Section 6.5 Fuel System Priming

Section 6.5
Fuel System Priming

During service or maintenance of the fuel system air can be introduced, and the system will need to be purged. If the air in the system is not properly purged, longer than normal crank times or electronic service codes related to unstable rail pressure may occur. If a service code is set after work is performed on the fuel system, clear the codes and retest the system.‪

Section 6.5.1
After Filter Change (Using J-47912 Priming Can)

Proceed as follows:‪

  1. Ensure priming canister is ¾ full (approximately 9 liters) of fuel.
  2. Install fuel priming canister to the priming port on the fuel filter module.
  3. Ensure priming canister shutoff valve is closed.
  4. Pressurize priming canister to maximum pressure.
  5. Open shutoff valve and allow system to fill for 60 seconds.
  6. Close shutoff valve.
  7. Check for fuel leaks, repair as necessary.
  8. Crank engine for 20 seconds.
  9. If the engine starts, go to step 12 .
  10. If engine does not start, allow for a 60 second cool down and repeat steps 4-8. The starting cycle can be repeated up to three times.
  11. If engine still fails to start:
    1. Use DDDL to check for fault codes, repair as necessary.
    2. Repeat steps 4 through 9 .
  12. Remove priming canister from filter module.
  13. Allow engine to reach operating temperature (140°F/60°C).
  14. Increase engine RPM to 1800 for three minutes.
  15. Reduce RPM and check for fuel leaks or service codes. Repair or clear if necessary.

Section 6.5.2
After filter Change (Using Hand Primer on Module)

Proceed as follows:‪

  1. Operate hand primer for three minutes or 250 strokes.
  2. Check for leaks, repair as necessary.
  3. Crank engine for 20 seconds.
  4. If engine starts, go to step 7 .
  5. If engine does not start, allow for a 60 second cool down and repeat step 3. The starting cycle can be repeated up to three times.
  6. If engine still fails to start:
    1. Use DDDL to check for fault codes, repair as necessary.
    2. Repeat steps 2 through 3 .
  7. Allow engine to reach operating temperature (140°F/60°C).
  8. Increase engine RPM to 1800 for three minutes.
  9. Reduce RPM and check for fuel leaks or service codes. Repair or clear if necessary.

Section 6.5.3
High Pressure Pump Change or Completely Dry System (Using J-47912 Priming Can)

Proceed as follows:‪

  1. Ensure priming canister is ¾ full (approximately 9 liters) of fuel.
  2. Install fuel priming tool to the priming port on the fuel filter module.
  3. Ensure priming canister shutoff valve is closed.
  4. Pressurize priming canister to maximum pressure.
  5. Open shutoff valve and allow system to fill for 2 1/2 minutes.
  6. Close shutoff valve.
  7. Check for fuel system leaks.
  8. Repressurize priming canister to maximum pressure.
  9. Open shutoff valve. Pressure in the priming canister will drop.
  10. As the system is filling, continue to pump the priming canister for one minute minimum. This process may take an additional 5 – 15 pumps of the priming canister.

    Note: If using an electric priming pump, ensure the pump is capable of producing 70 psi.

  11. Close shutoff valve.
  12. Crank engine for 20 seconds.
  13. If engine starts, go to step 16 .
  14. If engine does not start, allow for a 60 second cool down and repeat steps 8 through 10 .
  15. If engine still fails to start, use DDDL to check for fault codes, repair as necessary. Begin process again with step 1 .
  16. Allow engine to reach operating temperature (140F/60C).
  17. Increase engine RPM to 1800 for three minutes.
  18. Reduce RPM and check for fuel leaks. Repair if necessary.
  19. Remove priming canister.
  20. Reduce RPM and check for fuel leaks or service codes. Repair or clear if necessary.

Section 6.5.4
Priming Port Pressures

Priming Port (J-48876) Pressures‪

Normal Pressures‪

Replace Filter‪

Check for Stuck Open High Pressure Relief Valve for the Low Pressure Pump‪

Check for Fuel Aeration‪

600 RPM‪

70-115 PSI‪

>115 PSI‪

<60 PSI‪

<20 PS‪

1800 RPM‪

100-150 PSI‪

>150 PSI‪

<80 PS‪

<20 PSI‪


DD15 Fuel System Technician's Guide - DDC-SVC-MAN-0037
Generated on 10-13-2008

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