3807834 Volvo.Penta Cap

Table 1
Diagnostic Trouble Codes    
J1939 Code    Code Description    Comments    
157-16     Engine Injector Metering Rail #1 Pressure: High - moderate severity (2)     No other 157-XX codes are active.
3509-XX codes are not active.
3510-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     Engine Injector Metering Rail #1 Pressure: Low - moderate severity (2)     No other 157-XX codes are active.
3509-XX codes are not active.
3510-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     Engine Fuel Leakage 1: High - most severe (3)     3509-XX codes are not active.
3510-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 shut down.    
5571-18     High Pressure Common Rail Fuel Pressure Relief Valve : Low - moderate severity (2)     3509-XX codes are not active.
3510-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 trouble codes
Electrical connectors
Fuel filters
Fuel rail pressure sensor
Fuel systemRecommended Actions
Diagnostic Trouble Codes
Use one of the following methods to check for active diagnostic trouble codes:
The electronic service tool
The display on the control panelElectronic Service Tool
Connect the electronic service tool to the diagnostic connector.
Check for active diagnostic trouble codes on the electronic service tool.
Investigate any active codes before continuing with this procedure. Refer to Troubleshooting, "Troubleshooting with a Diagnostic Code".Display on the Control PanelNote: The following procedure is only applicable if the application is equipped with a display on the control panel.
Check the display on the control panel for active diagnostic trouble codes.
Troubleshoot any active codes before continuing with this procedure. Refer to Troubleshooting, "Diagnostic Trouble Codes".Electrical Connections
Check for correct installation of the P1 and P2 connectors on the ECM. Check for correct installation of all other applicable connectors. Refer to Troubleshooting, "Electrical Connectors - Inspect".
Use the electronic service tool to perform a wiggle test.
If necessary, perform any repairs to the connectors or the wiring.
Check if the fault has been eliminated. If the fault is still present, proceed to "Fuel Filters".Fuel Filters
Replace the in-line fuel strainer that is installed upstream of the Electric Fuel Lift Pump (EFLP).
Replace the primary fuel filter and the secondary fuel filter. Refer to the applicable procedure in the Operation and Maintenance Manual.
Check if the fault has been eliminated. If the fault is still present, proceed to "Fuel Rail Pressure Sensor".Fuel Rail Pressure Sensor
With the engine shutdown, use the electronic service tool to check the status of the "Fuel Rail Pressure". After the engine has been shut down for 10 minutes, the "Fuel Rail Pressure (absolute)" must be less than 5,000 kPa (725 psi) (gauge).
If the "Fuel Rail Pressure" on the electronic service tool is less than 5,000 kPa (725 psi), proceed to Step 4.
If the "Fuel Rail Pressure" on the electronic service tool does not fall to less than 5,000 kPa (725 psi) (gauge), the fuel rail pressure sensor may be faulty. Refer to Troubleshooting, "Engine Pressure Sensor Open or Short Circuit - Test".
Use the electronic service tool in order 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".
If the fault is still present, proceed to "Fuel System".Fuel System
High Fuel Rail Pressure
Use the electronic service tool in order to perform the Fuel Rail Pressure Test. If the test fails, replace the SCV and solenoid. Refer to Disassembly and Assembly, "Fuel Pump Solenoid - Remove and Install".
If a fault is not identified for the SCV, use the electronic service tool to perform the "High Pressure Fuel Pump Calibration".
If the fuel rail pressure is still high, perform the following procedure:Note: Before performing the following fuel system tests, the engine must be stopped for a minimum of 30 minutes.Note: When performing the following fuel system tests, the Electric Fuel Lift Pump (EFLP) will only operate for 2 minutes unless the engine is running. If necessary, cycle the keyswitch in order to reactivate the pump.
Illustration 1 g02460136
(1) Transfer pump inlet regulator (TPIR) (2) Transfer pump inlet regulator return portTransfer Pump Inlet Regulator (TPIR) Flow TestRefer to Illustration 1.
Disconnect the TPIR return line from the drain port on the TPIR. Install a suitable blanking cap on the open port in the TPIR return line
Connect a temporary drain line to the drain port on the TPIR.
Place the end of the temporary drain line into a suitable calibrated container.
With the keyswitch in the ON position but the engine not running, use a suitable multimeter to measure the input voltage to the EFLP. Record the reading.
With the keyswitch in the ON position but the engine not running, measure the fuel flow from the temporary drain line. Refer to Illustration 2 for the minimum acceptable flow rate.
Illustration 2 g02355130
Minimum TPIR flow rate
Remove the temporary drain line from the drain port on the TPIR. Connect the TPIR return line to the TPIR.
If the fuel flow in Step 5 is greater than the minimum limit, contact the technical communicator at a Caterpillar dealer.
If the fuel flow in Step 5 is below the minimum limit or there is no fuel flow, replace the EFLP.Transfer Pump Inlet Regulator (TPIR) Return TestIn order to check the return flow from the TPIR, perform the following procedure:
Make sure that the TPIR return line is not blocked or kinked.
If the TPIR return line is clear, confirm that the Electric Fuel Lift Pump (EFLP) is operating. Make sure that the fuel lines between the EFLP and the TPIR are not blocked or kinked.
If the fuel lines to the