Diagnostic Tests - Two-Filter System

3 DD Platform EuroV Electronics and Troubleshooting Manual (DDC-SVC-MAN-0203)
Diagnostic Tests - Two-Filter System
3.1 Chassis Fuel System Isolation Test

This test is used to determine if the cause of a hard start or no start condition is on the engine side or the chassis
side.
Service Tools Used in the Procedure

Tool Number Description
J-48708 Fuel Flow Tool
W470589039100 Fuel System Tool Update Kit w/o MCM cooler
Detroit Approved Fuel Priming Unit
DiagnosticLink™
1. EUROV INFO TO COME
1
DD Platform EuroV Electronics and Troubleshooting Manual (DDC-SVC-MAN-0203) 3
3.2 FIS Low Pressure Leak Test

Tool Number Tool Description Tool Graphic
J-48710 Air Pressure Test Kit, Fuel System
W470589039100 Fuel System Tool Update Kit without an

MCM (Motor Control Module) cooler
DiagnosticLink
Note : Please review 13 TL-11REV to ensure changes to essential tool J-48710 have been made to improve the
accuracy of detecting low pressure fuel system leaks.
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.
2
5. Connect an air supply to J-48710 tool.

6. Pressurize the fuel system to 517 kPa (75 psi) for six minutes.
7. Close the ball valve on J-48710 tool.
8. Wait two minutes.
9. Remove the return line from the fuel filter module and install J-48710 cap tool (1) on the fuel filter module
return line fitting.
3
10. Install the fuel tank fill caps.

11. Ignition ON, engine OFF, connect to the MCM using DiagnosticLink.
12. Click the “service routines” tab in DiagnosticLink.
4
13. Click the “FIS Low Pressure Leak Test” tab in DiagnosticLink.
5
WARNING
test.
14. Using J-48710 tool, pressurize the fuel system to 517 kPa (75 psi) for four minutes.
15. 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. Press the “Start” button on DiagnosticLink.
17. Once the test is complete, review the DiagnosticLink log file test results.
18. Did the fuel system pass the FIS Low Pressure Leak Test?
18.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.
18.b No; Go to step 19.
6
WARNING
test.
19. Connect an air supply to the J-48710 tool.

20. Open the ball valve and pressurize the fuel system to 517 kPa (75 psi).
21. Locate leak by using a soapy solution, spray connectors, fittings and hoses shown in the "Potential Fuel
Leak Points-Two-Filter Fuel System" procedure. Refer to section "Potential Fuel Leak Points - Two-Filter Fuel System" .
7
3.3 Low Pressure Fuel System – Measuring Fuel Pressure

Using Fuel System Integrity Check – Two-Filter Fuel
System
Tool Number Description KM59 Gen 1 KM63 Gen 2
W470589099100 Fuel Pressure Test Plug X N/A
(doser regulator)
W470589149100 Pre-Filter Cap (with test port) X X
DiagnosticLink 8.x X X
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.
This procedure is used to measure and record fuel pressures in the low pressure side of the fuel system at given
locations and rpm. Once completed, it will provide electronic results that can be viewed in a DDDL log file.
Note : Step 1 only applies to the KM59 Gen 1 fuel system. For a KM63 Gen 2 fuel system, begin the test with step
2.
Check as follows:
1. For KM59 Gen 1 systems only , install tool number W470589099100 Fuel Pressure Test Plug into the high
pressure flange. Refer to Tool Letter 11 TL-9 for installation instructions.
2. For KM59 Gen 1 fuel systems and KM63 Gen 2 fuel systems, install tool number W470589149100 Filter
Cap w/Test Port. Refer to Tool Letter 12 TL-8 for installation instructions. Inspect the pre-filter at this time. If
the filter is plugged, clean or replace only this filter as needed.
3. Connect the DDDL to the vehicle and turn the ignition on. From the “Service Routines,” open the Fuel
System Integrity Check tab.
4. Start the Fuel System Integrity Check routine and follow the instructions in DDDL.
5. Monitor the low pressure pump outlet (LPPO) fuel pressure, the fuel compensation pressure and the low
pressure pump inlet (LPPI) fuel pressure while the Fuel System Integrity Check routine is running.
8
6. Add the LPPI fuel pressure values as a user event into the log file. Press CTRL, SHIFT, and space bar at
the same time, and add the pressure reading from the gauge.
9
7. Compare the recorded fuel pressure values with the normal fuel pressures. Refer to section "Normal Fuel System
Pressures - Two-Filter System" .
8. Return to original troubleshooting. Remove the special tools from the engine after troubleshooting is
completed.
10
3.4 Low Pressure Fuel System - Pressure Measurement –

