1109-14

11 09-14
1
11 09-14
SUBJECT
DATE
Diagnostic Test
November 2014
Additions, Revisions, or Updates
Publication Number / Title
Platform
Section Title
DDC-SVC-MAN-0084
DDC-SVC-MAN-0184
DDC-SVC-MAN-S184
DD Platform
Euro IV
Engine Fuel Leaks - Fuel Dye Method-Two-Filter Fuel
System
DDC-SVC-MAN-0084
DD Platform
Engine Fuel Leaks - Fuel Dye Method - Three-Filter Fuel
System
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
Change
These are new sections
3
2 Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System
2
Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System
NOTE: This test is only to be performed if a fuel leak is present and a visual inspection of the engine did not
pinpoint a fuel leak path.
Service Tools Used in the Procedure
4
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 11 09-14
11 09-14
Table 1.
J-48710
Fuel system air pressure tool
W470589039100
Fuel System Update kit
J-48708
Fuel Flow tool
J-48707
FFM in and outlet hose
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
5
2 Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System
ESOC 350
Fuel Priming Pump
J-28431-B (recommended)
Fluorescent Fuel Dye that is diesel compatible
Check as follows:
NOTE: When diagnosing an engine fuel leak, the source and location of the leak MUST be positively identified
prior to repair.
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. Check if ESOC 350 is empty. If not, prime the fuel filter module, Refer to section "Priming the Fuel System Using
ESOC 350 Fuel Priming Pump - Two-Filter System" until the ESOC is empty.
4. 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.
6
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 11 09-14
11 09-14
5. Install J-48710 tool (1) on to the fuel filter module.
6. Connect an air supply to J-48710 tool.
7. Pressurize the fuel system to 345 kPa (50 psi) for six minutes.
8. Remove the J-48710 tool.
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.
NOTE: When configuring the amount of dye to be added. Consider this procedure will be run with approximately
two gallons of fuel.
9. Add diesel fuel compatible fuel dye, per manufacturer’s recommendation, to the two fitting container on the Fuel flow
tool J-48708.
10. Remove the OEM Fuel return line off the fuel filter module.
11. Connect Fuel System Update Kit W470589039100 connectors to Fuel Filter Module supply and return fittings.
12. Install the FFM in and outlet Hoses J-48707 to Fuel System Update kit W470589039100.
13. Connect the other end of the FFM in and outlet hoses J-48707 to the Fuel Flow tool J-48708.
NOTE: 0.8 L of fuel is in the module after the above draining is performed. This amount is compensated for when
priming.
14. Measure 6.8 L of Diesel fuel into the single fitting container of the Fuel Flow tool J-48708.
15. Add fuel from the single fitting container of the Fuel Flow tool J-48708 to the ESOC 350.
16. Prime the fuel system Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Two-Filter
System" until the ESOC 350 is empty.
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.
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
7
2 Engine Fuel Leaks - Fuel Dye Method - Two-Filter Fuel System
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.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
17. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine at 900 rpm.
18. Using the black light, inspect the fuel system for the source of the fuel leak. Refer to section "Potential Fuel Leak
Points - Two-Filter Fuel System".
8
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 11 09-14
11 09-14
3
Engine Fuel Leaks - Fuel Dye Method - Three-Filter Fuel System
NOTE: This test is only to be performed if a fuel leak is present and a visual inspection of the engine did not
pinpoint a fuel leak path.
Service Tools Used in the Procedure
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
9
3 Engine Fuel Leaks - Fuel Dye Method - Three-Filter Fuel System
Table 2.
J-48710
Fuel system air pressure tool
W470589039100
Fuel System Update kit
J-48708
Fuel Flow tool
J-48707
FFM in and outlet hose
10
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 11 09-14
11 09-14
ESOC 350
Fuel Priming Pump
J-28431-B (recommended)
Fluorescent Fuel Dye that is diesel compatible
Check as follows:
NOTE: When diagnosing an engine fuel leak, the source and location of the leak MUST be positively identified
prior to repair.
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. Check if ESOC 350 Fuel Priming Pump is empty. If not, prime the fuel filter module, Refer to section "Priming the
Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter System" until the ESOC is empty.
4. 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.
5. Install J-48710 tool (1) on to the fuel filter module.
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
11
3 Engine Fuel Leaks - Fuel Dye Method - Three-Filter Fuel System
6. Connect an air supply to J-48710 tool.
7. Pressurize the fuel system to 345 kPa (50 psi) for six minutes.
8. Remove the J-48710 tool.
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.
NOTE: When configuring the amount of dye to be added, consider this procedure will be run with approximately
two gallons of fuel.
9. Add diesel fuel compatible fuel dye, per manufacturer’s recommendation, to the two-fitting container on the Fuel flow
tool J-48708.
10. Remove the OEM fuel return line off the fuel filter module.
11. If fuel filter module is equipped with SAE fittings (post EPA07), connect Fuel System Update Kit W470589039100
connectors to Fuel Filter Module supply and return fittings.
12. Install the FFM inlet and outlet hoses J-48707 to Fuel System Update kit W470589039100.
13. Connect the other end of the FFM inlet and outlet hoses J-48707 to the fuel flow tool J-48708.
NOTE: 0.8 L of fuel is in the module after the above draining is performed. This amount is compensated for when
priming.
14. Measure 6.8 L of diesel fuel into the single-fitting container of the fuel flow tool J-48708.
15. Add fuel from the single-fitting container of the Fuel flow tool J-48708 to the ESOC 350 Fuel Priming Pump.
16. Prime the fuel system; Refer to section "Priming the Fuel System Using ESOC 350 Fuel Priming Pump - Three-Filter
System" until the ESOC 350 is empty.
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.
12
All information subject to change without notice.
Copyright © 2015 DETROIT DIESEL CORPORATION 11 09-14
11 09-14
WARNING: PERSONAL INJURY
To avoid injury from hot surfaces, wear protective gloves, or allow engine to cool before removing
any component.
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.
• Always start and operate an engine in a well ventilated area.
• If operating an engine in an enclosed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system or emission control system.
17. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine at 900 rpm.
18. Using the black light, inspect the fuel system for the source of the fuel leak. Refer to section "Potential Fuel Leak
Points - Three-Filter Fuel System".
All information subject to change without notice.
11 09-14
Copyright © 2015 DETROIT DIESEL CORPORATION
13