03:14-01

Issue 5

XPI fuel system

Troubleshooting

Scania CV AB 2012, Sweden

en-GB

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

fault codes

There are active fault

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
the tank and no
water

There is no fuel in the

tank but there is 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
external leakage
or it is not
possible to build
up the pressure

There is external
leakage
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.
No fuel comes
out during both
checks

The problem may be between

the fuel tank and the feed
pump. Renew the fuel filter as
described in L2. Repair all the
faults that are detected and
continue from S-a.

... with the hand pump but not

with the starter motor

Fuel comes
out ...

... during both

checks

... with the starter

motor but not with the
hand pump.

Check the feed pump as

described in L3.

L-c Measure the feed pump as described

in L6.

No fuel
comes out

The
pressure
is too low

A little fuel
comes out

The feed pump

drive is not
working

The pressure is normal

The problem may be on the high

pressure side. If the engine can be
started, continue from H-a.
Otherwise continued from H-b.

Check the feed pump drive as

described in L4.

The feed
pump is
defective

The cause may be the feed pump

drive. Also check the high
pressure pump drive as described
in L5. Then continue from S-a.

Renew both fuel filters. Bleed the fuel

system and measure the feed pressure as
described in L6 again.

The
pressure
is still
too low

The cause may be the feed pump. Renew the pump, bleed
the fuel system and continue from S-a.

The hand pump may be

faulty. Renew the hand
pump and resume
troubleshooting from L-a.

Scania CV AB 2012, Sweden

The pressure is
normal
The cause may be blocked fuel
filters. Rectify the cause of the
blockage, bleed the 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 valve.
Renew the valve
and continue from
S-a.

The safety
valve is
defective

H-a The engine starts. Check the

safety valve as described in H3.

The safety valve is working

The safety valve opens
when idling

Check for internal leaks as described

in H1.
The pressure is
normal

... cylinder is not identified

Check the return fuel
pressure as described in H2.
The pressure
is normal

... cylinder is
identified

Verify the faulty injector and plug as

described in H5.

The pressure
is too high

The fault
cannot be
verified

Check the fuel inlet metering

valve using SDP3.

The fuel inlet

metering
valve is
defective

The pressure is falling

and ...

Check for internal leaks as

described in H6.

The fuel inlet

metering valve is
working

The fault
cannot be
verified

The cause may be the fuel inlet metering

valve. Renew the valve and continue from
S-a.
The problem may be in the high pressure pump. Check
the high pressure pump as described in H9 and repair all
faults that are detected. Continue from S-a.

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Fault
verified

Scania CV AB 2012, Sweden

Fault
verified

... there is
external
leakage
The cause may
be external
leakage.
Rectify the leak
and continue
from S-a.

The cause may be the

injector. Renew the
injector and continue
from S-a.

The cause may be the high

pressure connections. Detach and
visually inspect all high pressure
connections and torque tighten
them. Continue from S-a.

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
or maintain
pressure

Can build up and

maintain 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
pressure is normal
or low

The return fuel pressure

is too high

The cause may be the high pressure

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

working

The safety valve is

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
1 Open the test connection on the high
pressure pump.
2 Pump using the hand pump. Check that
fuel comes out of the test connection.

L3 Checking the feed

pump
1 Detach the pipe for outlet fuel from the
feed pump. Place a container under the free
end of the pipe.

4 Close the test connection.

2 Turn the engine over using the starter

motor for about 20 seconds. The feed
pump provides about 1.2 l/min. The
correct quantity for 20 seconds is
0.3-0.4 litres.

L2 Checking the suction

filter

L4 Checking the feed

pump drive

3 Turn the engine over using the starter

motor. Check that fuel comes out of the
test connection.

Note: When renewing the suction filter, check

the following with the suction filter removed.

1 Pump with the hand pump and check that

fuel free from air flows out of the hole on
the inside of the filter housing.
2 If no fuel comes out, check the suction
strainer and all joints on the suction pipe
up to the fuel tank armature. Renew the
seals and check-tighten the connections.

1 Remove the feed pump from the highpressure pump bracket.

2 Turn the feed pump by hand. The pump
should rotate freely and the drive shaft in
the pump should be intact.
3 Check that the drive pins in the high
pressure pump are intact.
4 Turn the engine over using the starter
motor. Check that the feed pump drive in
the high pressure pump rotates.

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

pressure pump drive
1 Remove the high pressure pump.
2 Turn the engine over using the starter
motor. Check that the high pressure pump
drive rotates in the timing gear.
3 Renew the pump drive gear if it does not
rotate or is damaged. Check for resulting
damage to the high pressure pump gear.
Damaged gears should be renewed.
4 If the pump drive gear in the timing gear
rotates and is not damaged:
Check that the high pressure pump gear is
properly seated on the shaft. If the gear is
loose, the shaft may be damaged. Do not
tighten the gear. Renew the high pressure
pump.
If the gear is jammed, the high pressure
pump is defective. Renew the high
pressure pump.

