general information · 2018-09-11 · the fuel line from the engine control module (ecm) cooling...

9/11/2018 QuickServe Online | (4022250) ISX15 CM2250 Service Manual

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General InformationWARNING

Wear appropriate eye and face protection when usingcompressed air. Flying debris and dirt can cause personalinjury.

WARNING

When using a steam cleaner, wear safety glasses or aface shield, as well as protective clothing. Hot steam cancause serious personal injury.

CAUTION

Clean all fittings before disassembly. Dirt or contaminantscan damage the fuel system.

CAUTION

Hold banjo fittings while tightening the banjo bolt toprevent fitting rotation. Allowing the banjo fitting to rotate

may damage the fuel line.

Before servicing any fuel system components, such as fuellines, fuel pump, injectors, which will expose the fuel system orinternal engine component to potential contaminants prior todisassembly, clean the fittings, mounting hardware, and thearea around the component to be removed. Dirt orcontaminants can be introduced into the fuel system andengine if the surrounding areas are not cleaned, resulting in

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Low-Pressure System Check

Measurement - Engine Will Start

damage to the fuel system and engine. Refer to Procedure000-009 in Section 0.(/qs3/pubsys2/xml/en/procedures/132/132-000-009.html)

To reduce the possibility of engine damage from debris orcontamination, cover, cap, or plug any openings as soon aspossible when servicing the fuel system. Caps and plugs canbe found in Clean Care Kit, Part Number 4919073.

The following procedures are used to diagnose fuel systemissues. These checks and measurements are referencedthroughout the applicable troubleshooting and fault code trees,as needed.

This procedure is not intended to take the place of thetroubleshooting tree repair direction.

Reference the appropriate troubleshooting symptom tree forrepair direction.

The low-pressure system check consists of a number ofmeasurements and checks to make sure that the low-pressurefuel system is functioning properly. These checks will vary,depending on whether or not the engine will start.

The fuel line from the engine control module (ECM) coolingplate to the high-pressure fuel pump contains a filter screen atthe high-pressure fuel pump banjo fitting. The screen must beexamined and cleaned, or the banjo bolt replaced, if the screenis damaged.

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Verify the fuel system has been primed. Refer to Procedure005-234 in Section 5.(/qs3/pubsys2/xml/en/procedures/132/132-005-234-tr-mixar5.html)

Check for air in the fuel. Refer to Procedure 006-003 in Section6. (/qs3/pubsys2/xml/en/procedures/132/132-006-003-tr-mixar5.html)

Measure the fuel inlet restriction. Refer to Procedure 006-020in Section 6. (/qs3/pubsys2/xml/en/procedures/132/132-006-020-tr-mixar5.html)

Measure Fuel Pressure

Remove the threaded plug from the outlet side of the fuelfilter head and install a Compuchek™ fitting, Part Number3100221, or equivalent.Install the orificed diagnostic fuel line, Part Number3164621, at the Compuchek™ fitting.

Install a 0 to 2068 kPa [0 to 300 psi] pressure gauge at theCompuchek™ fitting at the inlet to the fuel filter head.Install a 0 to 2068 kPa [0 to 300 psi] pressure gauge at theCompuchek™ fitting at the outlet to the fuel filter head.Wait for the lift pump cycle to complete (approximately 60seconds).Operate the engine at high idle and observe the filter inletpressure.

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Measurement - Engine Will Not Start

Operate the engine at high idle and observe the filteroutlet pressure.

Fuel Filter Restriction

kpa psi

69 MAX 10 If the difference between the filter inlet pressure and filter outletpressure is greater than the specification, replace the fuel filter.

Operate the engine at high idle and observe the fuel gearpump pressure at the fuel filter inlet.

Gear Pump Pressure at High Idle

kpa psi

1000 MIN 145

Verify the fuel system has been primed. Refer to Procedure005-234 in Section 5.(/qs3/pubsys2/xml/en/procedures/132/132-005-234-tr-mixar5.html)

Check for air in the fuel. Refer to Procedure 006-003 in Section6. (/qs3/pubsys2/xml/en/procedures/132/132-006-003-tr-mixar5.html)

Install a 0 to 207 kPa [0 to 30 psi] pressure gauge at theCompuchek™ fitting at the inlet to the fuel filter head.

