Pinpoint tests of the fuel supply system

WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.

CAUTION: The generator must be protected from contamination. Failure to follow this instruction may result in premature failure of the generator.

A1: CHECK THE VALVE FOR LEAKAGE

1Cover the generator with a lint-free material to prevent contamination.

2Inspect the valve in the fuel supply line from the fuel filter to the high-pressure fuel pump for signs of diesel fuel leakage. If the base of the valve is wet, this indicates damage to the O-ring.

• Is the valve leaking?

→ Yes

INSTALL a new fuel supply line from the fuel filter to the high-pressure fuel pump. Make sure the fuel supply line valve from the fuel filter to the high-pressure fuel pump is in the closed position (fully screwed in). Check that the system operates correctly.

→ No

Go to A2.

A2: INSPECTING THE FUEL FILTER RETURN LINE FOR LEAKAGE

1Disconnect the fuel return line from the high pressure fuel pump to the fuel filter from the fuel filter.

2Inspect the fuel return line from the high pressure fuel pump to the fuel filter at the fuel filter.

• Are the O-rings or fuel return line damaged?

→ Yes

INSTALL a new fuel return line from the high pressure fuel pump to the fuel filter. Check that the system is operating properly.

→ No

Go to A3.

A3: CHECKING POINTS OF AIR ENTRY INTO THE SYSTEM

1Cover the generator with a lint-free material to prevent contamination.

2Using a suitable piece of clear plastic pipe, fabricate a line that can be installed between the high pressure fuel pump and the fuel return line from the high pressure fuel pump to the fuel filter.

3Install a clear plastic line between the high pressure fuel pump and the fuel return line from the high pressure fuel pump to the fuel filter.

4Start the engine, wait a few minutes, and then visually inspect the clear plastic line for signs of air intrusion.

5Using a suitable clean engine oil, apply it to all connections, couplings and nipples of the fuel supply and return lines in turn and after each application, observe the clear plastic line for visible signs of air.

• After lubricating any of the joints, couplings or nipples, does the amount of air in the clear plastic tubing decrease?

→ Yes

INSTALL the new fuel line(s) in question. Check the system for proper operation.

→ No

Go to A4.

A4: CHECKING FOR AIR PENETRATION INTO THE FUEL SYSTEM

1Cover the generator with a lint-free material to prevent contamination.

2Drain the fuel from the fuel tank.

3Pour 10 liters of diesel fuel into the fuel tank.

4Disconnect the fuel supply line from the fuel tank to the fuel filter from the connection on the bulkhead.

5Disconnect the fuel supply line from the fuel tank to the fuel filter from the fuel filter.

6Using a suitable piece of clear plastic pipe, fabricate and install a line between the fuel filter and the connection at the bulkhead between the fuel tank and the fuel filter.

7Remove the clear plastic line from the area between the high pressure fuel pump and the fuel return line from the high pressure fuel pump to the fuel filter.

8Using the special tool, prime the fuel pump until air-free fuel enters the vacuum pump reservoir.

9Remove the special tool and connect the fuel return line from the fuel pump to the fuel filter.

10Start the engine, wait a few minutes to remove any remaining air from the fuel system. It is acceptable for a small amount of air to enter the fuel system, but a constant flow of air in the fuel system is not acceptable.

11Leave the car overnight.

• Are there any signs of air in the clear plastic piping?

→ Yes

INSPECT the fuel tank level sensor and fuel tank connections for damage or leaks. INSTALL new components if necessary.

→ No

Install a new fuel filter. Refer to Section 310-01A for additional information.

B1: CHECKING FOR AIR INTAKE INTO THE FUEL SYSTEM

WARNING: Do not smoke or carry a lighted cigarette or open flame of any kind when working on or near fuel-related components. Highly flammable mixtures are always present in such situations and may ignite. Failure to follow these instructions may result in injury.

WARNING: This procedure involves handling fuel. Always be prepared for possible fuel splashing and follow proper fuel handling precautions. Failure to follow these instructions may result in injury.

CAUTION: The generator must be protected from contamination. Failure to follow this instruction may result in premature failure of the generator.

1Cover the generator with a lint-free material to prevent contamination.

2Using a suitable piece of clear plastic pipe, fabricate a line that can be installed between the high pressure fuel pump and the fuel return line from the high pressure fuel pump to the fuel filter.

3Install a clear plastic line between the high pressure fuel pump and the fuel return line from the high pressure fuel pump to the fuel filter.

4Start the engine, wait a few minutes, and then visually inspect the clear plastic line for signs of air intrusion.

• Are there any signs of air in the clear plastic piping?

→ Yes

Go to B2

→ No

REMOVE the clear plastic line and CONNECT the fuel return line from the fuel pump to the fuel filter. For additional information on diagnosing the fuel delivery system and related controls, refer to Section 303-04A / 303-04B / 303-04C / 303-04D / 303-04E / 303-04F / 303-04G for additional information.

B2: CHECKING POINTS OF AIR ENTRY INTO THE SYSTEM

1Using a suitable clean engine oil, apply it to all connections, couplings and nipples of the fuel supply and return lines in turn and after each application, observe the clear plastic line for visible signs of air.

• After lubricating any of the joints, couplings or nipples, does the amount of air in the clear plastic tubing decrease?

→ Yes

INSTALL the new fuel line(s) in question. Check the system for proper operation.

→ No

Install a new fuel filter. Refer to Section 310-01A for additional information.