Fuel Inlet Restriction Page 1 of 9

Measure TOC

with Electronically Actuated Injector

WARNING
Depending on the circumstance, fuel
is flammable. Keep all cigarettes,
flames, pilot lights, arcing
equipment, and switches out of the
work area and areas sharing SMALL | MEDIUM | LARGE
ventilation to reduce the possibility of
severe personal injury or death when
working on the fuel system.

CAUTION
Do not spill or drain fuel into the
bilge area when disconnecting or
removing fuel lines, replacing filters,
and priming the fuel system. Do not
drop or throw filter elements into the
bilge area. The fuel and fuel filters
must be disposed of in accordance
with local environmental regulations.
Previous Summary 8

Stage 1 Filters
Next

z Remove the air bleed hose (1)

from the air bleed check valve
(2).
z Remove the air bleed check
valve (2) from the drain manifold
block (3).

Install the fuel system tester, (1), Part

Number 4918612, in place of the air
bleed check valve.

Install the air bleed hose.

Fuel System 55 [41 ft-

Tester n.m lb ] SMALL | MEDIUM | LARGE

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Fuel Inlet Restriction Page 2 of 9

Previous
45 [33 ft-
Air Bleed Hose
n.m lb ]
Next

Industrial Applications

Remove the threaded hex head o-ring

plug (1) in the inlet and the threaded
hex head o-ring plug (2) in the outlet of
Stage 1 filter head manifolds and
replace them with Compuchek®
fittings.

SMALL | MEDIUM | LARGE

Previous

Next

Connect a vacuum gauge and adapter

to the Compuchek® fitting in the inlet
port.

Start and operate the engine at low

idle, no load.

Record the Stage 1 inlet restriction.

SMALL | MEDIUM | LARGE

Previous

Next

Remove the vacuum gauge and

adapter from the inlet port and install it
on the Compuchek® fitting in the outlet
port.

Start and operate the engine at low

idle, no load.

SMALL | MEDIUM | LARGE

Previous

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Fuel Inlet Restriction Page 3 of 9

Next

Record the Stage 1 outlet restriction.

Subtract the measurement obtained at

the Stage 1 inlet from the measurement
obtained at the Stage 1 outlet. This is
the Stage 1 restriction.

Example:
SMALL | MEDIUM | LARGE

Stage 1 inlet restriction is 25 mm-Hg [1

in-Hg]
Stage 1 outlet restriction is 113 mm-Hg
[4.5 in-Hg]

Stage 1 restriction is 113 mm-Hg [4.5

in-Hg] minus 25 mm-Hg [1 in-Hg]
equals 88 mm-Hg [3.5 in-Hg].

Stage 1 Filter Restriction (Clean)

mm-hg in-hg
76 MAX 3
Stage 1 Filter Restriction (Dirty)
mm-hg in-hg
152 MAX 6
Previous
If the restriction is above specifications,
replace the Stage 1 fuel filters. Refer to Next
Procedure 006-015 (Fuel Filter (Spin-
On Type)) in Section 6.

If the restriction is below the maximum

specifications, inspect the fuel lines.
Refer to the OEM Troubleshooting and
Repair Manual to determine the source
of the high restriction.

Remove the vacuum gauge and

adapter from the Stage 1 fuel filter
head.

SMALL | MEDIUM | LARGE

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Fuel Inlet Restriction Page 4 of 9

Previous

Next

Remove the Compuchek® fittings and

install the threaded hex head o-ring
plugs into the inlet port (1), and outlet
(2) in the filter head.

Threaded Hex
27 [20 ft-
Head O-ring
Plugs n.m lb ]
SMALL | MEDIUM | LARGE

Previous

Next

Marine Applications

Remove the threaded hex head o-ring

plug (1) in the inlet and the threaded hex
head o-ring plug (2) in the outlet of Stage
1 filter head manifolds and replace them
with Compuchek® fittings.

SMALL | MEDIUM | LARGE

Previous

Next

Connect a vacuum gauge and adapter to

the Compuchek® fitting in the inlet port.

Start and operate the engine at low idle,

no load.

Record the Stage 1 inlet restriction.

SMALL | MEDIUM | LARGE

Previous

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Fuel Inlet Restriction Page 5 of 9

Next

Remove the vacuum gauge and

adapter from the inlet port and install it
on the Compuchek® fitting in the outlet
port.

Start and operate the engine at low

idle, no load.

SMALL | MEDIUM | LARGE

Previous

Next

Record the Stage 1 outlet restriction.

Subtract the measurement obtained at

the Stage 1 inlet from the measurement
obtained at the Stage 1 outlet. This is
the Stage 1 restriction.