Turn the keyswitch to the ON position to activate the lift pump.Repeat this action, if necessary.

Measure the fuel lift pump pressure.





Fuel Drain Line Restriction

High-Pressure System Leak Down Test

Fuel Lift Pump Pressure

kpa psi

Fuel Lift Pump Pressure

kpa psi

69 MIN 10

Install a 0 to 207 kPa [0 to 30 psi] pressure gauge at theCompuchek™ fitting at the inlet to the fuel filter head.

Disconnect the lift pump electrical connector, if equipped.

Crank the engine and observe the fuel gear pump pressure.

Gear Pump Pressure While Cranking at a Minimum of150 rpm for 10 Seconds

kpa psi

69 MIN 10

CAUTION

Hold banjo fittings while tightening the banjo bolt toprevent fitting rotation. Allowing the banjo fitting to rotate

may damage the fuel line.

Measure the fuel drain line restriction. Refer to Procedure 006-012 in Section 6. (/qs3/pubsys2/xml/en/procedures/132/132-006-012-tr-mixar5.html)

Note : Engines with excessive return restriction in thehigh-pressure fuel pump return circuit may also displayFault Code 1911. This fault code is a result of the fuelpressure relief valve opening.

Note : This test can not be performed if the engine willnot start.

Connect INSITE™ electronic service tool.Operate the engine.




High-Pressure Fuel Pump Performance TestInitial Setup

Perform INSITE™ electronic service tool Fuel SystemLeakage Test.Monitor the fuel rail pressure. Fuel rail pressure will riseand stabilize. This could take up to 5 minutes.Shut the engine OFF and wait for it to completely stop.Turn the keyswitch ON quickly.Record the fuel rail pressure measured value. This is thefirst measurement.Monitor for exactly 30 seconds.Record the fuel rail pressure measured value again. Thisis the second measurement.Subtract the second measured value from the firstmeasured value.A decay in fuel pressure greater than 1500 bar [21756 psi]in 30 seconds is an indication of a high-pressure fuelsystem leak.See the appropriate troubleshooting symptom tree forrepair direction.

WARNING

Normal engine operation creates highly pressurized fuelin the fuel line which will remain in the fuel line afterengine shutdown. Never open the fuel system when theengine is operating. Before servicing the fuel system,always loosen the pump-to-rail fuel line at the rail to ventthe pressure. Keep hands clear of the line whenloosening. High-pressure fuel spray can penetrate theskin, resulting in serious personal injury or death.

WARNING

High-pressure fuel spray can cause serious injury ordeath.

WARNING



Depending on the circumstance, diesel fuel is flammable.When inspecting or performing service or repairs on thefuel system, to reduce the possibility of fire and resultingsevere personal injury, death, or property damage, neversmoke or allow sparks or flames (such as pilot lights,electrical switches, or welding equipment) in the workarea.

Note : If the low-pressure fuel system is degraded orthe fuel pressure relief valve leakage is out ofspecification, this test will not provide accurate results.Note : Troubleshoot the low-pressure system and anyhigh-pressure fuel system leakage before performingthis test.

Before servicing the high-pressure fuel system, loosen thepump-to-rail at the rail to vent the pressure.

When loosening the nut, keep hands clear of the line.

Tighten the fuel rail nut.

Torque Value: 47 n•m [ 35 ft-lb ]

Note : A machined slot in this fitting directs the fuelspray toward the engine.

WARNING

When servicing the engine, do not use the starting motorto rotate the engine with a high-pressure fuel system jointopen. Rotating the engine can create highly pressurizedfuel in the fuel system. High-pressure fuel spray canpenetrate the skin, resulting in serious personal injury ordeath.

CAUTION

Do not install the isolation tool at the high-pressure pumpoutlet fitting. Severe engine damage will result. This toolmust only be installed at the fuel rail for the purpose ofisolating the high-pressure fuel supply from individual

injectors.

