XPI Fuel System: en-GB

03:14-01
Issue 14 en-GB
XPI fuel system
Troubleshooting
©
Scania CV AB 2017, Sweden
Contents
Contents
Troubleshooting the XPI fuel
system Introduction .............................................................. 3
Using the troubleshooting guide............................... 3
Before troubleshooting the fuel system ................... 4
Troubleshooting S-a Basic check......................................................... 6

S-b Start-up check .................................................... 7
L-a Low pressure check............................................ 8
H-a High pressure check when the engine can
be started................................................................... 9
H-b High pressure check when the engine can-
not be started........................................................... 10
Descriptions, Low pressure check L1 Low pressure check........................................... 11

L2 Checking the suction filter ................................ 11
L3 Checking the feed pump ................................... 11
L4 Checking the feed pump drive .......................... 11
L5 Checking the high pressure pump drive............ 12
L6 Checking the supply pressure ........................... 12
L7 Elimination of air in the fuel system................. 13
Descriptions, High pressure check H1 Checking for internal leaks............................... 14

H2 Checking the return fuel pressure when the
engine can be started .............................................. 15
H3 Checking the safety valve when the engine
can be started .......................................................... 15
H5 Verification of faulty injector when the
engine can be started .............................................. 17
H6 Verification of faulty injector when the
engine cannot be started ......................................... 22
H7 Checking the return fuel pressure when the
engine cannot be started ......................................... 25
H8 Checking the safety valve when the engine
cannot be started ..................................................... 25
H9 Checking the high pressure pump .................... 26
©
2 Scania CV AB 2017, Sweden 03:14-01
Troubleshooting the XPI fuel system
Introduction Using the troubleshooting

This guide contains instructions for guide
troubleshooting the XPI fuel system. Also see
supplementary material: Start troubleshooting by looking at
troubleshooting tree S-a. This troubleshooting
• 03:14-07 Troubleshooting overview, an tree helps you to choose where to start
overview of this troubleshooting guide troubleshooting.
• 03:14-06 XPI fuel circuit, 9 and 13 litre The troubleshooting trees are read from the top
engines, an overview of the fuel circuit down. The boxes contain instructions you can
follow. These instructions sometimes refer to
• 03:14-08 XPI fuel circuit, 16 litre other more detailed instructions further on in
engines, an overview of the fuel circuit the document. When an instruction has been
carried out, follow the arrow to the next
• 03:14-09 XPI fuel circuit, 16 litre instructions.
engines, details from 03:14-08
©
03:14-01 Scania CV AB 2017, Sweden 3
Before troubleshooting When troubleshooting all vehicle types:
the fuel system • Ensure that all staff are at a safe distance
and protected from any jets of fuel from
The XPI fuel system has very high fuel the engine when the fuel system is
pressure. To avoid personal injury when pressurised.
troubleshooting the fuel system, it is therefore
important to ensure safe ways of working. • Always use protective goggles during
troubleshooting, even when the fuel
system is depressurised.
WARNING! • Make sure that the fuel system is

depressurised using SDP3 before you carry
The fuel system has a very high fuel pressure out any work on the system.
of up to 3,000 bar. The fuel system must be
depressurised using SDP3 before any work is • Make sure that the vehicle has no power
started. before carrying out any work on the
system.
A jet of fuel at high pressure can cut through
the skin. • On vehicles with the engine in an engine
compartment: Make sure that the fire
The system should always be treated as extinguishing equipment for the engine
pressurised, even when the engine is switched compartment is switched off, so that it is
off. not inadvertently triggered during
Use eye protection and gloves. troubleshooting.
• Carry out a final leak trace if there has
been any interference carried out on the
fuel system during troubleshooting.
©
IMPORTANT!
The whole fuel system is very sensitive to dirt

and also very small particles. Foreign particles
in the system can cause serious malfunctions. It
is therefore very important that everything is as
clean as possible when work is carried out on
the fuel system. Wash the engine before
carrying out repair work. If possible, a hot
wash should be used.
It is strictly forbidden to carry out any

machining work or work with compressed air
near an open fuel system.
Be extra careful and always use clean, lint-free

and dust-free clothes and disposable gloves
when working on the fuel system. Scania
recommends use of Tegera 848 gloves.
Clean tools before they are used and do not use

any worn or chrome-plated tools. Material and
flakes of chrome may come off.
Clean connections and the surrounding area

before removal. When cleaning, cloths or paper
which shed fibres must not be used. Use clean
and lint free cloths, part number 588 879.
Plug or cover the connections during removal.

