Injector Metering Rail Number 1 Pressure - Data Valid But Above Normal Operating ...

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FAULT CODE 449 (ISC/QSC/ISL/QSL Automotive,

Industrial, and Marine Applications)
Injector Metering Rail Number 1 Pressure - Data Valid
But Above Normal Operating Range - Most Severe Level
Overview

CODE REASON EFFECT

Fault Code: 449 Injector Metering Rail Number 1 Pressure - None or possible
PID: P94 Data Valid But Above Normal Operating power interruption
SPN: 157 Range - Most Severe Level. Fuel pressure associated with
FMI: 0 signal indicates that fuel pressure has dump valve reset.
LAMP: Amber exceeded the maximum limit for the given
SRT: engine rating.

Fuel System

Circuit Description

The electronic control module (ECM) monitors engine-operating conditions, including the
reading of rail fuel pressure, and changes the flow command to either increase (OPEN the
fuel pump actuator) or decrease (CLOSE the fuel pump actuator) the fuel supply to the
high-pressure pump.

Component Location

The fuel pump actuator is installed on the high-pressure fuel pump.

Shop Talk

Fault Code 449 is activated when the sensed rail fuel pressure exceeds the opening
pressure of the rail fuel pressure relief valve.

In normal engine operation the ECM calibration varies the flow command to the fuel pump
actuator to achieve the correct fuel rail pressure. System failures that cause loss of
pressure control can cause the fuel rail pressure relief valve to open. The fuel rail pressure
relief valve acts to protect the high pressure components from over-pressurization. If the
ECM detects that the fuel rail pressure relief valve is open without a detection of a fuel

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pump actuator circuit error, Fault Code 449 will become active.

On certain applications, the ECM will try to reset automatically causing a momentary loss of
power for less than one second.

Conditions that can cause Fault Code 449:

z Purging air through the fuel system can cause a pressure overshoot, therefore
causing Fault Code 449 to log.
z Sustained periods of very low pressure under load followed by pressure recovery
overshoot. This can be caused by high restriction due to plugged filters.
z A tampered fuel pressure sensor that reads low, a biased pressure sensor, or a poor
electrical connection.
z If an intermittent electrical circuit problem, of the fuel pump actuator circuit, exists it is
possible for Fault Code 449 to become active then inactive during normal engine
operation. ECM Fault Code 2311 is designed to detect electrical circuit issues with the
actuator. Therefore, it is only necessary to look for bad connectors or harness issues
for Fault Code 449 if no other fault codes exist.
z Other conditions include faulty ECM wiring harness such as poor grounds, battery
voltage spikes, electrical noise, low alternator output, and large disturbances of
battery voltage, as when jump starting the vehicle.

Troubleshooting Steps

STEPS SPECIFICATIONS
STEP 1. Check the fault codes.
STEP 1A. Read the fault codes. Are Fault Code(s) 271, 272, 2311, or
1117 active or high inactive counts?
STEP 2. Check for air in the fuel.
STEP 2A. Check for air in fuel. Air in the fuel?
STEP 3. Check the low pressure fuel
system.
STEP 3A. Measure the gear pump Is gear pump pressure low?
pressure at the outlet of the
pressure side fuel filter.
STEP 3B. Measure the pressure Is filter restriction high?
at the inlet to the pressure side
fuel filter.
STEP 3C. Measure the inlet Is the gear pump inlet restriction to
restriction at the gear pump inlet. high?
STEP 3D. Measure the inlet Is OEM inlet restriction to high?
restriction at the OEM connection
point.
STEP 3E. Check for a restriction Debris or damage?
at the OEM connection point.

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STEP 4. Check the rail fuel pressure

sensor.
STEP 4A. Verify the rail fuel Is the pressure 0 ± 40 bar [ 0 ± 580
pressure sensor reads in-range. psi]?
STEP 4B. Inspect the fuel Dirty or damaged pins?
pressure sensor signal wire and
connector pins.
STEP 5. Check customer complaints.
STEP 5A. Check customer Does the engine start and stall or
complaints. surge at idle?
STEP 6. Check the fuel pump actuator.
STEP 6A. Check the fuel pump Dirty or damaged pins?
actuator and harness connector
pins.
STEP 6B. Inspect the fuel pump Are the o-rings on the fuel pump
actuator for damage. actuator damaged?
STEP 6C. Monitor the fuel rail Does measured fuel rail pressure
pressure at idle. deviate more than 200 bar [2901 psi]
and surge at idle?
STEP 7. Check the ECM to ground strap.
STEP 7A. Inspect the ECM to Is the ECM to ground strap missing or
ground strap. have the connections degraded?
STEP 8. Clear the fault codes.
STEP 8A. Disable the fault code. Fault codes inactive?
STEP 8B. Clear the inactive fault All fault codes cleared?
codes.