This test requires five leak test isolation tools, Part Number4919546.



Measurement

Block off five injectors at the fuel rail in place of the high-pressure fuel line. Keep the injector line supply port that ismost accessible unblocked.


Install the high-pressure fuel pump service tool, Part Number5299753, from kit, Part Number 5299721, at the unblocked fuelrail connection.


Note : Cranking speed must be above 130 rpm. Ifnecessary, use a battery charger to maintain propercracking speed.Note : Units equipped with starter lockout features mayrequire additional cranking aids.

Note : Do not crank the engine for 30 secondscontinuously. Crank the engine in intervals with a 15second pause between intervals. This reduces thepossibility of overheating the starting motor.

With the following conditions met:Connect the fuel drain line, Part Number 3164673, tohigh-pressure fuel pump service tool, Part Number5299753.Disconnect the fuel pump actuator from the electricalharness.Disconnect the injector pass-through harness fromthe engine wiring harness.

Route the hose, Part Number 3164673, into a graduatedbeaker, Part Number 4919139, for measurement.Connect INSITE™ electronic service tool.Log the engine speed and fuel rail pressure measure withINSITE™ electronic service tool.Initial air purge - no measurement required.

Crank until fuel flow exits the hose making sure airhas been purged or for a maximum of 15 seconds. Ifno fuel flow exists after three 15 second crankcycles, inspect the fuel pump head. See thecorresponding Service Manual. Refer to Procedure005-227 in Section 5.(/qs3/pubsys2/xml/en/procedures/132/132-005-227-tr-mixar5.html)




Discard purged fuel from service tool hose. Disposeof in accordance with local and environmentalregulations.

Thirty Second Fuel Volume Measurement – Two 15second crank cycles. (Measurement begins when the fuelpump performance test service tool opens. A pressurepulse can be heard and felt through the high-pressure fuelpump service tool).

Collect the fuel that exits the high-pressure fuelpump service tool during the initial 15 secondmeasurement cycle.Allow the starting motor to cool for 15 seconds.Repeat a 15 seconds measurement cycle.Add the initial and final 15 second fuel volumemeasurements exiting the high-pressure fuel pumpservice tool. (30 second volume total).

Note : After completing the test, fuel may still becontained in the drain line. Make sure to empty the lineinto the measuring container to obtain a propermeasurement.

Flow from the service tool is directly related to engine speed.

Use the graph to determine the minimum flow from the servicetool.

Engine speed can be found on the horizontal axis.Service tool flow in milliliters can be found on the verticalaxis.

If the measured fuel flow from the high-pressure fuel pumpservice tool at the recorded engine speed is in the upperregion of the graph, the fuel pump is functioning properly.

If the measured fuel flow from the high-pressure fuel pumpservice tool at the recorded engine speed is in the lower regionof the graph, the fuel pump is not functioning properly andmust be replaced.

If the measured flow is in the gray area of the graph:

Check to make sure the correct specifications are beingused.Verify proper high-pressure fuel pump service toolinstallation.Make sure there are not external leaks.Verify all low-pressure system checks were made. Performthe High-Pressure Fuel Pump Performance Test again.



High-Pressure Fuel Pump Return Flow TestInitial Setup

If the test readings are still in the gray area, the fuel pumphead must be removed and the fuel pump camshaft andfuel pump camshaft tappet rollers must be inspected. Ifthe fuel pump passes the inspection, contact technicalsupport.

Remove the test equipment.Install the fuel injector supply lines. Refer toProcedure 006-060 in Section 6.(/qs3/pubsys2/xml/en/procedures/132/132-006-060-tr-mixar5.html)Connect the fuel pump actuator to the electricalharness.Connect the injector pass-through harness to theengine wiring harness.

Note : Do not disassemble the service tool,Part Number 5299753.

CAUTION

Installation of the banjo flow adapter at any place otherthan the fuel drain manifold can cause damage to high-

pressure fuel system components.