Also clean the connections before the
components are fitted. Place removed
components on a thoroughly cleaned, dust-free
surface. Scania recommends using a stainless
steel bench top, part number 2 403 296. Cover
the components with a lint-free cloth.
©
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. Start

troubleshooting the fuel system from S-b. If
there is no other XPI-related fault, the cause
may be outside the fuel system.
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 if any 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.
©
Troubleshooting
S-b Start-up check
Check that there is some fuel in the tank and

that it does not contain water.
There is fuel in There is no fuel in the

the tank but no tank but there is water
water. in the tank.
Rectify the problem and continue from S-a.
Pump the hand pump until pressure has built

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
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.
©
Troubleshooting
L-a Low pressure check

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 out... The hand pump may be
pump. Renew the fuel filter as 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 motor

...with the hand pump but not but not with the hand
with the starter motor ...during both pump
checks
Check the feed pump as L-c. Measure the supply pressure as

described in L3. described in L6.
No fuel comes A little fuel The The pressure is normal

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 continue from H-b.
The feed pump The feed

drive is not pump is
working defective Renew both fuel filters. Eliminate air in
the fuel system according to L7 and
measure the supply pressure once more
The cause may be the feed pump according to L6.
drive. Also check the high pressure
pump drive as described in L5.
The The pressure is
Then continue from S-a.
pressure is normal
still too low
The cause may be blocked fuel
filters. Rectify the cause of the
blockage, eliminate air in the
The cause may be the feed pump. Renew the feed pump, fuel system according to L7 and
eliminate air in the fuel system according to L7 and continue continue from S-a.
from S-a.
©
Troubleshooting
H-a High pressure check when the engine can be

started
The safety valve is The engine starts. Check the safety
Renew the safety
defective valve as described in H3.
valve and continue
from S-a.
The safety valve opens The safety valve is working

when idling
Check for internal leaks as described

in H1.
The pressure is
normal
The pressure is falling

...a cylinder is not identified and...
The pressure is too high or ...there is

Check the return fuel ...a cylinder is
normal and there is a small external
pressure as described in H2. identified
high pressure leakage leakage
The pressure is Rectify the leak

normal and there is a and continue
large high pressure Verify the faulty injector and plug as
described in H5. from S-a.
leakage
Check the fuel inlet The fault cannot Fault verified

metering valve using be verified
SDP3.
The cause may be the high
pressure connection. Detach
The fuel inlet The fuel inlet and inspect the high pressure
metering metering valve connection and torque tighten
valve is is working it. Verify that the system
defective retains pressure. Then
continue from S-a.
Renew the fuel inlet metering valve and

continue from S-a.
The fault cannot be
verified
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. The cause may be the injector.
Renew the injector and continue
from S-a.
©
Troubleshooting
H-b High pressure check when the engine cannot be

started
Engine will not start. Check the fuel pressure in the accumulator (T111 or T199) with SDP3 and
run the starter motor. For SDP3 version 2.18 or later, follow the instructions for Plug test –
checking for internal leakage using the starter motor in SDP3.
Cannot build up or Can build up and

maintain pressure. maintain pressure.
The cause is probably not the fuel

injection system. Continue searching
for other causes.
Check the safety valve as described in H8.
The safety valve is The safety valve is

working. defective. Renew the valve and continue from
S-a.
Check the return fuel pressure as

