Fuel Leak Diagnosis

Fuel Leak Diagnosis

1. Clean all of the fuel lines between the fuel injection pump and the fuel injectors using brake cleaning solvent, and let dry.
2. 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).
3. Start and idle the engine for 3-5 minutes.
4. Command the fuel pressure control to 180 MPa (26,100 psi) with a scan tool.
5. 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 System Description (Fuel System Description)
* Fuel Feed and Return Pipe Replacement (Fuel Feed and Return Pipe Replacement)
* Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector) (Fuel Feed Pipe Replacement (Pump to Indirect Fuel Injector))
* Fuel High Pressure Pipe Replacement - Rail to Rail (Fuel High Pressure Pipe Replacement - Rail to Rail)
* Fuel High Pressure Pipe Replacement - Pump to Rail (Fuel High Pressure Pipe Replacement - Pump to Rail)
* Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block (Fuel Hose Replacement - Fuel Filter/Heater Element Housing to Fuel Feed Block)
* Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block (Fuel Hose Replacement - Fuel Injection Pump to Fuel Feed Block)
* Fuel Injection Fuel Feed Manifold Replacement (Fuel Injection Fuel Feed Manifold Replacement)
* Fuel Injection Fuel Feed Pipe Replacement - Left Side (Fuel Injection Fuel Feed Pipe Replacement - Left Side)
* Fuel Injection Fuel Feed Pipe Replacement - Right Side (Fuel Injection Fuel Feed Pipe Replacement - Right Side)
* Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (Right Side) (Fuel Injection Fuel Rail Assembly Replacement - Bank 1 (Right Side))
* Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (Left Side) (Fuel Injection Fuel Rail Assembly Replacement - Bank 2 (Left Side))
* Fuel Line Replacement - Chassis (Cab/Chassis) (Fuel Line Replacement - Chassis (Cab/Chassis))Fuel Line Replacement - Chassis (Cab/Chassis with Balance Pump) (Fuel Line Replacement - Chassis (Cab/Chassis with Balance Pump))Fuel Line Replacement - Chassis (Pickup) (Fuel Line Replacement - Chassis (Pickup))
* Fuel Return Hose Replacement (Fuel Return Hose Replacement)
* Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump (Fuel Return Hose Replacement - Fuel Return Pipe to Fuel Injection Pump)

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