Note : If the unit is equipped with an air bleed fueltransfer tube, it must be removed from the engine priorto performing the High-Pressure Fuel Pump ReturnFlow Test. Use the following procedure to identify theair bleed fuel transfer tube. Refer to Procedure 200-001in Section F. (/qs3/pubsys2/xml/en/procedures/132/132-200-001-tr-mixar5.html) Use Part Number 3678921from the fuel system service tools kit to plug the outletof the fuel filter head. Attach the banjo flow adapterfitting as directed below to the high-pressure fuel pumpreturn line. Use the following procedure for the torquevalue during installation of the air bleed fuel transfertube. Refer to Procedure 006-013 in Section 6.(/qs3/pubsys2/xml/en/procedures/132/132-006-013-tr-mixar5.html)







Return fuel is routed from the injectors, the fuel rail pressurerelief valve, and the fuel pump head through three differentdrain lines. Measurement of fuel injector leakage requires theuse of a fuel return hose, Part Number 3164618. The fittinghas a closed end, four holes in the smooth section near thehex, and a male threaded section that attaches to the flexiblehose.

The tool is used to isolate the leakage from just the injectors,so it can be measured with a graduated cylinder.

Obtain a graduated cylinder that is marked in cubiccentimeters. Use graduated cylinder, Part Number 4919139, orequivalent.

Remove the banjo bolt from the fuel pump head drain line atthe fuel drain manifold.

Install the banjo flow adapter fitting, Part Number 3164618, atthe fuel drain manifold.

Torque Value: 12 n•m [ 105 in-lb ]

Route the hose into a collection device.

Use graduated cylinder, Part Number 4919139, formeasurement when directed.

Close the engine cover while performing thismeasurement.Operate the engine until it is at operating temperature.Allow the engine to idle with fuel flowing into a collectiondevice (bucket).Perform INSITE™ electronic service tool Fuel SystemLeakage Test.Monitor the fuel pressure rise on the screen.Allow the pressure to stabilize and create a steady streamof flow. This could take up to 5 minutes.




Move the banjo flow adapter line from the collection device(bucket) to the graduated cylinder, Part Number 4919139.Compare it to the specification below.Allow fuel to flow into the graduated cylinder for exactly 30seconds.Immediately return the banjo flow adapter line back to thecollection device (bucket).Record the volume of fuel collected in the graduatedcylinder. Compare it to the specification below.

Maximum Fuel Volume Measurement During High-Pressure Leakage Test

Time ml/cc30 Seconds 450

If 450 ml/cc pump head drain flow is collected in less than 30seconds, the fuel pump head has malfunctioned and must bereplaced.

Note : This specification is valid for engines operatingon diesel fuels. Low fuel viscosity will increase theleakage rate; for example, kerosene, or aviation fuelswill result in excessive leakage. Verify the fuel typebeing measured before replacing a fuel pump head forexcessive leakage.

Note : Do not crank the engine for 30 secondscontinuously. Crank the engine in 15 second intervalswith a 15 second pause between intervals. This reducesthe possibility of overheating the starting motor.

Connect the fuel pump diagnostic line at the fuel drainmanifold.Disconnect the lift pump.Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.

Begin cranking the engine.Obtain a steady stream of fuel flow from the drainline. Move the drain line to the graduated cylinder for15 seconds then back to the bucket.



High-Pressure Injector Return Flow TestInitial Setup

Stop cranking and allow the engine to rest for 15seconds.

Repeat the three steps above a total of two times.Record the amount of fuel flow from the injector drain linein 30 seconds while the engine is cranking.Record the volume of fuel collected in the graduatedcylinder. Compare it to the specification below.

Maximum Fuel Volume Measurement During High-Pressure Leakage Test

Time ml/cc30 Seconds 320

If 320 ml/cc pump head drain flow is collected in less than 30seconds, the fuel pump head has malfunctioned and must bereplaced.

Note : This specification is valid for engines operatingon diesel fuels. Low fuel viscosity will increase theleakage rate; for example, kerosene or aviation fuelswill result in excessive leakage. Verify the fuel typebeing measured before replacing a fuel pump head forexcessive leakage.

