Fuel Leak Diagnosis

Fuel Leak Diagnosis

1. Remove the air cleaner assemble. Refer to Air Cleaner Assembly Replacement (Service and Repair).
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 (Fuel System Description).
4. Start and idle the engine for 3-5 minutes.
5. Command the fuel pressure control to 160 MPa (23,206 psi) with a scan tool.
6. 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 (Specifications)
* Fuel Injection Line Routing Diagram ([1][2]Fluid Diagrams)
* Fuel Injection Fuel Return Pipe Replacement - Left Side (Service and Repair)
* Fuel Injection Fuel Return Pipe Replacement - Right Side (Service and Repair)
* Fuel Feed Pipe Replacement (Service and Repair)
* Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (Fuel Injection Fuel Rail Assembly Replacement - Bank 1)
* Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (Fuel Injection Fuel Rail Assembly Replacement - Bank 2)
* Fuel Injection Pump Replacement (Service and Repair)
* Fuel Injector Replacement (Left) (Service and Repair)Fuel Injector Replacement (Right) (Service and Repair)

7. A fuel leak may be caused by restricted return fuel lines. Refer to Fuel Return System Diagnosis (Fuel Return System Diagnosis).