Optimized 03 2 Service Tests
Optimized 03 2 Service Tests
Optimized 03 2 Service Tests
Service Tests
Section 3_1
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Fuel Pump
Fuel Drain
Connection
Fuel Supply
Connection
ECM Cooling Plate
ECM Cooling Plate
Check Valve
Section 3, Page 10/30 (10/04) Media # KT900603
Low Pressure Components
7) IMV In
3) LPP In
8 - Fuel Inlet to
High Pressure 7 - Fuel Outlet
Pump 6 - Fuel Inlet to From Fuel Filter
Fuel Filter
1 - Fuel Inlet
4 - Fuel Inlet to
Gear Pump
● The ECM cooling plate check valve prevents fuel from flowing
through the ECM cooling plate when the fuel lift pump is in
operation.
● Without the ECM cooling plate check valve, fuel would
continuously circulate through the lift pump when the lift pump is
not running.
● The check valve can become damaged upon installation. Inspect
the check valve for damage or debris when troubleshooting low
power and performance problems.
● High fuel inlet restriction will be measured at the gear pump inlet
if the check valve is damaged.
Check Valve
Pump Drain
•The high pressure pump and injector drain flows as well as the drain
collector.
•The accumulator has a pressure dump valve which is also plumbed
into the drain collector.
•The Injector Drain connector includes a check valve which maintains
the required back pressure of 0.7 to 2.0 BAR to the injectors
To Fuel Tank
● Fault code 2215 indicates that measured fuel pressure in the fuel
rail cannot meet commanded fuel pressure from the ECM.
● Several different failure modes can cause this fault code.
Loose or damage HPC connectors
High fuel inlet restriction
Plugged suction fuel filter
ECM cooling plate check valve broken or plugged
OEM fuel supply lines collapsed or damaged
Failed fuel pump actuator causing the high pressure relief valve to open
Failed gear pump
Stuck open fuel injector
● Replacing a failed component, the engine must run to clear the
fault and the ECM must have a successful power-down cycle.
A successful power-down cycle consists of turning the keyswitch power off
and waiting 10 seconds before removing the main ECM power.
● Procedure
Install CUC fitting and diagnostic T-Adapter at the pressure filter outlet
Install the pressure gauge and the 0.043” orificed diagnostic fuel line at
the T-Adapter
Operate the engine at idle Fuel Filter Inlet Fuel Filter Outlet
● Procedure
Install Compuchek fitting and the 0.043” orificed diagnostic fuel
line at pressure filter outlet
Route the output of the 0.043” orificed diagnostic fuel line into a
bucket
Operate the engine at idle
Allow fuel to fill the collection bucket until the outlet of the fuel
line is submerged
Check for excessive amounts of air bubbles exiting the fuel line
● When to Perform Test
Engine runs rough or excessive smoke
Surge (continuous surging)
Engine difficult to start / loss of prime
● High pressure relief valve acts like a ‘fuse’ in the fuel system.
● If fuel pressure exceeds the relief valve pop-off pressure, fuel rail
pressure will be regulated to 900 bar and the excess fuel will be
returned to drain.
● If the high pressure relief valve opens, fault code 449 will activate
indicating high fuel pressure.
Edge Filter
The built in edge filter ensures that
HPC Body particles larger than 80 microns can
not enter the injector.
Anti-rotation pin
Injector Cut-out
Test
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Section 3, Page 39/30 (10/04) Media # KT900603
END OF
Testing & Adjusting
Service Tests
Section 3_1