Engine rattle at idle. Wierd power surge at 2k rpm

[6speed3rdgen]

Okay so here is the list 03 6 speed, new injectors as of a week ago with new updated crossover tubes. FCA replaced about a year ago. Rail pressure sensor and pressure relief valve changed a couple months ago. All new high pressure lines, Fass 95 with new fuel filters about a month ago. New ats 3000 turbo 7 months ago.
The trucks runs decent, i could just be crazy , but the rattle noise kind of like a fuel knock is what gets me. Idk if its a cp3 knock but i havent seen the cp3 knock cause any power concerns that i have found. The trucks gets 17.5 mpg hand calculated so i dont think the motor is hurt. I cant see any blow by when the oil cap is removed. I have checked valve lash it is in spec. When driving somedays its fine other days its weak. It feels like the FCA is lagging or doesnt know the correct position to be at. Possible MAP issue? There is no codes and i have been chasing this for a while as you can see. All the parts were replaced with cummins or bosch branded parts nothing junk. The low side pressure is 16 psi at idle and if i really get on it, goes no lower then 14 even when loaded. Had a gmc envoy on a car trailer and it never skipped a beat. I work on 6.7s all the time and the diagnostics are smarter compared to the old 5.9 controllers. I dont think the cp3 is bad cause it can hit 24,000 lbs of pressure with the fca unplugged. I have watched it like a hawk and the desired doesnt stray far from actual pressure no more then chrysler diag says it should. I know quite a bit but not everything. Just trying to get some others input and see what else it could possibly be. Also some days its idle right at or just below 700rpms. Other days it sits just between 700 and 800 rpms. I know the fca controls idle. Possible i got a bad fca or bad wiring? You think it would throw a code though. Anyway thanks for any future input

 

[6speed3rdgen]

Also when shifting through the gears sometimes mostly lower gears. When getting closer to 2k it power spikes. I dont notice a jump in rpms either. Feels like im stomping the pedal before i shift

 

[cerberusiam]

FCA and connector if those have never been replaced, good place to start. Do you have a scanner you can see what is going when the idle does something weird? Is th eidle actually off or is the cluster?

What injectors specifically did you use? New or reman and from where? If the SOP meeter says you are accelerating and you cannot see rpms and speed increase that would indicate a possible cluster or bus issue.

 

[6speed3rdgen]

I used brand new bosch injectors from a local cummins mechanic who has been buying from the same place for years. As far as idle i do have a tach and i have tested the cluster and the self test passes. I have watched the ecm readings with a drb3 and i cant see anything unusual the map readings are spot on with my boost gauge, rail pressure is a mirror to desired, the only thing i havent done is a cold soak and checked all the temps to make sure one isnt varying from others. I have replaced both the fca and connector with both cummins parts. I do know if i clear the injector duty cycles it runs perfect for a day a two then the rattle noise eventually makes it way back. There is a cluster update last time i looked but it was for an out or park alarm recall for auto trucks not 6 speeds

 

[cerberusiam]

Yeah, forget the out of park alarm stuff, it is just an annoyance. What does clearing the injector duty cycles actually do? Have you run a cylinder contribution test to see what they are reading?

Have you tried disconnecting\replacing the fan and checking the AC compressor wire for chafing on the AC lines? If clearing the learned duty cycles fixes it it sounds like you are getting garbage into the system that is messing with the injector drivers. Also, the 03's have a TSB for corrosion in the ECM A & B connectors due to bad seal that could cause the symptoms you see.

 

[6speed3rdgen]

I have looked and dont think there is a contribution test for my year, unless the DRB3 at my work is that out if date. Will try disconnecting the fan and see what that does and if nothing i will check the ac connector and the ecm connectors. Is it the actual Ac compressor connector or the high side pressure switch connector?

 

[6speed3rdgen]

As far as reseting the duty cycle im assuming it just resets them to a pre determined point fixed in the programming then adjusts them from there to the how the truck runs

 

[cerberusiam]

It is the AC clutch activation wire that rubs on things and loads garbage into the network.

Should have a contribution test in there somewhere as that is one of Dodge troubleshooting items.

 

[6speed3rdgen]

Ac wire was a bust. Little bit of rub on the tubing but nothing into the wire. Will check them ecm plugs this weekend