Code Number Fault Code Description Fault Code Information
Code Number Fault Code Description Fault Code Information
The rail pressure sensor is part of the common rail and is not
interchangeable as a separate part.
The rail pressure is closed-loop controlled. A comparison is made between the rail
pressure demands determined by the ECU and the rail pressure feedback measured by
the common rail pressure sensor.
The common rail pressure release valve has the following functions:
x Controlling the rail pressure by a controlled leak of fuel from the common rail
during a malfunction in the high-pressure fuel system.
x Limp-home function by permitting a minimum rail pressure
MX-11
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If the common rail pressure release valve (1) opens, the fuel is dumped via pipe (2) into
the supply pipe of the fuel module (3).
MX-13
The common rail pressure release valve is part of the common rail and is
not interchangeable as a separate part.
Control
During normal rail pressure control (normal engine operation), the valve is controlled
to keep it closed. The current to keep the valve closed varies (duty cycle) and depends
on the requested rail pressure.
Learning function
The current to control the common rail pressure release valve is determined by the PCI
ECU and is stored in its memory. If a common rail pressure release valve is replaced,
the stored value in the PCI ECU must be reset with DAVIE.
Limp-home function
If the common rail pressure release valve is not electronically controlled (e.g., faulty
valve or wiring), it acts like a spring-loaded valve. The valve is then a normally closed
valve and opens at approximately 320 ± 70 bar [4641 ± 1015 psi].
x Controls the rail pressure if the normal rail pressure control is lost (e.g., a
failure in high-pressure fuel system components is detected)
x Limits the maximum rail pressure in emergency situations
Common rail pump units 1 and 2 supply fuel to the common rail.
1 Outlet port
2 Solenoid connector
3 Sealing ring fuel supply gallery - outside
4 Sealing ring fuel supply gallery - fuel return
gallery
5 Sealing ring fuel return gallery - crankcase
6 Spring
7 Roller lifter
8 Common rail pump unit cam
9 Fuel return port
10 Fuel supply port
Operation
The internal plunger is actuated via a roller lifter on the camshaft. Each pump has three
pumping events for every two crankshaft revolutions.
Fuel from the fuel gallery can enter the pumping plunger area via an internal valve.
A pumping event starts when the plunger travels up, the PCI ECU activates the solenoid
briefly and the internal valve closes the opening to the fuel gallery. The internal valve is
kept closed hydraulically, and the fuel is pumped to the rail via a check valve in the
outlet bore of the pump unit.
The pumping event stops when the roller lifter passes the top of the camshaft lobe,
causing the plunger to travel downwards again. Due to this, the pressure above the
plunger decreases and the internal valve opens the opening to the fuel gallery. The
check valve in the outlet bore closes and prevents fuel from flowing back from the rail
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to the plunger area.
Control
The amount of fuel pumped to the rail depends on the duration of the pumping event
(pump delivery percentage). The earlier the solenoid is activated by the PCI ECU in the
up stroke of the pumping plunger the more fuel (mg/stroke) is pumped to the rail.
The rail pressure is closed-loop controlled. A comparison is made between the actual
rail pressure and rail pressure demands determined by the ECU. The rail pressure is
adjusted by pumping more or less fuel to the rail with the common rail pump units.
Solenoid valve injector cylinders 1-6 (B421, B422, B423, B424, B425, B426)
Control
The amount of fuel injected depends on the duration of the injector solenoid activation
in combination with the rail pressure. The longer the solenoid is activated by the PCI
ECU at the same rail pressure, the more fuel is injected.
The injectors do not open below a rail pressure of 180–190 bar [2610–2756 psi].
Injector codes
Every fuel injector is calibrated during production to compensate for any production
tolerances. An injector calibration code is present on the housing and connector of the
injector. These injector codes must be (re)programmed with DAVIE if one or more
injectors have been replaced or fitted in another position, or if the PCI ECU is replaced.
x Prefilter
x Hand priming pump
x Fine filter/water separator
x Fuel heater
x Water-in-fuel sensor/water drain valve
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x Activated carbon filter
Prefilter
This suction side filter is a 300 micron filter. The filter contains two non-return valves
that are necessary for operation of the priming pump.
