(7) Connect a sca n tool, select from Main Menu ,
System Select , Engine, Syst em Tests, Fu el Qu antity
Test, Engin e Cra nking Test and follow t he screen.
(8) After ten seconds, a maximu m of 2.5 m l
(between2&3graduation lines) may be reach ed in
the inn er vials. If th e level ha s exceeded the 2.5 ml,
repla ce that affect ed cylinder’s injector, clear the
memor y usin g the sca n tool, empty t he test vials, an d
retest.
RUNNING TEST
NOTE: If an injector is found to be out of specifica-
tion, repeat this test procedure after the injector
replacement. Hydraulic flow will take the path of
least resistance and multiple failures may be identi-
fied. Engine temperature must be above 80° C
(176°F) to perform the running test.
Perfor m th is test with the engine at opera ting tem -
perat ure. This test will assist in determining a defec-
tive or int erna lly leakin g injector(s) is presen t by
measu ring th e amou nt of fuel return.
(1) Turn the ignition off.
(2) Remove th e engine cover (Refer t o9-ENGINE
- REMOVAL).
(3) Disconn ect the fu el retur n hoses at th e top of
the injector s.
(4) Pinch off the fuel ret urn line at the ba njo bolt
fitting of the fuel rail.
(5) In st all the t est via ls ont o t he injectors and
secure with t he return hose clips (F ig. 2).
(6) Connect a sca n tool, select from Main Menu ,
System Select , Engine, Syst em Tests, Fu el Qu antity
Test, Engin e Run ning Test an d follow t he screen.
(7) After ten secon ds, a maximum of five gradua-
tion lines (40 m l) of t he large test vial m ay be
reach ed. If the level ha s exceeded the five gradua tion
lin e, replace tha t affected cylinder’s injector, clear the
memor y usin g the sca n tool, empty t he test vials, an d
retest.
STAN DARD PROCEDU RE
STANDARD PROCEDURES - CLEANING FUEL
SYSTEM COMPONENTS
CAUTION: Cleanliness cannot be overemphasized
when handling or replacing diesel fuel system com-
ponents. This especially includes the fuel injectors,
high-pressure fuel lines, fuel rail, and fuel injection
pump. Very tight tolerances are used with these
parts. Dirt contamination could cause rapid part
wear and possible plugging of fuel injector nozzle
tip holes. This in turn could lead to possible engine
misfire. Always wash/clean any fuel system compo-
nent thoroughly before disassembly and then air
dry. DO NOT wire brush injector nozzles when
cleaning. Cap or cover any open part after disas-
sembly. Before assembly, examine each part for
dirt, grease or other contaminants and clean if nec-
essary. When installing new parts, lubricate them
with clean engine oil or clean diesel fuel only.
STANDARD PROCEDURES - DRAINING WATER
FROM FUEL FILTER
Connect a hose to the Water in F uel (WIF) dra in
and place it in a clearly marked and suit able con-
tainer. Open th e WIF dra in by tur ning counterclock-
wise (Fig. 3). Turn the ign ition key on for 20 seconds
(Refer to low pr essu re fuel pump opera tion ). Repeat
the procedu re until all water is removed, close t he
dr ain and remove the hose.
Fig. 2 Special Tool # 9545
1 - SPECIAL TOOL #9545
VA FUEL SYSTEM 14 - 3
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