Anyone fail a rail pres sender?

[BMeier]

My '03 has been sputtering occasionally, the rail pressure is bouncing around. I just replaced the lift pump and its running a constant 9-10 psi to the CP3. I unplugged the rail pres gauge from the sender and continued to drive just in case that was the problem. I noticed the engine still sputtered. I cycled the key and checked for codes, there was a P0194 (rail pressure sender voltage high). A new sender is $480 from the dealer. The motor is still under warranty, but I have to remove all my add ons ( rail pressure gauge, Banks 6 gun, and second fuel filter in between the factory filter and CP3 ) in order for the dealer to even look at it. My dealership is HORRABLE to work with. Do I spend the money on a sender? I have not heard of any problems with these, but I suppose anything is possible.

 

[BMeier]

Did your truck sputter, or did it just not start all of a sudden? Is there a way to verify that its the sensor and not an actual pressure problem.

 

[BMeier]

Good idea, my buddy also has an '03 I can swap sensors with.



Thanks.

 

[MMeier]

Happened to me.



https://www.turbodieselregister.com...-2007/207103-p0192-p0088-no-start-solved.html

How much was the sensor at Cummins?

 

[JStieger]

I had the same problem... or so I thought... and all the factory service manual tests pointed to the rail pressure sensor needing to be replaced.



Not pleased with the prospect of spending beaucoup $, I then noticed that the manual neglected to test one of the circuits coming off the sensor for continuity.



So I put an ohm meter on this circuit and found a short with the pressure box connected to the circuit still. I then removed the pressure box only and there wasn't any short so the pressure box harness was good. I then checked continuity on the pressure box when it was powered up and sure enough it had a short.



Details here:



Dual CP3, PO193, and engine miss - Dodge Diesel - Diesel Truck Resource Forums



I noticed you have a Banks 6-gun. Do your problems still happen with it disconnected?

 

[BMeier]

I started to wiggle the wires at the sensor and while pulling on the banks harness the rpm jumped around. I unplugged the harness and installed the factory harness and it ran fine. I pulled the connector apart at the banks harness and found the signal wire was broke at the socket. I soldered the wire and plugged it back together and the engine runs perfect again. I put 400 miles on today and the engine never missed a beat. I guess thats the draw back of aftermarket parts, but I blame myself I was in a hury hooking it up and did not zip tie the harness enough to keep it from moving.

 

[Red_Rattler]

My trucks doing the same crap and I have a 6 Gun as well... Came on the truck so I don't have a manual for it, fun! I'll have to look into this as well thanks for the shared info!

 

[BMeier]

Are you having erratic rail pressure? I ran into another instance on my buddys truck where he cut the o-ring on the filter base cover when he replaced the fuel filter and was sucking air causing erratic pressure. Put a new o-ring in and fixed the problem.



Just another thing to look at while troubleshooting, good luck.