Two-Filter Fuel System
PLV return line.
The low pressure side of the fuel system can be measured using either DDDL or a manual pressure gauge.
Suction pressure is now measured using a prefilter cap with a test port (W470589149100). Some tests (KM59
Gen1 system only) will also require the use of fuel pressure test plug (W470589099100). The following section
explains the correct way to identify how pressures are going to be measured on each variation of fuel filter
module.
3.4.1 KM59 GEN1 Fuel Filter Module
1. Priming port fitting

2. Low pressure fuel sensor
3. Pre-filter cap w/ test port - W470589149100
4. Fuel pressure test plug - W470589099100
Fig 3.1, KM59 GEN1 Fuel Filter Module Pressure Measurement Points
11
Pressure Measured Measurement Point Measurement Method

LP pump outlet
LP pump outlet
LP pump inlet
HP pump inlet
3.4.2 KM63 GEN2 Fuel Filter Module
1. Priming port fitting

2. Low pressure fuel sensor
3. Pre-filter cap w/ test port - W470589149100
Fig 3.2, KM63 GEN2 Fuel Filter Module Pressure Measurement Points
Pressure Measured Measurement Point Measurement Method

LP pump outlet
LP pump outlet
LP pump inlet
HP pump inlet
12
3.5 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.
PLV return line.
WARNING
FIRE HAZARD
Do not power wash or steam clean the engine bay in the area of vehicle electrical
components, unless specified by vehicle manuals or service literature. Power
washing/steam cleaning can permanently damage these components, which could result
in fire, personal injury, or property damage.
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.
2. Start engine and allow it to reach operating temperature 60°C (140°F ).
13
3. Perform a Fuel System (FSIC) Leak Test. Refer to section "FSIC Leak Test" . Did the test detect a leak? If the
diagnostic that led you here already had you perform one, Go to step 4.
3.a Yes; Go to step 4.
3.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?
4.a Yes; replace the lines (1). Refer to section "Removal of the High Pressure Fuel Injector Lines - Two-Filter System" .
5. Inspect fuel injector fuel line rail connections (1) for external leaks. Are leaks found or are there any loose
lines?
5.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 - Two-Filter System" .
14
6. Inspect the fuel rail pressure sensor (3) for leakage. Is the sensor leaking or is it loose?
6.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" .
15
7. Inspect Pressure Limiting Valve (PLV) (2) for leakage. Is the PLV leaking externally or is it loose?
7.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" .
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?
8.a Yes; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter
System"
16
8.c KM59 GEN1 High Pressure Fuel Pump shown below:
8.d KM63 GEN2 High Pressure Fuel Pump shown below:
17
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 the Fuel System - KM59 GEN1 - Two-Filter System"
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.
WARNING
HOT OIL
To avoid injury from hot oil, do not operate the engine with the rocker cover(s) removed.
WARNING
PERSONAL INJURY
18
WARNING
PERSONAL INJURY
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)?
12.a Yes; replace any leaking fuel injector(s) or replace any leaking fuel line(s).
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.
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14. Perform amplifier/needle return flow test and measurements. Refer to section "Amplifier Return Flow Test - Two-Filter
Fuel System" .
14.a If the amplifier/needle return flow test passes, Go to step 15.

