811505 Mercruiser REGULATOR

Table 1
Diagnostic Trouble Codes
CDL Code J1939 Code Code Description
(code descriptions may vary) Comments
E096 (2) 5580-16 High Fuel Pressure The code is logged.
The fuel pressure is above the trip point pressure.
Table 2
Troubleshooting Test Steps Values Results
1. Determine the Code
A. Connect Cat ET to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
B. Determine if a diagnostic trouble code is present.
Diagnostic trouble code
Result: A E096 (2) or 5580-16 code is present.
Proceed to Test Step 2.
Result: A code other than E096 (2) or 5580-16 code is present.
Troubleshoot the code. Refer to the proper troubleshooting procedure.
Table 3
Required Tooling
8t-7860 Connector
110-6349 Fitting as
8t-0855 Pressure Gauge
6v-3990 Coupler
Illustration 1 g02893220
(1) Fuel temperature sensor
(2) Fuel sampling port
(3) Fuel pressure sensor
(4) Secondary fuel filter base Do not use the fuel sampling port (2) for measuring the pressure. Follow the steps below.
Table 4
Troubleshooting Test Steps Values Results
2. Check the Fuel Pressure Sensor
A. Record the fuel pressure from Cat ET. Record the data in Table 5.
B. Remove the fuel pressure sensor (3).
C. Install an 8T-7860 Connector into the port of the pressure sensor (3).
D. Install the 110-6349 Fitting as onto the 8T-7860 Connector.
E. Install a 8T-0855 Pressure Gauge onto a 6V-3990 Coupler.
F. Install the 6V-3990 Coupler onto the 110-6349 Fitting as.
After the pressure sensor is removed, a code for low fuel pressure will become active. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position, after the sensor is reinstalled.
G. Record the fuel pressure on the pressure gauge. Record the data in Table 5.
Fuel pressure
Result: The gauge value of the fuel pressure is within 137 kPa (20 psi) of the fuel pressure reading shown in ET.
Proceed to Test Step 3.
Result: The gauge value of the fuel pressure is not within 137 kPa (20 psi) of the fuel pressure reading shown in ET.
Replace the pressure sensor. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 3.
Table 5
Engine RPM Fuel pressure from Cat ET Fuel pressure from the mechanical gauge
800
1800
Illustration 2 g02893396
Fuel supply lines
Illustration 3 g02893278
Return fuel line
Table 6
Troubleshooting Test Steps Values Results
3. Inspect the Fuel Supply Lines
A. Visually inspect the fuel lines between the primary filter base and the inlet to the cylinder head. 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.
Restrictions, pinching, and swelling
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. Reset all active codes and clear all logged codes by cycling the keyswitch to the Off position. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 4.
Illustration 4 g02893398
(5) Return fuel pressure regulator
Table 7
Troubleshooting Test Steps Values Results
4. Replace the Return Fuel Pressure Regulator
A. Replace the fuel pressure regulator.
Fuel pressure reg