Fuel Leak Diagnosis

FUEL LEAKS

1. Remove the air cleaner assemble.
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 data link connector.
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, 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:
- Fastener Tightening Specifications
- Fuel Injection Line Routing Diagram
- Fuel Injector Return Pipe Replacement -Left
- Fuel Injector Return Pipe Replacement - Right
- Fuel Return Pipe Replacement
- Fuel Rail Assembly Replacement - Bank 1
- Fuel Rail Assembly Replacement - Bank 2
- Fuel Return Junction Block Replacement
- Fuel Injection Pump Replacement
- Fuel Injector Replacement (Left) Fuel Injector Replacement (Right)
8. A fuel leak may be caused by restricted return fuel lines. Refer to Fuel Return System Diagnosis. Component Tests and General Diagnostics