Hey Gang, 

 

I've managed to get Thor running for the first time in 2 years. I opted for a stock fuel pump for right now since I'm missing parts yet for the AirDog 150 fuel system I've got I'm looking for a bracket for the pump. I have good positive pressure for the CP3 injection pump. I need to find out what the misfire and studdering are about. Cold start it's a bit long cranking not bad. Once it starts it runs rough and smokes white. I've got a set of @dieselautopower +50 HP injectors installed and had them sent back to DAP and found one injector had an issue and was repaired and sent back. Then I ordered a set of o-rings and replaced all o-rings on injectors and cross-over tubes.

 

Once warmed up all roughness is gone. It runs good and strong for what it is. I can even do the oil cap test and the cap does not even move. I'm trying to figure out the cold idle roughness and warm up smoke them once warm it drives and runs great. Even yesterday I drove to town and got 50 dollars of fresh diesel fuel to make sure its got enough cetane and pour point depressants. Currently 39*F here. Last problem in this category is the grid heater light came on yesterday and dinged 10 times signaling its high flow rates of the CP3.  It idles at about 7,9xx PSI of fuel rail. At 1,500 RPM its pumping up to 11,8xx roughly and appears the fuel rail is building good pressure. 

 

With Thor being my project I plan on writing articles as I get things figured out. So anyone give me a hand on this? Monday I'm going to put insurance and registration on Thor and he's going to become my daily runner. Why? Beast finally needs shop time and the rear main seal is leaking. Thor becomes the primary rig for now while I gather supplies for Beast and get my help here to remove the transmission and transfer case so we can access the rear main seal.

 

 

Thor is also going to lose the heavy flat bed and front bumper soon. I'm going back to the lighter factory box and tailgate then factory bumpers and ditch close to a full ton of steel. Thor is fat at 9,300 pounds even empty.

9 minutes ago, Tractorman said:

 

I agree - that's why I am recommending temporarily plumbing the lift pump to a remote fuel container and then going for a test drive.

 Yes, I saw that. It may be worth looking into. Would low lift pressure cause the fluctuation that he is seeing? I don't know but, any fuel starvation is bad. Also, could there be air in the fuel. Bubbles would certainly cause dips in pressures. Obviously that would be isolated to the suction side of the lift pump. Anything on the pressure side would be in the form of a leak.

10 minutes ago, Doubletrouble said:

Would low lift pressure cause the fluctuation that he is seeing?

 

It is possible.  I have worked on a few common rail Dodge Cummins engines.  What I have found is that it can be very difficult to troubleshoot this fuel system, even with the use of the right diagnostic equipment.  You may be fairly certain that a high fuel return rate is occurring, but that could be caused by a leaking PRV, a CP3 pump, one or more injectors, crossover tube / tubes not seating, etc, or even a combination of the these.

 

It is for the above reasons that I would want to prove (which can easily be done) that there are no issues with fuel supply, first - then move on to other diagnostics if the fuel supply is good.

 

One thing for sure..., if there is a problem with the fuel supply, then the high pressure part of the injection system cannot run right.

 

- John

So. I'm going to chase a few different things here. First off I've already talked to @dieselautopower about this and got a clue. So the over pressure valve is a serviceable item which is possible it's leaking DAP has a rail plug to block that possible leak and see if there are any changes. NAPA wants $417 for the valve then DAP can do much better under my vendor side.

 

I called another member @towhungerford and chatted about this issue and he's agrees the over pressure valve could be leaking. This could affect restart because air could be introduced by the return rail. 

 

Personal note...

Sadly today it was like +7°F this morning. I just done with my 6 month check up. My back is killing me found out I've got L3 and L4 compressed and 1.5 inch shorter now. No cancer found but still fighting with my kidneys.

 Glad to hear you cancer free @Mopar1973Man! Chiropractor for the spinal compression? 

1 hour ago, Mopar1973Man said:

today it was like +7°F this morning.

 

8°F below zero at my house this morning, 20°F below zero at the airport reporting station (National Weather Service).

 

- John

You could also fuel field the cp3 and watch it hopefully make full pressure.

