
1. Fuel Temperature Sensor O-ring 2. Doser Fuel Line Sealing Washers
3. Low Pressure Fuel Lines O-rings 4. HC Doser Fuel Supply Pressure Control Valve O-rings
Figure 4. KM59 GEN1 High Pressure Flange (Front Side)
3 Potential Fuel Leak Points - Two-Filter Fuel System
10 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Fuel Temperature Sensor O-ring 2. Doser Fuel Line Sealing Washers
3. Low Pressure Fuel Lines O-rings
Figure 5. KM63 GEN2 High Pressure Flange (Front Side)
1. High Pressure Flange Gaskets 2. High Pressure Flange Sealing Plate Figure 6. KM59 GEN1 High Pressure Flange (Back Side)
10 67-12
All information subject to change without notice. 11 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. High Pressure Flange Gaskets 2. High Pressure Flange Plug Figure 7. KM63 GEN2 High Pressure Flange (Back Side)
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. Fuel Cooler Gasket Fuel In 2. Fuel Cooler Gasket Fuel Out
3 Potential Fuel Leak Points - Two-Filter Fuel System
12 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
Figure 8. Fuel Filter Module; Fuel Cooler Gaskets
1. Fuel line fitting leak points 2. MCM Cooler Sealing washer Figure 9. MCM Cooler (if equipped)
1. Two-Stage Valve and Low Pressure Relief Valve O-rings 2. Low Pressure Pump O-ring 3. Quantity Control Valve O-ring
4. Pumping Element O-rings 5. Pumping Element fitting
Figure 10. KM59 GEN1 High Pressure Fuel Pump
10 67-12
All information subject to change without notice. 13 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. Two-Stage Valve O-rings 2. Low Pressure Pump O-ring 3. Quantity Control Valve O-rings
4. Pumping Element Fittings 5. Pumping Element O-rings
Figure 11. KM63 GEN2 High Pressure Fuel Pump
1. High pressure fuel pump weep hole Figure 12. High Pressure Fuel Pump (bottom view)
3 Potential Fuel Leak Points - Two-Filter Fuel System
14 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Fuel Rail Pressure Sensor 2. Fuel Rail 3. Fuel Injector
4. Pressure Limiting Valve (PLV) 5. High Pressure Fuel Injector Line Rail Fitting Nuts
Figure 13. Fuel Rail
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
10 67-12
All information subject to change without notice. 15 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
4 Alternative Contrast Spray Method for Determining a Leak Path - Two- Filter Fuel System
Contrast spray method: 1. Completely wash, clean and dry the entire fuel system side of the engine. 2. Spray all external fuel lines, fittings, hoses, plugs, adaptors, fuel filter module and high pressure fuel pump with
contrast spray.
NOTE: Contrast spray will change color when the fuel leak contacts the spray.
3. Start the engine and inspect for external seepage of fuel. a. If there is no external leak, perform the Alternative Fuel Dye Method for Determining a Leak Path. b. If there is a leak, repair as necessary.
4 Alternative Contrast Spray Method for Determining a Leak Path - Two-Filter Fuel System
16 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
5 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System
Table 2. Service Tools Used in the Procedure
Tool Number Description
J-48708 Fuel Flow
Fuel dye method:
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 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.
1. Prime the fuel system. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter System" .
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.
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.
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?
10 67-12
All information subject to change without notice. 17 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
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.
5 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System
18 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1 10 67-12
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
3 Potential Fuel Leak Points - Two-Filter Fuel System
4 Alternative Contrast Spray Method for Determining a Leak Path - Two-Filter Fuel System
Fuel Injection System Low Pressure Leak Test, Potential Fuel Leak Points, Alternative Contrast Spray Method for Determining a Leak Path, Alternative Fuel Dye Method for Determining a Leak Path –
Two-Filter Fuel Systems
DDC-SVC-MAN-0084 EPA10
Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
New procedure
System
Determining a Leak Path – Two-Filter System
Alternative Fuel Dye Method for Determining a Leak Path – Two-Filter
System
10 67-12
All information subject to change without notice. 3 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
Table 1. Service Tools Used in the Procedure
Tool Number Description
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.
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
4. Install J-48710 tool (1) on to the fuel filter module.
5. Connect an air supply to J-48710 tool. 6. Pressurize the fuel system to 345 kPa (50 psi) for six minutes. 7. Close the ball valve on J-48710 tool. 8. Remove the return line from the fuel filter module and install J-48710 cap tool (1) on the fuel filter module return line
fitting.
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
4 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
9. Install the fuel tank fill caps. 10. Ignition ON, engine OFF, connect to the MCM using DDDL. 11. Click the “service routines” tab in DDDL.
12. Click the “FIS Low Pressure Leak Test” tab in DDDL.
10 67-12
All information subject to change without notice. 5 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
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).
15. Press the “Start” button on DDDL.
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
6 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
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.
WARNING: PRESSURIZED AIR AND FLYING PARTICLES
To avoid injury to eye or face, wear a face shield or goggles when conducting a pressure test.
18. Connect an air supply to the J-48710 tool. 19. Open the ball valve and pressurize the fuel system to 517 kPa (75 psi). 20. Using a soapy solution, spray connectors, fittings and hoses shown in the Potential Fuel Leak Points. Was a leak found?
a. Yes; repair as necessary. Repeat the FIS Low Pressure Leak Test to verify the repair. b. No; contact the Detroit™ Customer Support Center at (800) 445-1980.
10 67-12
All information subject to change without notice. 7 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
3 Potential Fuel Leak Points - Two-Filter Fuel System
Torque all fuel system fittings; Refer to section "Fuel System Torque Specifications –Two Filter System" .
