Fuel Leak Diagnosis - Outside of Engine

Fuel Leaks (Outside of Engine)




1. Remove the upper intake manifold sight shield using the following procedure:
1.1. Remove the retaining bolt in the front of the shield.
1.2. Lift up on the front of the shield.
1.3. Lift the shield off the rear bracket.
2. Clean all of the fuel lines between the fuel injection pump and the fuel injectors using brake cleaning solvent, and let dry.
3. Add 8 ounces of oil dye to the fuel tank. On dual tanks add the dye to the front, or primary, tank. Refer to Fuel System Description.
4. Connect a scan tool to the DLC.
5. Start and idle the engine for 3-5 minutes.
6. Command the fuel pressure control to 160 MPa (23,206 psi) with a scan tool.
7. Inspect for fuel leaks around the fuel injection pump, junction block, fuel rails, and fuel injector supply lines with a J 28428-E High Intensity Black Light Kit.

Tighten or replace any leaking lines or components. Refer to the following:
- Fuel Injection Line Routing Diagram
- Fastener Tightening Specifications
- Fuel Rail Assembly Replacement - Bank 1
- Fuel Rail Assembly Replacement - Bank 2
- Fuel Junction Block Replacement
- Fuel Injection Pump Replacement