03:14-01

Issue 5 en-GB

XPI fuel system

Troubleshooting

Scania CV AB 2012, Sweden
Contents

Contents
XPI fuel system Background............................................................... 3
Using the troubleshooting guide............................... 3

Troubleshooting S-a Basic check......................................................... 4

S-b Start-up check .................................................... 5
L-a Low pressure check............................................ 6
H-a High pressure check when the engine starts...... 7
H-b High pressure check when the engine does
not start ..................................................................... 8

Descriptions, Low pressure check L1 Low pressure check.......................................... 9

L2 Checking the suction filter ............................... 9
L3 Checking the feed pump .................................. 9
L4 Checking the feed pump drive ......................... 9
L5 Checking the high pressure pump drive......... 10
L6 Checking the supply pressure at the test
connection on the high pressure pump ................... 10

Descriptions, High pressure check H1 Checking for internal leaks............................ 11

H2 Checking the return fuel pressure.................. 11
H3 Checking the safety valve.............................. 12
H5 Verification of a faulty injector ..................... 14
H6 Checking for internal leaks............................ 14
H7 Checking the return fuel pressure.................. 16
H8 Checking the safety valve.............................. 17
H9 Checking the high pressure pump ................. 17

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 XPI fuel system

XPI fuel system

Background
It has been difficult to troubleshoot the XPI
fuel system with the current troubleshooting
guide, Workshop Manual 03:14-01 issue 3.
The troubleshooting trees are clearer in this
issue of the presentation. Both the
troubleshooting trees and instructions have
been revised so that it is easier to troubleshoot
the XPI system.

IMPORTANT!

The fuel system is very sensitive to dirt. It is

therefore very important that everything is as
clean as possible when work is carried out on
the fuel system.

Using the troubleshooting

guide
Start troubleshooting by looking at
troubleshooting tree S-a. This troubleshooting
tree helps you to choose where to start
troubleshooting.
The troubleshooting trees are read from the top
down. The boxes contain instructions you can
follow. These instructions sometimes refer to
other more detailed instructions further on in
the document. After having carried out the
instructions, you should continue to the next
set of instructions indicated by the arrows.

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Troubleshooting

Troubleshooting

S-a Basic check

Before and after troubleshooting the XPI fuel system, check the following:

Check any fault codes using SDP3.

There are no active There are active fault

fault codes codes
Troubleshoot according to the troubleshooting
text.

Can the engine be started?

Yes No There may be a fault in the fuel system. If

there is no other XPI-related fault, the cause
may be outside the fuel system. Start
troubleshooting the fuel system from S-b.

The engine starts but there are inactive fault

codes or other indications of faults in the fuel
system.

No Yes
There may be a fault in the fuel system. Run
the engine until warm and check that no new
fault codes have been generated. If not, start by
troubleshooting from L-c.

The cause of the problem is not the fuel

system. Finish troubleshooting and continue
looking for other causes of the fault.

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 Troubleshooting

S-b Start-up check

S-b Check that there is fuel in the tank and that

it does not contain water.

There is fuel in There is no fuel in the

the tank and no tank but there is water
water in the tank
The cause may be no fuel or water in the
tank. Rectify the problem and continue from
S-a.
Pump with the hand pump until resistance
builds up. Check for external fuel leaks at the
feed pump, filter housing and fuel pipes. Open
the ventilating valve to release the pressure.

There is no There is external

external leakage leakage
or it is not
possible to build
up the pressure The cause may be external leakage. Rectify
the leakage and continue from S-a.

The problem may be present in the low

pressure section or in the high pressure
section. Start by troubleshooting the low
pressure section from L-a.

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Troubleshooting

L-a Low pressure check

L-a Check the feed pump as described in
L1.

The problem may be between No fuel comes Fuel comes

the fuel tank and the feed out during both out ... The hand pump may be
pump. Renew the fuel filter as checks faulty. Renew the hand
described in L2. Repair all the pump and resume
faults that are detected and troubleshooting from L-a.
continue from S-a.

... with the starter

... with the hand pump but not ... during both motor but not with the
with the starter motor checks hand pump.

Check the feed pump as L-c Measure the feed pump as described
described in L3. in L6.

No fuel A little fuel The The pressure is normal

comes out comes out pressure
is too low
The problem may be on the high
pressure side. If the engine can be
Check the feed pump drive as started, continue from H-a.
described in L4. Otherwise continued from H-b.

