FUEL SYSTEM
TABLE OF CONTENTS
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FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM
PRESSURE ...........................1
WARNING ............................1
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH
PRESSURE FUEL LINES .................1
DIAGNOSIS AND TESTING - AIR IN FUEL
SYSTEM .............................2
DIAGNOSIS AND TESTING - INJECTOR
LEAK QUANTITY .......................2
STANDARD PROCEDURE
STANDARD PROCEDURES - CLEANING
FUEL SYSTEM COMPONENTS ............3
STANDARD PROCEDURES - DRAINING
WATER FROM FUEL FILTER ..............3
STANDARD PROCEDURE - LOW
PRESSURE FUEL PUMP TEST ............4
FUEL DELIVERY ..........................6
FUEL INJECTION ........................31
FUEL SYSTEM
WARNING
WARNING - HIGH FUEL SYSTEM PRESSURE
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE INJECTORS. THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD PLACED IN THE SUSPECTED
AREA WHILE THE ENGINE IS NOT RUNNING.
START THE VEHICLE AND ALLOW THE ENGINE TO
RUN FOR A SHORT PERIOD. TURN THE ENGINE
OFF AND INSPECT THE PIECE OF CARDBOARD.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
WARNING
WARNING: UNDER NO CIRCUMSTANCES SHOULD
GASOLINE BE MIXED WITH DIESEL FUEL (NOT
EVEN DURING WINTER). THE HIGH PRESSURE
PUMP IS LUBRICATED BY DIESEL FUEL. IMMEDI-
ATE FUEL SYSTEM DAMAGE MAY OCCUR CAUS-
ING REPLACEMENT AND FLUSHING OF THE
COMPLETE DIESEL FUEL SYSTEM. HIGH PRES-
SURE PUMP SEIZURE WILL CAUSE METAL PARTI-
CLES TO SPREAD THROUGH OUT THE FUEL
CIRCUIT. ALL CDI FUEL SYSTEM COMPONENTS
CONNECTED TO THE FUEL CIRCUIT WILL HAVE TO
BE EXCHANGED AND THE LINES FLUSHED.
DIAGNOSIS AND TESTING
DIAGNOSIS AND TESTING - HIGH PRESSURE
FUEL LINES
WARNING: HIGH-PRESSURE FUEL LINES DELIVER
FUEL UNDER EXTREME PRESSURE FROM THE
INJECTION PUMP TO THE INJECTORS. THIS
MAYBE AS HIGH AS 1600BAR (23,200PSI). USE
EXTREME CAUTION WHEN INSPECTING FOR HIGH-
PRESSURE FUEL LEAKS. FUEL UNDER THIS
AMOUNT OF PRESSURE CAN PENETRATE SKIN
CAUSING PERSONAL INJURY OR DEATH. INSPECT
FOR HIGH-PRESSURE FUEL LEAKS WITH A SHEET
OF CARDBOARD PLACED IN THE SUSPECTED
AREA WHILE THE ENGINE IS NOT RUNNING.
START THE VEHICLE AND ALLOW THE ENGINE TO
RUN FOR A SHORT PERIOD. TURN THE ENGINE
OFF AND INSPECT THE PIECE OF CARDBOARD.
WEAR SAFETY GOGGLES AND ADEQUATE PRO-
TECTIVE CLOTHING WHEN SERVICING FUEL SYS-
TEM.
High-pressure fuel line leaks can cause starting
problems and poor engine performance.
• Turn the engine off.
• Place a piece for cardboard in the suspected area
(Fig. 1).
• Start the engine and allow to run for a short
period.
• Turn the engine off.
• Inspect the cardboard.
VA FUEL SYSTEM 14 - 1
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