IK1500066 - Electric Fuel Pump and Low Pressure Fuel System Diagnostics EPA 2010 ...

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Countries :

CANADA, UNITED STATES Document ID: IK1500066

Availability:

ISIS, Bus ISIS, FleetISIS

Revision :

2

Major System:

FUEL SYSTEMS

Created :

3/7/2012

Current Language: English

Last Modified: 12/13/2012

Other Languages: Français, Español ,

Author:

Viewed:

Kevin Bishop

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Title: Electric Fuel Pump and Low Pressure Fuel System Diagnostics EPA 2010 MaxxForce® DT, 9 and 10
Applies To: 2010 Emissions Model Year MaxxForce® DT, 9 and 10

Description
A revised procedure is available to diagnose the electric fuel pump and low pressure fuel system on the EPA 2010 MaxxForce® DT, 9 and 10 engines. This is a suppliment to
the EGES-455-1 Diagnjostic/Troubleshooting Manual, Chapter 5 "Hard Start and No Start Diagnostics".
The electric fuel pump may turn ON-OFF-ON when testing the fuel system while dead heading the fuel system. The pressure gauge will move between a high and low fuel
pressure every few seconds. That is a normal response during the tests. The peak pressure is used in certain diagnostic steps.
Note: The fuel return fitting to the fuel tank is a dry-break connector. Disconnecting the fuel return fitting at the fuel header blocks the fuel return line and dead
heads the fuel pump.
Note: The mechanical ZTSE4681 Fuel Pressure Gauge and ZTSE4526 Fuel/Oil Test Coupler are necessary to accurately measure the fuel pressure and flow volume
in this procedure. ServiceMaxx should not be used to measure fuel pressure.

Symptoms
Low Fuel Pressure
High Fuel Pressure

Possible Diagnostic Trouble Codes
SPN
94
94
3471

FMI
0
1
1

Description
Fuel Delivery Pressure above maximum
Fuel Delivery Pressure below minimum
Fuel Pressure 1 below desired (Low system pressure)

Fuel Pump Prefilter (Strainer) Kit Availability
The prefilter is available with the O-ring seals in a service kit.

1899335C91

KIT,FUEL PUMP STRAINER W/ADPTR

PART NUMBER

PART DESCRIPTION

QTY

1894302C1

SCREW, PUMP COVER

3

1884085C1

RING, O PUMP COVER & HOUSING

1

1899336C91

KIT, PUMP ADAPTER

1

Diagnostic Procedure
The low pressure fuel system and fuel pump are diagnosed with a fuel pressure gauge to pinpoint issues. Fuel pressure and flow volume are measured at the port on the fuel
filter housing. The dry-break fuel return connector may be disconnected to dead head or pressure test the fuel pump to isolate fuel pump and fuel pressure regulator concerns.
The fuel pump may cycle ON-OFF-ON when the pump is dead headed, so the PEAK fuel pressure is the value that is used in the diagnostic procedures. This is a normal
condition, not a sign of a defective pump. The PEAK fuel pressure is used to diagnose the fuel pump and regulator when the fuel pump cycles ON-OFF-ON.

Step
1

Action
Measure Fuel Pressure

Values
80-100
psi

Yes
Step 2

No
Step 6

Connect Fuel Pressure Gauge to the fuel filter test port
(CompuCheck) and measure fuel pressure with the engine
off.
ZTSE4681 – Fuel Pressure Gauge
ZTSE4526 – Fuel/Oil Pressure Test Coupler
Is the fuel pressure within limits?

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IK1500066 - Electric Fuel Pump and Low Pressure Fuel System Diagnostics EPA 2010 ...

2

Note: The fuel pump only operates for 10-20 seconds after
Key-ON Engine-OFF. The ignition switch must be turned
off for 30 seconds to reset the ECM
Measure Fuel Pump Volume

See
Table 1

Step 3

Step 9

System
OK

Step 5

Page 2 of 3

Route the clear hose from the Fuel Pressure Gauge to an
approved diesel fuel container to measure fuel volume.
Open the Fuel Pressure Gauge shutoff valve to flow fuel
through the clear hose.
Measure ECT in the Service Tool.
Look up the volume specification for fuel pump volume
based on ECT in Table 1.
Cycle the fuel pump 4 times and measure the fuel pump
volume.

3

Is the fuel volume within the limits in Table 1?
Visually inspect the primary fuel filter on the engine.

4

Is the fuel filter clean?
Intentionally left blank

-

-

5

Replace fuel filter and retest

Step 1

-

6

Measure Fuel Pressure

0 psi

Step 7

Step
10

7

Is the fuel pressure 0 psi?
Measure Voltage and Ground to fuel pump

9 volts

Step 9

Step 8

8

Is the voltage above the specification with the fuel pump
energized?
Diagnose the electrical supply to the fuel pump.

-

-

9

Go to the EFP section in "Electronic Control System
Diagnostics" in the Diagnostic Manual
Replace fuel pump and retest.

Step 1

-

10

Measure Fuel Pressure

Step 11

Step
14

Step 12

Step
13

12

Note: The dry-break fuel return connection dead heads the
fuel pump and may cause the fuel pump to cycle ON-OFFON.
Replace stuck closed fuel pressure regulator

Step 1

-

13

Clean the fuel filter housing and retest
Reconnect or repair the fuel return connection and retest.

Step 1

-

Step 17

Step
15

Connect EFP Breakout harness ZTSE6023 to the fuel
pump.
Measure voltage between pins 1 and 4 with the fuel pump
energized.
Measure voltage between pins 1 and 6 with the fuel pump
energized.

100 psi

Does the fuel pressure exceed the specification?

11

Note: The fuel pump may turn ON-OFF-ON if the electric
motor is overloaded when the pressure is too high. PEAK
pressure is used in this step, if the fuel pressure bounces
between low and high pressures.
Check Fuel Return Connection
Is the fuel return line connected completely?

14

Measure Fuel Pump Volume with Fuel Return Connection
disconnected to isolate the fuel pressure regulator.

See
Table 1

Disconnect the dry-break fuel return connection to the
tank at the fuel filter housing.
Route the clear hose from the Fuel Pressure Gauge to an
approved diesel fuel container to measure fuel volume.
Open the Fuel Pressure Gauge shutoff valve to flow fuel
through the clear hose.
Measure ECT in the Service Tool.
Look up the volume specification for fuel pump volume
based on ECT in Table 1.

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IK1500066 - Electric Fuel Pump and Low Pressure Fuel System Diagnostics EPA 2010 ...

Page 3 of 3

Cycle the fuel pump 4 times and measure the fuel pump
volume.

15

Is the fuel volume within the limits in Table 1?
Inspect the fuel pump strainer and O-rings on the fuel
pump.

Step 16

Step18

16

Is the strainer plugged or are the O-rings damaged?
Replace the fuel pump strainer and O-rings and retest

Step 1

-

17

Replace stuck open fuel pressure regulator

Step 1

-

18

Clean the fuel filter housing and retest
Inspect the optional chassis-mounted fuel filter

Step 19

Step 9

19

Is the optional chassis-mounted fuel filter plugged?
Replace optional chassis-mounted fuel filter

Step 1

-

Table 1: Minimum Fuel Pump Volume Specification
Key Cycles
ECT Deg F
ECT Deg C
Fuel Pump Run Time (seconds)
Min Fuel Pump Volume (gallons)

Hide Details

4
32
0
20
0.76

4
50
10
18
0.68

4
68
20
18
0.68

4
86
30
15
0.57

4
104
40
10
0.38

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