CAUTION



Return fuel is routed from the injectors, the fuel rail pressurerelief valve, and the fuel pump head through three differentdrain lines. Measurement of fuel injector leakage requires theuse of a fuel return hose, Part Number 3164618. The fittinghas a closed end, four holes in the smooth section near thehex, and a male threaded section that attaches to the flexiblehose.

The tool is used to isolate the leakage from just the injectors,so it can be measured with a graduated cylinder.




Obtain a graduated cylinder that is marked in cubiccentimeters. Use graduated cylinder, Part Number 4919139, orequivalent.

CAUTION

Hold the banjo fittings while tightening the banjo bolt toprevent the fitting from rotating. Allowing the banjo fitting

to rotate may damage the fuel line.

Note : Make sure the engine is at operatingtemperature before beginning this test.

Remove the banjo bolt from the injector drain line at thefuel drain manifold.Install the banjo flow adapter fitting, Part Number3164618, at the fuel drain manifold.


Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Make sure a steady flow of fuel is present at the drain linebefore beginning the measurement. Air in the line andmovement of the hose during measurement can result ininaccurate measurements.

Close the engine cover while performing thismeasurement.Perform INSITE™ electronic service tool High-PressureLeakage Test.Connect INSITE™ electronic service tool,Start the engine and allow it to idle with fuel flowing into acollection device.Wait for the lift pump cycle to complete (approximately 60seconds).



Operate engine until it is at operating temperature.Begin the High-Pressure Leakage Test.When fuel pressure stabilizes, allow fuel to flow into thecollection device for 60 seconds.

Note : Make sure a steady flow of fuel is present at thedrain line before beginning the measurement. Air in theline and movement of the hose during measurementcan result in inaccurate measurements.

Monitor the fuel pressure rise on the screen.Allow the pressure to stabilize and create a steady streamof flow. This could take up to 5 minutes.When fuel pressure stabilizes, allow fuel to flow into thecollection device for 60 seconds.

Move the banjo flow adapter line from the bucket to thegraduated cylinder, Part Number 4919139.Allow fuel to flow into the graduated cylinder for exactly 60seconds.Immediately return the banjo flow adapter line back to thecollection device (bucket).Record the volume of fuel collected in the graduatedcylinder. Compare it to the specification below.

Maximum Injector Return Flow MeasurementTime ml/cc

60 Seconds 200

Note : Fuel temperature and fuel type will influence thismeasurement. For example, as the engine is warmedup and the injectors become hot, the leakage rate willincrease. Also, low viscosity fuels such as kerosene oraviation fuels, will cause the leakage rate to increase.The above specification is correct for on-highway dieselfuels, where the diesel fuel inlet temperature is lessthan 49°C [120°F].

After recording the fuel leakage quantity, record the fuelrail pressure measured valve.Stop INSITE™ electronic service tool High-Pressure LeakTest and turn the keyswitch to OFF.

If injector drain flow is excessive, it will be necessary to isolatethe injector(s) or fuel connector(s) that are damaged or worn.




High-Pressure Injector Return Flow Isolation Test


Injector drain line connected at the fuel drain manifold.Lift pump disconnected.Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.

Begin cranking the engine until fuel exits the drainline.Move the drain line to the graduated cylinder for 15seconds then back to the bucket.Stop cranking and allow the engine to rest for 15seconds.

Repeat the three steps above one more time.Record the amount of fuel flow from the injector drain linein 30 seconds while the engine is cranking.The leakage should only be a few drops.If injector drain flow is excessive, it will be necessary toisolate the injector(s) or fuel connector(s) that aredamaged or worn.

See the appropriate troubleshooting symptom tree for repairdirections.



Initial Setup

WARNING

Normal engine operation creates highly pressurized fuelin the fuel line which will remain in the fuel line afterengine shutdown. Never open the fuel system when theengine is operating. Before servicing the fuel system,always loosen the pump-to-rail fuel line at the rail to ventthe pressure. Keep hands clear of the line whenloosening. High-pressure fuel spray can penetrate theskin, resulting in serious personal injury or death.

Note : Make sure the engine is at operatingtemperature before beginning this test.

