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CTM320 - PowerTech™ Plus 4.5L and 6.

8L Diesel Engines Level

Electronic Fuel System With Denso HPCR
Test for Air in Fuel
Test for Air in Fuel
To check for air in the fuel system, follow the procedure below.
1. Preliminary checks:
Check for loose fittings between fuel tank and fuel supply pump.
Check for loose fittings on the fuel cooler, if applicable.
Make sure primary filter element is on tight and gasket is intact.
Check for damaged fuel pick-up tube in tank.
Check for low fuel level in tank.
Check for foaming in tank. Foaming strongly suggests air leaking past injectors. If there is foaming,
inspect the
injector hold down clamp torque, O-rings and seals. See REMOVE ELECTRONIC INJECTORS (EIs) and
INSTALL ELECTRONIC INJECTORS (EIs) in Section 2 of this manual.
Air may enter system when engine is turned off. Verify lines are properly tightened between the
secondary filter
and the high pressure fuel pump and between high pressure fuel pump leak-off port and cylinder head.
2. Check for air in fuel system:
RG15382-UN: Test for Air in Fuel (Mechanical Pump Shown, Electric Pump is Similar)
A - Fuel Supply Line from Tank
B - Clear Fuel Line at Primary Filter Inlet
C - Clear Fuel Line at Secondary Filter Outlet
D - Fuel Line Between Secondary Filter Outlet and High Pressure Pump Inlet
E - Clear Plastic Hose
F - Container with Clean Fuel
G - Fuel Leak-Off “T”
a. Disconnect the return-to-tank line from the leak-off fuel T-connector (G). The location of the T-connector
vary by application.
b. Install a clear plastic hose (E) with proper fittings from JT03513C, Fuel Supply System Test Kit, between
the Tconnector
and the return-to-tank line, OR submerge hose in a container of clean fuel (F), as shown.
c. Start engine. Run engine for 1 minute at 1500 rpm. Observe hose and container (if used) for bubbles.
d. If bubbles were present in the return fuel, go to the next step to determine source of the air. Reconnect
3. Check for air in fuel tank supply line:
a. Disconnect the fuel tank supply line (A) at fuel transfer pump inlet.
b. Install a clear plastic hose (B) with proper fittings between the fuel tank supply line and the fuel transfer
c. Operate engine and check for air bubbles in hose. If bubbles are present, check for loose or damaged
pickup tube, fuel supply lines or hoses.
d. If no problem was found, go to the next step. Reconnect fuel lines.
4. Check for air in the high pressure pump fuel supply line:
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