Professional Documents
Culture Documents
1 9 07-11
SUBJECT DATE
Fuel System Diagnostic Tests September 2011
Test as follows:
1. Shut off the engine, apply the parking brake, chock the wheels, and perform any other applicable safety steps.
2. Remove the fuel feed line at the fuel filter module.
3. Install J-48710 Low Pressure Leak test kit and air hose. Use regulator and adjust the system pressure to 50 psi (345 kPa).
After two minutes the system should be drained of fuel. Return the regulator to 0 PSI pressure, close the ball valve. Go
to step 4.
NOTE: On engines without an MCM cooler, W470589039100 Fuel System Tool Update Kit will be required to install
J-48710.
4. Remove the return line and install J-48710 cap onto the return fitting of the module.
5. Turn ignition ON (key ON, engine OFF) and connect to the MCM with DDDL and open the “Fuel System Integrity Check”
panel under “Service Routines.”
7. Turn regulator (1) counterclockwise until it stops. The regulator is now set to zero pressure.
8. Connect tool J-48710 to a shop air hose (80 psi gauge minimum).
9. Turn the shutoff valve to the ON position.
10. Turn the regulator clockwise to increase pressure in the fuel system to 75 psi on the gauge.
11. Once the system pressure has reached 75 psi, let the system pressure stabilize for one minute. Turn the shutoff valve to
the OFF position and disconnect shop air from the regulator.
12. Click on the “Manual FSIC” button on the bottom of the Fuel System Integrity Check panel.
NOTE: The fuel compensation pressure sensor reads in absolute pressure, therefore the pressure should read
about 14.5 psi (100 kPa) (depending on elevation) higher than the gauge on the J-48710 Air Pressure Test tool. This
reading should be around 90 psi (620 kPa) on the FSIC panel.
13. Monitor the fuel compensation pressure on the FSIC panel. The system pressure should not drop more than 0.5 psi (3.4
kPa) in 10 minutes.
14. Does the fuel compensation pressure drop more that than 0.5 psi (3.4 kPa) in 10 minutes?
a. Yes, Go to step 16.
b. No, Go to step 15.
15. Was the air hose removed from tool J–48710, and the ball valve closed?
a. Yes, return to initial diagnostics that directed you to the fuel system leak test.
b. No, Go to step 11.
16. Attach shop air and open ball valve and pressurize fuel system to 75 psi. Go to step 17.
17. Use a soapy solution and spray around all connectors, fittings, and braided hoses as shown in the following pictures. Was
a leak found?
a. Yes, repair as necessary and verify repairs by performing the leak test.
b. No, contact the Customer Support Center (800-445-1980).
1. Fuel line fitting leak points 2. Sealing gasket for low pressure flange
1. Fuel line fitting leak points 3. HC Doser fuel supply pressure control valve with O-ring
2. Sealing gasket for high pressure flange 4. Banjo bolt with sealing washers
NOTE: Do not remove fuel filter module from engine to check for leaks on the engine side of the fuel filter module.
The use of a mirror can be helpful in locating leaks.
NOTE: The fuel cooler and feed line for the amplifier circuit is located behind the fuel filter module. Ensure this area
is not overlooked.
1. Fuel line fitting leak points 2. Banjo bolt with sealing washer
1. Two stage valve and Low pressure relief valve O-rings 4. Pumping element O-rings
2. Low Pressure Pump O-ring 5. Pumping element fitting
3. Quantity Control Valve O-ring
NOTE: It will take a few minutes for the dye in the test bottle to make its way into the high pressure system and up
to the fuel injectors.
3. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" and install tool W470589009800 Cam Gear
Cover onto the rear of the cam frame.
4. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine at 900 RPM.
Using the black light, inspect the fuel injectors (1) and fuel lines (2) for signs of leakage. Are there any leaks coming from
any of the fuel injectors or lines?
a. Yes, replace any leaking fuel injector(s) or replace any leaking fuel line(s).
b. No; Go to step 5.
