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Fuel System Pressure - Test

SMCS - 1250-081; 1256-081

Low Fuel Pressure

Low fuel pressure can cause low power. Low fuel pressure can also cause cavitation of the fuel
which can damage the fuel injectors. The following conditions can cause low fuel pressure:

z Plugged fuel filters

z Air in the fuel

z Debris in the check valve for the fuel priming pump or the pressure regulating valve

z Debris in the fuel tank, fuel lines, or fuel system components that create restrictions

z Leak on the inlet side of the fuel pump or the fuel lines

z Faulty fuel pressure regulating valve in the fuel transfer pump

z Faulty return fuel pressure regulating valve in the fuel filter base

z Worn fuel transfer pump

z Damaged fuel lines or fuel line fittings

z Fuel lines with deteriorating interior surfaces

z Undersized fuel lines or undersized fuel line fittings

High Fuel Pressure

Excessive fuel pressure can cause fuel filter gaskets to rupture. The following conditions can cause
high fuel pressure:

z Plugged orifices in the fuel pressure regulating valve

z Stuck fuel pressure regulating valve in the fuel transfer pump

z Pinched fuel return line, fuel line, or fuel filter

Fuel Pressure Readings

The typical fuel pressure of the engine at operating temperature can vary. At low idle, the fuel

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pressure can be 538 kPa (78 psi). At high rpm, the fuel pressure can be 641 kPa (93 psi).

The performance of the unit injector deteriorates when the fuel pressure drops below 241 kPa (35
psi). Low power complaints and erratic operation can occur in this situation. Check for a plugged
fuel filter or air in the fuel lines as possible causes for these complaints before replacing fuel system
components.

Checking Fuel Pressure

Table 1

Tools Needed
Part Number Part Name Quantity
1U-5470 Engine Pressure Group 1
3Y-2888 Connector 1
3J-1907 O-Ring Seal 1

9LHZ,PDJH

Illustration 1 g00294866
1U-5470 Engine Pressure Group

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Illustration 2 g00911299
Typical location of the fuel pressure tap

To check the fuel transfer pump pressure, remove the plug from the fuel filter base. Install the 3Y-
2888 Connector with a 3J-1907 O-Ring Seal. Install a pressure gauge, and start the engine.

The 1U-5470 Engine Pressure Group can be used in order to check the fuel pressure of the engine.
The engine pressure group includes Special Instruction, SEHS8907, "Using the 1U-5470 Engine
Pressure Group ". This instruction provides information about the usage of the group.

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