low power stalls losing fuel rail pressure

[DodgeSales]

I have a 04 with a problem, I have had it in service and am at a loss, the truck has a fast system and it has been replaced in the quest to fix this problem with no success. have also replaced the injection pump 3 times with the same results. also the pressure limiting valve has been replaced and replaced the fuel rail pressure sensor. we are at a standstill on this truck can anyone on here give me any feedback on this. we have tried everything we and star can come up with and need advice anyone please.

thanks in advance

 

[jhyatt]

how about numbers rail pres. rpm. stock inj. or aftermarket? what is lift pump output gpm and pres.

 

[SP Diesel]

I assume you are not seeing any codes when this happens? So basically the truck starts and then stalls when it is idling.

 

[wsteffes]

Injector connecter tubes been checked for damage?

With the common rail one bad tube and pressurized fuel could be leaking out the back side return all the time.

 

[Chris Jewell]

Don't forget to check the simple stuff first.

Bad fuel?

water in fuel?

air leak?

loose wire, blown fuse?

dirty filter?

I always tend to think something huge is wrong when I have a problem with any machine ut more often tha not it's something simple.

 

[Chris Jewell]

May want to unhook any aftermarket performance stuff ( box )

 

[sag2]

Ran into one (03) the other day that lost power and set the check engine light after driving seven miles with an ECM check sum error. Turns out the connector tubes were all loose from a previous injector replacement. Watching the rail pressure, as the truck got hot, the pressure would drop several thousand pounds below the set point. Checking the fuel return, it had over a liter returning or about six times the spec. Surprised it ran at all.

Before I saw it, the dealer had replaced three lift pumps, two injection pumps, the ECM and all six injectors. So don't think the dealer can't get one past STAR. Remember, garbage in, garbage out.

 

[1badplr]

I had this same issue go on for about three weeks. I took it to the dealer and had the CP3 replaced, Pop off and some other parts, It turns out the #1 injector tip was loose and letting fuel into the cylinder causing severe engine damage. I thank the great mechanic who fixed the problem

 

[DodgeSales]

Thanks for trying to help, the return volume from the cp3 to the tank is 650 ml in one minute at idle and the injector return is 80 ml per min at idle, stock injectors, no box. This is driving us crazy.

 

[DodgeSales]

Yes we checked all the simple stuff, fuel, filters ect.

 

[Big_H316]

Is the truck doing this constantly or just every now and again? Mine has the same symptoms but when it goes funky like that the engine will lose rpm's then jump way up and knock and clatter REAL BAD. First time I took it in for this was at 57,000 miles and they said "Nothing wrong!!". BULL CRAP. Five times in the shop with same problem and they give me the same answer everytime. Yesterday it got SUPER BAD. Check engine light came on and 9 codes. It has 160,000 on it now and I just have a bad feeling that they're gonna say $5,000 and we can fix it now. This is the first time that it has turned on the engine light when this happens to it. I can never get the truck to smoke until the engine starts to stumble and race up and the whole time it's doing this there is a very noticeable "pop" out of the exhaust pipe. I hope someone else is finally having this problem so that it can be fixed. I'm tired of this happening and not knowing how many times it's gonna die on me.

 

[SP Diesel]

BIG_H316,



Do u know what codes your truck threw? It sounds like you might have a flaky connection at either the fuel pressure or map sensor. Check the wiring harness around the connectors to make sure nothing is loose. You may also want to wiggle the wiring harnesses and connectors when the truck is running to see if you can duplicate the problem.

 

[Big_H316]

There has never been a code come up which is why I don'y understand whats wrong with it. It mostly does this after several hours of towing.

 

[DodgeSales]

As it turns out, the injectors had been changed and the #4 injector was loose and not functioning. replaced it properly and all is well.

Thanks to everyone for all the help. There is a wealth of knowledge on this board.