System Operation Description:
The probable causes of high fuel pressure
- Fuel pressure sensors
- Fuel lines
- Fuel transfer pump
- Fuel return pressure regulator
Use this procedure in order to troubleshoot high fuel pressure. Use this procedure if the following event code is active. Refer to Troubleshooting, “Event Codes” for information about event codes. For information on the engine monitoring system, refer to Troubleshooting, “Engine Monitoring System”.
| Diagnostic Trouble Codes | |||
| J1939 Code | CDL Code | Code Description | Comments |
| 94-16 | E1218 (2) | High Unfiltered Fuel Pressure | The code is logged. The fuel pressure is above the trip point pressure. |
| Associated Diagnostic Trouble Codes | |
| J1939 Code | CDL Code |
| 5584 | E390 |
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 1. Determine the CodeA. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, “Electronic Service Tools”, if necessary.
B. Download the “Warranty Report” from the engine Electronic Control Module (ECM) before performing any troubleshooting or clearing diagnostic trouble codes. C. Determine if a diagnostic trouble code is present. |
Codes | Result: An E1218 (2) code is present.Proceed to Test Step 2.
Result: A code other than a E1218 (2) code is present. Troubleshoot the code. Refer to the proper troubleshooting procedure. STOP |
Illustration 1 g02041554
(1) Fuel temperature sensor
(2) Fuel pressure sensor “A”
(3) Fuel pressure sensor “B”
(4) Fuel filter base
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 2. Check Fuel Pressure Sensor “A”A. Record the unfiltered fuel pressure from Cat ET. Record the value in Table 6.
B. Remove fuel pressure sensor “A” (2) . C. Install a 5P-1318 Adapter into the port of the pressure sensor “A” (2) . D. Install the 123-0783 Fluid Sampling Valve Gp onto the 5P-1318 Adapter . |
Pressure sensor | Result: The gauge value of the fuel pressure is within 69 kPa (10 psi) of the unfiltered fuel pressure reading shown in Cat ET.Proceed to Test Step 3.
Result: The gauge value of the fuel pressure is not within Replace the pressure sensor. Verify that the problem has been resolved. If the problem is not resolved, proceed to Test Step 3. |
| Required Tooling for Pressure Sensor “A” |
| 5P-1318 Adapter |
| 123-0783 Fluid Sampling Valve Gp |
| 8T-0855 Pressure Gauge |
| 6V-3990 Coupler |
| Engine RPM | Unfiltered fuel pressure from Cat ET | Fuel pressure from the mechanical gauge |
| 800 | ||
| 1800 |
Illustration 2 g02041759
Fuel supply lines
Illustration 3 g02041781
Fuel return line
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 3. Inspect the Fuel Supply and Return LinesA. Visually inspect the fuel lines between the primary filter base and the inlet to the fuel injection pump. Also, inspect the fuel cooler, if equipped. Inspect the fuel return line from the head to the fuel tank. Inspect the lines for restrictions, pinching, and swelling. Refer to Systems Operation/Testing and Adjusting, “Fuel System – Inspect” for additional information. | Inspect lines | Result: The fuel lines and the cooler (if equipped) are OK.Proceed to Test Step 4.
Result: The fuel lines and the cooler (if equipped) are not OK. Make the necessary repairs. Verify that the problem has been resolved. If the problem is not resolved, proceed to Test Step 4. |
Illustration 4 g02041814
(5) Return fuel pressure regulator
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
| 4. Replace the Return Fuel Pressure RegulatorA. Replace the fuel pressure regulator. | Pressure regulator | Result: The regulator was replaced. Verify that the problem is resolved.If the problem is not resolved, proceed to Test Step 5. |
Illustration 5 g02031818
Typical fuel transfer pump
(6) Relief valve
| Troubleshooting Test Steps | Values | Results |
|---|---|---|
|
5. Inspect the Relief Valve for the Fuel Transfer Pump
A. Inspect the relief valve for the transfer pump. The spring must move freely. |
Transfer pump |
Result: The relief valve is stuck CLOSED.
Replace the fuel transfer pump. Verify that the problem has been resolved. STOP Result: The relief valve is OK. Clean the relief valve and reinstall the relief valve. Verify that the problem has been resolved. STOP |
Test Step 1.
Complete the procedure in the order in which the steps are listed.
Results:
- The procedure corrected the issue. – STOP
- The procedure did not correct the issue. –Repair: Contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solutions Network (DSN).
STOP