14.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?
15.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?
16.a Yes; replace the High Pressure Fuel Pump. Refer to section "Removal of the High Pressure Fuel Pump - Two-Filter
System" .
16.b No; replace all six fuel injectors. Refer to section "Removal of the Fuel Injector - Two-Filter System" .
20
3.6 Aerated Fuel Test – Two-Filter Fuel System

J-48708 Fuel Flow Tool
J-48709 Sight Glass Tools
W470589209100 Fuel Flow/Aeration Test Adapters
W470589039100 Fuel System Tool Update Kit w/o MCM cooler
ESOC 350 Fuel Priming Unit
DDDL 7.09 or later
1. Disconnect the chassis side fuel supply and return lines from the fuel filter module.
2. Using the appropriate adaptors from the W470589039100 Fuel System Tool Update Kit, install the two J-
48709 Sight Glass Tools onto the fuel filter module. Connect the other end of the sight glass lines to the
chassis side fuel supply and return lines.
3. Prime the fuel system using the hand priming pump or the ESOC 350 fuel priming pump.
4. Connect the DDDL to the vehicle, access the Service Routines section and select the Fuel System Integrity
Check (FSIC) tab.
21
WARNING
ENGINE EXHAUST
To avoid injury from inhaling engine exhaust, always operate the engine in a well-
ventilated area. Engine exhaust is toxic.
Note : Use a flashlight behind the sight glass lens to make any air bubbles more visible.
5. Carry out the FSIC routine and watch the fuel inlet and outlet flow through the sight glasses for air bubbles.
6. Is the fuel aerated in the fuel supply line?

6.a Yes; repair the fuel supply chassis lines from the fuel tank(s) to the fuel filter module.
7. Is the fuel aerated in the fuel return line?
7.b No; return to initial diagnostics that referred you to this procedure "Aerated Fuel Test - Two-Filter Fuel
System."
8. Carry out a low pressure leak test. Refer to section "FIS Low Pressure Leak Test" . Does the low pressure leak test
pass?
8.a Yes, Go to step 9.
8.b No, repair the leak(s) as necessary.
9. Install the W470589209100 Fuel Flow/Aeration Test Adapters for the needle and amplifier return lines flow
test. Refer to Tool Letter 12 TL-7 for installation instructions.
10. Carry out the FSIC routine and observe the fuel flow from the amplifier and needle return circuits through
the clear lines.
10.a If there is any air coming out of the needle or amplifier return lines, Go to step 12.
22
10.b If there is no air coming out of the needle or amplifier return lines, Go to step 11.
Note : If there is no air coming out of the needle or amplifier return lines, the initial concern may have been caused
by a loose line, cylinder head fitting or damaged cylinder head fitting sealing washer.
11. Remove the special service tools, install the cylinder head fittings with new sealing washers, reconnect the
fuel return lines, then Go to step 1. to verify if the fuel is still aerated. Refer to Tool Letter 12 TL-7 for the needle
and amplifier return lines flow test tool removal instructions.
12. Perform a cranking compression test using DDDL. Is any cylinder below 90% compression?
12.b No; contact the Customer Support Center at (800) 445-1980.
13. Remove the injector for the cylinder(s) found with compression below 90%. Refer to section "Removal of the Fuel
Injector - Two-Filter System" .
14. Remove and discard the fuel injector cup(s). Refer to section "Removal of the Fuel Injector Cup" .
15. Install new injector cup(s). Refer to section "Installation of the Fuel Injector Cup" .
16. Install the injector(s) removed with new hold down bolt(s), O-ring seals and copper washer(s). Refer to section
"Installation of the Fuel Injector" .
17. Repeat the cranking compression test using DDDL. Contact the Customer Support Center at (800) 445-
1980 if any of the cylinder compression is below 90%.
23
3.7 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.
Refer to section "Priming the Fuel System - KM63 GEN2 - Two-Filter System" for fuel system priming.
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
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).
5.a If the fuel return flow rate is within specifications, the system passed. Return system to original
condition. Refer to section "Verify Repairs" .
5.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 Idle Speed Balance" . Did the Idle Speed Balance (ISB) test
identify a bad injector?
6.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.
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.
24
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).
WARNING
ENGINE EXHAUST
WARNING
PERSONAL INJURY
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.
25
Amplifier Leakage Rate Worksheet

