Persistent P0193 and CEL please help

[Skeptic]

The truck is a 2008 Ram 2500. The emissions system is mostly deleted (the ccv filter and tube are still present). The exhaust manifold is a BD 2 piece unit for a 5.9 along with an Industrial Injection turbo. The intake horn is a GDP unit.The tuning is done using an XRT Pro.

The problem:
A week ago the CEL came on and when I pulled the codes I found it to be P0341 Cam Position Sensor. I figured replace the sensor, problem solved. So I replaced the sensor and cleared the codes using the XRT. The P0341 code came back with a friend. I checked it again and came up with more codes.

The codes were as follows:

P0193 Fuel Rail Pressure Sensor Input High
P0341 Cam Position Sensor
P000F Fuel system over pressure, relief valve activated
P0087 Fuel Rail system pressure too low
P0652 Sensor Reference voltage b circuit 5 volt
P0192 Fuel Rail Pressure Sensor Input Low
P0107 MAP sensor circuit low
P2228 Barometric Pressure Sensor Circuit low

This led me to believe the issue was in the wiring. Sure enough I found a wire bundle on the driver's side near the crank position sensor that was rubbing on a hard line and had worn through the insulation on one of the wires. I resealed the wire using RTV and zip tied the wire bundle up and away from the hard line.

This fixed all but the P0193 code and the charging system light (lightning bolt on the dash) is still on. I just put two brand new batteries in the truck so I'm fairly certain that batteries are not the issue.

I've tried to clear the code multiple times only for it to come right back while the key is in the run position without the engine started. There is a very distinct knocking noise coming from the engine compartment when I try to clear the code, almost as if an injector was attempting to fire.

any advice would be greatly appreciated.

 

[DonFitzwater]

At this point, you need to figure out if the fuel pressure really is that high OR if you've got a defective sender.............I don't know enough to speak intelligently on this subject but if the part is cheap, throw a new one at it. i wouldn't rule out another chaffed spot in the wiring either.

 

[Skeptic]

I don't currently have any way to measure fuel rail pressure. I'm likely going to just replace the Sensor, Rail, and Relief Valve since it's near impossible to get the sensor out by its lonesome self and its more cost effective to buy the already assembled rail with sensor and valve from my usual parts vendor. about 380 bucks or so... a little much for the old "throw parts at it 'till its fixed" but I need to get this truck back on the road.

 

[Skeptic]

I don't currently have any way to measure fuel rail pressure. I'm likely going to just replace the Sensor, Rail, and Relief Valve since it's near impossible to get the sensor out by its lonesome self and its more cost effective to buy the already assembled rail with sensor and valve from my usual parts vendor. about 380 bucks or so... a little much for the old "throw parts at it "till its fixed" routine but I need to get this truck back on the road.

 

[DonFitzwater]

Be sure to post back if that fixes your problem or not. Maybe a few of the other guys can post some ideas of what to check next.

 

[DonFitzwater]

Skeptic, any update?

 

[Skeptic]

So the new assembled fuel rail arrived friday afternoon and I finally got around to putting it in yesterday. It's not a fun process but if you're going to do it, get a piece of 1.25 to 1.5 inch diameter 3/16 wall by at least 2.5 feet long steel tube stock. Makes for a great all around cheater bar.

Anyhow, here's the update.

The code is gone.

There are at least two things that could have contributed to this end state:

1. I replaced the entire fuel rail including the sensor for which the P0193 indicated an error

2. While inspecting the wires after removal of the old rail, I discovered another place where the insulation had worn off of two wires.

 

[Skeptic]

In the course of the last three weeks, I have found at least two locations specific to the 6.7 where wire insulation is damaged or worn from contact with metal surfaces. Save yourself the hassle and check these two places first if you have an issue with codes or odd behavior from the engine.

1. The wiring leading from the crank position sensor that is located near the flywheel on the drivers side of the engine tends to rub on a metal line that runs close by it.

2. The fuel rail pressure sensor wiring tends to lay on metal line that runs around the back of the engine and wear through or the insulation breaks causing all sorts of electrical mayhem.

These problems are only visible if you inspect the wires CLOSELY. The spots can be really small and are easily overlooked.