5. Using the black light, inspect the entire high pressure system for leaks. Repair as necessary.
a. If no leaks are found, re-pressurize the system with tool J-48710 and inspect the filter module, low pressure fuel
lines and low pressure fuel pump for leaks. Repair as necessary.
Figure 11.
A B
Fuel Pressure Measured Without Low Pressure Pump Out Fuel With Low Pressure Pump Out Fuel
Pressure Sensor Pressure Sensor
TOOLS
1 HP Inlet DDDL v7.06sp2 & W470589099100 – Plug, Doser regulator
2 LP Outlet J-48706 - four gauge manifold tool DDDL v7.06sp2 (LPPO sensor)
3 LP Inlet W470589089100 - filter cap w/ test port
4 Compu check J-48876 - Test Gauge, Primer Port
1.3 Low Pressure Fuel System – Measuring Fuel Pressure Using Automatic Fuel
System Integrity Check
This procedure is used to measure and record fuel pressures in the low pressure side of the fuel system at given locations and
RPM. Once completed, it will provide electronic results that can be viewed in a DDDL log file.
1. Install tool number W470589099100 Fuel Pressure Test Plug (doser regulator) into the high pressure flange. Refer to Tool
Letter 11 TL-9 for installation instructions.
2. Install tool number W470589089100 Filter Cap (with test port) in place of the pre-filter cap and connect J-48706 low
pressure pump inlet (LPPI) gauge. Inspect prefilter at this time. If the filter is plugged, clean or replace only this filter as
needed.
3. If the module is equipped with a Low Pressure Pump Outlet (LPPO) fuel pressure sensor, Go to step 4. If the engine is
not equipped with a LPPO fuel pressure sensor, install the LPPO gauge J-48706 on the engine.
4. Turn on the ignition and connect to the MCM, CPC, and ACM (if applicable). Open the “Service Routines” tab in DDDL
and open the service routine labeled Fuel System Integrity Check (FSIC).
5. Start the Automatic Fuel System Integrity Check (FSIC) routine and follow the instructions in DDDL.
6. Monitor the LPPO, fuel compensation pressure and LPPI while the FSIC is running. Refer to normal fuel system pressure
chart.
7. LPPI and LPPO (if engine is not equipped with LPPO sensor) values should be added as a user event into the log file.
Press CTRL, SHIFT, space bar at the same time and add the pressure reading from the gauge(s).
8. After pressure readings are obtained and recorded, return to original troubleshooting.
1.4 Low Pressure Fuel System - Measuring Fuel Pressures Using Gauges
This procedure would only be used in the event DDDL is not available and the engine is equipped with fuel system test ports.
This procedure will allow the low pressure fuel system to be monitored using pressure gauges.
1. Place a towel or container under the fittings in the low pressure lines to catch any draining fuel.
2. Install W470589089100 Filter Cap (with test port). Connect low pressure pump inlet gauge J-48706.
3. Remove three 8mm plugs in each of the three lines: (2) low pressure pump outlet; (3) high pressure pump inlet; and (4)
high pressure pump outlet. Fittings will be reinstalled when testing is complete.
4. Insert all quick disconnect fittings (J-48706-3 - part of J-48706) into each of the fuel line test ports.
NOTICE: If chassis application prevents access, a 90° or 45° pipe fitting (1/8" NPT Female to Male) can be used if
needed for access. The elbow must be installed on the brass Schrader valve and into the adaptor with a thread
sealant. Do not thread the pipe thread into the fuel line on the engine.
9. Start the engine; Refer to section "Normal Fuel System Pressures" and compare the pressures to the table found there.
10. Remove test equipment and remove any caps or fittings installed for test.
If the LPPI is greater than the specified range, check for inlet restrictions.
If the high pressure pump Inlet pressure is lower than the acceptable pressure, check the pressure difference across the low
pressure pump outlet pressure sensor and fuel compensation pressure sensor. If engine does not have a low pressure pump outlet
pressure sensor, install J-48706 to view LPPO pressure.