Before servicing the high-pressure fuel system, loosen thepump to rail line at the rail to vent the pressure.

When loosening the nut, keep hands clear of the line.

Tighten the fuel rail nut.


Note : A machined slot in this fitting directs the fuelspray toward the engine.

CAUTION

Do not install the isolation tool at the high-pressure pumpoutlet fitting. Severe engine damage will result. This toolmust only be installed at the fuel rail for the purpose ofisolating the high-pressure fuel supply from individual

injectors.

CAUTION

Make sure the keyswitch is in the OFF position (enginenot operating) when loosening or tightening high-

pressure fuel lines.

Use leak test isolation tool, Part Number 4919546, to isolateexcessive fuel drain from injectors or fuel connectors.

Follow the pressure relief step (described in the previous step)prior to every installation of the isolation tool.




Isolate the injector and fuel connector for each cylinder byinstalling the isolation tool at the fuel rail in place of the high-pressure fuel line that supplies the fuel connector.


Operate the engine until it is at operating temperature.Disconnect the lift pump.Connect the injector drain line at the fuel drain manifold.Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.Connect INSITE™ electronic service tool.Start the engine and allow it to idle with fuel flowing into acollection device (bucket).Begin the High-Pressure Leakage Test.Monitor the fuel pressure rise on the screen.Allow the pressure to stabilize and create a steady streamof flow. This could take up to 5 minutes.

Record the fuel rail pressure measure value.Move the banjo flow adapter line from the bucket to thegraduated cylinder, Part Number 4919139.Allow fuel to flow into the graduated cylinder for exactly 60seconds.Immediately return the banjo flow adapter line back to thecollection device (bucket).Record the quantity of fuel collected in the graduatedcylinder. Compare it to the specification below.

Do this up to six times, once while each Injector is isolated


Maximum Injector Return Flow Measurement




Time ml/ccMaximum Injector Return Flow Measurement

Time ml/cc

60 Seconds 200If isolating any single injector results in a significantincrease in fuel rail pressure measured, or a reduction inthe maximum injector return flow measurement.Check or re-torque that fuel connector. Refer to Procedure006-052 in Section 6.(/qs3/pubsys2/xml/en/procedures/132/132-006-052-tr-mixar5.html)Remove the Isolation toolRun the High-Pressure Injector Return Flow Test again.If a significant increase in fuel rail pressure, or themaximum injector return flow measurement is now withinspec, the leak was caused by a leaking fuel connector.If the leakage is now only a few drops, the leak wascaused by a leaking fuel connector.

Do this up to six times, once while each injector is isolated



Connect the injector drain line at the fuel drain manifold.Disconnect the lift pump.Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.

Begin cranking the engine to obtain a steady streamof fuel flow from the drain line.Move the drain line to the graduated cylinder for 15seconds then back to the bucket.Stop cranking and allow the engine to rest for 15seconds.

Repeat the three steps above a total of four times.




Fuel Pressure Relief Valve Return Flow TestInitial Setup

Record the amount of fuel flow from the injector drain linein 1 minute while the engine is cranking.If isolating a single injector results in a significant reductionin the return flow measurement or the engine starts:Check or tighten that fuel connector. Refer to Procedure006-052 in Section 6.(/qs3/pubsys2/xml/en/procedures/132/132-006-052-tr-mixar5.html)Run the High-Pressure Injector Return Flow Test again.If the leakage is now only a few drops, the leak wascaused by a leaking fuel connector.If the leak remains, the fuel injector must be replaced.

Do this up to six times, once while each injector is isolated.


CAUTION



Return fuel is routed from the injectors, the fuel rail pressurerelief valve, and the fuel pump head through three differentdrain lines. Measurement of fuel injector leakage requires theuse of a fuel return hose, Part Number 5299319.

The tool is used to isolate the leakage from just the fuelpressure relief valve, so it can be measured with a graduatedcylinder.

Obtain a graduated cylinder that is marked in cubiccentimeters; example: graduated cylinder, Part Number4919139, or equivalent.





