C4.4 and C7.1 Engines Fuel Rail Pressure Problem Caterpillar

Fuel Rail Pressure Problem

C4.4 and C7.1 Engines [UENR0629]

C4.4 and C7.1 Engines Power Take-Off - Test

C4.4 and C7.1 Engines Sensor Signal (Analog, Active) - Test

FUEL SYSTEM

C4.4 and C7.1 Engines Exhaust Has Excessive Black Smoke

C4.4 and C7.1 Engines Oil Contains Fuel

C4.4 and C7.1 Engines Fuel Rail Pressure Problem

C4.4 and C7.1 Engines Fuel Pressure Problem

C4.4 and C7.1 Engines Fuel Consumption Is Excessive

C4.4 and C7.1 Engines Fuel Contains Water

C4.4 and C7.1 Engines Exhaust Has Excessive White Smoke

1.1. Probable Causes

2.1. Recommended Actions

Use this procedure to troubleshoot abnormal fuel rail pressure or use this procedure if any of the following diagnostic trouble codes are active. Refer to Troubleshooting, "Diagnostic Trouble Codes" for information about the codes.

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Table 1
Diagnostic Trouble Codes
J1939 Code	CDL Code	Code Description (code descriptions may vary)	Comments
157-16	E396-2	High Fuel Rail Pressure : Level 2	No other 157 (1797) codes are active. 262 (3509) codes are not active. No codes for the high-pressure fuel pump or the injectors are active. The fuel rail pressure is above an acceptable level. The code is logged. Engine power is derated.
157-18	E398-2	Low Fuel Rail Pressure : Level 2	No other 157 (1797) codes are active. 262 (3509) codes are not active. No codes for the high-pressure fuel pump or the injectors are active. The fuel rail pressure is below an acceptable level. The code is logged. Engine power is derated.

Probable Causes

Diagnostic codes
Electrical connectors
Fuel filters
Fuel rail pressure sensor
High-Pressure fuel pump calibration
Fuel system
High-pressure fuel pump suction control valve

Recommended Actions

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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. Determine if a diagnostic is active or recently logged.	Diagnostic codes	Result: One of the diagnostic codes listed in Table 1 is active or recently logged. Proceed to Test Step 2. Result: A code other than listed in Table 1 is present. Repair: Troubleshoot the code. Refer to the applicable troubleshooting procedure.
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: Use the electronic service tool to perform the "Wiggle Test". 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: Test the fuel rail pressure sensor. Refer to Troubleshooting, "Sensor Signal (analog, Active) - Test". Use the electronic service tool to perform the "Fuel Rail Pressure Test". If the test fails, replace the fuel rail. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". Confirm that the fault has been eliminated. Result: The "Fuel Rail Pressure (absolute)" is less than 5,000 kPa (725 psi). For a 157-16 (E396 (2)) code, contact the Dealer Solutions Network (DSN). For a 157-18 (E398 (2)) code, proceed to Test Step 5.
5. Fuel System A. Make sure that the level of fuel in the fuel tank is sufficient. B. Check the high-pressure fuel system for leaks. C. Check for air in the low-pressure fuel system. Refer to Systems Operation, Testing, and Adjusting, "Air in Fuel - Test".	Fuel system	Result: A fault was found in the fuel system. Repair: Rectify any faults and confirm that the fault is eliminated. Result: The fuel system is OK. Proceed to Test Step 6.
6. Pressure Limiting Valve (PLV) A. Use the electronic service tool to perform the "Fuel Rail Pressure Relief Valve Test". Note: This test will identify excessive leakage through the PLV in the fuel rail.	Pressure limiting valve	Result: The PLV has excessive leakage. Repair: Replace the fuel rail. Refer to Disassembly and Assembly, "Fuel Manifold (Rail) - Remove and Install". Confirm that the fault is eliminated. Result: The PLV is OK. Contact the Dealer Solutions Network (DSN).
7. High-Pressure Fuel Pump Suction Control Valve Use the electronic service tool to perform a solenoid test on the fuel injection pump. Refer to Troubleshooting, Solenoid Valve - Test.	High-pressure fuel pump	Result: The solenoid vale test fails. Repair: Replace the high-pressure fuel pump suction control valve and solenoid assembly. Result: The solenoid valve test passes. Contact the Dealer Solutions Network (DSN).