Guided Step 1 - Check the fault codes.

Guided Step 1A - Read the fault codes.

Conditions

z Connect INSITE™ electronic

service tool.
z Turn keyswitch ON.

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Action

Read the fault codes.

z Start the engine and let it idle for

one minute.
z Use INSITE™ electronic service
tool, to read the fault codes.
z Check for fault codes related to the
fuel pump actuator shorted low or
high.

Are Fault Code(s) 271, 272, 2311, or Are Fault Code(s) 271, 272, 2311, or
1117 active or high inactive counts? 1117 active or high inactive counts?
YES NO
No Repair No Repair
Appropriate Troubleshooting Tree Go to 2A

Guided Step 2 - Check for air in the fuel.

Guided Step 2A - Check for air in the fuel.

Conditions

z Turn keyswitch ON.

Action

Check for air in the fuel.

Air in the fuel? Air in the fuel?

YES NO
Air detected No Repair

Correct the source of the air leak. Refer to

Procedure 006-003 in the ISC, ISCe,
QSC8.3, ISL, and QSL9 Engines
Troubleshooting and Repair Manual,
Bulletin 4021418.

Appropriate Troubleshooting Tree Go to 3A

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Guided Step 3 - Check the low pressure fuel system.

Guided Step 3A - Measure the gear pump pressure at the outlet of the
pressure side fuel filter.

Conditions

z Turn keyswitch OFF.

z Connect the diagnostic
fittings.
z Turn keyswitch ON.

Action

Measure the pressure at the

outlet of the pressure side fuel
filter.

z Install a T-fitting at the

outlet of the pressure side
fuel filter.
z Install a diagnostic fuel line
at the T-fitting with an
orifice of 0.109 cm [0.043
in].
z Install a 0 to 1379 kPa [0 to
200 psi] pressure gauge at
the T-fitting.
z Start the engine.
z Measure gear pump
pressure at high idle.

Minimum gear pump pressure at

high idle engine speed 483 kPa
[70 psi].

Refer to Procedure 005-025 in

the ISC, ISCe, QSC8.3, ISL, and
QSL9 Engines Troubleshooting
and Repair Manual, Bulletin
4021418.

Is gear pump pressure low? Is gear pump pressure low?

YES NO

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No Repair No Repair
Go to 3B Go to 4A

Guided Step 3B - Measure the pressure at the inlet to the pressure side fuel
filter.

Conditions

z Turn keyswitch OFF.

z Connect the diagnostic
fittings.
z Turn keyswitch ON.

Action

Measure the pressure at the inlet

to the pressure side fuel filter.

z Install a T-fitting at the

outlet of the pressure side
fuel filter.
z Install a diagnostic fuel line
at the T-fitting with an
orifice of 0.109 cm [0.043
in]. Run the output of this
fuel line into a collection
device or the vehicle's fuel
tank.
z Install a 0 to 1379 kPa [0 to
200 psi] pressure gauge at
the T-fitting.
z Install a 0 to 1379 kPa [0 to
200 psi] pressure gauge at
the inlet of the pressure
side fuel filter.
z Start the engine.
z Measure gear pump
pressure at high idle.

Maximum fuel filter pressure

drop 138 kPa [20 psi].

Refer to Procedure 005-025 in

the ISC, ISCe, QSC8.3, ISL, and
QSL9 Engines Troubleshooting
and Repair Manual, Bulletin
4021418.

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Is filter restriction high? Is filter restriction high?

YES NO
The fuel filter is plugged. No Repair

Replace the pressure side fuel

filter.

Refer to Procedure 006-015 in the

ISC, ISCe, QSC8.3, ISL, and QSL9
Engines Troubleshooting and
Repair Manual, Bulletin 4021418.

Go to 8A Go to 3C

Guided Step 3C - Measure the inlet restriction at the gear pump inlet.

Conditions

z Turn keyswitch OFF.

z Connect the diagnostic
fittings.
z Turn keyswitch ON.