CAUTION

Hold the banjo fittings while tightening the banjo bolt toprevent the fitting from rotating. Allowing the banjo fitting

to rotate may damage the fuel line.

Remove the banjo bolt from the injector drain line at thefuel pressure relief valve.Install banjo flow adapter fitting, Part Number 5299319, atthe fuel pressure relief valve.Route the hose from this adapter to a collection device.

Alternatively, fuel return hose Part Number 3164618, canbe installed at the fuel drain manifold.


If the fuel rail return flow does not meet the specificationwhen checking at the fuel drain manifold, measure the fuelrail return flow at the fuel rail pressure relief valve, not atthe fuel drain manifold.If the fuel rail return flow does not meet the specificationat the fuel rail pressure relief valve, then a malfunctioningfuel rail relief valve has been detected.

Operate the engine until it is at operating temperature.Connect the fuel pressure relief valve line connected atthe fuel pressure relief valve.Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.Connect INSITE™ electronic service tool.Start the engine and allow it to idle with fuel pressure reliefvalve line in a collection device (bucket).Perform INSITE™ electronic service tool High-PressureLeakage Test.Monitor the fuel pressure rise on the screen.Allow the pressure to stabilize. This could take up to 5minutes.




Move the fuel pressure relief valve line to a graduatedcylinder, Part Number 4919139,Allow fuel to flow into the graduated cylinder for 60seconds.The leakage must be less than 10 drops per minute.Replace the fuel pressure relief valve if leakage is greaterthan 10 drops in 60 seconds

Note : If Fault Code 449 or 2311 is active, do notreplace the fuel pressure relief valve without firstdetermining the cause of the fault condition.Note : A steady leak from the fuel pressure relief valvecan be an indication that the valve seat is worn. Thiscondition will often coincide with Fault Code 1911and/or Fault Code 3727.

Use the appropriate fault code troubleshooting tree in SectionTF in the following manuals:

PowerGen QSX15 CM2250 Fault Code TroubleshootingManual, Bulletin 4310740.PowerGen QSX15 CM2250 ECF Fault CodeTroubleshooting Manual, Bulletin 4310739.ISB6.7 CM2250, ISC8.3 CM2250, ISL9 CM2250,ISX12/ISX11.9 CM2250, and ISX15 CM2250 Fault CodeTroubleshooting Manual, Bulletin 4022225.QSB6.7 CM2250, QSL9 CM2250, QSX11.9 CM2250 ECF,QSX15 CM2250 ECF Fault Code TroubleshootingManual, Bulletin 2883477.


Connect the fuel pressure relief valve line at the fuelpressure relief valve.Disconnect the lift pump.Route the hose into a collection device (bucket).Use graduated cylinder, Part Number 4919139, formeasurement when directed.Close the engine cover while performing thismeasurement.

Begin cranking the engine.



Last Modified: 06-Apr-2018

Move the drain line to the graduated cylinder for 15seconds then back to the bucket.Stop cranking and allow the engine to rest for 15seconds.

Repeat the three steps above a total of four times.Record the amount of fuel flow from the fuel pressurerelief valve line in 1 minute while the engine is cranking.The leakage should be less than 10 drops per minute.Replace the fuel pressure relief valve if leakage is greaterthan 10 drops in 60 seconds.

Note : If Fault Code 449 or 2311 is active, do notreplace the fuel pressure relief valve without firstdetermining the cause of the fault condition.

Use the appropriate fault code troubleshooting tree in SectionTF in the following manuals:

PowerGen QSX15 CM2250 Fault Code TroubleshootingManual, Bulletin 4310740.PowerGen QSX15 CM2250 ECF Fault CodeTroubleshooting Manual, Bulletin 4310739.ISX15 CM2250 Fault Code Troubleshooting Manual,Bulletin 4022225.QSB6.7 CM2250, QSB6.7 CM2250 EC, QSL9 CM2250,QSX11.9 CM2250 ECF, and QSX15 CM2250 ECF FaultCode Troubleshooting Manual, Bulletin 2883477.

general information · 2018-09-11 · the fuel line from the engine control module (ecm) cooling...

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