Please Help! Fuel/Electrical Gremlins - Dodge Cummins Diesel Forum
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post #1 of 4 (permalink) Old 02-07-2019, 03:19 PM Thread Starter
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Please Help! Fuel/Electrical Gremlins

Hello all,

I have spent countless hours searching and reading about all the issues going on with my truck right now and just can't seem to narrow this down.

Background- I recently got what I believe was a bad tank of fuel. My fuel level sending unit began not working properly, I had a ton of sediment in the fuel filter canister, the truck idled as if it had a bad "miss", and I began popping low fuel rail pressure code (p0087 I think). After pulling the tank, it looks as though the whole OEM fuel pump/sending unit assembly fell apart. I drained and cleaned the tank/lines, installed a Fleece PowerPro Lift Pump, GDP Big Line Kit, and new fuel filter.

Current problems- As soon as it was all hooked back up and started, I immediately got the red lightning bolt idiot light, an Exhaust Service Required, See Dealer Now message, a fuel rail pressure too high code (p0088) and an EGR Temperature Sensor "A" Circuit High code (p040d). The truck idled a little rough and the injectors were louder than normal, but the "miss" was gone. Took it for short test drive for fresh fuel and it ran OK. As soon as I restarted it, the fuel rail pressure was above 23k and it barely ran. Shut it off and tried a couple more times and it eventually ran, but FRP at idle was 12-13k. Now no matter what the throttle, the FRP stays at 12-13k.

What I've tried so far- Set the truck back to stock and reloaded the tune. Then I cleaned all the battery cables and grounds and even managed to get my batteries warrantied, so they are brand new. I tried the brake-brake/gas-gas pedal reset and even the oil reset for SAG and those did nothing. I unplugged the FCA yesterday and started it, but the FRP still only stayed right at 12-13k.

This thing is driving me insane and I need my truck! Any insights would be greatly appreciated!

Thanks


11 Mega Cab 2500 4X4, MiniMaxx w/OD, ARP625s, SD 2nd Gen Swap, S467.7FMW, BD-Power Exhaust Brake, FloPro 5" Exhaust, Fleece PowerFlo Lift Pump, BMP CAT Fuel Filter, Air Boss Grid Heater Delete, Megaflow TV Delete w/Grid Heater, GDP S2 Intake Horn, GDP Big Line Kit
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post #2 of 4 (permalink) Old 02-14-2019, 10:05 AM Thread Starter
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Does anyone have any experience with these issues?

11 Mega Cab 2500 4X4, MiniMaxx w/OD, ARP625s, SD 2nd Gen Swap, S467.7FMW, BD-Power Exhaust Brake, FloPro 5" Exhaust, Fleece PowerFlo Lift Pump, BMP CAT Fuel Filter, Air Boss Grid Heater Delete, Megaflow TV Delete w/Grid Heater, GDP S2 Intake Horn, GDP Big Line Kit
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post #3 of 4 (permalink) Old 02-15-2019, 10:45 PM
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That's quite and assortment of issues. If I were you, I'd swap in a spare CP3 only because I have one sitting in the corner...

2011 2500 CCSB|Carli|5 blade 72mm|S&S 150%|S&S 12mm|Wilson Patterson 48RE|Freedom Racing Engines 6.8|CTT
2013 3500 MCSB |Carli Backcountry|Baja Designs|Stainless s465|RevMax ZeroFlex|L19|CTT
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post #4 of 4 (permalink) Old 02-21-2019, 10:30 AM Thread Starter
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I finally fixed it. It turned out that the FCA was faulty and caused every one of the symptoms. I put in a new FCA, cleared the DTC's and it's as good as new!

11 Mega Cab 2500 4X4, MiniMaxx w/OD, ARP625s, SD 2nd Gen Swap, S467.7FMW, BD-Power Exhaust Brake, FloPro 5" Exhaust, Fleece PowerFlo Lift Pump, BMP CAT Fuel Filter, Air Boss Grid Heater Delete, Megaflow TV Delete w/Grid Heater, GDP S2 Intake Horn, GDP Big Line Kit
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