Action

Measure the inlet resriction.

z Install a diagnostic fitting at

the inlet to the fuel gear
pump.
z Install a 0 to 762 mm-Hg [0
to 30 in-Hg] vacuum gauge
at the inlet to the gear
pump.
z Install a M10 standard
thread o-ring diagnostic
fitting at the pressure side
fuel filter outlet port.
z Operate the engine at high
idle no load and measure
the restriction at the inlet to
the gear pump.

If the engine will not start or the

engine starts and stalls, be sure
the fuel is primed to the gear
pump. This test is only valid if

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the engine is running.

Maximum gear pump inlet

restriction 254 mm-Hg [10 in-
Hg].

Refer to Procedure 006-020 in

the ISC, ISCe, QSC8.3, ISL, and
QSL9 Engines Troubleshooting
and Repair Manual, Bulletin
4021418.

Is the gear pump inlet restriction Is the gear pump inlet restriction too high?
too high?
YES NO
No Repair Replace the gear pump.

Refer to Procedure 005-025 in the ISC, ISCe,

QSC8.3, ISL, and QSL9 Engines Troubleshooting
and Repair Manual, Bulletin 4021418.

Go to 3D Go to 8A

Guided Step 3D - Measure the inlet restriction at the OEM connection point.

Conditions

z Turn keyswitch OFF.

z Connect the diagnostic
fittings.
z Turn keyswitch ON.

Action

Measure the inlet restriction.

z Install a 0 to 762 mm-Hg [0

to 30 in-Hg] vacuum gauge
at the OEM connection
point.
z Install a M10 standard
thread o-ring diagnostic
fitting at the pressure side
fuel filter outlet port.
z Install a diagnostic fitting at
the pressure side outlet

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port with an orifice of 0.109

cm [0.043 in].
z Operate the engine at high
idle no load and measure
the restriction at the inlet to
the gear pump.

If the engine will not start or the

engine starts and stalls, be sure
the fuel is primed to the gear
pump. This test is only valid if
the engine is running.

Maximum OEM inlet restriction

203 mm-Hg [8 in-Hg].

Refer to Procedure 006-020 in

the ISC, ISCe, QSC8.3, ISL, and
QSL9 Engines Troubleshooting
and Repair Manual, Bulletin
4021418.

Is OEM inlet restriction too high? Is OEM inlet restriction too high?
YES NO
A fuel restriction exists upstream of No Repair
the OEM connection point.

Refer to the OEM service manual.

Appropriate Troubleshooting
Go to 3E
Manual

Guided Step 3E - Check for a restriction at the OEM connection point.

Action

Inspect the ECM cooling plate

and check valve.

Refer to Procedure 006-006 in

the ISC, ISCe, QSC8.3, ISL, and
QSL9 Engines Troubleshooting
and Repair Manual, Bulletin
4021418.

Debris or damage? Debris or damage?

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YES NO
Clean or replace the ECM cooling No Repair
plate.

Clean or replace the check valve.

Go to 8A Go to 4A

Guided Step 4 - Check the rail fuel pressure sensor.

Guided Step 4A - Verify the rail fuel pressure sensor reads in-range.

Conditions

z Connect INSITE™ electronic

service tool.
z Turn keyswitch ON.

Action

Verify the sensor reads in-range.

Is the pressure 0 ± 40 bar [ 0 ± 580 psi]? Is the pressure 0 ± 40 bar [ 0 ± 580 psi]?
YES NO
No Repair The fuel pressure sensor is incorrectly
reading a fuel pressure.

Replace the rail fuel pressure sensor.

Refer to Procedure 019-115.

Go to 4B Go to 8A

Guided Step 4B - Inspect the fuel pressure sensor signal wire and
connector pins.

Conditions

z Turn

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keyswitch
OFF.
z Disconnect
ECM from
engine
harness

Action

Inspect the fuel

pressure sensor
signal wire and
connector pins for
the following:

z Loose
connector
z Corroded
pins
z Bent or
broken pins
z Pushed back
or expanded
pins
z Moisture in
or on the
connector
z Missing or
damaged
connector
seals
z Dirt or debris
in or on the
connector
pins
z Wire
insulation
damage
z Connector
shell broken.

A bad connection
on the fuel
pressure sensor
SIGNAL wire can
cause the signal
reading to
fluctuate and
cause this fault
code to become
active on an
intermittent basis.

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For general
inspection
techniques, refer
to Procedure 019-
361 Component
Connector and Pin
Inspection.

