C3.4B Engines Caterpillar

Fuel Rail Pressure Problem

Usage:

CCS7 4B2

This procedure covers the following diagnostic codes:

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Table 1
Diagnostic Trouble Codes for the Fuel Rail Pressure
J1939 Code	Description	Notes
157-0	Engine Injector Metering Rail #1 Pressure : High - most severe (3)	The Electronic Control Module (ECM) detects the following conditions: The fuel rail pressure is greater than 199000 kPa (28863 psi) when the fuel rail Pressure Relief Valve (PRV) has been activated. If equipped, the warning lamp will flash. The engine will be derated.
157-2	Engine Injector Metering Rail #1 Pressure : Erratic, Intermittent, or Incorrect	The ECM detects one of the following conditions: The amount of fuel delivered by the high-pressure fuel pump is greater than 850 mL/min (29 oz/min) for at least 2.5 seconds when the engine is at low idle. If equipped, the warning lamp will flash. The engine will be derated.
157-16	Engine Injector Metering Rail #1 Pressure : High - moderate severity (2)	The ECM detects one of the following conditions: The fuel rail pressure is greater than 195000 kPa (28283 psi) for at least 1 second. OR The measured fuel rail pressure is greater than the desired fuel rail pressure for at least 3.5 seconds. OR The fuel pressure remains too high after the keyswitch has been turned to the OFF position. If the engine is running, the warning lamp will flash. The engine will be derated. If the engine fuel pressure is high after the keyswitch has been turned to the OFF position, the warning lamp will come on the next time that the keyswitch is turned to the ON position.
157-17	Engine Injector Metering Rail #1 Pressure : Low - least severe (1)	The ECM detects the fuel rail pressure is less than 13000 kPa (1886 psi)(or 16000 kPa (2321 psi) depending on engine operating conditions). The fault has been detected for at least 0.6 seconds. The diagnostic code will clear if the rail pressure is within normal operating range for at least 0.5 seconds. The warning lamp will flash. Fuel injection will be disabled.
157-18	Engine Injector Metering Rail #1 Pressure : Low - moderate severity (2)	The ECM detects that the measured fuel rail pressure is lower than the desired fuel rail pressure for at least 5 seconds. The threshold for this diagnostic code depends on engine speed. If equipped, the warning lamp will flash. The shutdown lamp will come on. The engine will be derated. The engine may shut down.
1239-0	Engine Fuel Leakage 1 : High - most severe (3)	The ECM detects that the amount of fuel being delivered by the high-pressure fuel pump is too high for the engine operating conditions. If equipped, the warning lamp will flash. The engine will be derated.
5357-31	Engine Fuel Injection Quantity Error for Multiple Cylinders	The ECM detects that the number of requested fuel injections is not compatible with the engine hardware. No lamps will come on.
5571-2	High Pressure Common Rail Fuel Pressure Relief Valve : Erratic, Intermittent, or Incorrect	The ECM detects that the fuel rail pressure is out of the expected range after the fuel Pressure Relief Valve (PRV) has been opened. This condition can either be high pressure (relief valve not fully open) or low pressure (fuel leak). If equipped, the warning lamp will flash. The engine will be derated.
5571-7	High Pressure Common Rail Fuel Pressure Relief Valve : Not Responding Properly	The PRV has been activated. The PRV activation is caused by another active diagnostic code. Troubleshoot any other active diagnostic codes. This diagnostic code will clear when the other fault has been rectified. If equipped, the warning lamp will flash. The engine will shut down.
5571-10	High Pressure Common Rail Fuel Pressure Relief Valve : Abnormal Rate of Change	The ECM detects that the volume of fuel being delivered is too low to open the PRV during a PRV test. If equipped, the warning lamp will flash. Troubleshoot any other diagnostic codes before attempting to test the PRV again.
5571-14	High Pressure Common Rail Fuel Pressure Relief Valve : Special Instruction	The ECM detects one of the following conditions: The PRV has been open for a total of at least 300 minutes. OR The PRV has been activated at least 50 times. Perform this procedure to identify the cause of the PRV activation before replacing the PRV. If equipped, the warning lamp will flash. The engine will be derated.
5571-16	High Pressure Common Rail Fuel Pressure Relief Valve : High - moderate severity (2)	The ECM detects that the PRV is open. If equipped, the warning lamp will flash. The engine will be derated. This code will be reset when the PRV is closed and the keyswitch has been cycled.

Use this procedure to troubleshoot abnormal fuel rail pressure.

Probable Causes

Diagnostic trouble codes
Electrical connectors
Fuel filters
Fuel rail pressure sensor
Fuel system inspection
Fuel rail Pressure Relief Valve (PRV)
Cylinder cutout test
Low battery voltage
High-pressure fuel pump

Contact with high pressure fuel may cause fluid penetration and burn hazards. High pressure fuel spray may cause a fire hazard. Failure to follow these inspection, maintenance and service instructions may cause personal injury or death.

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NOTICE

Contact with high pressure fuel may cause personal injury or death. Wait 60 seconds after the engine has stopped to allow fuel pressure to purge before any service or repair is performed on the engine fuel lines.

