Diesel Diagnostics AUSTRALIAN WORKSHOP MANAGER
& Aftermarket Training [Link] [Link]
“I’ve replaced a fuel filter on a common rail
diesel (CRD) and now it won’t start.”
By Clinton Brett
“All diesel’s are not fond of air in the fuel system
and will not compress the air”
According to diesel diagnostics and aftermarket training Guru blanking caps immediately onto pipes and fittings to reduce
Clinton Brett from ([Link]), issues following the as much ‘drain back’ as possible.
replacement of diesel fuel filters are increasing.
6. Install the new filter (preferably genuine) and check all seals
Other scenarios outside of failure to start include vehicles are clean and free of cuts or nicks and lubricate with rubber
starting or idling for a short time, then stalling and not restarting, grease prior to installation.
stalling soon after a Road Test, and then not restarting, and a
repeating start/stall cycle.
The reason for this is that all diesels are not fond of air in the
fuel system, whether they are CRD or early non-CRD, and will
not compress the air. At the same time, it does not help with the
lubrication of the moving diesel components. The diesel fuel is a
lubricant based liquid fuel that provides lubrication to the high
pressure pump and injectors ensuring correct operation and
reliability. Just like an engine requiring oil to lubricate moving
components.
The most popular diesel on the road today is the CRD, which has
finer tolerances and very little or no bleeding outlets – this means
that without the knowledge and correct equipment, it can be
difficult to bleed the air from a CRD system.
By carrying out the following guidelines and having the correct
low-cost equipment, this somewhat difficult process – and some
very expensive repairs - can be avoided. Low cost equipment
can include a manual rubber bulb type hand primer, clear PVC
hose and the correct quick release fittings to connect directly to
the factory plumbing of the fuel system. A great adaptable kit is
the Optimus Primer. An innovation created by DIESEL DO AT
which includes 34 aftermarket quick release fittings which are
adaptable to both diesel & petrol as well as some water cooling
applications. The kit also contains a rubber bulb type hand
primer, 6, 8, 10mm clear PVC hose, reducing barbs, hose clamps
and dust caps.
1. The fuel system must be bled free of air before attempting to
crank the engine or cycle the electric primer pump (only if
fitted).
2. Carry out the fuel filter replacement after the oil has been
changed and the vehicle test driven.
3. Ensure there is more than a quarter of a tank of diesel and
the vehicle is on level ground. The electric in-tank pump (only 7. Reconnect cleaned fuel fittings.
if fitted) has been known to fail in certain vehicles if the fuel
level is too low. When disconnecting pipes, the fuel drains 8. Bleed the air - the most efficient procedure of bleeding the air
back below the pick-up, thus starving the electric pump which is with a removable bulb type hand primer with non-return
can also cause it to fail. valve (BHP) fitted to the return outlet of the high pressure
pump. Remember, some CRD systems are not fitted with a
4. Before any work is carried out on a fuel system, it should be hand primer. It is recommended to all mechanics to have
cleaned by spraying brake cleaner on the fittings and then one readily available in your tool kit. These hand primers
blowing with compressed air. are available as part of the Optimus primer diesel filter
replacement kit.
5. When removing pipes from the filter head assembly, place
26 JULY/AUGUST 2016
Diesel Diagnostics AUSTRALIAN WORKSHOP MANAGER
& Aftermarket Training [Link] [Link]
14. Ensure there is sufficient battery voltage to the starter motor
(may require jump pack).
15. A fter using the clear tube to assist in checking the system is
free of air, remove the BHP and fit a clear pipe to the return to
separate supply and crank and the engine. It may take two to
three cranks up to approximately six seconds at a time with
10 second breaks (avoid overheating the starter motor).
16. Once the engine is running, give the engine a quick couple of
revs above idle (approximately 2000 rpm) to assist the venting
process.
17. Remove the separate fuel supply and refit the original without
exposing too much air in the system. The engine will restart
9. With or without a manual or electric primer pump (in tank or
and repeat the quick high revving of the engine. The fuel will
out of tank) it is still recommended to draw the fuel through
continue to bleed and vent through the system whilst fine air
using a hand primer. As I mentioned earlier it is difficult to
bubbles maybe present quite some time which is not a major
compress the air through the system especially with no bleed
concern as the engine will continue to run and eventually
screws.
completely vent.
10. Do not ‘crack’ or loosen any high pressure pipes in the
Finally, DIESEL DO AT strongly advises to maintain above-idle
process to look for fuel and air escaping. These pipes are high
revs as the vehicle is taken on a test drive – without breaking the
pressure components and must not loosened unless absolutely
law or damaging the vehicle of course. This final step ensures the
necessary.
air will be eventually vented from the system thus the vehicle will
11. Using quick release fittings just like the factory fittings or remain running without stalling & surging.
barbed connectors and clear PVC hoses, connect the BHP to
In following issues of this trade journal we propose to cover:-
the most accessible return outlet of the high pressure pump.
The clear lines will assist in seeing the system is free of air • E
ngineering overlook or saving money? Injector washer
whilst working the BHP. failure = engine failure
• S
uck it and see- Fault code P0093 Suction control valve (SCV).
‘I’ve replaced the SCV and the fault re-appears. Find out how
a $2 part that takes 5 minutes to rectify this star fault.
• H
ot summer diesel- My Nissan Patrol Common rail diesel
ZD30 hard to start hot, intermittently loses power and Fault
code P1089 (Fuel pump). Do I have to replace the fuel pump at
100k?
• D
iesel trucks get a million km’s don’t they? Serviceable items
overlooked. Fault code P2623-001 (CHARGE AIR SYSTEM
OFFSET DRIFT UNDER ENGINE LOAD). Turbo fault?
These are just a few of the tip and fixes offered during DIESEL
DO AT’s CRD diagnostic courses which has been delivered to
more than 400 mechanics nationally over the last few years alone.
DIESEL DO AT – (Diesel Diagnostics &
Aftermarket Training)
Clinton Brett has more than 20 years’ experience as a diesel fuel injection
specialist solving real life diesel faults daily. In each issue he will share
his knowledge diagnosing electronic diesel faults mechanically and not just
relying on computer scantools, demonstrating how to test injectors, fuel pumps
& rails without removing from the engine and more.
For more detailed
information about Diesel
12. In extreme cases when a mechanic has been unsuccessful Diagnostic Training for
with drawing fuel from the vehicles own system, connect a common rail diesels or
clean separate fuel supply with clear tube directly to the inlet ‘Diesel Help’ membership,
of the pump and returning back to the separate supply. *Using contact Clinton Brett
its own inbuilt feed/transfer pump, the CRD fuel pump has the on 0432 738003 or email
capability to draw fuel from the tank. [Link]@dieseldoat.
com & visit www.
13. In cases where the vehicle electric pump is activated whilst [Link]
cycling the ignition, connect the outlet pipe of the fuel filter
assembly to feed into the separate supply and blank off any
exposed pipes to avoid air and contamination.
JULY/AUGUST 2016 27