Example:
SMALL | MEDIUM | LARGE

Stage 1 inlet restriction is 25 mm-Hg [1

in-Hg]
Stage 1 outlet restriction is 113 mm-Hg
[4.5 in-Hg]

Stage 1 restriction is 113 mm-Hg [4.5

in-Hg] minus 25 mm-Hg [1 in-Hg]
equals 88 mm-Hg [3.5 in-Hg].

Stage 1 Filter Restriction (Clean)

mm-hg in-hg
76 MAX 3
Stage 1 Filter Restriction (Dirty)
mm-hg in-hg
152 MAX 6
Previous
If the restriction is above specifications,
replace the Stage 1 fuel filters. Refer to Next
Procedure 006-015 (Fuel Filter (Spin-
On Type)) in Section 6.

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Fuel Inlet Restriction Page 6 of 9

If the restriction is below the maximum

specifications, inspect the fuel lines.
Refer to the OEM Troubleshooting and
Repair Manual to determine the source
of the high restriction.

Remove the vacuum gauge and

adapter from the Stage 1 fuel filter
head.

SMALL | MEDIUM | LARGE

Previous

Next

Remove the Compuchek® fittings and

install the threaded hex head o-ring
plugs into the inlet port (1), and outlet
(2) in the filter head.

Threaded Hex
27 [20 ft-
Head O-ring
Plugs n.m lb ]
SMALL | MEDIUM | LARGE

Previous

Next

Remove the air bleed hose and fuel

system tester (1) from the drain
manifold block.

SMALL | MEDIUM | LARGE

Previous

Next

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Fuel Inlet Restriction Page 7 of 9

Install the original air bleed check valve

(2) into the drain manifold block (3).

Air Bleed Check 55 [41 ft-

Valve n.m lb ]

Install the air bleed hose to the air

SMALL | MEDIUM | LARGE
bleed check valve.

Previous
45 [33 ft-
Air Bleed Hose
n.m lb ] Next

Stage 2

z Remove the pressure sensor (1) in

the Stage 2 filter head. Refer to
Procedure 019-119 (Pressure
Sensor) in Section 19 in the
Troubleshooting and Repair Manual,
Electronic Control System Series
QSK19 CM850 Modular Common SMALL | MEDIUM | LARGE

Rail System Engine, Bulletin

4021493.
z Remove the temperature sensor (2)
in the Stage 2 filter head. Refer to
Procedure 019-398 (Temperature
Sensor) in the Troubleshooting and
Repair Manual, Electronic Control Previous
System Series QSK19 CM850
Modular Common Rail System Next
Engine, Bulletin 4021493.
z Replace them with Compuchek®
fittings.

Connect a pressure gauge and adapter

to the Compuchek® fitting in the
pressure sensor side of the filter head.

Start and operate the engine at high

idle.

Record the Stage 2 inlet pressure.

SMALL | MEDIUM | LARGE

Previous

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Fuel Inlet Restriction Page 8 of 9

Next

Remove the pressure gauge and

adapter from the pressure sensor side
fitting and install the pressure gauge
and adapter on the fitting on the
temperature sensor side of the filter
head.

Start and operate the engine at high

idle. SMALL | MEDIUM | LARGE

Previous

Next

Record the Stage 2 outlet pressure.

Subtract the measurement obtained at the

Stage 2 outlet from the measurement
obtained at the Stage 2 inlet. This is the
Stage 2 filter restriction.

Example:
SMALL | MEDIUM | LARGE

Stage 2 inlet pressure is 731.5 kPa [104.5

psi]
Stage 2 outlet pressure is 714.0 kPa
[102.0 psi]

Stage 2 restriction is 728.0 kPa [104.5 psi]

minus 714.0 kPa [102.0 psi] equals 17.5
kPa [2.5 psi].

Stage 2 Filter Restriction (Clean

Filter)
kpa psi
28 MAX 4
Previous
Stage 1 Filter Restriction (Dirty Filter)
kpa psi Next
138 MAX 20

If the restriction is above specifications,

replace the Stage 2 fuel filters. Refer to
Procedure 006-015 (Fuel Filter (Spin-On
Type)) in Section 6.

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Fuel Inlet Restriction Page 9 of 9

Remove the pressure gauge and

adapter from the second stage filter
head.

SMALL | MEDIUM | LARGE

Previous

Next

Remove the Compuchek® fittings from

the second stage filter head.

Install the pressure sensor (1) into the

filter head. Refer to Procedure 019-119
(Pressure Sensor) in Section 19 in the
Troubleshooting and Repair Manual,
Electronic Control System Series
QSK19 CM850 Modular Common Rail SMALL | MEDIUM | LARGE

System Engine, Bulletin 4021493.

Install the temperature sensor (2) into

the filter head. Refer to Procedure 019-
398 (Temperature Sensor) in the
Troubleshooting and Repair Manual,
Electronic Control System Series
Previous
QSK19 CM850 Modular Common Rail
System Engine, Bulletin 4021493.

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