04.5 Intermittant power loss, P0148

[jnall63]

New to the site, but have read many of the posts. I have a 2004.5 2500, 4x4, auto trans, bone stock now. Had a Edge Attitude box, I only ran on stock for the EGT gauge. Bought it around a year and a half ago, 185k or so miles, 195k now. Lesson learned, never buy a silver truck in the rain, but that's another topic. Its a weekend truck, pulls a utility trailer or pontoon. First time with the boat, lost the governor solenoid, no big issue, had it fixed. Fuel mileage was great, 23 MPG, reman injectors and crossover tubes dropped it to 14.5. First time it got cold, winter 2014, check engine light came on, pulled in to work, it died. Truck restarted fine. Pulled codes P0251 and P0148, cleared them, no issue. Replaced the FCA, no issues for a while. Same issue and codes again, 3 in tank fuel pumps later, finely one that read the level correct, no issues, ran fine for a while. Now is intermittently dropping from 70mph to 35mph on a slight long uphill grade, EGT above 1300, boost around 23 psi, let off and it died, restarted and drove fine. I'm a equipment and truck tech as my side job, 10 years at it so I hate to ask for help or get robbed for diagnostics. Took to the dealership, told the programmer was the issue, took it back to the shop and removed it, ran fine. Left work the next day and went up the same long uphill grade, did the same power loss problem. No visible leaks under valve cover while running, FCA unplugged, #4 injector had a slightly different sound, so pulled all and had checked, all ok. Removed the rail pressure regulator, blew air through the rail side port, has small air bubbles with just shop pressure. Checked flow from in tank pump, great flow to CP3 at fitting, return line not blocked. Just drove it, still has a tick at idle, all valve lash in spec when the engine is cold. Thinking I need to replace the rail regulator. Cheaper to buy the whole rail assembly than the regulator seperately. Dealership and other shops with the software say CP3, one says ECU, one wants the sensor, etc. Thoughts?

 

[p-Bar]

Did they check rail pressure ? also how about return fuel from injectors that would pop a code if to great . Who's remans did you put in?

 

[jnall63]

Supposedly so, no clue to return rate, I am supposed to submit to the mercy of the "people who know more than I do" I guess. Turbo Diesel did the remans. I deal with compact track loaders, so I do not have the specialty tools and software for this troubleshoot, much less the money to spend for this one truck just to check and make sure the dealership correctly did the tests. I unplugged the rail pressure sensor and a rail pressure too high code came up, same thing with removing the relief valve banjo bolt. Sorry if I seem irritated, but I am fed up with a service rep answer that always seems to involve more money to find the actual cause. Who knows anymore. I got 2 airbags though and a tie rod end check if that helps last time the dealership had it for diagnostics. Too much money, time, and moral character to just sell it and make it someone else's problem.

 

[p-Bar]

Understand where you are coming from. Better to find an independent shop that works on Cummins and has the DRBIII to test all this stuff. Injectors are a tricky thing especially for a High pressure common rail,the only remans I would buy are Bosch remans (done by them) . So at this point do we really know that the injectors are working right? The lower fuel mileage isn't a good thing . Check your oil to make sure you aren't making any with a leaky injector. I think you may have to do some research online so you can go into the S t e a l e r and tell them what you want done.

 

[Wayne M.]

Welcome to the TDR. I will make three reccomendations.
1- get a set of factory books.
2- get the best scanner you can afford. Some of us here use the PC based autoenginuity.com. You'll need Chrysler specific add on.
3- do the return volume test to start.
Without even looking up the code, your mileage change is disturbing.

 

[CKelley1]

do what wayne said, there is a 4 part video on youtube
see if this works and the tools is about $100
Everyone Should Watch These Vids Tons Info
________________________________________
YouTube - Dodge Ram/Cummins 5.9L High Pressure Common Rail Diesel Engine Part 1 of 4

YouTube - Dodge Ram/Cummins 5.9L High Pressure Common Rail Diesel Engine Part 2 of 4

YouTube - Dodge Ram/Cummins 5.9L High Pressure Common Rail Diesel Engine Part 3 of 4

YouTube - Dodge Ram/Cummins 5.9L High Pressure Common Rail Diesel Engine Part 4 of 4
http://www.youtube.com/watch?feature=player_embedded&v=fvFHzrwiQfA

 

[jnall63]

Ordered the tools needed in that video, I had seen it before but forgot all about it, very helpful. I prefer to turn my own wrenches, and this is a good learning experience although expensive. I might even get the data tool above, not a bad price for the domestic bundle and we have a variety of trucks, but nothing beats a Cummins. I will get back and let you all know what I find. Thanks.

 

[Ozymandias]

AutoEnginuity is IMHO the best you can buy for a reasonable price.

 

[CKelley1]

i agree on the autoenginuity