45261-94301 Suzuki Lever, Release

Table 1
Event Code
CDL Code Description Conditions which Generate this Code
E398(3) Engine Injector Metering Rail #1 Pressure : Most Severe (3) The fuel rail pressure is lower than expected.
E398(1) Engine Injector Metering Rail #1 Pressure : Least Severe (1) The fuel rail pressure is lower than expected.
E398(2) Engine Injector Metering Rail #1 Pressure : Moderate Severity (2) The fuel rail pressure is lower than expected.
E1106(1) High Fuel Rail Pump Flow : Least Severe (1) The ECM has detected that the fuel leakage on the high-pressure fuel system is above an acceptable threshold.
E1106(2) High Fuel Rail Pump Flow : Moderate Severity (2) This code will only trip if an issue is detected in the low rail pressure range of operation. The check engine light will turn on when the code is tripped. This action signifies an increased risk that the engine might not restart if the engine is shut off. The truck should be taken to safe place for service.
Table 2
Associated Codes
J1939 Code CDL Code
95-0 E390(3)
95-15 E390(1)
95-16 E390(2)
5578-3 289-3
5578-4 289-4
5580-3 460-3
5580-4 460-4
5580-17 E198(1)
5580-18 E198(2) Probable Causes
Diagnostic codes and event codes
Pressure relief valve leakage
High-pressure fuel pump leakage
High-pressure fuel rail leakage
Fuel control valve problemRecommended Actions
Table 3
Troubleshooting Test Step Value Result
1. Diagnostic Codes and Event Codes
A. Turn the keyswitch to the "ON" position.
B. Connect Caterpillar Electronic Technician (ET) to the service tool connector. Refer to Troubleshooting, "Electronic Service Tools", if necessary.
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.
Codes
Result: An associated code is present.
Repair: Troubleshoot any associated codes before continuing with this test.
Refer to the appropriate troubleshooting story.
Result: An E398, 157-1, 157-17, or 157-18 code is present.
Proceed to Test Step 2.
Result: An E1106 or 1440-16 code is present.
Proceed to Test Step 2.
2. Check the Low Pressure Fuel System
A. Start the engine.
B. Connect Cat ET to the service tool connector.
C. Monitor the "Fuel Pressure (absolute)" and "Atmospheric Pressure" parameters in Cat ET.
D. With the engine running at low idle, record the "Fuel Pressure (absolute)" value.
E. With the engine running at high idle, record the "Fuel Pressure (absolute)" value.
F. Subtract the "Atmospheric Pressure" from each recorded value to determine the gauge value.
Note: The "Fuel Pressure (absolute)" and the "Atmospheric Pressure" readings are in absolute values. By subtracting the "Atmospheric Pressure" from the "Fuel Pressure (absolute)" readings, a gauge value is determined.
Pressure
Result: The gauge value is greater than 250 kPa (36 psi) at low idle and greater than 450 kPa (65 psi) at high idle.
Proceed to Test Step 3.
Result: The gauge value is less than 250 kPa (36 psi) at low idle and/or less than 450 kPa (65 psi) at high idle.
A problem has been detected with the low-pressure fuel system.
Refer to Troubleshooting, "Fuel Pressure Is Low (Fuel Transfer System)" in order to troubleshoot the cause of the low pressure.
3. Diagnostic Codes and Event Codes
A. Turn the keyswitch to the "ON" position.
B. Connect Cat ET to the service tool connector.
C. Determine if the diagnostic trouble code that directed to this procedure is present.
Codes
Result: An E398, 157-1, 157-17, or 157-18 code is present.
Proceed to Test Step 4.
Result: An E1106 or 1440-16 code is present.
Proceed to Test Step 8.
4. Check the Fuel Rail Pressure Sensor
A. Turn the keyswitch to the "OFF" position.
B. Allow the engine to sit for 10 minutes.
C. Turn the keyswitch to the "ON" position.
D. Connect Cat ET to the service tool connector.
E. Monitor the "Fuel Rail Pressure".
Rail Pressure
Result: The fuel rail pressure is less than 5000 kPa (725 psi) after 10 minutes.
Proceed to Test Step 6.
Result: The fuel rail pressure is greater than 5000 kPa (725 psi) after 10 minutes.
Proceed to Test Step 5.
5. Check the Fuel Rail Pressure Sensor
A. Turn the keyswitch to the "ON" position.
B. Vent the pressure from the fuel system. Refer to Testing and Adjusting, "Fuel Rail Pressure – Release".
C. Turn the keyswitch to the "ON" position.
D. Connect Cat ET to the service tool connector.
E. Monitor the "Fuel Rail Pressure".
Rail Pressure
Result: The fuel rail pressure is less than 5000 kPa (725 psi) after mechanically venting the pressure from the fuel system.
Proceed to Test Step 6.
Result: The fuel rail pressure is greater than 5000 kPa (725 psi) after mechanically venting the pressure from the fuel system.
The fuel system has been mechanically vented. A failed fuel rail pressure sensor has been detected.
Replace the fuel rail pressure sensor.
Proceed to Test Step 12.
Illustration 1 g02797521
Locations of the test points at the high-pressure fuel pump
(1) Valve block
(2) Head for the high-pressure fuel pump
(3) Location of the block assembly that contains the in-line high-pressure fuel filter element
Table 4
Troubleshooting Test Step Value Result
6. Check the High Pressure Pump Pressure Relief Valve
A. Start the engine and allow the engine to reach normal operating temperature.
B. Once operating temperature has been reached, operate the engine at high idle.
C. Use the 349-4203 Infrared Thermometer to measure the difference between the valve block and the pump head.
Leak
Result: Temperature differential is less than 40° C (72° F).
Proceed to Test Step 8.
Result: Temperature differential is greater than 40° C (72° F).
A plugged in-line high-pressure fuel filter element has been detected.
Replace the in-line high-pressure fuel filter element that is in block as