Abnormal Fuel System Pressures Air in System (Connector at Line to MCM - if Installed)
Ports Warm Engine 600 RPM
LPP Inlet (in Hg) -1 to -5 (oscillating)
LPP Outlet (PSI) 14
HPP Inlet (PSI) 14
HPP Outlet (PSI) 1 to 2
Priming Port (PSI) 14
WARNING: FIRE
To avoid injury from fire caused by heated diesel-fuel vapors:
• Keep those people who are not directly involved in servicing away from the engine.
• Stop the engine immediately if a fuel leak is detected.
• Do not smoke or allow open flames when working on an operating engine.
• Wear adequate protective clothing (face shield, insulated gloves and apron, etc.).
• To prevent a buildup of potentially volatile vapors, keep the engine area well ventilated during
operation.
1. Steam clean the entire fuel system prior to inspecting for leaks. If there are obvious external leaks, repair the leak(s). Go
to step 2.
2. Start engine and allow it to reach operating temperature 60°C (140°F ).
3. Perform a Rail Pressure Bleed-Off (RPBO) Test. Refer to section "Fuel Injection System (FIS) Leak Detection - Rail
Pressure Bleed off" . Was the bleed-off time less than 35 seconds?
a. Yes; Go to step 4.
b. No; return to original troubleshooting.
4. Inspect the high pressure pump to rail feed fittings at the rail and the pump (2) for leakage. Are any leaks found? Are the
line fittings loose?
a. Yes; torque the line fittings (2), start the engine and recheck. If leaks are still found, replace the lines (1). Refer to
section "Removal of the High Pressure Fuel Injector Lines" .
b. No; Go to step 5.
5. Inspect fuel injector fuel line rail connections (1) for external leaks. Are leaks found or are there any loose lines?
a. Yes; torque the fuel line rail connections, start the engine and recheck. If leaks are still found, replace the lines.
Refer to section "Removal of the High Pressure Fuel Injector Lines" .
b. No; Go to step 6.
6. Inspect the fuel rail pressure sensor (3) for leakage. Is the sensor leaking or is it loose?
a. Yes; torque the fuel rail pressure sensor, start the engine and recheck. If leaks are still found, replace the fuel rail
pressure sensor. Refer to section "Removal of the Fuel Rail Pressure Sensor" .
b. No; Go to step 7.
7. Inspect Pressure Limiting Valve (PLV) (2) for leakage. Is the PLV leaking externally or is it loose?
a. Yes; torque the PLV, start the engine and recheck. If leaks are still found, replace the Pressure Limiting Valve (PLV).
Refer to section "Removal of the Pressure Limiting Valve" .
b. No; Go to step 8.
8. Inspect the high pressure fuel pump for external leaks. Are there any leaks coming from the high pressure pump?
a. Yes; replace the high pressure fuel pump. Refer to section "Removal of the High Pressure Fuel Pump" .
b. No; Go to step 9.
NOTE: It will take a few minutes for the dye in the test bottle to make its way into the high pressure system and up
to the fuel injectors.
9. Install fuel test bottle kit (J-48708). Fill one container with ultra-low sulfur diesel fuel and add fuel dye to the fuel in the
bottle per the fuel dye manufacturer’s recommendation. Connect the hoses to the fitting on the top of the cap. This will
isolate the engine from the chassis fuel system.
10. Prime the fuel system. Refer to section "Priming of the Fuel System Using ESOC 350 Fuel Priming Pump" .
11. Remove the rocker cover. Refer to section "Removal of the Rocker Cover" . Install tool (W470589009800) Cam Gear
Cover onto the rear of the cam frame.
12. Start engine and allow it to reach operating temperature 60°C (140°F). To perform the test, run the engine at 900 rpm.
Using the black light, inspect the fuel injectors and fuel lines for signs of leakage. Are there any leaks coming from any
of the fuel injectors or lines?
a. Yes; replace any leaking fuel injector(s) or replace any leaking fuel line(s).
b. No; Go to step 13.
13. Using the black light, inspect the entire high pressure system for leaks. Repair as necessary. If no leaks are found, Go to
step 14.
14. Perform amplifier/needle return flow test and measurements. Refer to section "High Amplifier Return Flow Test" .
a. If the amplifier/needle return flow test passes, Go to step 15.
b. If the amplifier/needle return flow test fails, repair as necessary.