The hand priming pump must be screwed out before it can be operated.
The filter/water separator is a combined filter element. The element has the no filter-
no run feature. The absence of the filter element results in non-starting of the engine.
The use of a non-original filter results in severely reduced engine performance.
Fuel heater
The fuel heater is a 300-W self-regulating heater (bi-metal switch and PTC). The heater
switches ON below ±2 ± 5˚C and switches OFF above +24 ± 5˚C.
The water-in-fuel sensor/water drain valve is a combined component. The water level
in the lower bowl is sensed by the water-in-fuel sensor.
If water is present the PCI ECU activates the water drain valve for 1 second to open the
entrance to the AC filter canister. A safety valve (floating ball) prevents external
drainage of fuel.
When the AC canister is full the clean water is drained to the environment.
x This diagnostic runs when the rail pressure operating state is: Pump unit only.
Set condition of fault code The PCI ECU (D420) detects that the actual rail pressure is more than 200 bar lower
than the commanded rail pressure for more than 3 seconds.
Reset condition of fault code This DTC changes to inactive when the fault is no longer detected.
To validate the repair, drive the vehicle until the coolant temperature is at least 70°C
[158°F]. Once the minimum target temperature has been reached, perform several low
to higher speed accelerations with moderate engine load. Also perform high-load to
low-load transitions. This activity should be conducted within the range of 15 km/h [10
mph] to 65 km/h [40 mph] for no more than 5 to 8 km [3 to 5 miles].
A44 2 Ground
Handle connectors and pins with care and use matching measuring probes.
C26 1 Ground
Wiring harness connector D420.C front Wiring harness connector L094 front view
view
Handle connectors and pins with care and use matching measuring probes.
Handle connectors and pins with care and use matching measuring probes.
Solenoid valve injector cylinder 1-6 (B421, B422, B423, B424, B425, B426)
Handle connectors and pins with care and use matching measuring probes.
Handle connectors and pins with care and use matching measuring probes.
3 2 5V Ignition Keyed on
Pin Pin
Value Additional information
(+ probe) (- probe)
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(+ probe) (- probe)
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(+ probe) (- probe)
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(+ probe) (- probe)
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Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
A3 A4 6 – 11.5 Ω
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
Pin Pin
Value Additional information
(+ probe) (- probe)
If the fuel system or parts of it have been emptied during maintenance or repair,
this DTC may become active temporarily after the engine is started. If the DTC stays
inactive when the engine is running, no further investigation is necessary.
Additional information x The rail pressure is closed-loop controlled. A comparison is made between the
rail pressure commanded by the ECU and the rail pressure feedback measured
by the common rail pressure sensor.
x The actual rail pressure is measured in the common rail by the common rail
pressure sensor (F854).
x P0094 can also be active when this DTC is active.
It is necessary to use DAVIE to clear all current trouble codes from the PCI
and EAS-3 ECUs, and then run the Quick Check to identify a change in
fault status.
This DTC can be set as a result of multiple failure modes. For proper fault
isolation, complete all troubleshooting steps in the sequence provided.
Before troubleshooting this trouble code, take notice of any other active or inactive
trouble codes. One or multiple other trouble codes could have been the cause for this
trouble code.
Action
1. Use DAVIE Diagnostics to perform a Quick Check for current trouble codes.
Yes No
Possible restriction in the fuel supply, fuel
primer pump, or rail pressure sensor.
Go to step 2.A
Action
1. Using DAVIE to monitor individual component selections for rail pressure,
confirm that the actual value measures 200 bar below the requested value.
Yes No
Use DAVIE to perform a Quick Check for
current trouble codes.
Action
1. Inspect the associated components or systems for any of the following:
x Low fuel level in fuel tank
x Damaged fuel filtration system (L097) that needs replacement
x Air in fuel system
x Fuel leaks
x Damaged or kinked fuel lines
Yes No
Step 3.B Rapido maintenance: check fuel system, low pressure (job ID 68721)
Action
1. Perform the identified maintenance job, outlined in “check fuel system low
pressure (Fuel system).”
