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Fuel Rail Pressure Sensor Offset Test High






2008-FUEL RAIL PRESSURE SENSOR OFFSET TEST HIGH





For a complete wiring diagram Refer to the Wiring Information Electrical Diagrams

- When Monitored:
With the engine running.

- Set Condition:
The ECM determines that the fuel rail pressure is too high for a given engine speed and load.





Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.Pre-Diagnostic Troubleshooting Procedure

1. CHECKING FOR OTHER ECM DTCS

WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury.

1. Turn the ignition on.
2. With the scan tool, read the ECM DTCs.

Are there any other DTCs present?

Yes

- Diagnose and repair the DTC(s).
- Perform the ECM VERIFICATION TEST.ECM Verification Test

No

- Go To 2

2. CURRENT DTC

NOTE: Refer to the Service Information and perform the Air Bleed Procedure before continuing diagnosis.

1. Turn the ignition on.
2. With the scan tool, erase the ECM DTCs.

NOTE: Driving the vehicle up and down steep hills or rapid cornering with a low fuel level can cause this DTC to set. Verify with customer if Low Fuel Light was illuminated when fault occurred.

3. Test drive the vehicle under various load and speed conditions to attempt to duplicate the fault.
4. With the scan tool, read the ECM DTCs.

Does the scan tool display this DTC?

Yes

- Go To 3

No

- Refer to the *CHECKING FOR AN INTERMITTENT DTC Diagnostic Procedure.Checking for an Intermittent DTC

3. FUEL SYSTEM LEAK
1. Turn the ignition off.

WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury.

2. Inspect the entire fuel system for leakage.

Is there any evidence of leakage?

Yes

- Repair as necessary.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 4

4. FUEL SYSTEM CONTAMINATION

NOTE: Mixing any other fuels such as gasoline or kerosine can cause this DTC to set.

WARNING: High Pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 23,200 PSI (1600BAR). Use extreme caution when inspecting for high pressure fuel leaks. Failure to follow these instructions may result in possible serious or fatal injury.

WARNING: Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury. Inspect for high pressure fuel leaks with a sheet of cardboard. Wear safety goggles and adequate protective clothing when servicing fuel system. Failure to follow these instructions may result in possible serious or fatal injury.

1. Inspect the fuel system for contamination.

Is the fuel contaminated?

Yes

- Repair as necessary.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 5

5. FUEL PRESSURE SENSOR CALIBRATION
1. Turn the ignition on.
2. With the scan tool, read the Fuel Pressure Sensor volts.

Does the scan tool display between 0.45 and 0.60 volts for the Fuel Pressure Sensor?

Yes

- Go To 6

No

- Check the Fuel Pressure Sensor wiring and connectors for corrosion or poor terminal contact that could cause high resistance. repair as necessary. If wiring and connectors are ok., replace the Fuel Pressure Sensor.
- Perform the ECM Verification Test.ECM Verification Test

6. ATTEMPT TO START ENGINE
1. With the scan tool, erase the ECM DTCs.
2. Attempt to start the engine.

Does the engine start and idle?

Yes

- Go To 7

No

- Go To 12

7. CHECKING FOR AIR IN FUEL SYSTEM
1. With the scan tool in Sensors, compare the Fuel Pressure Setpoint with the Actual Fuel Pressure readings.

NOTE: If there is air in the fuel system, the Actual Fuel Pressure will oscillate more than 100 psi above and/or below the Fuel Pressure Setpoint.

Does Actual Fuel Pressure oscillate more than 100 psi above and/or below the Fuel Pressure Setpoint?

Yes

- Refer to the Service Information to purge air from the fuel system.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 8

8. FUEL PRESSURE SOLENOID
1. With the scan tool, compare the Fuel Pressure Setpoint with the actual Fuel Pressure.

NOTE: A sticking Fuel Pressure Solenoid is indicated by the actual Fuel Pressure gradually dropping below the Fuel Pressure Setpoint then suddenly increasing (spiking) above the Fuel Pressure Setpoint.

Does the actual Fuel Pressure gradually decrease then suddenly increase (spike) above the Fuel Pressure Setpoint?

Yes

- Replace the Fuel Pressure Solenoid.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 9

9. CHECKING FUEL DELIVERY SYSTEM
1. Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel Delivery System table.Checking the Fuel Delivery System

NOTE: The following is a list of problems that can cause fuel pressure to deviate from specification: restricted fuel filter or fuel lines, failed fuel pressure solenoid, air in fuel system, failed fuel sending unit, contaminated fuel, faulty injector.

Were there any problems with the Fuel Delivery System?

Yes

- Repair as necessary.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 10

10. FUEL INJECTOR(S)

NOTE: An injector that sticks open can cause this DTC. A sticking injector will cause the engine to misfire and emit excessive black smoke from the exhaust system.

Does the engine exhibit the symptoms described in the above note?

Yes

- Using the Service Information, remove and inspect the Fuel Injectors for signs of damage or debris that may cause the injector to stick. Sticking injectors may cause the combustion chamber to become black and oil soaked. Replace Injector(s) as necessary.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 11

11. FUEL PRESSURE SOLENOID
1. Turn the ignition off.
2. Replace the Fuel Pressure Solenoid.
3. Turn the ignition on.
4. With the scan tool, erase the ECM DTCs.
5. Attempt to start and test drive the vehicle.
6. With the scan tool, read the ECM DTCs.

Does the ECM display this DTC?

Yes

- Replace the Fuel Pump.
- Perform the ECM Verification Test.ECM Verification Test

No

- Test Complete.

12. CHECKING FUEL DELIVERY SYSTEM
1. Refer to the appropriate Service Information and refer to Diagnosis and Testing Fuel Delivery System table.Checking the Fuel Delivery System

NOTE: The following is a list of problems that can cause fuel pressure to deviate from specification: restricted fuel filter or fuel lines, failed fuel pressure solenoid, air in fuel system, failed fuel sending unit, contaminated fuel, faulty injector.

Were there any problems with the Fuel Delivery System?

Yes

- Repair as necessary.
- Perform the ECM Verification Test.ECM Verification Test

No

- Go To 13

13. FUEL PRESSURE SOLENOID
1. Turn the ignition off.
2. Replace the Fuel Pressure Solenoid.
3. Turn the ignition on.
4. With the scan tool, erase the ECM DTCs.
5. Attempt to start and test drive the vehicle.
6. With the scan tool, read the ECM DTCs.

Does the ECM display this DTC?

Yes

- Go To 14

No

- Test Complete.
- Perform the ECM Verification Test.ECM Verification Test

14. FUEL QUANTITY SOLENOID
1. Turn the ignition off.
2. Replace the Fuel Quantity Solenoid.
3. Turn the ignition on.
4. With the scan tool, erase the ECM DTCs.
5. Attempt to start and test drive the vehicle.
6. With the scan tool, read the ECM DTCs.

Did this DTC set again?

Yes

- Replace the Fuel Pump.
- Perform the ECM Verification Test.ECM Verification Test

No

- Test Complete.
- Perform the ECM Verification Test.ECM Verification Test

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