15. Cap the rail at all six injector feed connections using J-48704 injector rail caps and attempt to start the engine. Does the
ASL001 Rail Pressure reach AS098 Desired Rail Pressure?
a. Yes; Go to step 16.
b. No; replace high pressure fuel pump. Refer to section "Installation of the High Pressure Fuel Pump" .
16. Does the rail pressure bleed down under a 100 bar in less than five minutes?
a. Yes; replace the High Pressure Fuel Pump and contact the Customer Support Center (800-445-1980).
b. No; contact the Customer Support Center (800-445-1980). Be prepared to provide the FSIC log files and completed
troubleshooting.
NOTE: Different style modules will need to use adapter fittings Tool Number W470589039100.
NOTE: Prime the fuel system using the hand priming pump or the ESOC 350 fuel priming pump. Refer to section
"Priming of the Fuel System Using ESOC 350 Fuel Priming Pump" .
NOTE: Use a flashlight behind the sight glass lens to make any air bubbles more visible.
2. Perform automatic FSIC and watch the fuel inlet and outlet at the fuel filter module for air leaks, then Go to step 3.
b. If the air is still coming out of the return from the module with the amp and needle lines removed, Refer to section
"Low Pressure Fuel System - Leak Test" .
7. Perform a cranking compression test using DDDL. Is any cylinder(s) below 90% compression?
a. Yes, inspect for loose injector hold-down bolt. Remove injector and inspect for loose injectors or leaking seal washers
or damaged injector cups.
b. No, perform low pressure leak test. Refer to section "Low Pressure Fuel System - Leak Test" .
NOTE: When measuring amplifier return flow, the needle return line MUST be removed from the fuel module and
put into a separate container to equalize pressure in the fuel gallery in the cylinder head. Only the amplifier return
fuel is measured. If these instructions are not followed, incorrect return flow measurements will occur.
Set up as follows:
1. Drain fuel system.
2. Disconnect amplifier return line (1) from the Fuel Filter Module.
3. Using one cap supplied in J-48708 Fuel Flow Tool, cap the fitting at the Fuel Filter Module.
4. Connect amplifier return line to the clear return line J-48708-4 supplied in kit.
5. Attach the opposite end of the clear return line to the J-48708 container.
2. Using one cap supplied in the J-48708 Fuel Flow Tool, cap the fitting at the high pressure manifold.
3. Connect needle return line to the clear return line J-48708-4 supplied in kit.
4. Attach opposite end of the clear return line J-48708-4 to the opposite J-48708-1 container.
NOTE: When measuring amplifier return flow, the needle return line MUST be removed from the fuel module and
put into a separate container to equalize pressure in the fuel gallery in the cylinder head. Only the amplifier return
fuel is measured.
NOTE: The system may contain residual high pressure when engine is turned off. Allow the residual pressure to
bleed off for ten minutes.
Parameter Description
This counter will decrease by one when the leakage was less than the
learned threshold plus the aux value. This counter will increase by one
HP Leak Counter when:
• HP Leak Actual Value > (HP Leak Leaned Value + 0.688)
• When the counter reaches 5, an error code will set.
This value is stored when an engine goes through a learn cycle for the
HP Leak Learned Value leakage threshold. The HP Leak Learned Value will only be stored
when a test has successfully passed.
This counter will only increase each time a successful learn cycle is
HP Leak Learned Counter completed. When the counter reaches 10, the Threshold Learning is
considered complete.
Rail Pressure Governor (RPG) Compensation is displayed in liters per
hour. This value is directly proportional to how the system is
compensating for leakages either internal or external.
• A new fuel system with little leakage, RPG Compensation value
is around 15–20 l/h (operating around 280–650 bar rail pressure
and at idle).
Rail Pressure Governor Compensation
• A fuel system with a 9 l/h leakage, RPG Compensation is around
25–28 l/h (operating around 280–650 bar rail pressure and at
idle).
• A fuel system with a 45 l/h leakage, RPG Compensation is
around 66 l/h (operating around 280–650 bar rail pressure and
at idle).
