C175-16 Engine Fuel Flow Is High Caterpillar


Fuel Flow Is High
`
1.1. Probable Causes
2.1. Recommended Actions

Use this procedure in order to troubleshoot a high fuel flow in the high-pressure fuel system. Also, use this procedure if the following event code is active.

Table 1
Event Code 
J1939 Code and Description  Conditions which Generate this Code  System Response 
157-17 Engine Injector Metering Rail #1 Pressure : Low - least severe (1)   The fuel rail pressure is below the trip point pressure for the programmed delay time.  The code is logged. 
157-18 Engine Injector Metering Rail #1 Pressure : Low - moderate severity (2)  The code is logged.
Engine power is derated.
1440-6 Engine Fuel Flow Rate #1 : High - moderate severity (2)   The Electronic Control Module (ECM) has determined that there is a high fuel flow in the high-pressure fuel system.  The code is logged.
This code is latched in the active state until power to the ECM is cycled. 

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 problem

Recommended Actions

Table 3
Troubleshooting Test Step  Value  Result 

1. Diagnostic Codes and Event Codes

A. Turn the keyswitch to the "ON" position.

B. Connect AVSpare 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 1g02797521
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 it 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 20° C (36° F).

Proceed to Test Step 8.

Result: Temperature differential is greater than 20° C (36° 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 assembly.

Proceed to Test Step 7.
 

7. Check the High Pressure Pump Pressure Relief Valve

A. Start the engine and allow it 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 20° C (36° F).

Proceed to Test Step 8.

Result: Temperature differential is greater than 20° C (36° F).

The pressure relief valve is not serviceable. Replace the high-pressure fuel pump.

Proceed to Test Step 12.
 

8. Check for High Pressure Fuel System Leakage

Refer to Testing ad Adjusting, "Fuel Rail Leakage – Check".
 

Leak
 

Result: There was not any leakage detected.

Proceed to Test Step 9.

Result: Excessive leakage was detected.

Repair the cause of excessive leakage.

Proceed to Test Step 12.
 

9. Check for Injector Bypass Leakage

Refer to Testing ad Adjusting, "Injector Bypass Fuel Flow - Test".
 

Leak
 

Result: There was not any leakage detected.

Proceed to Test Step 10.

Result: Excessive leakage was detected.

Repair the cause of excessive leakage.

Proceed to Test Step 12.
 

10. Check the High-Pressure Fuel Pump

A. Start the engine. Run the engine until normal operating temperature is achieved. B.

B. Connect Cat ET to the service tool connector.

C. Monitor the following parameters:

- Fuel Temperature

- Fuel Rail Temperature

D. Check the temperature difference between the 2 parameters. Compare the value of each parameter while the engine is at normal operating temperature.
 

40° C (72° F)
 

Result: The temperature differential exceeds 40° C (72° F).

Replace the high-pressure fuel pump. Replace the in-line high-pressure fuel filter element in the block assembly that is part of the front fuel injection line.

Proceed to Test Step 12.

Result: The temperature differential is OK.

Proceed to Test Step 11.
 


Illustration 2g02797587
Typical locations of the drain plugs
(4) Drain plug at the high -pressure fuel pump
(5) Drain plug at the fuel pump adapter

Table 5
Troubleshooting Test Step  Value  Result 

11. Check for Debris on the High Pressure Fuel Pump Drain Plug

Note: These engines have been built with two different types of high-pressure fuel pumps, pumps with a dry sump and pumps with a wet sump. Pumps that have a wet sump contain approximately 900 mL (30.5 oz) of engine oil. Be sure to have a suitable container available as you remove the drain plug. Also, for pumps with a wet sump, refill the sump with engine oil prior to returning the engine to service. Use the automatic pre-lube cycle to refill the sump prior to starting the engine.

A. If equipped, remove drain plug (4) from the high-pressure fuel pump.

If not equipped with drain plug (4) remove the drain plug (5) from the fuel pump adapter.

Expect that engine oil will drain from the opening. Check the magnetic plug for excessive debris. Clean the plug prior to reinstallation.
 

Excessive Debris
 

Result: There was NOT excessive debris on the magnetic drain plug.

Proceed to Test Step 12.

Result: A continuous stream of fuel is flowing from the drain hole.

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.

Proceed to Test Step 12.
 

12. Check for Diagnostic Codes

A. Start the engine and operate at high idle for 1 minute.

B. Connect Cat ET to the service tool connector.

C. Look for active or logged diagnostic codes.
 

Codes
 

Result: No codes present.

Return to service.

Result: An E398, E1106, 157-1, 157-17, 157-18, or 1440-16code is present.

Contact your TC for assistance. 

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