Fuel Injection System Low Pressure Leak Test Two-Filter Fuel System. Potential Fuel Leak Points Two-Filter. System

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1 SUBJECT 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 DATE November 2012 Additions, Revisions, or Updates Publication Number / Title Platform Section Title Change Fuel Injection System Low Pressure Leak Test Two-Filter Fuel System Potential Fuel Leak Points Two-Filter DDC-SVC-MAN-0084 EPA10 GHG14 DD Platform System Alternative Contrast Spray Method for Determining a Leak Path Two-Filter System New procedure Alternative Fuel Dye Method for Determining a Leak Path Two-Filter System All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

2 2 Fuel Injection System Low Pressure Leak Test Two-Filter Fuel System 2 Fuel Injection System Low Pressure Leak Test Two-Filter Fuel System Table 1. Tool Number Service Tools Used in the Procedure J Air Pressure Test, Fuel System DDDL 7.09 or later Description 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 tool (1) on to the fuel filter module. 5. Connect an air supply to J tool. 6. Pressurize the fuel system to 345 kpa (50 psi) for six minutes. 7. Close the ball valve on J tool. 8. Remove the return line from the fuel filter module and install J cap tool (1) on the fuel filter module return line fitting. 4 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

3 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. All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

4 2 Fuel Injection System Low Pressure Leak Test Two-Filter Fuel System 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 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 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 tool. The fuel compensation sensor will read close to 620 kpa (90 psi) of pressure when the J tool is reading 517 kpa (75 psi). 15. Press the Start button on DDDL. 6 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

5 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 cap tool from the fuel filter module. Remove the J 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 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) All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

6 3 Potential Fuel Leak Points - Two-Filter Fuel System 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 Figure 1. Return Lines 3. Return Line Nuts 8 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

7 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 Figure 2. KM59 GEN1 Fuel Filter Module 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 All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

8 3 Potential Fuel Leak Points - Two-Filter Fuel System 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 Figure 3. KM63 GEN2 Fuel Filter Module 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 1. Fuel Temperature Sensor O-ring 3. Low Pressure Fuel Lines O-rings 2. Doser Fuel Line Sealing Washers 4. HC Doser Fuel Supply Pressure Control Valve O-rings Figure 4. KM59 GEN1 High Pressure Flange (Front Side) 10 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

9 Fuel Temperature Sensor O-ring 3. Low Pressure Fuel Lines O-rings 2. Doser Fuel Line Sealing Washers 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) All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

10 3 Potential Fuel Leak Points - Two-Filter Fuel System 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 12 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

11 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 Figure 10. KM59 GEN1 High Pressure Fuel Pump 4. Pumping Element O-rings 5. Pumping Element fitting All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

12 3 Potential Fuel Leak Points - Two-Filter Fuel System 1. Two-Stage Valve O-rings 2. Low Pressure Pump O-ring 3. Quantity Control Valve O-rings Figure 11. KM63 GEN2 High Pressure Fuel Pump 4. Pumping Element Fittings 5. Pumping Element O-rings 1. High pressure fuel pump weep hole Figure 12. High Pressure Fuel Pump (bottom view) 14 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

13 Fuel Rail Pressure Sensor 2. Fuel Rail 3. Fuel Injector Figure 13. Fuel Rail 4. Pressure Limiting Valve (PLV) 5. High Pressure Fuel Injector Line Rail Fitting Nuts 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 All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

14 4 Alternative Contrast Spray Method for Determining a Leak Path - Two-Filter Fuel System 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. 16 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION

15 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System Table 2. Tool Number Service Tools Used in the Procedure J Air Pressure Test, Fuel System J Fuel Flow W Fuel dye method: Cam Gear Cover DD13/DD15 Description 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 W 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? All information subject to change without notice Copyright 2012 DETROIT DIESEL CORPORATION

16 5 Alternative Fuel Dye Method for Determining a Leak Path - Two-Filter Fuel System a. Yes; replace the leaking fuel injector O-rings or leaking high pressure injector line(s). b. No; Go to step Using a black light, inspect the entire high pressure system for leaks. Repair as necessary. If no leaks are found, repressurize the system with tool J and inspect the fuel filter module, low pressure fuel lines and low pressure fuel pump for leaks. Repair as necessary. 18 All information subject to change without notice. Copyright 2012 DETROIT DIESEL CORPORATION