 

22 minutes ago, Mace said:

You could also fuel field the cp3 and watch it hopefully make full pressure.

 

No problem grid heater light pops on it locks to 19k to 20k rail pressure cruising faster than 40 MPH. 

 

25 minutes ago, Tractorman said:

 

8°F below zero at my house this morning, 20°F below zero at the airport reporting station (National Weather Service).

 

- John

Everyone here is like nope stay in day too cold to mess around as well the sun is heading down, shadows are coming, temperature already failing. Try again tomorrow.

 

Yes I know date and time are wrong. 

Edited February 12Feb 12 by Mopar1973Man

We are currently experiencing freezing rain. They're calling for up to 1/4 inch of ice.

Might get out today and work on Thor...

Now on Thor i went through and for sure torqued all crossovers to Industrial injection specs of 44 ft/lbs and then added 4 more on a second pass on torque. 

 

Now...

 

I need the chime list for sure. Drove the truck runs way better and more power. Still extremely long starting and loss of prime instantly. Turn off the engine and prime is gone instantly. Also my repaired injector #1 is now tossing P0301 code misfire cylinder one.

 

Chime list - 1, 5, 7, 8, and 10 chimes with grid heater light. Every cycle I would either clear the light with my code reader or it would self reset just idling.

 

I've call Industrial Injection only thing he's will do is sell me a entire fuel system for $4k. Nope not happening.

 

Alligator performance was helpful but no clue on chimes or meanings. Again just would sell a full fuel system, injectors, cross over tubes, cp3, and rail pressure sensor with relief valve. 

 

I'm looking for that chime list.

 

Now @dieselautopower I talked to Lenny and he's going to retest everything for me again being this is the 4th time pulling these injectors in under 1,000 miles.

Edited February 21Feb 21 by Mopar1973Man

You replaced the rail prv?

 

 

2 hours ago, Mace said:

You replaced the rail prv?

 

 

No need when no fuel is leaking out. If you can remove the banjo bolt lightly tweak the line a little and fire it up and watch the PRV top for any changes. No leakage of fuel.

 

Oh just fun to now have a 3 chime grid heater light. I WANNA KNOW WHAT THESE CHIMES MEAN. 

 

As for what I've done today.

 

Mark was a huge help getting the a frame out and then getting the bed cut free from the frame. You have no idea how wild it was to keep lifting the bed and watch the weight transfer and seeing the natural rake of stance return. That bed is farking heavy! Those rear spring had alot of weight. 

Edited February 21Feb 21 by Mopar1973Man

 Is it possible that you are pumping aerated fuel from the lift pump to the injection pump and that is causing the loss of prime? Somehow the lift pump could be sucking in air as it also draws fuel and sends it on its way full of bubbles which would facilitate a rapid loss of prime.

Great minds think alike. I just filled Thor rim full with 98 dollars of fuel and got the bed off and its dry up top of the module and pump is drowning in the tank.

 That should eliminate it from drawing in any air then.

So the last run i was getting P0301 code for misfire cylinder 1 which you could hear clearly. Not to mention it was my repaired terminal injector. Back out all 6 injectors came out again and I got @dieselautopower Lenny is going to bench test them again. See if we can get Thor to run right without all the grid heater chimes. Refused to hold prime too.

 

im going to call around and find the answers to the grid heater chimes and what they mean. Im going to find it and be the first website with the info. No more grid heater might means injector replacement but understand the difference in chime count.

Edited March 6Mar 6 by Mopar1973Man

 That would be great info to have on hand. Hopefully you can get a reliable and accurate source for those chime codes.

Oh ill find it for sure. I've got the gift of gab. I can always talk to some one and get it. 

All I can say is don't call either Cummins or Dodge dealers because they will not help you. They will request the truck be brought to their shop for repair even though you tell them your already a diesel repair shop and just need information. 

 

• Cummins Care - (800) 286-6467 
• Dodge Corporate - (800) 334-9200

Remember ECM stuff is all Dodge corporate and will not get any information for and Cummins electronics. 

Yep, all proprietary info. TOP SECRET!