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post #1 of 28 (permalink) Old 06-17-2013, 10:58 PM Thread Starter
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P1222 help can't figure it out!!

So I was towing the camper last weekend and driving down the road my wait to start light came on. I just took a smarty off the truck And went back to a stock tune about a week before. So I cleared it and Started down the road again and then it did it about 20 miles down the road again. I believe it's defueling or something because the truck gets gutless When the light is on. Soon as I clear it's fine again. I just had a Turbo go out could this be something to do with it?? It seems to Only throw the code when there is a load behind the truck. I can drive it around town all week and nothing but as soon as I go up the mtn with a load it does it. The only code is p1222 (excessive fuel return). What do I do?

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post #2 of 28 (permalink) Old 06-17-2013, 11:23 PM
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Usually a sign of injectors going south. You should pull them and have them flow tested

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post #3 of 28 (permalink) Old 06-18-2013, 12:24 AM Thread Starter
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But I have no sign of bad injectors in any way. No smoke mor than normal at all. Sounds great runs great except when throws codes. Or can injectors go with no signs at all?
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post #4 of 28 (permalink) Old 06-18-2013, 12:54 AM
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The truck is returning fuel which prolly why it feels gutless. Usually it's a first sign of bad injectors. Do a search on here and you'll see

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post #5 of 28 (permalink) Old 06-18-2013, 03:19 AM
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Grab a beverage and sit down for a read.

WTSL TSB

NUMBER: 18-006-12
GROUP: Vehicle Performance
DATE: February 04, 2012




THIS BULLETIN SUPERSEDES SERVICE BULLETIN 18-011-11 REV. B., DATED JULY
1, 2011, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE
HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL OVERVIEW AND
DIAGNOSTIC INFORMATION.
HELP USING THE wiTECH DIAGNOSTIC APPLICATION FOR FLASHING AN ECU IS
AVAILABLE BY SELECTING “HELP” THEN “HELP CONTENTS” AT THE TOP OF
THE wiTECH DIAGNOSTIC APPLICATION WINDOW.
THE wiTECH SOFTWARE LEVEL MUST BE AT RELEASE 12.02 OR HIGHER TO
PERFORM THIS PROCEDURE.
THE DRBIIIģ FLASH FILES FOR THIS BULLETIN ARE AVAILABLE ON
DealerCONNECT.
SUBJECT:
Flash: Diagnostic Enhancements For Fuel System
OVERVIEW:
This bulletin provides Engine Control Module (ECM) software enhancements to improve
robustness to fuel system issue detection and two new Diagnostic Trouble Codes (DTC's).
This bulletin involves selectively erasing and reprogramming the Engine Control Module
(ECM) with new software.
Diagnostic procedures for these new DTC's are included in this Service Bulletin on the last
2 pages which may be printed.
The two new injector Diagnostic Trouble Codes (DTC's) for excessive injector return flow
are:
∑ P1222 - LEAK DETECTION DURING MOTORING
∑ P1223 - LEAK DETECTION BASED ON QUANTITY BALANCE
**When the fault(s) occur, a solid Wait to Start lamp will illuminate in the cluster along with
chiming 10 times. When the fault goes inactive, it will clear the wait to start lamp with no
chimes**.
and for the p0148

P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM

For the Engine circuit diagram (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -SCHEMATIC -ELECTRICAL)

For a complete wiring diagram Refer to Section 8W.

When Monitored:

• While the engine is running.
Set Condition:

• A deviation between the fuel pressure set point and the actual fuel pressure.
Possible Causes

OTHERS DTC’S PRESENT
FUEL LEAKS
FUEL CONTROL ACTUATOR
FUEL PRESSURE SENSOR
CASCADE OVERFLOW VALVE
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
LIFT PUMP FLOW
AIR IN FUEL SYSTEM
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
HIGH PRESSURE FUEL PUMP
INTERMITTENT CONDITION

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. (Refer to 9 -ENGINE
DIAGNOSIS AND TESTING)

Diagnostic Test

1. OTHERS DTC’S PRESENT
With the scan tool, read DTCs.

Are any other DTC’s present?

Yes >> Repair other DTC’s first.

Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL).
No >> GoTo2

2. FUEL LEAKS
Ensure that the fuel level is above 15% using the scan tool.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components.


Do you have any fuel leaks or damaged components?

Yes >> Repair the fuel leak.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

No >> GoTo3


DR/DH ENGINE -ELECTRICAL DIAGNOSTICS -DIESEL 9 -1117


P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)

3. FUEL CONTROL ACTUATOR
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.

NOTE: The fuel control actuator will only click when cycled off..

Do you hear a click from the actuator when you cycle the actuator off with the scan tool?

Yes >> GoTo4
No >> Replace the fuel Injector pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

4. FUEL PRESSURE SENSOR
Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM

Is the fuel rail pressure reading higher at 2000 RPM than at idle?

Yes >> GoTo5
No >> Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

5. HIGH FUEL PRESSURE
Using the scan tool compare the fuel rail pressure set point with the actual fuel rail pressure.

Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Yes >> GoTo6
No >> GoTo9

6. CASCADE OVERFLOW VALVE
Perform the no trouble code test 9*fuel pump return flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Did the fuel injection pump pass the test?

Yes >> GoTo7
No >> Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

7. CHECK VALVE DAMAGED OR BLOCKED
Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.

Is the check valve damaged or blocked?

Yes >> Repair the cause of the damaged or blocked check valve or replace the valve.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo8


9 -1118 ENGINE -ELECTRICAL DIAGNOSTICS -DIESEL DR/DH


P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)

8. FUEL RETURN LINE OBSTRUCTION, DAMAGED OR DEBRIS
Check the fuel return lines for signs of obstruction, damage, or debris.

Are the fuel drain lines damaged or blocked?

Yes >> Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo9

9. LIFT PUMP FLOW
Perform the no trouble code 9Lift Pump flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Did the Lift pump pass the test?

Yes >> GoTo10
No >> Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

10. PRESSURE LIMITING VALVE
Perform the no trouble code test . Pressure Limiting Valve on the Fuel Rail for internal leaks9.

Did the pressure limiting valve pass the test procedure?

Yes >> GoTo11
No >> Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)

11. LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
Perform the no trouble test 9*Injector return flow test9. (Refer to 9 -ENGINE -DIAGNOSIS AND TESTING)

Are any Injectors leaking or high pressure connectors leaking?

Yes >> Replace or repair the leaking fuel injectors or high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
No >> GoTo12

12. HIGH PRESSURE FUEL PUMP
Perform the no trouble code test 9HIGH PRESSURE FUEL PUMP PERFORMANCE TEST9. (Refer to 9 -ENGINE
-DIAGNOSIS AND TESTING)

Did the fuel pump pass the high pressure fuel pump performance test?

Yes Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 -ENGINE
DIAGNOSIS AND TESTING)

No Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER -1 (DIESEL). (Refer to 8 -ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL MODULE -DIAGNOSIS AND TESTING)
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post #6 of 28 (permalink) Old 06-18-2013, 05:31 AM
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as the guys have told you, think injectors.
inj. return valve rates due to valve corrosion and wear, increasing just slightly beyond spec will cause this code. still will start fine but the damage is done.

1. either have the injectors tested by a REAL HPCR injector test lab or
2. buy new Bosch.
3. sell the truck and buy a simple car.


Quote:
Originally Posted by Ryker Peterson View Post
But I have no sign of bad injectors in any way. No smoke mor than normal at all. Sounds great runs great except when throws codes. Or can injectors go with no signs at all?

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post #7 of 28 (permalink) Old 06-18-2013, 11:26 AM Thread Starter
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So I have been reading a bunch on this same problem and there has been a bunch of guys replacing the injectors and it hasn't solved the problem at all. they have said its a programing issue more than anything and don't waste 3gs in injectors. what will happen if I run it until there is a sign of bad injectors? everything I have read says its the latest update from dodge stock programing which I have in right now. what do you guys think? because im not sure about engine provblems, im new to this, I haven't had a problem besides front end stuff and 2 turbos in the 3 years iv owned it. its been an awesome truck.
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post #8 of 28 (permalink) Old 06-18-2013, 12:46 PM
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There a bunch of guys replacing bad injectors with bad injectors and wondering why the conditions that cause the DTC don't go away, that is a lot more likely scenario.