described in H7. Verify the faulty injector and plug as
The return fuel described in H6.
pressure is too high
The return fuel pressure is or normal. Minor
normal. Major high high pressure The fault The fault can be
pressure leakage leakage according to cannot be verified
according to an SDP3 an SDP3 check. verified
check.
The problem may be in the high

pressure pump or the fuel inlet metering The cause may be the high pressure
valve. Carry out check H9 and repair all connection. Detach and inspect the
faults that are detected. Continue from The fault
cannot be high pressure connection and torque
S-a. tighten it. Verify that the system
verified
retains pressure. Then continue from
S-a.
The cause may be the injector. Renew the

injector and continue from S-a.
©
Descriptions, Low pressure check
L1 Low pressure check L3 Checking the feed

1 Open the test connection on the high
pump
pressure pump.
1 Connect a hose to the test connection on
2 Pump using the hand pump. Check that the pressure filter. Position the hose in a
fuel comes out of the test connection. test vessel and open the test connection
fully.
3 Crank the engine using the starter motor.
Check that fuel comes out of the test 2 Turn the engine over using the starter
connection. motor for about 20 seconds. The feed
pump provides about 1.2 l/min. The
4 Close the test connection. correct quantity during 20 seconds is
0.3-0.4 litres.
L2 Checking the suction Note: Eliminate any air found in the fuel
filter system according to L7 before measuring.
Note: When renewing filters, check the

following with the suction filter removed.
L4 Checking the feed
pump drive
1 Pump with the hand pump and check that 1 Remove the feed pump from the high-
fuel free from air flows out of the hole on pressure pump bracket.
the inside of the filter housing.
2 Turn the feed pump by hand. The pump
2 If no fuel comes out, check the suction should rotate freely and the drive shaft in
strainer and all joints on the suction pipe the pump should be intact.
up to the fuel pick-up unit. Renew the seals
and check-tighten the connections. 3 Check that the drive pins in the high
pressure pump are intact.
3 If fuel comes out, fit new filters and
eliminate air in the fuel system according 4 Crank the engine using the starter motor.
to L7. Check that the feed pump drive in the high
pressure pump rotates.
©
L5 Checking the high L6 Checking the supply

pressure pump drive pressure
1 Remove the high pressure pump. 1 Connect pressure gauge 2 308 208 to the
test connection on the high pressure pump
2 Crank the engine using the starter motor. (9 and 13 litre engines) or to the pressure
Check that the high pressure pump drive filter (16 litre engines) and open the test
rotates in the timing gear. connection.
3 Renew the pump drive gear if it does not 2 Run the starter motor and read the
rotate or is damaged. Check for resulting manometer while the starter motor is
damage to the high pressure pump gear. running. The pressure should be at least
Damaged gears should be renewed. 2 bar. Cancel when the pressure has been
reached or after a maximum of 20 seconds.
4 If the pump drive gear in the timing gear
rotates and is not damaged: 3 If the engine starts, increase engine speed
to 1,500 rpm. Read the pressure. The
Check that the high pressure pump gear is pressure should be between 9 and 14 bar.
properly seated on the shaft. If the gear is
loose, the shaft may be damaged. Do not
tighten the gear. Renew the high pressure Note: Low feed pump pressure may be caused
pump. by a defective feed pump, or may be a
symptom of a high pressure pump with a
If the gear is jammed, the high pressure defective cylinder head.
pump is defective. Renew the high
pressure pump.
Note: Make sure that the battery state of charge
is high enough to run the engine at 90 rpm with
the starter motor.
Note: There is currently no method to confirm

whether a fuel filter is blocked. If the complaint
is that fault code 135 is activated when under
heavy load the fuel filter is probably blocked.
The feed 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.
©
L7 Elimination of air in the

fuel system
1 Undo the cover (A) to the water separating
suction filter to reveal the green O-ring.
Note: Undo the cover no more than 1 turn. If

the cover is opened more than 1 turn, the
drainage is opened and the fuel is drained back
into the tank.
2 Pump by hand until fuel runs out past the

