5 38-12

1 5 38-12

SUBJECT DATE
Aerated Fuel Test June 2012

Additions, Revisions, or Updates

Publication Number / Title Platform Section Title Change

DDC-SVC-MAN-0084 DD Platform Aerated Fuel Test Removed linking and combined sections to the test.

All information subject to change without notice. 3

5 38-12 Copyright © 2012 DETROIT DIESEL CORPORATION
2 Aerated Fuel Test

2 Aerated Fuel Test

This condition will exist if there is an external leak of the low pressure fuel system, combustion pressure entering the fuel system,
or a vehicle side fuel system concern.

Table 1.
Service Tools Used in the Procedure
Tool Number Description
J-48708 Fuel Flow Tool
J-48709 Sight Glass Tools
W470589039100 Fuel System Tool Update Kit w/o MCM cooler
ESOC 350 Fuel Priming Unit
DDDL 7.06 sp2 or later

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" .

WARNING: ENGINE EXHAUST (i)(eov34)

To avoid injury from inhaling engine exhaust, always operate the engine in a well-ventilated area.
Engine exhaust is toxic.

1. Install J-48709 sight glass tools on to the fuel filter module.

NOTE: Use a flashlight behind the sight glass lens to make any air bubbles more visible.

2. Perform automatic Fuel System Integrity Check (FSIC) and watch the fuel inlet and outlet at the fuel filter module for air
leaks.

4 All information subject to change without notice.

Copyright © 2012 DETROIT DIESEL CORPORATION 5 38-12
 5 38-12

3. Is the fuel aerated in the suction line?

a. Yes; repair suction leak on the chassis fuel lines.
b. No; Go to step 4.
4. Is the fuel aerated in the return line?
a. Yes; Go to step 5.
b. No; return to initial diagnostics that directed you to “Aerated Fuel Test”.
5. Drain the fuel system.
6. Disconnect the amplifier return line (1) from the fuel filter module.

7. Using one cap supplied in J-48708 Fuel Flow Tool, cap the fitting at the fuel filter module.
8. Connect the amplifier return line to the clear return line J-48708-4 supplied in kit.
9. Attach the opposite end of the clear return line to the J-48708-1 container.
10. Remove the needle return line (1) from the high pressure manifold located on the high pressure pump.

All information subject to change without notice. 5

5 38-12 Copyright © 2012 DETROIT DIESEL CORPORATION
2 Aerated Fuel Test

11. Using one cap supplied in the J-48708 Fuel Flow Tool, cap the fitting at the high pressure manifold.
12. Connect needle return line to a second clear return line J-48708-4 supplied in kit.
13. Attach the opposite end of the clear return line J-48708-4 to the opposite J-48708-1 container.
14. Perform an automatic FSIC and watch the fuel coming out of the return line from the module and the clear retrun lines
coming from the amp and needle lines.
a. If there is any air coming out of the needle or amp return lines, Go to step 15.
b. If there is any air coming out of the return line from the module with the amp and needle lines removed, Refer to
section "Low Pressure Fuel System - Leak Test" .
15. Perform a cranking compression test using DDDL. Is any cylinder(s) below 90% compression?
a. Yes; inspect for a 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" .

6 All information subject to change without notice.

Copyright © 2012 DETROIT DIESEL CORPORATION 5 38-12