L6 Checking the supply

pressure at the test
connection on the high
pressure pump
1 Connect pressure gauge 99 362 to the test
connection on the high pressure pump and
open the test connection.
2 Turn the engine over using the starter
motor. Read the pressure after
approximately 20 seconds. The pressure
should be more than 2 bar.
Note: Low feed pump pressure may be caused
by a defective feed pump, or may be a
symptom of a high pressure pump with a
defective cylinder head.

Note: Make sure that the battery level is high

enough to run the engine at 90 rpm with the
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
leaks

H2 Checking the return

fuel pressure

Note: Always use the latest version of SDP3 if

possible.

1 Connect pressure gauge 99 362 to the test

connection on the return fuel manifold and
open the test connection.

For SDP3 version 2.8 onwards:

2 Start the engine. Read the pressure with the

engine idling. The pressure should be
below 0.8 bar. If the pressure exceeds
0.8 bar the overflow valve on the return
fuel manifold should be cleaned and
visually inspected. Start again from step 1.

1 Follow the instructions for Fuel leak test in

SDP3.
For SDP3 version 2.7:
1 Start the engine.
2 Start the test Checking for internal leaks in
SDP3.
3 Switch off the engine. Read the pressure
remaining in the accumulator using SDP3.
There should be some pressure remaining.
If the pressure falls more than 300 bar
within one (1) minute, there are internal
leaks.
4 Check cylinder balancing at idling speed
using SDP3. Note if any cylinder deviates.

Note: When the overflow valve is removed air

will be introduced, opposite the flow direction.
It takes time for the system to bleed itself.
During this time the measurement is not
reliable. Leave the engine idling for a while
before repeating the test. If the pressure still
exceeds 0.8 bar, there is internal leakage in an
injector.

3 Switch off the engine, remove the pressure

gauge and close the test connection.

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

valve
1 Start and run the engine at idling speed for
15 seconds and then switch off 15 voltage.
Check whether the return pipe from the
safety valve to the return fuel manifold is
hot.

WARNING!

The accumulator may be under high pressure.

Reduce the pressure using SDP3 before starting
work. Wear protective goggles. There is a risk
of burn injuries when the safety valve is open.

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
Plastic hose
Union nut
Ferrule
Insert sleeve
Plug
Straight uniona
Sealing washera

Part No.
813 869
814 555
813 223
812 913
813 878
813 198
1 373 793

Quantity
1
2
1
1
1
1
1

a. Only applies to 16 litre engines.

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Descriptions, High pressure check

H5 Verification of a
faulty injector

H6 Checking for internal

leaks

1 Remove the high pressure pipe to the

injector which has been identified in H1.
2 Plug the outlet of the identified injector at
the outlet port on the fuel accumulator
using tool 99 019. If the outlet port of
cylinder 1 has to be plugged, see the
instructions in TI 03-08 01 28.
3 Start the engine and repeat H1. This
system must be able to maintain pressure.
Note: Remember that several injectors can
sometimes be faulty at the same time.
Therefore if a faulty injector cannot be
verified, plug it and repeat step H1. If a second
faulty injector cannot be verified, continue
troubleshooting as described in H6.

WARNING!

Wear protective goggles. There is a risk of fuel

splashing from the high pressure connections
when pressurised.
The accumulator may be under high pressure.
Reduce the pressure using SDP3 before
starting work.

A tool must be made to determine whether the

fuel system is leaking. A pressure regulator, a
shut-off valve, 2 hose couplings, hose clamps,
hose and Tema quick release coupling 1100N
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

the return fuel manifold and open the test
connection.

IMPORTANT!

Open the fuel filler flap so that the pressure

does not deform the tank.

3 Pressurise the return fuel manifold. Slowly

increase the pressure. Listen for a bubbling
noise in the tank. The bubbling noise
indicates at what pressure the overflow
valve opens. The pressure should be higher
than 0.5 bar. Then pressurise the manifold
to max. 3 bar.

5 Renew the injector or injectors with

internal leakage as described above. When
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
be performed.

IMPORTANT!

After renewing an injector with internal

leakage, the engine oil must be changed and
the oil filter renewed. If there is internal
leakage, soot quickly builds up in the engine
oil.

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.
3 Refit the engine pipe. Torque tighten.

Parts
Applies to 9, 13 and 16 litre engines.
Designation
Plastic hose
Union nut
Ferrule
Insert sleeve
Plug
Straight uniona
Sealing washera

Part No.
813 869
814 555
813 223
812 913
813 878
813 198
1 373 793

Quantity
1
2
1
1
1
1
1

2 If the cylinder head is not faulty and there

are still problems, it may be due to a faulty
fuel inlet metering valve. Try fitting a new
fuel inlet metering valve.
3 If the problem remains, the problem may
be present in the high pressure pump.
Renew the high pressure pump and
continue to S-a.

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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