O-ring.
3 Tighten the cover to the water separating 9 and 13 litre engines
suction filter. Undo the cover until the O-ring is visible
4 Open the ventilating valve on the pressure (approx. 1 turn)
filter.
5 Pump by hand until fuel begins to leak
from the ventilating valve.
6 Tighten the ventilating valve.
16 litre engine
Undo the cover until the O-ring is visible
(approx. 1 turn)
©
Descriptions, High pressure check
H1 Checking for internal Cylinder balancing (mg/strokes)

leaks
Note: Always use the latest version of SDP3 if
possible.
• Follow the instructions for Fuel leak test in

SDP3.
Note: Remember that several injectors can Cylinder 1 deviates most clearly
sometimes be faulty at the same time.
Cylinder output test (Nm)

There are more tests in SDP3 which can help to
identify which cylinder you should start to
plug, e.g. if there are any deviating sounds
during the tests Activating unit injector
solenoid valves and Cylinder shut-off.
Examples of cylinder balancing

and cylinder output test
Please see an example of the results from a
cylinder balancing and cylinder output test to
the right.
Cylinder 1 and 2 deviate most clearly
If the test results in this example are compared,
the first two results firstly identify cylinder 1
and secondly cylinder 2.
Note: Deviating bars is only an indication that
Therefore, start by plugging injector 1 something may be wrong. It is not proof!
according to H5.
©
H2 Checking the return H3 Checking the safety

fuel pressure when the valve when the engine can
engine can be started be started
1 Connect pressure gauge 2 308 208 to the 1 Start and run the engine at idling speed for
test connection on the fuel manifold and 15 seconds and then switch off 15 voltage.
open the test connection. Check whether the return pipe from the
safety valve to the return fuel manifold is
2 Start the engine and run it at idling speed hot.
for at least 1 minute before the pressure is
read. The pressure should be between 0.5 2 If the return pipe is hot, this is because the
and 0.7 bar. If the pressure is lower than safety valve was open when the engine was
0.5 bar, the overflow valve should be last run. The most probable cause of this is
cleaned or renewed. that the fuel inlet metering valve is stuck in
the open position. Continue
• If the overflow valve is removed, air troubleshooting by renewing the fuel inlet
will leak in. Run the engine at idling metering valve.
speed for approx. 5 minutes after
reinstallation, and then restart from 3 If the return pipe is not hot, start the engine
step 1. and run the check Leak testing the safety
valve using SDP3 with the return pipe in
3 If the pressure is higher than 0.8 and H1 situ.
fails, follow H5 to find the defective
injector or high pressure connection.
4 If the pressure is less than 0.7 bar and H1 WARNING!
fails, the fault can be caused either by a
defective injector or cracked cylinder For safety reasons it is important that the return
head. pipe is not removed during step 3. If the safety
valve opens during the check with the pipe
• If the internal leak (H1) turns out to be removed, hot fuel would spray out with great
serious, the cylinder head is probably force.
cracked. If it is difficult to reach
2,400 bar, the cylinder head is probably
cracked.
5 If the internal leak (H1) turns out to be
minor, it is more likely that the fault is in
an injector. Follow H5 to locate the
defective injector.
6 Switch off the engine. Remove the
pressure gauge and close the test
connection.
©
4 If the return pipe becomes hot during the Parts

check Leak testing the safety valve the
safety valve is faulty. Continue Applies to 9, 13 and 16 litre engines.
troubleshooting by renewing the safety
valve. Designation Part No. Qty
5 If the return pipe does not become hot and Plastic hose 813 869 1
the accumulator pressure does not reach Union nut 814 555 2
2,400 bar, the safety valve is probably Ferrule 813 223 1
working. Cancel the check and continue
Insert sleeve 812 913 1
troubleshooting the fuel system.
Plug 813 878 1
Straight uniona 813 198 1
WARNING! Sealing washera 1 373 793 1
a. Applies only to 16 litre engine
The accumulator may be under high pressure.
Reduce the pressure using SDP3 before
beginning work. Use eye protection. There is a
risk of burn injuries when the safety valve is
open. 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
6 If the return pipe does not become hot but the vessel. If the safety valve leaks more than
the accumulator pressure reaches 10 drops a minute it is faulty and must be
2,400 bar, remove the return pipe, plug the renewed.
fuel manifold (9- and 13 litre engines) or
the high pressure pump (16 litre engines).
Fit a plastic hose routed with a fall down WARNING!
into a dry vessel so that small amounts of
fuel can be discovered. 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.
Note: Assemble the plastic hose using parts in