The feed pump The feed

drive is not pump is
working defective Renew both fuel filters. Bleed the fuel
system and measure the feed pressure as
described in L6 again.
The cause may be the feed pump
drive. Also check the high
pressure pump drive as described
The The pressure is
in L5. Then continue from S-a.
pressure normal
is still
too low The cause may be blocked fuel
filters. Rectify the cause of the
blockage, bleed the system and
The cause may be the feed pump. Renew the pump, bleed continue from S-a.
the fuel system and continue from S-a.

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 Troubleshooting

H-a High pressure check when the engine starts

The cause may be The safety H-a The engine starts. Check the
the safety valve. valve is safety valve as described in H3.
Renew the valve defective
and continue from
S-a. The safety valve is working
The safety valve opens
when idling

Check for internal leaks as described

in H1.

The pressure is The pressure is falling

normal and ...

... there is
... cylinder is not identified ... cylinder is external
identified leakage

Check the return fuel Verify the faulty injector and plug as The cause may
pressure as described in H2. described in H5. be external
leakage.
Rectify the leak
The pressure The pressure The fault Fault and continue
is normal is too high cannot be verified from S-a.
verified

Check the fuel inlet metering

valve using SDP3. Check for internal leaks as
described in H6. The cause may be the
injector. Renew the
injector and continue
The fuel inlet The fuel inlet from S-a.
metering metering valve is The fault Fault
valve is working cannot be verified
defective verified

The cause may be the fuel inlet metering

valve. Renew the valve and continue from The cause may be the high
S-a. pressure connections. Detach and
visually inspect all high pressure
The problem may be in the high pressure pump. Check connections and torque tighten
the high pressure pump as described in H9 and repair all them. Continue from S-a.
faults that are detected. Continue from S-a.

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Troubleshooting

H-b High pressure check when the engine does not start

H-b The engine does not start. Check the

fuel pressure in the accumulator (T111)
with SDP3 and run the starter motor.

Cannot build up Can build up and

or maintain maintain pressure
pressure

The cause is probably not the fuel

injection system. Continue searching
for other causes.
Check the return fuel pressure as
described in H7.

The return fuel The return fuel pressure

pressure is normal is too high The cause may be the high pressure
or low connections. Detach and visually
inspect all high pressure connections
and torque tighten them. Continue from
S-a.

Check the safety valve as described in H8.

The safety valve is The safety valve is

working defective

The cause may be the safety valve.

Renew the valve and continue from
S-a.
The problem may be in the high pressure
pump or the fuel inlet metering valve.
Carry out check H9 and repair all faults
that are detected. Continue from S-a.

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 Descriptions, Low pressure check

Descriptions, Low pressure check

L1 Low pressure check L3 Checking the feed

1 Open the test connection on the high pump
pressure pump.
1 Detach the pipe for outlet fuel from the
2 Pump using the hand pump. Check that feed pump. Place a container under the free
fuel comes out of the test connection. end of the pipe.

3 Turn the engine over using the starter 2 Turn the engine over using the starter
motor. Check that fuel comes out of the motor for about 20 seconds. The feed
test connection. pump provides about 1.2 l/min. The
correct quantity for 20 seconds is
4 Close the test connection. 0.3-0.4 litres.

L2 Checking the suction L4 Checking the feed

filter pump drive
1 Remove the feed pump from the high-
Note: When renewing the suction filter, check pressure pump bracket.
the following with the suction filter removed.
2 Turn the feed pump by hand. The pump
should rotate freely and the drive shaft in
the pump should be intact.
1 Pump with the hand pump and check that
fuel free from air flows out of the hole on 3 Check that the drive pins in the high
the inside of the filter housing. pressure pump are intact.

2 If no fuel comes out, check the suction 4 Turn the engine over using the starter
strainer and all joints on the suction pipe motor. Check that the feed pump drive in
up to the fuel tank armature. Renew the the high pressure pump rotates.
seals and check-tighten the connections.
3 If fuel comes out, fit a new filter and bleed
the fuel system.

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Descriptions, Low pressure check

L5 Checking the high L6 Checking the supply

pressure pump drive pressure at the test
1 Remove the high pressure pump. connection on the high
pressure pump
2 Turn the engine over using the starter
motor. Check that the high pressure pump 1 Connect pressure gauge 99 362 to the test
drive rotates in the timing gear. connection on the high pressure pump and
open the test connection.
3 Renew the pump drive gear if it does not
rotate or is damaged. Check for resulting 2 Turn the engine over using the starter
damage to the high pressure pump gear. motor. Read the pressure after
Damaged gears should be renewed. approximately 20 seconds. The pressure
should be more than 2 bar.
4 If the pump drive gear in the timing gear
rotates and is not damaged:
Note: Low feed pump pressure may be caused
Check that the high pressure pump gear is by a defective feed pump, or may be a
properly seated on the shaft. If the gear is symptom of a high pressure pump with a
loose, the shaft may be damaged. Do not defective cylinder head.
tighten the gear. Renew the high pressure
pump.