The sensitivity of that DTC leaves a lot to be desired, but, don't think it is a glitch. If it was there would be a lot more instances of it happening on known good injectors. As many people that are running larger injectors and the number of these trucks on the road it would be nothing but mayhem if it was a glitch.

Easy way to tell if you have a problem or it is a glitch, do an injector return flow test and cylinder contribution to see what is really going on. If the injectors are returning more than they should, well there ya go.

The DTC is set by a calculation based on what the ECU sees a as fuel flow. Either it is actually too much menaing there is a mechanical problem, or, sensors are returning false information. Injectors, FCA, and PRV are the biggest culprits. Start your diagnostics there.

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post #9 of 28 (permalink) Old 06-18-2013, 03:07 PM Thread Starter
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Quote:
Originally Posted by cerberusiam View Post
There a bunch of guys replacing bad injectors with bad injectors and wondering why the conditions that cause the DTC don't go away, that is a lot more likely scenario.

The sensitivity of that DTC leaves a lot to be desired, but, don't think it is a glitch. If it was there would be a lot more instances of it happening on known good injectors. As many people that are running larger injectors and the number of these trucks on the road it would be nothing but mayhem if it was a glitch.

Easy way to tell if you have a problem or it is a glitch, do an injector return flow test and cylinder contribution to see what is really going on. If the injectors are returning more than they should, well there ya go.

The DTC is set by a calculation based on what the ECU sees a as fuel flow. Either it is actually too much menaing there is a mechanical problem, or, sensors are returning false information. Injectors, FCA, and PRV are the biggest culprits. Start your diagnostics there.
So what injectors would be alright? how about remans from industrial injection? or do I have to go new? I believe the remans from industrial are warrantied but not totally sure. I have no fuel upgrades of any sort and no chip just a stock motor. all I have done is a leveling kit with 315/70/17 tires and rims that's it. what injectors do I do? I just called and made an appointment for Thursday morning for an injector return flow test. we will see I guess.

Thanks for the input guys!!!!! Much appreciated!!
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post #10 of 28 (permalink) Old 06-18-2013, 03:10 PM Thread Starter
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Just curious could it be bad fuel causing it to throw it or bad filter? Probably not but just curious. Because I'm on the same tank every time it's thrown it.
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post #11 of 28 (permalink) Old 06-18-2013, 03:17 PM
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so you're down to 2 choices.
1. use it like a car, only hauling a few bags of groceries.
2. trade it in on that Prius you been dreaming about.

replacing worn injectors with new ones with high flow rate nozzles can also cause the fuel rationality ECM algorithm code problem.

this may have been Fiat Chrysler's way of solving all their still on the road engine warranty issues with the 5.9 HPCR caused by add on boy toy programmers damaging their engines. The Fiat software developers came up with the 5.9 ECM Bug from Hell.

Quote:
Originally Posted by Ryker Peterson View Post
So I have been reading a bunch on this same problem and there has been a bunch of guys replacing the injectors and it hasn't solved the problem at all. they have said its a programing issue more than anything and don't waste 3gs in injectors. what will happen if I run it until there is a sign of bad injectors? everything I have read says its the latest update from dodge stock programing which I have in right now. what do you guys think? because im not sure about engine provblems, im new to this, I haven't had a problem besides front end stuff and 2 turbos in the 3 years iv owned it. its been an awesome truck.

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post #12 of 28 (permalink) Old 06-18-2013, 03:24 PM
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Quote:
Originally Posted by Ryker Peterson View Post
Just curious could it be bad fuel causing it to throw it or bad filter? Probably not but just curious. Because I'm on the same tank every time it's thrown it.
Bad fuel might cause an issue. Plugged filter and the FCA having to go longer duty cycle to provide fuel thats a possibility. COV dropping case pressure and forcing longer duty cyclce on FCA, possibility.

Time to test what you can looking for issues. The fuel system is compicated enough it could be one of many things cause downstream problems.

Buying reman injectors is a good way to get the problem. No way most of these places can adequately test what the injector will perform like in the truck. Some aren't even using the Bosch approved test benches for testing. Just how good the testing is will forever be a huge question mark. Too many variables to say definitvely.

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