the part list below.
©
H5 Verification of faulty During the test, inactive fault codes may be

generated. If you make a note of the inactive
injector when the engine fault codes before running the test, you can
can be started compare them afterwards and remove the
inactive fault codes which have appeared
during the test.
WARNING!
Criteria
High pressure will be requested in the
accumulator. Use eye protection and gloves. • Leakage has been noted in the fuel system.
Keep your distance from the accumulator
during the test. In the event of leakage, fuel jets • Fault in the fuel inlet metering valve and
may spray out at high pressure. Reduce the the safety valve has been ruled out.
pressure using SDP3 before beginning work.
• The batteries should be fully charged,
Use eye protection and gloves.
otherwise use an auxiliary battery.
• If the parking brake is fitted, it must be
applied.
WARNING! • If there is a gear lever, it must be in neutral.
If all outputs on the accumulator are plugged, • The accelerator pedal and the brake pedal
the pressure cannot be reduced with SDP3. A must not be depressed during the test.
pressure of approx. 2,400 bar will remain in the
accumulator. It is very important to use the correct plugs for
the accumulator as the fuel ports on the
different accumulators are different. If you use
the wrong plug, the plug will not remain tight
and this is a safety risk.
About the check
See the plug table and accompanying pictures
This check is used to find leaks in one or more to select the correct plug.
injectors or in the high pressure pump. The
high pressure pipes are removed from the
accumulator, which then plugged before being
pressurised.
To avoid personal injury when troubleshooting
it is important to ensure safe ways of working.
See the chapter Before troubleshooting the fuel
system.
If it is not possible to build up sufficiently high
pressure in the fuel system, this may be due to
there being air in the fuel system. Lower the
pressure and exit the test. Run the test again to
eliminate air in the fuel system.
©
Plug table
Engine type Engine serial Accumulator Plugs Plug kit

number
9 litres up to 6 880 872 2 130 084a 2 488 717 cyl. 1-5 2 488 719
from 6 880 873 2 260 143 99 749 cyl. 1-5 99 748
13 litres up to 6 880 866 2 130 085a 2 488 716 cyl. 1 2 488 719
2 488 717 cyl. 2-6
from 6 880 867 2 260 144 2 488 716 cyl. 1b 2 488 719
99 749 cyl. 2-6 99 748
16 litres All All 99 749 cyl. 1-8 99 748
a. Note: The accumulator is replaced by a later accumulator as a spare part.
b. The plug is also available as a separate spare part.
Later accumulator (9-, 13 and 16 litre

Earlier accumulator (9- and 13 litre engine). Plug with part number 99 749:
engines). Plug with part number 2 488 717:
©
Connection union on accumulator cyl. 1

(13 litre engines). Plug with part number
2 488 716:
©
Troubleshooting
1 Remove the high pressure pipe to the injector
which was identified faulty in H1. If no injector
was identified in H1, use the results from
previous tests to find out which injector is the
most likely.
2 Plug the outputs of the injector and the
accumulator. Select the correct plugs by
checking which accumulator is involved. See
the plug table and illustrations in Criteria.
WARNING!
The wrong plug can result in leakage, which is a

safety risk.
IMPORTANT!
All plugs must be tightened to a torque of 38 Nm.
©
3 Ensure the correct injector is identified by

checking internal leakage using SDP3. The
system must be able to hold the pressure.
4 Should the test fail, leave the plug in place
and repeat steps 1-3 and plug the next
suspected injector.
WARNING!
If all outputs on the accumulator are plugged,