Total Leakage Rate (from step 4) mL per minute
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
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.
26
3.8 Fuel Filter Pressure Test – Two-Filter Fuel System

The fuel filtration system consists of two filters, the prefilter and coalescer/final filter. The prefilter has the task of
filtering material down to 100 micron. The coalescer/final filter has two tasks. The first task is to separate out
emulsified water from the fuel. The second task is to filter material down to 3-5 micron. Generally, the
coalescer/final filter is the filter that reaches the pressure limit first. With the current configuration, both filters are
changed at the same time. The pressure limits when both fuel filters are to be replaced are listed in the following
table below.
Filter Pressure Limits using LPPO Fuel Pressure (DDDL)

RPM New Filter Pressures Replace Filters
600 RPM 80-90 PSI Greater than 97 psi
1800 RPM 95-110 PSI Greater than 130 psi
3.8.1 Checking Fuel Filter Restriction - Two-Filter Fuel System

1. Install and connect DDDL 7.X.
2. Click on the “Service Routines” tab.
3. Click on the “Fuel System Integrity Check” tab.
27
4. Click on the “Run Test” tab.
28
Note : Once the Fuel System Integrity Check routine has completed, the engine will shut down.
5. Review the fuel pressure at 600 rpm. Is the fuel pressure within the specification listed in the Filter Pressure
Limits using LPPO Fuel Pressure (DDDL) table?
5.a Yes, Go to step 6.
5.b No, replace the fuel filters.
For prefilter replacement, Refer to section "Removal of the Fuel Prefilter" .
For coalescer/final filter replacement, Refer to section "Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter
System" .
6. Review the fuel pressure at 1800 rpm. Is the fuel pressure within the specification listed in the Filter
Pressure Limits using LPPO Fuel Pressure (DDDL) table?
6.a Yes, fuel filters have passed.
6.b No, replace the fuel filters.
For prefilter replacement, Refer to section "Removal of the Fuel Prefilter" .
For coalescer/final filter replacement, Refer to section "Removal of the Coalescer/Final Filter Stand Pipe - Two-Filter
System" .
29
3.9 Fuel System Integrity Check Routine -Two-Filter Fuel

System
Note : Note: Most fuel system troubleshooting procedures will include performing a Fuel System Integrity Check
(FSIC) routine.
The FSIC test runs the fuel system through several operational states and records important information which a
technician can use to determine a failed system or component without removing any components from the engine.
The following will give a good explanation of what the technician can expect and look for during the FSIC routine
or log file review.
When the FSIC routine is first activated, the fuel cutoff valve in the doser block will open allowing the fuel
compensation pressure sensor to read the regulated fuel pressure that is going into the doser block. At 0 rpm, the
fuel compensation pressure sensor will be at atmospheric pressure. When the engine starts to rotate, the fuel
compensation pressure sensor will increase in fuel pressure. Once the fuel compensation pressure reads 35 psi,
there will be enough supplied fuel pressure to build rail pressure. For KM59 GEN1 fuel systems, fuel pressure test
plug W470589099100 is installed in place of the doser pressure regulator; the actual fuel pressure available at the
high pressure pump inlet can be measured using the fuel compensation pressure sensor.
3.9.1 Fuel System Integrity Check Routine Operation Overview - Two-

