A). The pressure relief valve should not be leaking at all during a pressure test. It should not pop off until the rail is above 41,000 PSI.
B)> Just because the return line does not show a higher than normal flow, you need to use an injector cap-off kit (up to 3 injectors at a time) to ensure it is NOT the injectors causing it to drop off like that during the leak test. For all anyone knows, an injector or 2 could be bleeding fuel into the cylinders or in the return, but not enough to fail the return line tests.
did test for fuel pump -so pressurized to 30k and had around 50ml within 30 sec
than switched tool last port (relieve valve return line) pressurized the system ,would say no drops at all ,cleared codes, test drive 10minutes later code 1145 , trucks runs good and there was no issues before besides driver claims it drives good for 300-400 miles than pops white smoke and runs rough, after pulling on side of the road and restart all good for next 300-400miles
replaced ecm at first visit
this is second attempt to fix issue, any thoughts?
have another truck this time with 559 code
did rail leak test first, dropped 5k within 1min
with tool to fuel return manifold
-no drops on relieve valve
-on high pressure return line 300ml within 30sec
-on injector return line 50ml within 1min
cleaned high pressure pump inlet line banjo fitting with shop air
dont know how to test low pressure fuel side , have quickserve account
will have a truck back somewhere next week back, what else i can check
when fault code set up think commanded pressure was 34k measured 30k
fault count 640
all help is appreciated, thanks
have an update on this truck
truck came back and all 6 injectors were replaced,
mechanic that replaced them said that there were 3 different part numbers on injectors and should be one part number according to him
did a leak test after replacement and pressure dropped around 100psi within 1min
so before replacement it was 29000 to 100 within 16 sec and now there is no drop in pressure at all
thank you for all your help,
Nice, thanks for the update... I like seeing the conclusion to issues.