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Old 04-14-2010, 03:28 AM   #1 (permalink)
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Erratic Rail Pressure, Lost Power & MPG

I am having erratic rail pressure and rail pressure will not go over 19K. When accelerating the rail pressure would climb up with the RPM as normal till it come to a point of diminishing return and the more you step on the skinny pedal the rail pressure will drop about 6K PSI and will stay there till the RPM picks up and the rail pressure recovers or if you back off on the skinny pedal just a hair and the rail pressure will immediately climb till it maxes out at 19K.

When on cruise control on the highway @ 60 MPH the rail pressure will be at about 18K and as soon as you encounter a small hill or incline when the ECM demands more fuel and rail pressure to counter the load, instead of increasing the rail pressure, it drops to about 12K and does not build power as it should.

At times when I’m at a stop light the rail pressure bounces from 7K to less than 3K and the RPM bounces around in concert with the rail pressure and the truck feels like it will stall. One time I was on the highway cruising @ 60 MPH I noticed the truck surging, rail pressure and RPM bouncing. It only did this once. ECL came on and I checked the code with the SMARTY and it says "P0193 fuel pressure sensor voltage too high". Cleared it and never came back.

I’ve also lost power along with about 9% in fuel mileage. The truck feels sluggish and has lost the getup and go. It feels like a stock truck without all my mods. I’m suspecting possibly a bad FCA. I welcome any suggestions on what could be wrong? Sorry for the long post.
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Last edited by PRO-NRA; 04-14-2010 at 11:39 AM.
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Old 04-14-2010, 04:27 AM   #2 (permalink)
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Lift pump??? Clogged filter(s)?
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Old 04-14-2010, 04:37 AM   #3 (permalink)
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I'll change all my filters tomorrow and give that a try. This is driving me nuts as the truck been good to me with no issues since I bough it new.
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Old 04-14-2010, 04:39 AM   #4 (permalink)
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I would say check out your fuel rail press releife valve when they pop open they like to stay open until pretty low pressure is there kinda sounds like your problem but also your fuel control regulator might be but i would put more money on the press releife valve
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Old 04-14-2010, 11:32 AM   #5 (permalink)
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Quote:
Originally Posted by Hotshot3500 View Post
I would say check out your fuel rail press relief valve when they pop open they like to stay open until pretty low pressure is there kinda sounds like your problem but also your fuel control regulator might be but i would put more money on the press relief valve
Would a fuel pressure relieve valve causes erratic rail pressure at idle since the rail pressure is low? I can see it at higher pressure and initialy that's what I suspected it was since the rail pressure will not go over 19K but when it is erratic at idle sometimes I leaned towards the FCA. Who knows it might be both the pressure relieve valve and the FCA.
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Old 04-14-2010, 11:34 AM   #6 (permalink)
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i'd start with the relief valve, then check the cp3.
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Old 04-14-2010, 06:08 PM   #7 (permalink)
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another thing is the Fuel Pressure sensor if thats getting incorrect reading it will change fueling and make it stumble
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Old 04-14-2010, 11:34 PM   #8 (permalink)
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The FCA is what dictates pressure output of the CP3, my truck would stumble on take-off from a dead stop and had random "flat spots" when accelerating, never put a rail pressure gauge on it but I replaced the FCA and it runs like a top again. Sorry I don't have any rail pressure numbers to give you for a reference.
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Old 04-21-2010, 01:47 AM   #9 (permalink)
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Not the FCA

I borrowed an FCA from a member from another site. I installed it and took it for a test drive. Basically no change to the rail pressure dropping with power demand. I am now narrowing it down to the rail sensor, relief valve or even the CP3 itself.

This started after the truck sat for 4 1/2 months without being started. The day I got back she started on the first crank and noticed the erratic rail pressure when I got on the interstate. The sensor could have corroded and went bad over the 4 1/2 siting? I already changed the two CAT 2 micron filter and the Baldwin 5 micron in the OEM fuel canister. I did noticed the Baldwin media was black. The FP went up 1 PSI after changing the filters. I have a rail cap coming in and I'll cap it to eliminate the relief valve. After that it will be the sensor. Man this thing is pissing me off.

What do you all think?
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Old 04-21-2010, 05:33 AM   #10 (permalink)
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bad case of bugs in diesel, algae/bacteria growth from setting 4+ months especially if you have any bio diesel. the bugs also pee water into the diesel adding to the corrosion.
plan on both the rail pressure sensor and the rail press. relief valve.

new RP relief valve is less costly than blown split injectors and diesel in the crankcase blown engine.

may have corroded FI injectors/noozles also.

try a double dose of Diesel Kleen.

mean nasty bugs, they make acids.

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Last edited by steelhead01; 04-21-2010 at 05:36 AM.
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Old 04-21-2010, 11:29 AM   #11 (permalink)
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bad case of bugs in diesel, algae/bacteria growth from setting 4+ months especially if you have any bio diesel. the bugs also pee water into the diesel adding to the corrosion.
plan on both the rail pressure sensor and the rail press. relief valve.

new RP relief valve is less costly than blown split injectors and diesel in the crankcase blown engine.

may have corroded FI injectors/noozles also.

try a double dose of Diesel Kleen.

mean nasty bugs, they make acids.

I never has any bio in the tank. I guess I'll have to get both rail pressure sensor and relief valve...anyone have a new one they want to sell?

Yep the Baldwin filter looked just like that picture. I could not see the two CAT filters downstream from the Baldwin since they are sealed.

I'll have to locate some Diesel Kleen...Who sells this stuff?
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Old 04-22-2010, 07:36 AM   #12 (permalink)
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Any luck? I have the exact same thing happening to my truck after it sat for over 4 months during winter last year untouched. I've replaced the filters numerous times and went up to 10 micron, I put in a new replacement FASS, brand new CP3, replaced FASS relay, swapped FCAs. I was going to try a rail pressure sensor but they want $564 for one up here. Let me know if you get it figured out. I put in a heavy dose of injector cleaner on Monday and I'm trying to run this tank out. Mine acts worse in the cold like at or below freezing.
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