Filter Fuel System
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if at any time unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the FISC routine
immediately by turning the ignition OFF and contact the Detroit™ Customer Support
Center for further assistance at 800-445-1980.
Using DiagnosticLink 8.06 or newer, the Automatic FSIC routine runs the engine through a routine that starts at
600 rpm, then goes to 850 rpm, 950 rpm, 1100 rpm, 1500 rpm and 1800 rpm. After 1800 rpm the engine will:
• return to 600 rpm
• ramp the rail pressure to 800 bar for 60 seconds
• request the ignition be turned off and back on
• perform a Fuel System Leak Detection routine
On occasion, the Motor Control Module (MCM) may not allow the rail pressure to ramp to 800 bar, at this point the
routine will substitute the rail pressure ramp with an idle speed adjustment to 1400 rpm.
Note : If the fuel mass is over 50 mg/st at 600 RPM (engine at operating temperature), abort the FSIC routine and
contact the Detroit™ Customer Support Center for further assistance at (800-445-1980).
Refer to section "Normal Fuel System Pressures - Two-Filter System" Refer to section "Normal Fuel System Pressures - Two-Filter System"
3.9.2 How to Run a Fuel System Integrity Check Routine - Two-Filter

Fuel System
30

Tool Number Description Graphic
W470589099100 Fuel Pressure Test Plug
DiagnosticLink 8.06 or later
NOTICE
During the Fuel System Integrity Check (FSIC) routine, if there are any unusual sounds or
anything that may indicate engine damage or unsafe conditions, abort the routine
immediately by turning the ignition OFF.
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
1. Connect to the vehicle with DiagnosticLink 8.06 or later.

2. Navigate in DiagnosticLink to “Actions.”
31
3. Select "Fuel System" and then “Fuel System Integrity Check” in the drop-down menu.
32
4. Select "FSIC Automatic Test" from the drop-down menu.
5. Follow the instructions on screen. Allow the routine to complete.
6. Once the routine completes, review the dialog box for the high pressure leak test results.
33
7. Return to the initial diagnostics that directed you to the FSIC Routine.
3.9.3 FSIC Leak Test

The FSIC Leak Test will allow a technician to identify a leak in the high pressure fuel system. The panel will
calculate if there is an acceptable pressure bleed-down rate. A leak in one of the following locations will show a
fast bleed-down rate over time:
• High pressure fuel pump (pumping elements)
• High pressure fuel rail feed lines
• High pressure fuel injector lines
• Fuel rail pressure sensor
• Pressure limiting valve
• Internal injector amplifier or needle leakage to the return
• Internal injector amplifier or needle leakage into the cylinder
1. Using DiagnosticLink , go to the "Actions" menu and click on the "Fuel System" menu option and then the
"Fuel System Integrity Check" option.
34
2. In the dropdown menu, select "FSIC Leak Test."
WARNING
PERSONAL INJURY
35
WARNING
PERSONAL INJURY
WARNING
ENGINE EXHAUST
3. Start engine and allow Fuel System Integrity Check (FSIC) Leak Test routine to run. The test will instruct
when to cycle the ignition to complete the test
4. Once the FSIC Leak Test routine has completed, review the results of the test in the dialog box of the test
panel.
36
5. Did the panel result in a "System Leaking" message?

5.a Yes; Refer to section "High Pressure Fuel System - Leak Test - Two-Filter System" .
5.b No; return to original troubleshooting.
37
3.10 Pressure Limiting Valve Flow Test – Two-Filter Fuel

System
J-48708 Fuel Flow Tool, Amp/Needle Valve, HDE
W470589209100 Fuel Flow/Aeration Test Adaptors
DiagnosticLink
Test as follows:
1. EUROV INFO TO COME>
38
3.11 Fuel Cooler Leak Test Procedure - Two-Filter Fuel