1. Pressure Limiting Valve (PLV) Return Line Sealing Washers
2. Cylinder Head Fittings Sealing Washers
3. Return Line Nuts
Figure 1. Return Lines
3 Potential Fuel Leak Points - Two-Filter Fuel System
8 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Water Drain Bowl O-ring 2. Fuel Feed Line Fitting O-ring 3. Priming Port Fitting O-ring 4. Low Pressure Fuel Sensor O-ring 5. Coalescer/Final Filter Cap O-ring 6. Hand Primer O-rings 7. Pre-Filter Cap O-ring
8. Return Lines Sealing Washers 9. Needle Return Pressure Control Valve O-rings
10. Water-In-Fuel (WIF) O-ring 11. Low Pressure Fuel Lines O-rings 12. Fuel Return Line Fitting O-ring 13. Water Drain Valve O-rings
Figure 2. KM59 GEN1 Fuel Filter Module
10 67-12
All information subject to change without notice. 9 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. Water Drain Bowl O-ring 2. Fuel Feed Line Fitting O-ring 3. Priming Port Fitting O-ring 4. Low Pressure Fuel Sensor O-ring 5. Coalescer/Final Filter Cap O-ring 6. Hand Primer O-rings 7. Pre-Filter Cap O-ring
8. Return Lines O-rings 9. Needle Return Pressure Control Valve O-rings
10. Water-In-Fuel (WIF) O-ring 11. Low Pressure Fuel Lines O-rings 12. Fuel Return Line Fitting O-ring 13. Water Drain Valve O-rings 14. Pressure Relief Valve O-rings
Figure 3. KM63 GEN2 Fuel Filter Module
1. Fuel Temperature Sensor O-ring 2. Doser Fuel Line Sealing Washers
3. Low Pressure Fuel Lines O-rings 4. HC Doser Fuel Supply Pressure Control Valve O-rings
Figure 4. KM59 GEN1 High Pressure Flange (Front Side)
3 Potential Fuel Leak Points - Two-Filter Fuel System
10 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Fuel Temperature Sensor O-ring 2. Doser Fuel Line Sealing Washers
3. Low Pressure Fuel Lines O-rings
Figure 5. KM63 GEN2 High Pressure Flange (Front Side)
1. High Pressure Flange Gaskets 2. High Pressure Flange Sealing Plate Figure 6. KM59 GEN1 High Pressure Flange (Back Side)
10 67-12
All information subject to change without notice. 11 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. High Pressure Flange Gaskets 2. High Pressure Flange Plug Figure 7. KM63 GEN2 High Pressure Flange (Back Side)
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. Fuel Cooler Gasket Fuel In 2. Fuel Cooler Gasket Fuel Out
3 Potential Fuel Leak Points - Two-Filter Fuel System
12 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
Figure 8. Fuel Filter Module; Fuel Cooler Gaskets
1. Fuel line fitting leak points 2. MCM Cooler Sealing washer Figure 9. MCM Cooler (if equipped)
1. Two-Stage Valve and Low Pressure Relief Valve O-rings 2. Low Pressure Pump O-ring 3. Quantity Control Valve O-ring
4. Pumping Element O-rings 5. Pumping Element fitting
Figure 10. KM59 GEN1 High Pressure Fuel Pump
10 67-12
All information subject to change without notice. 13 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
1. Two-Stage Valve O-rings 2. Low Pressure Pump O-ring 3. Quantity Control Valve O-rings
4. Pumping Element Fittings 5. Pumping Element O-rings
Figure 11. KM63 GEN2 High Pressure Fuel Pump
1. High pressure fuel pump weep hole Figure 12. High Pressure Fuel Pump (bottom view)
3 Potential Fuel Leak Points - Two-Filter Fuel System
14 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1. Fuel Rail Pressure Sensor 2. Fuel Rail 3. Fuel Injector
4. Pressure Limiting Valve (PLV) 5. High Pressure Fuel Injector Line Rail Fitting Nuts
Figure 13. Fuel Rail
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
10 67-12
All information subject to change without notice. 15 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
4 Alternative Contrast Spray Method for Determining a Leak Path - Two- Filter Fuel System
Contrast spray method: 1. Completely wash, clean and dry the entire fuel system side of the engine. 2. Spray all external fuel lines, fittings, hoses, plugs, adaptors, fuel filter module and high pressure fuel pump with
contrast spray.
NOTE: Contrast spray will change color when the fuel leak contacts the spray.
3. Start the engine and inspect for external seepage of fuel. a. If there is no external leak, perform the Alternative Fuel Dye Method for Determining a Leak Path. b. If there is a leak, repair as necessary.
4 Alternative Contrast Spray Method for Determining a Leak Path - Two-Filter Fuel System
16 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
5 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System
Table 2. Service Tools Used in the Procedure
Tool Number Description
J-48708 Fuel Flow
Fuel dye method:
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 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.
1. Prime the fuel system. Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter System" .
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.
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.
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?
10 67-12
All information subject to change without notice. 17 10 67-12 Copyright © 2012 DETROIT DIESEL CORPORATION
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.
5 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System
18 All information subject to change without notice. Copyright © 2012 DETROIT DIESEL CORPORATION 10 67-12
1 10 67-12
2 Fuel Injection System Low Pressure Leak Test – Two-Filter Fuel System
3 Potential Fuel Leak Points - Two-Filter Fuel System
4 Alternative Contrast Spray Method for Determining a Leak Path - Two-Filter Fuel System