the pressure can only be reduced by undoing
one of the plugs. Place a thick rag over a plug
and carefully undo it. The fuel is at a very high
pressure and can cut through the skin.
Note: Remember that several injectors can be

faulty at the same time. If checks H1 or H6
does not show signs of internal leakage,
perform a visual check of the high pressure
connections and torque tighten them before
renewing any injectors.
5 Continue as long as the engine can be

started. When it is no longer possible to
start the engine, continue from H6.
6 If the leakage has still not been located
when all fuel ports are plugged, it is
probably due to a cracked cylinder head on
the high pressure pump. Renew the
cylinder head and continue to step 7.
7 Reconnect the fuel pipes one at a time to
identify further leaks in the injectors and
make necessary repairs.
8 Update the tuning codes using SDP3 for all
injectors that have been renewed.
©
H6 Verification of faulty
injector when the engine
cannot be started
In order to verify a faulty injector even when
the engine is not running, it is possible to
troubleshoot manually or with SDP3.
WARNING!
High pressure will be requested in the

accumulator. Use eye protection and gloves.
Keep your distance from the accumulator
during the test. The fuel is at a very high
pressure and can cut through the skin if it
leaks. Reduce the pressure using SDP3 before
beginning work. Use eye protection and
gloves.
WARNING!
If all outputs on the accumulator are plugged or

if the connections A1 and B1 are disconnected,
SDP3 cannot be used to reduce the pressure. A
pressure of approx. 2,400 bar will remain in the
accumulator.
Note: Always use the latest version of SDP3 if

possible.
Troubleshooting with SDP3

version 2.18 or later
• Follow the instructions for Plug test –
checking for internal leakage using the
starter motor in SDP3.
©
Troubleshooting manually
1 Disconnect the connection from the fuel
inlet metering valve so that the engine
control unit does not inhibit pressurisation.
2 Disconnect connections A1 and B1 on the
engine control unit to disconnect the
injectors. This is to prevent the engine
from starting during the test.
3 Check the fuel pressure in the accumulator
(fuel pressure sensor T111 or T199) using
SDP3.
• It is important to monitor the fuel
pressure while the starter motor is
running. If the pressure exceeds
2,400 bar, there is a risk of activating 9 and 13 litre engines
the safety valve. Click the graph
symbol icon to monitor the pressure
more easily.
Note: Be aware that once the pressure has

started to rise, the reading can be reached
within a few seconds. If the pressure exceeds
2,800 bar, the safety valve is activated.
16 litre engine
Connections on the engine control unit
©
4 Let the starter motor run until the pressure 7 If the leakage has still not been located
reaches 2,000-2,400 bar. when all fuel pipes are plugged, it is
probably due to a cracked cylinder head on
• Reset the safety valve by turning off the high pressure pump. Renew the
the key and then redo step 4. cylinder head.
• Turn off the starter motor after max
15 seconds if the leakage is so serious Note: If the safety valve was activated during
that the high pressure pump cannot the test, check it before renewing the cylinder
build up the pressure to 2,000 bar. head.
5 If the pressure drops more than 300 bar per

min after switching off the starter motor,
the test has failed. 8 Connect the fuel pipes one at a time to
identify further leaks in the injectors and
6 Plug the remaining injectors one at a time make necessary repairs.
and redo step 3-5 until the system can hold
the pressure. Select the correct plugs by 9 Connect all electrical connectors when the
checking which accumulator is involved. system is free from leakage and delete any
See the plug table and illustrations in H5 > fault codes.
Criteria.
10 Update the tuning codes using SDP3 for all
injectors that have been renewed.
WARNING!
The wrong plug can result in leakage, which is

a safety risk.
IMPORTANT!
All plugs must be tightened to a torque of

38 Nm.
Note: Remember that several injectors can be

faulty at the same time. Check the high
pressure connection and torque tighten it
before renewing injectors.
WARNING!
If all outputs on the accumulator are plugged,

the pressure can only be reduced by undoing
one of the plugs. Place a thick rag over a plug
and carefully undo it. The fuel is at a very high
pressure and can cut through the skin.
©
H7 Checking the return H8 Checking the safety