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Table 2
Troubleshooting Test Steps	Values	Results
1. Diagnostic Codes A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary. B. Use the electronic service tool to check for active diagnostic codes.	Diagnostic codes	Result: One of the diagnostic codes listed in Table 1 is active. Proceed to Test Step 2. Result: A diagnostic code that is not listed in Table 1 is active. Repair: Troubleshoot the code. Refer to Troubleshooting, "Diagnostic Trouble Codes". Result: There are no active diagnostic codes. Return the engine to service.
2. Electrical Connectors A. Check for the correct installation of the ECM J1/P1 and the J2/P2 connectors. Check for correct installation of the connector on the fuel rail pressure sensor.	Connectors	Result: There are suspect connectors. Repair or replace connectors that are suspect. Result: There are no suspect connectors. Proceed to Test Step 3.
3. Fuel Filters A. Replace the primary fuel filter and the secondary fuel filters. Refer to the Operation and Maintenance Manual for further information.	Fuel filters	Result: The filters have been replaced and the fault is eliminated. Return the unit to service. Result: The filters have been replaced and the fault is still present. Proceed to Test Step 3.
4. Fuel Rail Pressure Sensor A. Make sure that the engine has been shut down for at least 10 minutes. Use the electronic service tool to check the status of the "Fuel Rail Pressure"	Pressure sensor	Result: The "Fuel Rail Pressure (absolute)" is more than 5,000 kPa (725 psi). Repair: Replace the fuel rail pressure sensor. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". When the fuel rail pressure sensor has been replaced, use the electronic service tool to perform the "Rail Pressure Sensor Replacement Reset" and the "Rail Pressure Valve Learn Reset". Confirm that the fault has been eliminated. Result: The "Fuel Rail Pressure (absolute)" is less than 5,000 kPa (725 psi). Proceed to Test Step 5.
5. Fuel System Inspection A. Check that the fuel shut-off valve is in the OPEN position. B. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax). C. Check for fuel supply lines that are restricted. D. Check that the low-pressure fuel lines are correctly installed. E. Check that the fuel tank breather is not blocked or restricted which could cause a partial vacuum in the fuel tank F. Check the pressures in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Fuel System Pressure - Test" G. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test". H. Check for air in the fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test". I. Ensure that the fuel system has been primed. Refer to Systems Operation, Testing, and Adjusting, "Fuel System - Prime".	Fuel System	Result: A defect was found in the fuel system. Repair: Make any necessary repairs. Result: No defects found. Proceed to Test Step 6.

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Illustration 1	g03705140

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Table 3
Troubleshooting Test Steps	Values	Results
6. Fuel Rail Pressure Relief Valve (PRV) A. Turn the keyswitch to the OFF position. B. Disconnect plastic tube assembly (4) from fuel manifold (1). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". C. Securely seal the end of plastic tube assembly (4). Note: Plastic tube assembly (4) must be sealed to prevent air ingress into the fuel system. D. Attach a length of hose to fuel manifold (1) and secure with a clip at position (3). E. Place the other end of the hose into a container that is suitable for fuel. Ensure that the hose is secure and will not come out of the container when the engine is running. F. Turn the keyswitch to the ON position. G. If the engine will start, use the electronic service tool to perform the "High Rail Pressure Test". This service test will run the engine with an elevated fuel rail pressure for a limited time. At this pressure, a PRV that is functioning correctly will remain closed. If the engine will not start, crank the engine for a maximum of 30 seconds. H. After the engine has stopped, check the container for fuel.	Fuel in container	Result: Fuel is present in the container. Repair: Install a replacement fuel Pressure Relief Valve (PRV). Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". When the PRV has been replaced, use the electronic service tool to perform the "Rail Pressure Valve Learn Reset". When reset is complete, turn the keyswitch to the OFF position and wait for 2 minutes or until the "Wait to Disconnect" indicator switches off (if installed). Turn the keyswitch to the ON position. Result: No fuel is present in the container. Proceed to Test Step 7.
7. Cylinder Cutout Test A. Use the electronic service tool to perform the "Cylinder Cutout Test". Click "Change" for an individual cylinder to switch off that cylinder manually. The cylinder will be automatically re-energized 10 seconds after the cylinder has been switched off. Wait a further 10 seconds before disabling the next cylinder. B. Listen for a change in the sound of the engine as each cylinder is disabled. If a cylinder is operating correctly, there will be a change in the sound of the engine as that cylinder is disabled. If a cylinder is disabled and there is no change in the sound of the engine, there may be a fault in that cylinder. Make a note of any cylinder that indicates a fault.	Cylinder cutout test	Result: At least one of the cylinders indicate a fault. Repair: Replace the fuel injector for any suspect cylinder. refer to Disassembly and Assembly, Electronic Unit Injector - Remove and Disassembly and Assembly, Electronic Unit Injector - Install. Result: None of the cylinders indicate a fault. Proceed to Test Step 8.
8. Low Battery Voltage A. Check that the charging circuit is operating correctly. Refer to Troubleshooting, Alternator Problem. B. Check the battery. Refer to Troubleshooting, Battery Problem.	Battery voltage	Result: The battery or the charging circuit has a fault. Repair: Make any necessary repairs. Use the electronic service tool check that the repair eliminates the fault. Result: The battery and the charging circuit are OK. Proceed to Test Step 9.
9. High-Pressure Fuel Pump A. If all previous test steps have not identified a fault, and a fuel rail pressure diagnostic code is still active, replace the high-pressure fuel pump. Refer to Disassembly and Assembly, Fuel Injection Pump - Remove and refer to Disassembly and Assembly, Fuel Injection Pump - Install. B. Run the engine and use the electronic service tool to check for active diagnostic codes.	Diagnostic codes	Result: There are no active diagnostic codes. Return the engine to service. Result: A diagnostic code that is not listed in Table 1 is active. Repair: Troubleshoot the code. Refer to Troubleshooting, Diagnostic Trouble Codes or refer to Troubleshooting, Event Codes. Result: One of the diagnostic codes listed in Table 1 is still active. Contact the Dealer Solutions Network (DSN).