If the gear is jammed, the high pressure Note: Make sure that the battery level is high
pump is defective. Renew the high enough to run the engine at 90 rpm with the
pressure pump. starter motor.

3 If the engine starts, increase engine speed

to 1,500 rpm. Read the pressure. The
pressure should be between 9 and 14 bar.

Note: Remember that there is currently no

method for confirming whether a fuel filter is
blocked. If the complaint is that fault code 135
is activated when under heavy load it is
probable that the fuel filter is blocked. The high
pressure pump can still create a pressure of
between 9 and 14 bar even with a blocked
filter.

4 Close the test connection and remove the

pressure gauge.

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 Descriptions, High pressure check

Descriptions, High pressure check

H1 Checking for internal H2 Checking the return

leaks fuel pressure
1 Connect pressure gauge 99 362 to the test
Note: Always use the latest version of SDP3 if connection on the return fuel manifold and
possible. open the test connection.
2 Start the engine. Read the pressure with the
engine idling. The pressure should be
For SDP3 version 2.8 onwards: below 0.8 bar. If the pressure exceeds
0.8 bar the overflow valve on the return
1 Follow the instructions for Fuel leak test in fuel manifold should be cleaned and
SDP3. visually inspected. Start again from step 1.
For SDP3 version 2.7:
Note: When the overflow valve is removed air
1 Start the engine. will be introduced, opposite the flow direction.
It takes time for the system to bleed itself.
2 Start the test Checking for internal leaks in During this time the measurement is not
SDP3. reliable. Leave the engine idling for a while
3 Switch off the engine. Read the pressure before repeating the test. If the pressure still
remaining in the accumulator using SDP3. exceeds 0.8 bar, there is internal leakage in an
There should be some pressure remaining. injector.
If the pressure falls more than 300 bar
within one (1) minute, there are internal
leaks.
3 Switch off the engine, remove the pressure
4 Check cylinder balancing at idling speed gauge and close the test connection.
using SDP3. Note if any cylinder deviates.
5 Perform a cylinder output test using SDP3.
Note which cylinder deviates from the
others by having a higher output.
6 By comparing the two results with each
other, a cylinder with deviations in both
tests can be identified.

Note: Remember that several injectors can

sometimes be faulty at the same time.

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Descriptions, High pressure check

H3 Checking the safety

WARNING!
valve
The accumulator may be under high pressure.
1 Start and run the engine at idling speed for Reduce the pressure using SDP3 before starting
15 seconds and then switch off 15 voltage. work. Wear protective goggles. There is a risk
Check whether the return pipe from the of burn injuries when the safety valve is open.
safety valve to the return fuel manifold is
hot.
2 If the return pipe is hot, this is because the
safety valve was open when the engine
was last run. The most probable cause of
this is that the fuel inlet metering valve is
stuck in the open position. Continue
troubleshooting by renewing the fuel inlet
metering valve.
3 If the return pipe is not hot, start the engine
and run the check Leak testing the safety
valve using SDP3 without removing the
return pipe.

WARNING!

For safety reasons it is important that the return

pipe is not removed during step 3. If the safety
valve opens during the check with the pipe
removed, hot fuel would spray out with great
force.

4 If the return pipe becomes hot during the

check Leak testing the safety valve the
safety valve is faulty. Continue
troubleshooting by renewing it.
5 If the return pipe does not become hot and
the accumulator pressure does not reach
2,400 bar, the safety valve is probably
working. Cancel the check and continue
troubleshooting the fuel system.

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 Descriptions, High pressure check

6 If the return pipe does not become hot but

the accumulator pressure reaches
2,400 bar, remove the return pipe, plug the
fuel manifold (9-13L) or the high pressure
pump (16L). Fit a plastic hose routed with
a fall down into a dry vessel so that small
amounts of fuel can be discovered.

Note: Assemble the plastic hose using parts in

the part list below.

Run the check Leak testing the safety valve

in SDP3 again and run it for approximately
5 min to allow any fuel drops to drip into
the vessel. Cancel the test if there are any
signs of fuel in the vessel. If the safety
valve leaks more than 3 drops a minute it is
faulty and must be renewed.

WARNING!

If the safety valve opens during the check,

large amounts of hot fuel would spray out.
Never run the test without monitoring.

7 Refit the engine pipe. Torque tighten.

Parts
Applies to 9, 13 and 16 litre engines.

