Circuit/System Testing
Test 1
- Ignition/Vehicle - Off
- In order to perform step 2 - 5, the fuel temperature must be greater than 10°C (50°F) or misdiagnosis may occur.
- Leave the electrical connector connected.
- Disconnect the component: Fuel Return Hose @ Q18B Fuel Pressure Regulator 2 & Plug the fuel return hose(s) in order to prevent leakage.
- Install suitable hose to the component: Outlet @ Q18B Fuel Pressure Regulator 2 & Place the other end of the hose into a suitable container.
- Engine - Cranking - Until air is purged from the hose
- Engine - Cranking - For 15 s
Verify the container contains less than 15 mL (0.5 US fl oz)
- If 15 mL (0.5 US fl oz) or greater
Replace the component: Q18B Fuel Pressure Regulator 2
- Go to next step: If less than 15 mL (0.5 US fl oz)
- If 15 mL (0.5 US fl oz) or greater
- Ignition/Vehicle - Off
- Install the component: Fuel Return Hose @ Q18B Fuel Pressure Regulator 2
- Disconnect the electrical connector: Q17 Fuel Injector - All
- Disconnect the component: Fuel Injection Fuel Return Pipe @ Q17 Fuel Injector - All - Refer to: Fuel Injector Fuel Return Pipe Replacement
Plug the fuel return hose(s) in order to prevent leakage. @ Diesel Fuel Separator & Fuel Rail
- Engine - Cranking - For 15 s
- Verify the condition does not exist: Leaking @ Q17 Fuel Injector
- If a condition exists
Replace the appropriate component: Q17 Fuel Injector
- Go to next step: If no condition exists
- If a condition exists
- Ignition/Vehicle - Off
- Install the component: Fuel Injection Fuel Return Pipe
- Perform the following steps:
- Disconnect the electrical connector: Q17 Fuel Injector - All
- Remove the component: F5BA Fuse @ X50B Fuse Block - Underhood Auxiliary
- Disconnect the electrical connector: E12 Glow Plug
- Remove the component: E12 Glow Plug - One at a time
- Place and hold a clean shop towel over the component: Threaded Hole @ Cylinder Head - Glow Plug
- Engine - Cranking - For 6 s
Verify the condition does not exist: Fuel @ Shop Towel
NOTE:The component must be discarded whenever removed and replaced with a NEW component:
- If a condition exists
Replace the appropriate component: Q17 Fuel Injector
- Go to next step: If no condition exists
- Test or replace the component: G18 Fuel Pump - High Pressure
Perform the following test for all 6 components. - One at a time
Test 2
- Engine - Idling
- Perform the following procedure/test: Cylinder Power Balance Test
Verify the procedure/test passes.
- If the procedure/test does not pass
Replace the component that failed the test: Q17 Fuel Injector
- Go to next step: If the procedure/test passes
- If the procedure/test does not pass
- Ignition/Vehicle - Off
- In order to perform step 4 - 7, the fuel temperature must be greater than 10°C (50°F) or misdiagnosis may occur.
- Leave the electrical connector connected.
- Disconnect the component: Fuel Return Hose @ Q18B Fuel Pressure Regulator 2 & Plug the fuel return hose(s) in order to prevent leakage.
- Install suitable hose to the component: Outlet @ Q18B Fuel Pressure Regulator 2 & Place the other end of the hose into a suitable container.
- Engine - Idling - Until air is purged from the hose
- Engine - Idling - For 15 s
Verify the container contains less than 15 mL (0.5 US fl oz)
- If 15 mL (0.5 US fl oz) or greater
Replace the component: Q18B Fuel Pressure Regulator 2
- Go to next step: If less than 15 mL (0.5 US fl oz)
- If 15 mL (0.5 US fl oz) or greater
- Ignition/Vehicle - Off
- Install the component: Fuel Return Hose @ Q18B Fuel Pressure Regulator 2
- Disconnect the electrical connector: Q17 Fuel Injector - All
- Disconnect the component: Fuel Injection Fuel Return Pipe @ Q17 Fuel Injector - All - Refer to: Fuel Injector Fuel Return Pipe Replacement
Plug the fuel return hose(s) in order to prevent leakage. @ Diesel Fuel Separator & Fuel Rail
- Engine - Cranking - For 15 s
- Verify the condition does not exist: Leaking @ Q17 Fuel Injector
- If a condition exists
Replace the appropriate component: Q17 Fuel Injector
- Go to next step: If no condition exists
- If a condition exists
- Ignition/Vehicle - Off
- Install the component: Fuel Injection Fuel Return Pipe
- Perform the following steps:
- Disconnect the electrical connector: Q17 Fuel Injector - All
- Remove the component: F5BA Fuse @ X50B Fuse Block - Underhood Auxiliary
- Disconnect the electrical connector: E12 Glow Plug
- Remove the component: E12 Glow Plug - One at a time
- Place and hold a clean shop towel over the component: Threaded Hole @ Cylinder Head - Glow Plug
- Engine - Cranking - For 6 s
Verify the condition does not exist: Fuel @ Shop Towel
NOTE:The component must be discarded whenever removed and replaced with a NEW component:
- If a condition exists
Replace the appropriate component: Q17 Fuel Injector
- Go to next step: If no condition exists
- Test or replace the component: G18 Fuel Pump - High Pressure
Perform the following test for all 6 components. - One at a time