Got a question on this fuel return test i followed genos instruction with the 9012 tool the cp3 return was 775ml at idle for 1 min. Then inj return was about 120ml return in 1 min at idle. I have also read where people say that isnt the best test, to unplug fca and idle up to 1000 rpm for 30 sec, when i try this i got almost 500ml on 2 different test. Would that deem these injectors to be bad then? They are stock on 03 with 350k. No real big issues just checking things, seems to not have the fuel mileage i used to get and maybe not the power. Starts fine and doesnt smoke. Also could spray pattern be partial blocked to effect performance but still pass return flow test ? Thanks for any help or advice.
-
September's Cummins of the Month, First Responder's, is now open for entries!
-
"Looking for Replies" is a new feature to help you find threads that still need answers or help
GIL5077
AFAIK, test for return is at idle.
AFAIK, should not disconnect FCA for more then a few seconds, to avoid damaging parts.
Can try use additives to gently clean injectors, info found in newbies guide.
1. FUEL PUMP RETURN FLOW TEST
Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive
(above 185,00 kpa/26,831 psi), if it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting #9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing
Install fuel system test fitting #9012 in place of the banjo connector.
Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder.
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 1000-ml/minute at idle, the test has successfully passed.
If the flow is greater than 1000 ml/minute at idle, replace the fuel injection pump.
Retest to confirm repair.
*INJECTOR RETURN FLOW TEST
Diagnostic Test
1. * INJECTOR RETURN FLOW TEST
1. Operate the engine until the engine is at operating temperature.
2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing.
3. Install fuel system test fitting (9012) in place of the banjo connector.
4. Remove the vehicle fuel return line from the engine fuel drain tube.
5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank.
6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated
cylinder.
7. Start the engine and let it idle for one minute.
8. Measure the amount of fuel in the graduated cylinder.
9. If the flow is less than 180-ml/minute, the test has successfully passed.
10. If the flow is greater than 180 ml/minute, shut off the engine and remove all of the fuel injector supply lines. Re
torque all of the high-pressure connector nuts. Install all of the fuel injector supply lines.
11. Start the engine and idle for one minute. Measure the amount of fuel in the graduated cylinder.
12. If the flow is less than 180ml/minute, the condition has been fixed.
13. If the flow is greater than 180 ml/minute after step 12, shut off the engine and remove the #1 fuel injector supply
line. Re torque the high-pressure connector nut. Cap the #1 fuel port using tool #9011 on the fuel rail and the #1
high pressure connector.
14. Start the engine. Measure the amount of fuel in the graduated cylinder.
15. If the amount of fuel is less than 180 ml/minute, shut off the engine and remove the #1 high pressure connector
and the #1 fuel injector. Inspect for damage, repair/replace as necessary.
16. If the amount of fuel is not less than 180-ml/minute, repeat steps 14-16 for cylinders 2-6.
17. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-8 to confirm
repair.
SPECIFICATION:Less than 180 ml/minute total fuel return flow
AFAIK, should not disconnect FCA for more then a few seconds, to avoid damaging parts.
Can try use additives to gently clean injectors, info found in newbies guide.
1. FUEL PUMP RETURN FLOW TEST
Using the scan tool, idle the engine and measure the rail pressure and determine if the rail pressure is excessive
(above 185,00 kpa/26,831 psi), if it is, troubleshoot for excessive rail pressure first.
Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting #9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow
into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting
valve, the test is complete.
NOTE: do not drive the vehicle with any portion of this test kit installed
Operate the engine until the engine is at operating temperature.
Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing
Install fuel system test fitting #9012 in place of the banjo connector.
Install a piece of fuel line onto the test fitting and put the open end into the graduated cylinder.
Start the engine and let it idle for one minute.
Measure the amount of fuel in the graduated cylinder.
If the flow is less than 1000-ml/minute at idle, the test has successfully passed.
If the flow is greater than 1000 ml/minute at idle, replace the fuel injection pump.
Retest to confirm repair.
*INJECTOR RETURN FLOW TEST
Diagnostic Test
1. * INJECTOR RETURN FLOW TEST
1. Operate the engine until the engine is at operating temperature.
2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing.
3. Install fuel system test fitting (9012) in place of the banjo connector.
4. Remove the vehicle fuel return line from the engine fuel drain tube.
5. Install a piece of fuel line onto the test fitting and into a fuel container or into the fuel tank.
6. Install one end of a test hose onto the fuel drain tube. Place the other end of the test hose into a graduated
cylinder.
7. Start the engine and let it idle for one minute.
8. Measure the amount of fuel in the graduated cylinder.
9. If the flow is less than 180-ml/minute, the test has successfully passed.
10. If the flow is greater than 180 ml/minute, shut off the engine and remove all of the fuel injector supply lines. Re
torque all of the high-pressure connector nuts. Install all of the fuel injector supply lines.
11. Start the engine and idle for one minute. Measure the amount of fuel in the graduated cylinder.
12. If the flow is less than 180ml/minute, the condition has been fixed.
13. If the flow is greater than 180 ml/minute after step 12, shut off the engine and remove the #1 fuel injector supply
line. Re torque the high-pressure connector nut. Cap the #1 fuel port using tool #9011 on the fuel rail and the #1
high pressure connector.
14. Start the engine. Measure the amount of fuel in the graduated cylinder.
15. If the amount of fuel is less than 180 ml/minute, shut off the engine and remove the #1 high pressure connector
and the #1 fuel injector. Inspect for damage, repair/replace as necessary.
16. If the amount of fuel is not less than 180-ml/minute, repeat steps 14-16 for cylinders 2-6.
17. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-8 to confirm
repair.
SPECIFICATION:Less than 180 ml/minute total fuel return flow
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
-
?