The buttons within the screen are listed in the following table.
Button Description
This button will start and stop a free running timer. This timer is used
Start/Stop Timer
as a reference only.
Read Accumulators This button will refresh the values in the panel.
This button will set the "HP Leak Counter" to 4. This will allow the
Reset Error Counter technician a chance to rerun the Leak Down Test. If the test fails again,
a leakage code will set.
Reset Learned Data This button will reset any previously learned leakage/threshold values.
Close Closes the panel.
4. Click on the tab labeled "Fuel System" and then "Leak Detection."
5. The dialog box that appears shows the parameters related to fuel system.
NOTE: The next step will change the "HP Leak Counter" to four (4). If the leak down test fails, a code will set on
next key cycle.
6. While in the "Leak Detection" screen, click the "Reset Error Counter" button.
7. Start engine and monitor "Coolant Temperature" and "Fuel Temperature." Both dialog boxes will turn green when
temperature conditions are met.
a. Coolant temperature must be between 70°C (158°F) and 100°C (212°F).
b. Fuel temperature must be between 35°C (95°F) and 89°C (192°F).
8. When temperature entry conditions are met, increase engine speed above idle using the throttle pedal for a minimum of
five minutes. Ensure the "Engine State" parameter in the screen indicates "Torque Demand." You can use the free running
timer located at the bottom right of the screen to monitor the time above idle.
NOTE: Do not allow the engine to stay at idle for more than five minutes or the test will need to be repeated.
9. When the five minute time is reached, decrease engine speed to idle.
10. Turn ignition OFF (key OFF, engine OFF).
11. Allow fuel system pressure to bleed down for approximately 10 seconds.
12. Turn ignition ON (key ON, engine OFF).
13. Reconnect to MCM-MCM2 and CPC.
14. Read the value for "HP Leak Actual Value."
a. If the value is less than "HP Leak Learned Value" + 0.688, the system leakage is acceptable. The "HP Leak Counter"
will decrease by one (1).
b. If the value is greater than "HP Leak Learned Value" + 0.688, the system leakage is unacceptable and should be
checked. The "HP Leak Counter" will increase by one (1).
1.11 Description and Operation of the Fuel System Integrity Check (FSIC)
Most fuel system troubleshooting procedures will include performing an FSIC routine.
The FSIC test will run the fuel system through several operational states and record important information which a technician
can use to determine the failed system or component without removing any components from the engine. The following will
give a good explanation of what the technician can expect and should be looking for during the FSIC routine or log file review.
When the FSIC routine is first activated, the Fuel Cutoff Valve in the doser block will open and allow the Fuel Compensation
Pressure sensor to read the regulated pressure that is going into the doser block. The pressure at the Compensation Pressure
Sensor will start at atmospheric pressure of 0 RPM and will increase as the engine starts to rotate. Once the compensation
pressure reads about 35 PSI, there should be enough supplied pressure to build rail pressure. If Tool W470589099100 Fuel
Pressure Test Plug (doser regulator) is installed in place of the Doser Pressure Regulator, the actual pressure available at the
high pressure pump inlet can be measured on the Fuel Compensation Pressure Sensor without installing any gauges.
NOTE: If the fuel mass is over 50 mg/st at 600 RPM (engine at operating temperature), abort the FSIC routine and
contact the CSC for further assistance.
1. Once the engine is rotating and there is sufficient low pressure supply to the high pressure pump, the high pressure pump
will start to pressurize the rail. Once the rail pressure sensor reads sufficient rail pressure (around 150 bar), it will allow
the MCM to release injection into the cylinder. At this point, the fuel mass should go above 0 mg/st indicating that the
MCM is commanding the injectors to inject fuel into the cylinder.
2. Once the engine starts, monitor the low pressure pump outlet pressure (if equipped) and the fuel compensation pressure
at 600 RPM. The pressure should be stable and should increase with engine speed.
3. As the engine increases RPM to the different set points, monitor the QCV current and the rail pressure. They should both
be stable at all RPM points.
