5032609 JOHNSON *WASHER SET

Table 1
Diagnostic Trouble Codes for Fuel Rail Pressure Problem
J1939 Code CDL Code Code Description
(Code descriptions may vary) Comments
157-16 E396 (2) Engine Injector Metering Rail #1 Pressure: High - moderate severity (2) No other 157-XX or 1797-XX codes are active.
3509-XX or 262-XX codes are not active.
3510-XX or 2131-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 E398 (2) Engine Injector Metering Rail #1 Pressure: Low - moderate severity (2) No other 157-XX or 1797-XX codes are active.
3509-XX or 262-XX codes are not active.
3510-XX or 2131-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.
1239-0 E499 (3) Engine Fuel Leakage 1: High - most severe (3) 3509-XX or 262-XX codes are not active.
3510-XX or 2131-XX codes are not active.
There is a probable fuel leak from the high-pressure fuel system. The amount of leakage is a calculated parameter.
The code is logged.
The engine will stop.
5571-18 E1264 (1) High-Pressure Common Rail Fuel Pressure Relief Valve : Low - moderate severity (2) 3509-XX or 262-XX codes are not active.
3510-XX or 2131-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.
5571-0 E1264 (2) High-Pressure Common Rail Fuel Pressure Relief Valve : High - most severe (3) 3509-XX or 262-XX codes are not active.
3510-XX or 2131-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 fuel rail pressure
Transfer Pump Inlet Regulator (TPIR)
Transfer Pump Inlet Regulator (TPIR) return
Return fuel lines
Low fuel rail pressure
Transfer Pump Inlet Regulator (TPIR)
Transfer Pump Inlet Regulator (TPIR) Return
Electric Fuel Lift Pump (EFLP)
Return fuel linesRecommended 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. Diagnostic Codes
A. Connect the electronic service tool to the diagnostic connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Download the Warranty Report and the Product Status Report 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 needed.
C. Determine if a diagnostic is active or recently logged.
Diagnostic codes
Result: A code other than the codes in Table 1 is present.
Repair: Troubleshoot the code. Refer to the applicable troubleshooting procedure.
Result: One of the codes in Table 1 is present.
Proceed to Test Step 2.
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 in-line fuel filter that is upstream of the electric fuel lift pump. Refer to the Operation and Maintenance Manual for further information.
B. 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 4.
4. Fuel Rail Pressure Sensor
A. Make sure that the engine has been stopped 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 5.
For a low fuel rail pressure symptom, proceed to Test Step 9.
5. High Fuel Rail Pressure
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".
Repair: Run the engine for a minimum of 30 minutes.
Proceed to Test Step 6.
Illustration 1 g03750256
Transfer Pump Inlet Regulator (TPIR) components
(1) Transfer Pump Inlet Regulator (TPIR)
(2) TPIR return port
Illustration 2 g02355128
Minimum TPIR flow rate in a 12 VDC system