BONNET 8N5284 - Caterpillar

Table 1
Event Codes
CDL Codes and Description Conditions which Generate this Code System Response
E499(1) Fuel Rail #1 Pressure Leak The fuel leak detection sensor has detected fuel leakage in the high-pressure fuel system. The code is logged.
E499(3) Fuel Rail #1 Pressure Leak Probable Causes
Diagnostic codes and event codes
Leak detection sensor problem
One-way check valve leak
High-pressure fuel rail leakRecommended Actions
Fuel leaked or spilled onto hot surfaces or electrical components can cause a fire. Clean up fuel spills immediately.
Illustration 1 g02558636
Location of the components for leak detection (right side engine view)
(1) Fuel leakage manifold
(2) Fluid level sensor
(3) One-way check valve
(4) Outer wall fuel drain line
(5) Plug 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.
E499
Result: An associated code is present.
Repair: Troubleshoot any associated codes before continuing with this test.
Result: An E499 code is present.
Proceed to the next step.
Result: No active codes
STOP
2. Check the Leak Detection Sensor
A. Determine if there is a leak to be detected .
1. Remove plug (5) from fuel leakage manifold (1).
2. Determine if fuel is present in the manifold.
Leak
Result: Fuel is found in the manifold.
The sensor is OK.
Proceed to Step 4.
Result: Fuel is not found in the manifold.
There is no leak to be detected.
Proceed to the next step.
3. Check the Sensor Circuit Components
A. Use Cat ET to monitor the following parameter:
"High Pressure Fuel Line Status"
B. Disconnect the sensor harness at the sensor (2).
The status for the parameter will read "Leakage Detected".
C. At the harness connector for the sensor, short the signal (terminal 2) to the ground (terminal 3) .
The status for the parameter will read "No Leakage Detected".
Parameter
status
Result: The parameter read as expected.
The wiring and ECM have checked OK.
Repair: Replace the sensor.
Result: The parameter did not read as expected.
There is a problem with the circuit for the sensor.
Repair: Repair the circuit.
Refer to Troubleshooting, "Switch Circuits - Test"
4. Check the High-pressure Fuel Rail for a Leak
A. Remove drain line (4) from the manifold.
B. Run the engine and observe the open drain line.
Leak
Result: Fuel is draining from the open drain line.
There is a leak in the high-pressure fuel system.
Repair: Determine the source of the leak.
Refer to Testing and Adjusting, "Fuel Rail Leakage - Check" for the correct troubleshooting procedure.
5. Check the One-way Check Valve for a Leak
B. Run the engine and observe the manifold port for fuel flow.
Leak
Result: Fuel is draining from the port for the plug (5).
Repair: Replace the one-way check valve.