4. The second set point in the test is 850 RPM; after the 850 point, the RPM increases to 950. This RPM change is enough
to activate the amplification system in the injectors and has little affect on the low pressure supply.
5. At the end of the log, the MCM will command the rail pressure to go to 800 bar and then it will perform an automatic rail
pressure bleed-off. It will record the rail pressure bleed-off time and it will display it in the labels, drop down menu under
(log / seek / event or time), and in the narrative block at the bottom of the chart. If the MCM is unable to ramp the rail
pressure to 800 bar because of the fuel map, it will resort to ramping the engine RPM up to 1400 and then it will perform
the same bleed-off. Compare the acceptable bleed-off time in the Rail pressure bleed-off section to your test results.
6. During the log, the FSIC panel will record the lowest fuel temperature at the 850 set point and it will take the highest fuel
temperature at 1800 and it will display it in the labels, drop down menu under (log / seek / event or time), and in the
narrative block at the bottom of the chart. This fuel temperature increase will help identify a possible restriction in the
return fuel line or an inlet restriction to the low pressure pump.
NOTE: During the test, if at any time there are any unusual sounds or anything that may indicate engine damage
or unsafe conditions, abort the test immediately by turning the ignition OFF (key OFF, engine OFF) and contact the
CSC for further assistance at (800-445-1980).
7. Throughout the log, fuel filter loading can be identified by calculating the difference between the Low Pressure Pump
Outlet Pressure Sensor (if equipped) and the Fuel Compensation Pressure Sensor. To get an accurate pressure differential,
you must install tool W470589099100 Fuel Pressure Test Plug (doser regulator). If the engine is not equipped with a
sensor, a pressure gauge can be connected to the Low Pressure Pump Outlet Hose and manual pressures can be taken and
noted in the log. Using the user event feature in DDDL, note the pressures at each RPM set point so they are easy to review
and they are electronically saved in the log file. These values can be reviewed at any time by reviewing the log file. To
add an editable user event into the log file, press Ctrl, shift, space bar at the same time and add the pressure reading from
the gauge.
NOTE: During the test, if there are any unusual sounds or anything that may indicate engine damage or unsafe
conditions, abort the test immediately by turning off the key.
6. Follow the instructions on screen and then start the engine. Allow the routine to complete.
7. Once routine completes you can view rail pressure bleed down time in text Box 1 and fuel temp rise in text box 2.
Manual FSIC
If the fuel system problem is not diagnosed using the automatic FSIC routine, there may be a need to drive or dyno the vehicle.
In this case, a Manual FSIC can be used. The Manual FSIC opens the Fuel Cutoff Valve and reads the fuel pressure to the High
Pressure Fuel Pump on the Fuel Compensation Pressure Sensor. To measure exact High Pressure Pump inlet pressure, follow
these steps:
1. Install W470589099100 Fuel Pressure Test Plug (doser regulator) in place of the Doser Pressure Regulator in the high
pressure flange.
2. Navigate in DDDL to “Service Routines.”
1.12 Fuel Injection System (FIS) Leak Detection - Rail Pressure Bleed off
The Rail Pressure Bleed Off (RPBO) test will allow a technician to identify a leak in the high pressure fuel system. A Leakage
rate of 280 bar to 10 bar in 35 seconds or more is considered acceptable. A fuel leak in one of the following locations will show
a fast bleed down rate over time.
• High pressure pump (pumping elements)
• Fuel lines from the high pressure pump to fuel rail
• Fuel lines to each fuel injector
• Leak at the fuel rail pressure sensor
• Leaking pressure limiting valve
• Internal amplifier or needle leakage to the return
• Internal amplifier or needle leakage to the cylinder
1.12.1 Rail Pressure Bleed Off Test Using DDDL (EPA07 and EPA10)
The Rail Pressure Bleed Off (RPBO) test will allow a technician to identify a leak in the high pressure fuel system. A leakage
rate of 280 bar to 10 bar in 35 seconds or more is acceptable. A leak in one of the following locations will show a fast bleed-
down rate over time.
