09305-10006 Suzuki Bushing

Table 1
Event Codes    
CDL Code and Description    Conditions which Generate this Code    System Response    
E396(1) High Fuel Rail Pressure     The fuel rail pressure is above the trip point pressure for the programmed delay time.     The code is logged.    
E396(2) High Fuel Rail Pressure    
E396(3) High Fuel Rail Pressure    Probable Causes
Diagnostic codes and event codes
Fuel rail pressure sensor
Pressure relief valve
High-pressure fuel pumpRecommended Actions
Note: The procedures have been listed in order of probability. Complete the procedures in the order of the listed test steps.
Table 2
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 "Product Status Report" from the engine ECM before performing any troubleshooting or clearing diagnostic trouble codes.
C. Determine if the diagnostic trouble code that directed to this procedure is present.
D. Look for active diagnostic codes that are associated with the system for the event code that directed to this procedure.
   
E396
   
Result: An associated code is present.
Repair: Troubleshoot any associated codes before continuing with this test.
Result: An E396 code is present.
Proceed to the next step.
Result: No active codes
STOP
   
2. Check the Fuel Rail Pressure Sensor
A. With the engine shutdown, use Cat ET to check the value for the "Fuel Rail Pressure (absolute)" parameter. After the engine has been shut down for 10 minutes, the "Fuel Rail Pressure (absolute)" will be less than 5,000 kPa (725 psi) (gauge).
If the pressure is not less than
5,000 kPa (725 psi) (gauge) after 10 minutes, vent the pressure from the fuel system. Refer to Systems Operation/Testing and Adjusting, "Fuel Rail Pressure - Release" for information.
   
Rail
pressure
   
Result: The sensor reports that the pressure that is in the fuel rail is less than
5,000 kPa (725 psi) (gauge) after venting the fuel system, the fuel rail pressure sensor and the electrical circuit are OK.
Repair: Proceed to the next step.
Result: The sensor reports that the pressure that is in the fuel rail does not fall to less than
5,000 kPa (725 psi) (gauge) after venting the fuel system, there may be a problem with the fuel rail pressure sensor or the electrical circuit for the sensor.
Repair: Perform the necessary repairs. Refer to Troubleshooting, "Sensor Signal (Analog, Active) - Test" for information that is related to testing the circuit.
If the problem is not resolved, proceed to the next step.
   
Illustration 1 g02913361
Locations of the test points at the high-pressure fuel pump (1) Valve block for the pressure regulating valve (2) Pump head assembly
Table 3
Troubleshooting Test Steps    Values    Results    
3. Check the Pressure Relief Valve
An excessive fuel pressure in the low-pressure fuel system will cause the pressure relief valve in the high-pressure fuel pump to bypass fuel. The bypass damages the pressure relief valve. Perform the following procedure in order to check for this condition and/or a damaged valve:
A. While the engine is at normal operating temperature, run the engine at high engine idle.
B. Use a 349-4203 Infrared Thermometer to measure the temperature difference between valve block (1) and pump head (2) .
   
Temperature
   
Result: If the temperature difference is less than
20° C (36° F), then the pressure in the low-pressure fuel system and the fuel pressure regulator are OK. Continue troubleshooting the original problem.
Repair: Proceed to the next step.
Result: If the temperature difference is greater than
20° C (36° F), then the pressure regulator is bypassing too much fuel. Check the pressure in the low-pressure fuel system. If the pressure is excessive, correct the problem. After the problem has been corrected, check the temperature difference again. If the temperature difference remains greater than
20° C (36° F), then the condition has caused a problem with the fuel pressure regulator.
Repair: Replace the high-pressure fuel pump. Also replace the in-line high-pressure fuel filter element in the block assembly that is part of the front fuel injection line. Ensure that the original problem has been resolved.
If the problem is not resolved, proceed to the next step.
   
4. Check the High Pressure Fuel Pump
Before proceeding, ensure that the fuel control valve and the fuel priming pump are powered. Check the circuit breaker.
A. Check for the proper operation of the fuel control valve.
1. Use Cat ET to check the value for the "Percent Fuel Position" parameter under the following conditions:
- Engine shutdown
- Power to the ECM keyswitch input.
The "Percent Fuel Position" should read 0 %.
2. Run the fuel priming pump.
The "Percent Fuel Position" should read 25 %.
   
Percent
fuel
position
   
Result: The "Percent Fuel Position" readings were OK.
Repair: Proceed to the next step.
Result: The "Percent Fuel Position" reading were NOT OK.
Repair: Replace the fuel control valve.
Before replacing, the valve ensure that the fuel control valve and the fuel priming pump are powered. Check the circuit breaker.
   
Table 4
5. Monitor the Related Parameters
A. Start the engine and run at low idle.
B. Use Cat ET to monitor the values for following parameters for fuel control valve:
- "Fuel Actuator Position Command"
- "Throttle Position"
- "Desired Fuel Rail Pressure"
- "Fuel Rail Pressure"
Do not confuse the following parameters to be the same:
- "Fuel Actuator Position Command"
- "Throttle Position"
For this application, the relationship between these parameters is not proportional.
C. Vary the engine speed and the engine load.
The following should closely match as the speed and load changes:
- "Fuel Actuator Position Command"
- "Percent Fuel Position"
   
Parameter
value
   
Result: The parameters do not closely match as speed and load are varied.
Repair: Replace the fuel control valve.
Result: The parameters closely matched as speed and load were varied.
Repair: The high-pressure fuel pump is generating too much pressure for the high-pressure fuel system. Replace the high-pressure fuel pump.