2500 4x2 Pickup L6-359 5.9L DSL Turbo (1994)
Fuel Supply Line: Testing and Inspection
Leak Testing
High-pressure fuel line leaks can cause starting problems and poor engine performance.
WARNING: DO TO EXTREME FUEL PRESSURES OF UP TO 120,000 kPa (17,400 PSI), USE EXTREME CAUTION WHEN
INSPECTING FOR HIGH-PRESSURE FUEL LEAKS. DO NOT GET YOUR HAND NEAR A SUSPECTED LEAK. INSPECT FOR HIGH-
PRESSURE FUEL LEAKS WITH A SHEET OF CARDBOARD. HIGH FUEL INJECTION PRESSURE CAN CAUSE PERSONAL INJURY
IF CONTACT IS MADE WITH THE SKIN.
Testing For Leaks With Cardboard
Start the engine. Move the cardboard over the high-pressure fuel lines and check for fuel spray onto the cardboard. If a high-pressure line connection is
leaking, bleed the system and tighten the connection. Refer to the Air Bleed Procedure for procedures. See: Service and Repair/Air Bleed Procedure
Replace damaged, restricted or leaking high-pressure fuel lines with the correct replacement line.
CAUTION: The high-pressure fuel lines must be clamped securely in place in the holders. The lines cannot contact each other or other components. Do
not attempt to weld high-pressure fuel lines or to repair lines that are damaged. Only use the recommended lines when replacement of high-pressure fuel
line is necessary.