Designation Part No. Quantity

Plastic hose 813 869 1
Union nut 814 555 2
Ferrule 813 223 1
Insert sleeve 812 913 1
Plug 813 878 1
Straight uniona 813 198 1
Sealing washera 1 373 793 1
a. Only applies to 16 litre engines.

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Descriptions, High pressure check

H5 Verification of a H6 Checking for internal

faulty injector leaks
1 Remove the high pressure pipe to the
injector which has been identified in H1.
WARNING!
2 Plug the outlet of the identified injector at
the outlet port on the fuel accumulator Wear protective goggles. There is a risk of fuel
using tool 99 019. If the outlet port of splashing from the high pressure connections
cylinder 1 has to be plugged, see the when pressurised.
instructions in TI 03-08 01 28.
The accumulator may be under high pressure.
3 Start the engine and repeat H1. This Reduce the pressure using SDP3 before
system must be able to maintain pressure. starting work.

Note: Remember that several injectors can

sometimes be faulty at the same time.
A tool must be made to determine whether the
Therefore if a faulty injector cannot be
fuel system is leaking. A pressure regulator, a
verified, plug it and repeat step H1. If a second
shut-off valve, 2 hose couplings, hose clamps,
faulty injector cannot be verified, continue
hose and Tema quick release coupling 1100N
troubleshooting as described in H6.
for connection to the test connection are
needed. Assemble the parts as illustrated on the
next page. It is vital that all couplings and
connections are tight.
1 Detach and remove all high pressure pipes
between the accumulator and the high
pressure connections.

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 Descriptions, High pressure check

2 Connect the tool to the test connection on 5 Renew the injector or injectors with
the return fuel manifold and open the test internal leakage as described above. When
connection. renewing an injector, the tuning code of
the new injector must be programmed to
the correct cylinder using SDP3 and Basic
setting of adaptation of the injectors must
IMPORTANT!
be performed.
Open the fuel filler flap so that the pressure
does not deform the tank.
IMPORTANT!

After renewing an injector with internal

3 Pressurise the return fuel manifold. Slowly leakage, the engine oil must be changed and
increase the pressure. Listen for a bubbling the oil filter renewed. If there is internal
noise in the tank. The bubbling noise leakage, soot quickly builds up in the engine
indicates at what pressure the overflow oil.
valve opens. The pressure should be higher
than 0.5 bar. Then pressurise the manifold
to max. 3 bar.
4 Listen for return leakage in the injectors by
blocking one high pressure connection at a
time and quickly removing the obstacle. If
there is internal leakage in the injector, a
hissing sound will be heard.

Tool for test pressurising the fuel system

A Shut-off valve
B - Pressure regulator
C Hose for connection to the fuel system

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Descriptions, High pressure check

H7 Checking the return

fuel pressure
1 Connect pressure gauge 99 362 to the test
connection on the return fuel manifold and
open the test connection.
2 Crank the engine using the starter motor.
Read the pressure after approximately
20 seconds. The pressure should be below
0.8 bar.
3 If there is no detectable value after
20 seconds, let the starter motor cool and
repeat step 2.

Note: If there is air in the filter housing,

pressure cannot build up. Bleed the filter
housing and try again.

4 Remove the pressure gauge and close the

test connection.

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 Descriptions, High pressure check

H8 Checking the safety

valve
1 Remove the return pipe, plug the fuel
manifold (9-13L) or the high pressure
pump (16L). Fit a plastic hose routed with
a fall down into a dry vessel so that small
amounts of fuel can be discovered.

Note: Assemble the plastic hose using parts in

the part list below.

2 Crank the engine using the starter motor. If

fuel leaks out of the safety valve, it is
faulty and must be renewed. 2 If the cylinder head is not faulty and there
are still problems, it may be due to a faulty
3 Refit the engine pipe. Torque tighten. fuel inlet metering valve. Try fitting a new
fuel inlet metering valve.
Parts 3 If the problem remains, the problem may
be present in the high pressure pump.
Applies to 9, 13 and 16 litre engines. Renew the high pressure pump and
continue to S-a.
Designation Part No. Quantity
Plastic hose 813 869 1
Union nut 814 555 2
Ferrule 813 223 1
Insert sleeve 812 913 1
Plug 813 878 1
Straight uniona 813 198 1
Sealing washera 1 373 793 1
a. Only applies to 16 litre engines.

H9 Checking the high

pressure pump
1 Check the cylinder head on the high
pressure pump as described in the
workshop manual, see section 03-00 Fuel
system Scania XPI. If a fault is detected,
renew the cylinder head.

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