(9 Months!!!) Very sick '04

[ShannonWilliams]

First thing in the morning she starts and idles fine for about 10min, Then will begin studdering for 2-3sec, level back out 2-3sec and drop 50-100rpm, level back and drop 100-150rpm, level back and drop 150-200rpm, level out and continue down around 300-400rpms until it can not catch back up.

Turn key off and let set 3-4mins and it cranks and idle fine for around 5-6mins and start droping and leveling RPMs. It gets worse as engine temp rises and around 160* you have to crank 9-10sec before it starts.

It will stay running if you give it fuel but RPM still goes up and down until you let it idle and die. We started at droping the fuel tank and installin lift pump, pullin FASS off, cleaned lines, filter, new Stage II Flore it Diesel Cp3 w/ FCA, Overflow valve, rail psi sencor, crank and cam sencor, map, swapped ECM, everything but pull DDP injectors with 50,000mi, and change wire harness. We did pull harness out and started checking Ohms for broke wires after every cheap and several thousand dollar scanners used saying low voltage or sencor bad. Did not find any signs of fluids mixing anywhere.

Problem Im dealin with now is 2 different harness options for 04 standard trans. and it does not go by the VIN#, they tell me only way to know is part number off harness and mine does not have one.

 

[BDaugherty]

I would suggest lift pump and fuel rail pressure gauges. Also, what is the fuel rail pressure relief valve doing at the time it acts up? Have you had any codes along the way?

 

[TCDiesel]

ShannonWilliams . . You are welcome to call... I am done posting at the TDR. . Thats does not mean I do NOT want to help... I am tried of running interference with the TDR Keystroke kings.

 

[ShannonWilliams]

My FASS had 15psi at Cp3 inlet when we pulled it off and installed liftpump in the fuel tank, with factory tank lift pump installed we are gettin 13psi at Cp3 inlet. Fuel rail relief valve was checked first by swapin it with another truck and it ran fine while mine still acted up, scanner showed high fuel rail psi, but thinkin its electrical problem thats just an idea. I have not had access to put a psi gauge on fuel rail yet but workin on it. In the codes department had not had very many, when changin out parts or sencors it would throw that code or low voltage from just about everywhere around the engine.

 

[mwilson]

Shannon,



Give me your ESN from the valve cover if you have it handy and I will try looking the harness up through Cummins if that has not been attempted yet. .



Mike.

 

[cerberusiam]

Have you checked the cross over tubes and retorqued them since injector install? You have all the symptoms of cross over tubes not tight enough or a cracked injector.

 

[NIsaacs]

Have you checked the cross over tubes and retorqued them since injector install? You have all the symptoms of cross over tubes not tight enough.

The OP said there was not any sign of fluid mixing, however maybe a small amount of fuel would be hard to tell without an oil sample.



Nick

 

[cerberusiam]

The OP said there was not any sign of fluid mixing, however maybe a small amount of fuel would be hard to tell without an oil sample.



Nick

Cross over tubes are in the return gallery in the head, leakage just returns with the injector return flow. There is an o-ring seal at the base of the hold down that keeps fuel from return gallery out of the oil.



Depending on where an injector cracks one may or may not seal fuel contamination. Half of the injector is below the o-ring seal where the cross over tubes feed it.



If it starts good cold but then starts throwing issues when warm the injectors and tubes are the first place to start. A rail pressure gauge may show the pressure swings when that happens, or not, depending on the exact circumstance.

 

[NIsaacs]

Oh, thanks for the lesson



Nick

 

[JJPage]

Have you checked the cross over tubes and retorqued them since injector install? You have all the symptoms of cross over tubes not tight enough or a cracked injector.

Exactly what I was thinking when I came across your post, been there.

 

[ShannonWilliams]

Finally back, Started ranch job June 2012 and moved to Nacodoches, Tx. My boss convenced me hauling it to Mike Perry dealership. Turned out engine bay harness was working against chassis harness. New engine harness didn't work with chassis and new chassis against engine. Short in both of them but different circuits. She ain't mist a lick and good to be back.