• High pressure fuel pump (pumping elements)
• Fuel feed lines from the high pressure pump to fuel rail
• Fuel transfer lines to each fuel injector
• Leak at the fuel rail pressure sensor
• Leaking pressure limiting valve
• Internal injector amplifier or needle leakage to the return
• Internal injector amplifier or needle leakage into the cylinder
Test as follows:
1. Using DDDL 7.X, go to the "Service Routines" window and click on the "Fuel System Integrity Check" tab.
3. Start engine and allow FSIC routine to run. The engine will shut down when the routine is complete. Keep the key in the
ON position until "Test complete" is shown.
4. Once the FSIC routine has completed, review rail pressure bleed down time in the log file. The rail pressure bleed down
results can be viewed in the text box at the bottom right corner of the log file screen.
5. Rail pressure bleed-down time should be no less than 35 seconds from 280 bar to 10 bar .
6. A system that has a leak in the high pressure fuel circuit will show the following characteristic.
7. Was the bleed-down rate less than 35 seconds from 280 to 10 bar?
a. Yes; Refer to section "High Pressure Fuel System - Leak Test" .
b. No; return to original troubleshooting.
Test as follows:
1. Remove the Pressure Limiting Valve (PLV) line (1) from the fitting at the top of the fuel filter module.
2. Install clear hose and fitting from J-48708-4 and J-48708 kit to the PLV return line.
3. Cap PLV return line fitting on the fuel filter module using J-48708-3.
4. Place the opposite end of the clear hose into a graduated container.
5. Start the engine and perform the Automatic FSIC routing in the Service Routines panel and note the return flow to the
graduated container.
a. If any return fuel is noted in the graduated container during the Automatic FSIC test, replace the Pressure Limiting
Valve (PLV) and reset the PLV counter to 0. Refer to section "Removal of the Pressure Limiting Valve" .
b. If no return flow is noted, the PLV is not leaking.
For diagnostic purposes, these values can be used to pinpoint a cylinder which is getting close to or at its maximum/minimum
limit. The limit values are set to positive (+100) and negative (-100). A value above or below the acceptable limit indicates that
the MCM-MCM2 software is compensating for a crankshaft speed variation. On a common rail system this can be caused by
internal engine damage, fuel injector fueling issue or failure of a high pressure supply to a particular fuel injector.
If the ISB values are 0, this indicates no fueling compensation is needed. Values of +40 and -40 are not uncommon for a new
fuel system. If values reach +70 or -70, injection quantities are reaching their limits and should be noted. If values are at +100
or -100, the respective cylinders should be checked for a failed component.
For example, for a low injection rate (low fueling from fuel injector), the software will try to compensate for this fuel injector
by increasing its pulse width to smooth out the engine. The value will go positive until the engine is performing properly. If the
value reaches (+100), no more compensation can occur. The fuel injector should only be replaced after a visual inspection of
the fuel supply to the fuel injector is checked. If the value reaches (-100), this would indicate that the fuel injector is over-fueling
to the point that the software cannot take out any more fuel.
NOTE: Mechanical failure can also cause a +100 or a -100 reading of ISB. Follow all of the troubleshooting
procedures for the particular system to determine the root cause of the failure.
NOTE: Fuel temp must be at least 10°C (50°F) and coolant temp must be at least 70°C (158°F).
1. Using DDDL 7.X, go to the "Service Routines" window and click on the "Idle Speed Balance" tab.
2. If there are any cylinders with a +100 or -100 Idle Speed Balance (ISB) value, run a compression test with DDDL 7.X.
Refer to section "Relative Cylinder Compression Test" .
a. If all cylinders pass the compression test, Go to step 3.
b. If any cylinder(s) fail, inspect for mechanical failure.
3. Run the engine at idle and monitor ISB parameters, making note of each cylinder that is showing a positive or negative
100% value.
NOTE: During the learning process, some cylinders may reach the positive or negative 100% limit, but will only stay
there for a short period of time. Looking at the parameters using the chart function can help determine between an
injector that is stuck at the 100% limit compared to an injector that has reached the limit for a short time.