Dirty or damaged Dirty or damaged pins?

pins?
YES NO
A defective No Repair
connection has been
detected in the
sensor or harness
connector.

Clean the connector

and pins.

Repair the damaged

harness, connector,
or pins. Refer to
Procedure 019-043
Engine Wiring
Harness.

Go to 8A Go to 5A

Guided Step 5 - Check customer complaints.

Guided Step 5A - Check customer complaints.

Action

Interview the customer or driver.

Does the engine start and stall or surge Does the engine start and stall or surge
at idle? at idle?
YES NO
No Repair No Repair

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Go to 6A Go to 7A

Guided Step 6 - Check the fuel pump actuator.

Guided Step 6A - Check the fuel pump actuator and harness connector
pins.

Conditions

z Turn keyswitch OFF.

z Disconnect the fuel pump actuator
from the engine harness.

Action

Inspect the fuel pump actuator, pigtail

wires, and harness connector pins for
the following:

z Loose connector
z Corroded pins
z Bent or broken pins
z Pushed back or expanded pins
z Moisture in or on the connector
z Missing or damaged connector
seals
z Dirt or debris in or on the
connector pins
z Wire insulation damage
z Connector shell broken.

For general inspection techniques, refer

to Procedure 019-361 Component
Connector and Pin Inspection.

Dirty or damaged pins? Dirty or damaged pins?

YES NO
Repair the connector and pins. Repair the No Repair
damaged harness, connectors, or pins.
Refer to Procedure 019-043 Engine Wiring
Harness.

Go to 8A Go to 6B

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Guided Step 6B - Inspect the fuel pump actuator for damage.

Conditions

z Turn keyswitch OFF.

z Remove the fuel pump
actuator.

Action

Inspect the fuel pump actuator o-

rings for damage.

Are the o-rings on the fuel pump Are the o-rings on the fuel pump actuator
actuator damaged? damaged?
YES NO
Replace the fuel pump actuator o- No Repair
rings.

Refer to Procedure 019-117

Go to 8A Go to 6C

Guided Step 6C - Monitor the fuel rail pressure at idle.

Conditions

z Connect INSITE™
electronic service tool.
z Start the engine.

Action

Run the engine at idle for at least

one minute to purge air induced
from previous steps.

z Use INSITE™ electronic

service tool, to monitor
commanded fuel rail
pressure and measured
fuel rail pressure.

Does measured fuel rail pressure Does measured fuel rail pressure deviate more
deviate more than 200 bar [2901 than 200 bar [2901 psi] and surge at idle?

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psi] and surge at idle?

YES NO
Replace the fuel pump actuator. No Repair

Refer to Procedure 019-117.

Go to 8A Go to 7A

Guided Step 7 - Check the ECM to ground strap.

Guided Step 7A - Inspect the ECM to ground strap.

Conditions

z Turn
keyswitch
OFF.

Action

Run the engine at

idle for at least
one minute to
purge air induced
from previous
steps.

z Check the
ground from
the ECM to
the block.
Refer to
Procedure
019-008
z Check
ground
connections
from block to
battery (-)
negative.

Is the ECM to Is the ECM to ground strap missing or have the connections
ground strap degraded?
missing or have the

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connections
degraded?
YES NO
Repair missing or Contact a Cummins Authorized Repair Location.
degraded ground
connections.

Go to 8A Go to 8A

Guided Step 8 - Clear the fault codes.

Guided Step 8A - Disable the fault code.

Conditions

z Connect all components.

z Connect INSITE™ electronic
service tool.
z Turn keyswitch ON.

Action

Disable the fault code.

z Start the engine and let it idle for

one minute.
z Use INSITE™ electronic service
tool to verify the fault codes are
inactive.

Fault codes inactive? Fault codes inactive?

YES NO
No Repair No Repair
Go to 8B Go to 1A

Guided Step 8B - Clear the inactive fault codes.

Conditions

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z Connect all components.

z Connect INSITE™ electronic
service tool.
z Turn keyswitch ON.

Action

Clear the inactive fault codes.

z Use INSITE™ electronic service

tool to erase the inactive fault
codes.

All fault codes cleared? All fault codes cleared?

YES NO
No Repair No Repair
Repair complete Appropriate troubleshooting steps

Last Modified: 07-Apr-2005

Copyright© 2005
Cummins, Inc.
All rights reserved

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