fuel pressure when the valve when the engine
engine cannot be started cannot be started
1 Connect pressure gauge 2 308 208 to the 1 Remove the return pipe, plug the fuel
test connection on the return fuel manifold manifold (9 and 13 litre engines) or the
and open the test connection. high pressure pump (16 litre engines). Fit a
plastic hose routed with a fall down into a
2 Crank the engine using the starter motor. dry vessel so that small amounts of fuel
Read the pressure after approximately can be discovered.
20 seconds. The value should be below
0.8 bar.
Note: Assemble the plastic hose using parts in
3 If there is no detectable value after the part list below.
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.
©
2 Crank the engine using the starter motor. If H9 Checking the high
fuel leaks out of the safety valve, it is
faulty and must be renewed. pressure pump
3 Refit the engine pipe. Torque tighten. 1 Check the cylinder head on the high
pressure pump as described in the
Workshop Manual. See 03-00 > Fuel
Parts system Scania XPI. If a fault is detected,
renew the cylinder head.
Applies to 9, 13 and 16 litre engines.
2 If the cylinder head is not faulty and there
Designation Part No. Qty are still problems, it may be due to a faulty
fuel inlet metering valve. Try fitting a new
Plastic hose 813 869 1
fuel inlet metering valve.
Union nut 814 555 2
Ferrule 813 223 1 3 If the problem remains, the problem may
be present in the high pressure pump.
Insert sleeve 812 913 1 Renew the high pressure pump and
Plug 813 878 1 continue to S-a.
Straight uniona 813 198 1
Sealing washera 1 373 793 1
a. Only applies to 16 litre engines.
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03:14-01

XPI fuel system

Troubleshooting S-a Basic check......................................................... 6

Descriptions, Low pressure check L1 Low pressure check........................................... 11

Descriptions, High pressure check H1 Checking for internal leaks............................... 14

Troubleshooting the XPI fuel system

Introduction Using the troubleshooting

Before troubleshooting When troubleshooting all vehicle types:

WARNING! • Make sure that the fuel system is

The whole fuel system is very sensitive to dirt

It is strictly forbidden to carry out any

Be extra careful and always use clean, lint-free

Clean tools before they are used and do not use

Clean connections and the surrounding area

Plug or cover the connections during removal.

S-a Basic check

Check any fault codes using SDP3.

There are no active There are active fault

Can the engine be started?

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

The engine starts but there are inactive fault

The cause of the problem is not the fuel

S-b Start-up check

Check that there is some fuel in the tank and

There is fuel in There is no fuel in the

Pump the hand pump until pressure has built

There is no There is external

The problem may be present in the low

L-a Low pressure check

The problem may be between No fuel comes Fuel comes

...with the starter motor

Check the feed pump as L-c. Measure the supply pressure as

No fuel comes A little fuel The The pressure is normal

The feed pump The feed

H-a High pressure check when the engine can be

The safety valve opens The safety valve is working

Check for internal leaks as described

The pressure is falling

The pressure is too high or ...there is

The pressure is Rectify the leak

Check the fuel inlet The fault cannot Fault verified

Renew the fuel inlet metering valve and

H-b High pressure check when the engine cannot be

Cannot build up or Can build up and

The cause is probably not the fuel

The safety valve is The safety valve is

Check the return fuel pressure as

The problem may be in the high

The cause may be the injector. Renew the

Descriptions, Low pressure check

L1 Low pressure check L3 Checking the feed

Note: When renewing filters, check the

L5 Checking the high L6 Checking the supply

Note: There is currently no method to confirm

4 Close the test connection and remove the

L7 Elimination of air in the

Note: Undo the cover no more than 1 turn. If

2 Pump by hand until fuel runs out past the

Descriptions, High pressure check

H1 Checking for internal Cylinder balancing (mg/strokes)

• Follow the instructions for Fuel leak test in

Cylinder output test (Nm)

Examples of cylinder balancing