0209445 JOHNSON SOUND BLANKET, Topx

Table 1
Diagnostic Trouble Codes for Fuel Rail Pressure Problem
J1939 Code Code Description Comments
157-16 Engine Injector Metering Rail #1 Pressure: High - moderate severity (2) No other 157-XX codes are active.
3509-XX codes are not active.
3510-XX 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 Engine Injector Metering Rail #1 Pressure: Low - moderate severity (2) No other 157-XX codes are active.
3509-XX codes are not active.
3510-XX 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.
5571-0 High Pressure Common Rail Fuel Pressure Relief Valve : Active 3509-XX codes are not active.
3510-XX codes are not active.
The pressure limiting valve in the fuel rail is open. This code is a calculated parameter.
The code is logged. Probable Causes
Diagnostic codes
Electrical connectors
Fuel filters
Fuel rail pressure sensor
High-pressure fuel pump calibration
Fuel systemRecommended Actions
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.
Table 2
Troubleshooting Test Steps Values Results
1. Download Information Using the Electronic Service Tool
A. Use the electronic service tool to download the "Product Status Report" (PSR) with histograms before performing any troubleshooting or clearing any diagnostic codes.
Note: The downloaded information will be required by the Dealer Solutions Network (DSN) if troubleshooting assistance is required.
Downloaded information
Result: The information was successfully saved.
Proceed to Test Step 2.
Result: The electronic service tool information was not successfully saved.
Contact the Dealer Solutions Network (DSN) for guidance.
2. Create an Electronic Service Tool Snapshot
A. Select "Snapshot Viewer" on the electronic service tool, using menus: Information -> Snapshot -> Viewer
B. Select the event code and then click "View Graph".
C. Select the following parameter and then click OK.
Engine Speed
D. Select Save to "File to save" a Snapshot File (*.xml). This file will contain all the data in the snapshot and not only the data shown on the graph.
Note: The downloaded information will be required by the DSN if troubleshooting assistance is required.
Snapshot saved
Result: The electronic service tool snapshot was successfully saved.
Proceed to Test Step 3.
Result: The electronic service tool snapshot was not successfully saved.
Contact the DSN for guidance.
3. 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 codes in Table 1 is present.
Proceed to Test Step 4.
Result: A code other than the codes in Table 1 is present.
Repair: Troubleshoot the code. Refer to the applicable troubleshooting procedure.
4. 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.
Check for correct installation of the connector for the flow control valve on the high-pressure fuel pump.
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 5.
5. Fuel Filters
A. Replace any filters and/or screens in the fuel system. Refer to 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 6.
6. 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 high fuel rail pressure symptom, proceed to Test Step 7.
For a low fuel rail pressure symptom, proceed to Test Step 8.
7. High-Pressure Fuel Pump Calibration
A. Use the electronic service tool to perform the "High Pressure Fuel Pump Calibration".
Fuel system
Result: Fuel rail pressure is normal after performing the "High Pressure Fuel Pump Calibration".
Return the unit to service.
Result: Fuel rail pressure is still high after performing the "High Pressure Fuel Pump Calibration".
Run the engine for a minimum of 30 minutes.
Proceed to Test Step 8.
8. Fuel System
A. Visually check the fuel tank for fuel.
Note: The fuel gauge may be faulty.
B. Inspect the high-pressure fuel system for leaks.
C. If the temperature is below 0 °C (32 °F), check for solidified fuel (wax).
D. Check the primary filter/water separator for water in the fuel.
E. Check for fuel supply lines that are restricted or not correctly installed.
F. Replace the in-line fuel filter that is installed upstream of the Electric Priming Pump (EPP).
G. Check that the EPP is operating correctly.
H. Replace any filters and/or screens in the fuel system. Refer to Operation and Maintenance Manual for further information.
I. Check for air in the fuel system and that the fuel system is primed.
J. Check the diesel fuel for contamination. Refer to Systems Operation, Testing, and Adjusting, "Fuel Quality - Test".
K. Use the electronic service tool to perform the "Fuel Rail Pressure Relief Valve Test".
Note: This test will identify excessive leakage through the Pressure Limiting Valve (PLV) in the fuel rail.
Fuel system
Result: There is a leak from the high-pressure fuel system.
Repair: Rectify any fuel leaks.
Result: The fuel contains solidified wax.
Repair: Replace the fuel with fuel of the correct specification for the ambient conditions.
Replace any filters and/or screens in the fuel system. Refer to Operation and Maintenance Manual for further information.
Result: There are fuel supply lines that are restricted or not correctly installed.
Repair: Install the fuel lines correctly. Replace any damaged or restricted fuel lines.
Result: The EPP is not operating