System
Test as follows:
Service Tools Used in This Test

J-45982-7 Air Pressure Regulator
W470589139100 Fuel Cooler Leak Test Plate
WARNING
PERSONAL INJURY
To avoid injury, never remove any engine component while the engine is running.
1. Remove the fuel cooler from the fuel filter module. Refer to section "Removal of the Fuel Cooler - Two Filter System" .
2. Thoroughly clean the surface of the fuel cooler.
3. Install W470589139100 Fuel Cooler Leak Test Plate (1) onto the fuel cooler using supplied mounting bolts.
39
4. Gradually tighten bolts in a cross pattern until a torque of 3.5 N·m (30 lb·in.) is achieved.
5. Connect J-45982-7 air pressure regulator to W470589139100 Fuel Cooler Leak Test Plate and turn the
regulator counter-clockwise until regulator stops.
40
WARNING
PRESSURIZED FUEL
test.
6. Attach shop air supply to the J-45982-7 air pressure regulator and turn the regulator clockwise until the
gauge on the tool reads 68 KPa (10 psi).
7. Close the shut-off valve on the J-45982-7 air pressure regulator and disconnect the shop air supply.
Note : If air bubbles are present between the fuel cooler leak test plate and the fuel cooler, it may be necessary to
tighten the mounting bolts. Only tighten enough to prevent air from escaping between the fuel cooler and the fuel
cooler leak test plate.
41
8. Submerge the fuel cooler into a tank filled with warm water and verify no leaks are present between the fuel
cooler and the fuel cooler leak test plate.
Note : Air can get trapped in the fuel cooler when the cooler is placed in the warm water.
9. Soak the fuel cooler in the warm water for two minutes to remove any air that may be trapped in the cooler.
10. Continue to monitor the fuel cooler for one minute and observe if air bubbles escape continuously from the
fuel cooler.
10.a If no air bubbles are present, reinstall the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
10.b If air bubbles are present, replace the fuel cooler. Refer to section "Installation of the Fuel Cooler – Two Filter
System" .
42

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3 DD Platform EuroV Electronics and Troubleshooting Manual (DDC-SVC-MAN-0203)

Diagnostic Tests - Two-Filter System

3.1 Chassis Fuel System Isolation Test

Service Tools Used in the Procedure

1. EUROV INFO TO COME

3.2 FIS Low Pressure Leak Test

W470589039100 Fuel System Tool Update Kit without an

4. Install J-48710 tool (1) on to the fuel filter module.

5. Connect an air supply to J-48710 tool.

10. Install the fuel tank fill caps.

19. Connect an air supply to the J-48710 tool.

3.3 Low Pressure Fuel System – Measuring Fuel Pressure

3.4 Low Pressure Fuel System - Pressure Measurement –

3.4.1 KM59 GEN1 Fuel Filter Module

1. Priming port fitting

Pressure Measured Measurement Point Measurement Method

3.4.2 KM63 GEN2 Fuel Filter Module

1. Priming port fitting

Pressure Measured Measurement Point Measurement Method

3.5 High Pressure Fuel System - Leak Test - Two-Filter

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

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

8.b No; Go to step 9.

8.c KM59 GEN1 High Pressure Fuel Pump shown below:

8.d KM63 GEN2 High Pressure Fuel Pump shown below:

14.a If the amplifier/needle return flow test passes, Go to step 15.

3.6 Aerated Fuel Test – Two-Filter Fuel System

6. Is the fuel aerated in the fuel supply line?

3.7 Amplifier Return Flow Test - Two-Filter Fuel System

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

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

Amplifier Leakage Rate Worksheet

3.8 Fuel Filter Pressure Test – Two-Filter Fuel System

Filter Pressure Limits using LPPO Fuel Pressure (DDDL)

3.8.1 Checking Fuel Filter Restriction - Two-Filter Fuel System

3. Click on the “Fuel System Integrity Check” tab.

4. Click on the “Run Test” tab.

3.9 Fuel System Integrity Check Routine -Two-Filter Fuel

3.9.1 Fuel System Integrity Check Routine Operation Overview - Two-

3.9.2 How to Run a Fuel System Integrity Check Routine - Two-Filter

Service Tools Used in the Procedure

W470589099100 Fuel Pressure Test Plug

DiagnosticLink 8.06 or later

1. Connect to the vehicle with DiagnosticLink 8.06 or later.

4. Select "FSIC Automatic Test" from the drop-down menu.

5. Follow the instructions on screen. Allow the routine to complete.

3.9.3 FSIC Leak Test

2. In the dropdown menu, select "FSIC Leak Test."

5. Did the panel result in a "System Leaking" message?

3.10 Pressure Limiting Valve Flow Test – Two-Filter Fuel

3.11 Fuel Cooler Leak Test Procedure - Two-Filter Fuel

Service Tools Used in This Test

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