78033 Mercury COVER, INTAKE

Table 2
Associated Codes
J1939 Code CDL Code
5584 E390 Probable Causes
The probable causes of high fuel pressure
Fuel pressure sensors
Fuel filters plugged
Fuel lines
Fuel transfer pump
Fuel return pressure regulatorRecommended Actions
Table 3
Required Tooling for Pressure Sensor "A"
5P-1318 Adapter
123-0783 Fluid Sampling Valve Gp
8T-0855 Pressure Gauge
6V-3990 Coupler
Table 4
Engine RPM Unfiltered fuel pressure from Cat ET Fuel pressure from the mechanical gauge
800
1800
Illustration 1 g06276226
(1) Fuel Pressure sensor
Table 5
Troubleshooting Test Steps Values Results
1. Check for Codes
A. 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) or 94-16 code is present.
Proceed to Test Step 2.
Result: A code other than an E1218 (2) or 94-16 code is present.
Repair: Troubleshoot the code. Refer to the proper troubleshooting procedure.
2. Replace the Fuel Filters
A. Replace the primary filter, secondary filter, and the tertiary fuel filters.
B. Reset all the active codes by cycling the keyswitch to OFF for 2 minutes.
C. Prime the fuel system.
Fuel Filters
Results: The problem has been resolved.
Return the unit to service.
Results: The problem has not been resolved.
Proceed to Test Step 3.
3. Check Fuel Pressure Sensor (1)
A. Record the unfiltered fuel pressure from Cat ET. Record the value in Table 4.
B. Remove fuel pressure sensor (1).
C. Install a 5P-1318 Adapter into the port of the pressure sensor (1).
D. Install the 123-0783 Fluid Sampling Valve Gp onto the 5P-1318 Adapter.
E. Install a 8T-0855 Pressure Gauge onto a 6V-3990 Coupler.
F. Install the 6V-3990 Coupler onto the 123-0783 Fluid Sampling Valve Gp.
G. Record the fuel pressure from the pressure gauge. Record the pressure in Table 4.
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 4.
Result: The gauge value of the fuel pressure is not within 69 kPa (10 psi) of the unfiltered fuel pressure reading shown in Cat ET.
Repair: Replace the pressure sensor. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 4.
4. Inspect the Fuel Supply and Return Lines
A. 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 5.
Result: The fuel lines and the cooler (if equipped) are not OK.
Repair: Make the necessary repairs. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 5.
5. Replace the Fuel Transfer Pump
Fuel Transfer Pump
Result: The fuel transfer pump was replaced.
Repair: Reset all active codes and clear all logged codes by using Cat ET. Verify that the problem has been resolved.
If the problem is not resolved, proceed to Test Step 6.
6. Replace the High-Pressure Fuel Pump
High-Pressure Fuel Pump
Result: The high-pressure fuel pump was replaced.
Repair: Reset all active codes and clear all logged codes by using Cat ET. Verify that the problem has been resolved. If this procedure did not correct the issue, contact your Cat dealer Technical Communicator (TC). For further assistance, your TC can confer with the Dealer Solution Network (DSN).