The procedure outlined in “check fuel system, low pressure (Fuel system)”
requires bleeding the fuel system. For the MX engine (North American markets),
ensure that “bleed (Fuel system),” job ID 66537 is used when bleeding the fuel
system.
Do any of the tests result in a failed state based on the criteria provided?
Yes No
Action
1. Visually inspect the associated component connections and wiring for any of
the following:
x Fuel leaks
x A fuel line from the high pressure common rail to the injector is
damaged
x Bent or broken fuel lines
x Common rail pressure sensor (F854) not installed correctly
x Common rail pressure release valve (L094) not installed correctly
x High pressure fuel lines not installed correctly
x Common rail pump unit 1 (L092) and unit 2 (L093) are not installed
correctly
Yes No
Action
1. Visually inspect the associated component connections and wiring for any of
the following:
x Damaged or loose connectors
x Bent, broken, corroded or loose connector pins
x Moisture or dirt in the connections
x Damage to the wire harness or insulation
x The correct sensor (F854) is not installed
x ECU connections are damaged or disconnected
x Batteries not fully charged or contacts are not tight
x Common rail pressure sensor (F854) broken or not installed
correctly
Yes No
Action
1. Confirm the supply voltage level as outlined in the corresponding checking
data, “Component Check, Common Rail Pressure Sensor (F854).”
Yes No
Step 4.D Rapido maintenance: common rail pressure release valve (L094) leak
down test
Action
1. Refer to Rapido procedure “Check fuel system high pressure (fuel system)”
to verify common rail pressure release valve does not leak.
Yes No
Contact the PACCAR Engine Support
Center for confirmation in replacing the
failed common rail.
Step 5.A Electrical checks, resistance, common rail pump unit 1 (L092) and
unit 2 (L093)
Action
1. Confirm the resistance as outlined in the corresponding checking data,
“Component check, Common Rail Pump Unit 1 (L092) and Unit 2 (L093).”
Yes No
Step 5.B Special test, isolating common rail pump unit 1 (L092) and unit 2 (L093)
Action
1. Set the ignition switch to OFF.
2. Disconnect the pump unit 1 pump (L092) electrical connector.
3. Start the engine and monitor how smoothly it runs.
A smooth running engine indicates that the unit 2 pump (L093) is
functioning properly. A rough running engine indicates the unit 2 pump
(L093) is not functioning properly.
4. Set the ignition switch to OFF.
5. Reconnect the unit 1 pump (L092) electrical connector.
6. Disconnect the unit 2 pump (L093) electrical connector.
7. Start the engine and monitor how smoothly it runs.
A smooth running engine indicates that the unit 1 pump (L092) is
functioning properly. A rough running engine indicates that the unit 1 pump
(L092) not functioning correctly.
Yes No
Correct any issues found, or replace the
corresponding unit pump as needed.
Step 6.A DAVIE test: automated cylinder performance (B421, B422, B423, B424,
B425, B426)
Action
1. Run the prescribed DAVIE performance test to determine if there is a
problem with one of the injectors.
Yes No
For any related issues found, contact the
PACCAR Engine Support Center on further
isolating possible issues with or replacing
a failed injector.
Before beginning these repair verification cycles, use the DAVIE Diagnostics,
Quick Check function to clear all current DTCs from the PCI and EAS-3 ECUs.
Action
1. System Initiation
Drive the truck under normal conditions until the coolant temperature
reaches a minimum of 150°F. This cycle can be conducted with a loaded
trailer or bobtail.
2. Steady State
This cycle is best performed on a level grad road (least amount of incline
possible) and under load using a trailer. If a loaded trailer is unavailable,
produce engine load by turning the A/C and fan to ON.
Yes No
Investigate and correct any issues
preventing these repair verification cycles
and rechecks from being completed, then
re-run. For additional assistance, contact
the PACCAR Engine Support Center.
Go to step 7.B Go to step 7.B
Action
1. Use DAVIE Diagnostics to perform a Quick Check for current trouble codes to
determine whether the actions taken have cleared this trouble code.
Yes No
Problem resolved. No further actions. If all steps have been completed and this
trouble code is still present, contact the
For further assistance in diagnosing this issue or for confirmation prior to the
replacement of suspect components, contact the PACCAR Engine Support Call
Center.
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