4. Click on “RUN TEST” to reset the values for all cylinders to zero. If all cylinders have not updated within three minutes,
run the engine to 1200 RPM for one minute and return to idle. This will cause the MCM-MCM2 software to relearn the
ISB values.
ISB Worksheet
Cylinder # ISB Value
Cylinder # 1
Cylinder # 2
Cylinder # 3
Cylinder # 4
Cylinder # 5
Cylinder # 6
5. Continue to monitor any cylinder(s) that have reached a positive or negative 100%. If the suspect cylinder is stuck at the
limit of positive or negative 100%, check the following components:
• Fuel line from fuel rail to fuel injector (kinked or plugged). Repair as necessary. Refer to section "Verify Repairs" .
Go to step 6.
• Fuel line connection at fuel injector or fuel rail (leaking). Repair as necessary. Refer to section "Verify Repairs" .
Go to step 6.
• Compression test; Refer to section "Relative Cylinder Compression Test" . Repair as necessary. Refer to section
"Verify Repairs" . Go to step 6.
6. If a cylinder is constantly higher than +70% or lower than -70% and there are no other mechanical concerns with the
engine, replace the fuel injector. Refer to section "Verify Repairs" .
7. If Idle Speed Balance values (ISB) are out of range after performing repairs, contact CSC (800-445-1980).
NOTE: Manual pressure readings can be entered into the log file while FSIC is running by putting a note in the log
file. While FSIC is running, you can add a user event by holding down CRTL+SHIFT+SPACE.
3. If Low Pressure Pump Out (LPPO) pressures are being taken with a manual gauge, the pressure reading at each rpm step
(600, 850, 950, 1100, 1500, 1800 rpm) of FSIC must be taken.
a. User Event:
5. Start engine and allow FSIC routine to run. Engine will shut down when the routine is complete.
6. Monitor pressures at 600 RPM.
a. If the pressure is greater than 115 psi at the priming port or the LPP Outlet, replace fuel filters. To replace the fuel
prefilter, Refer to section "Removal of the Fuel Prefilter" . To replace the water separator/coalescer, Refer to section
"Removal of the Water Separator/Coalescer" . To replace the final filter, Refer to section "Removal of the Final
Filter" .
b. If the pressure is less than 115 psi at the priming port or the LPP Outlet, Go to step 7.
7. Monitor pressures at 1800 RPM.
a. If the pressure is greater than 150 psi at the priming port or the LPP Outlet, replace fuel filters. To replace the fuel
prefilter, Refer to section "Removal of the Fuel Prefilter" . To replace the water separator/coalescer, Refer to section
"Removal of the Water Separator/Coalescer" . To replace the final filter, Refer to section "Removal of the Final
Filter" .
b. If the pressure is less than 150 psi at the priming port or the LPP Outlet, filters are OK.
8. Turn ignition OFF (key OFF, engine OFF).
9. If installed, remove J-48876 or J-48706 test gauge(s).
NOTE: On engines without an MCM cooler, Fuel System Tool Update Kit (W470589039100) will be required to
install J-48710.
2. Install J-48710 fuel pressure test kit onto the fuel feed line at the module.
3. DO NOT remove the return line from the module.
1. Remove the fuel cooler from the fuel filter module. Refer to section "Removal of the Fuel Cooler" .
2. Install W470589139100 Fuel Cooler Leak Test Plate onto the fuel cooler using supplied hardware. Tighten bolts until
rubber on the plate starts to compress.
3. Connect J-45982-7 air pressure regulator to W470589139100 and turn the regulator counter clockwise until the regulator
stops.
4. Attach shop air supply to the regulator and turn the regulator clockwise until the gauge on the tool reads 75 psi.
5. Close the ball valve on the tool and remove the shop air supply.
6. Submerse the cooler in hot water (not boiling) and verify no leakage between the tool and cooler.
7. Allow the cooler to sit for 30 minutes. Monitor the pressure on the gauge.
a. If the pressure does not drop at all in 30 minutes, there is no leak. Reinstall the cooler. Refer to section "Installation
of the Fuel Cooler" .
b. If the pressure drops, replace the fuel cooler. Refer to section "Installation of the Fuel Cooler" .