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SUBJECT DATE
Fuel Injection System Low Pressure Leak Test, Potential Fuel Leak
Points, Alternative Contrast Spray Method for Determining a Leak
November 2012
Path, Alternative Fuel Dye Method for Determining a Leak Path –
Two-Filter Fuel Systems

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
System
EPA10
DDC-SVC-MAN-0084 GHG14 DD Alternative Contrast New procedure
Platform Spray Method for
Determining a Leak Path
– Two-Filter System

Alternative Fuel Dye

Method for Determining
a Leak Path – Two-Filter
System

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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.
Service Tools Used in the Procedure
Tool Number Description
J-48710 Air Pressure Test, Fuel System
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.

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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.

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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-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.

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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.

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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 3. Return Line Nuts
Washers
2. Cylinder Head Fittings Sealing Washers
Figure 1. Return Lines

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1. Water Drain Bowl O-ring 8. Return Lines Sealing Washers

2. Fuel Feed Line Fitting O-ring 9. Needle Return Pressure Control Valve O-rings
3. Priming Port Fitting O-ring 10. Water-In-Fuel (WIF) O-ring
4. Low Pressure Fuel Sensor O-ring 11. Low Pressure Fuel Lines O-rings
5. Coalescer/Final Filter Cap O-ring 12. Fuel Return Line Fitting O-ring
6. Hand Primer O-rings 13. Water Drain Valve O-rings
7. Pre-Filter Cap O-ring
Figure 2. KM59 GEN1 Fuel Filter Module

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3 Potential Fuel Leak Points - Two-Filter Fuel System

1. Water Drain Bowl O-ring 8. Return Lines O-rings

2. Fuel Feed Line Fitting O-ring 9. Needle Return Pressure Control Valve O-rings
3. Priming Port Fitting O-ring 10. Water-In-Fuel (WIF) O-ring
4. Low Pressure Fuel Sensor O-ring 11. Low Pressure Fuel Lines O-rings
5. Coalescer/Final Filter Cap O-ring 12. Fuel Return Line Fitting O-ring
6. Hand Primer O-rings 13. Water Drain Valve O-rings
7. Pre-Filter Cap O-ring 14. Pressure Relief Valve O-rings
Figure 3. KM63 GEN2 Fuel Filter Module

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)

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1. 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)

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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

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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 4. Pumping Element O-rings
2. Low Pressure Pump O-ring 5. Pumping Element fitting
3. Quantity Control Valve O-ring
Figure 10. KM59 GEN1 High Pressure Fuel Pump

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3 Potential Fuel Leak Points - Two-Filter Fuel System

1. Two-Stage Valve O-rings 4. Pumping Element Fittings

2. Low Pressure Pump O-ring 5. Pumping Element O-rings
3. Quantity Control Valve 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)

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1. Fuel Rail Pressure Sensor 4. Pressure Limiting Valve (PLV)

2. Fuel Rail 5. High Pressure Fuel Injector Line Rail Fitting Nuts
3. Fuel Injector
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

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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.

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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-48710 Air Pressure Test, Fuel System
J-48708 Fuel Flow
W470589009800 Cam Gear Cover DD13/DD15

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?

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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 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.

18 All information subject to change without notice.

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