This is my first time posting to this forum, as I could use some help.
I believe I have done my do diligence searching and reading other posts before electing to post my own; however nothing I have found seems to fit the specifics of my issue. I hope someone out there will have an aha moment that can help me keep from throwing money at this issue, that I simply do not have. (Office closing at the end of this month.
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I have a 2004.5 Dodge 2500 4x4 Cummins that recently had the #4 High Pressure line fail, witch pumping a ton of diesel (i.e. More that I would have ever wanted) on the drivers side Engine Compartment and all down the drivers side of the truck, before dieing when I let off the throttle.
I replaced the #4 High Pressure Line, but the truck initially did not start.
After discovering that the system was suppose to be “Self Priming” I started doubting the functionality of my Lift Pump and proceeded to remove the top cover on the fuel separator cylinder, so I could visually check to see if fuel was being pumped when the key was turned on. After draining fuel using the drain valve, it appeared evident that the pump must be working as fuel was being pumped into the cylinder, so I put the cover back on and did more research.
I found a Priming Sequence, which required me to cycle the key to the on position for 25 seconds and repeat a couple times, then try to start the truck.
After a couple attempts including one time of cranking the key for about 15 seconds, the truck started and idled normally.
Unfortunately I now discovered that the Check Engine Light was on and proceeded to turn the truck off and check the codes. (It was throwing a P0148 “Fuel Delivery Error”.)
I did some research on this code and found a multitude of possibilities; however most of them dictated a trial and error approach replacing parts along the way.
Several posts indicated that the Lift Pump and/or a clogged fuel filter could cause the problem, so I pulled the cap back off the separator and discovered that the Fuel Filter defiantly should be replaced. It looked dark black in color with a sludgy appearance on the outside of the filter. (Please don't grill me on this one, as I will pay closer attention to this in the future and remember that the truck was running fine prior to the line letting go…) I replace the filter and the O-Ring on the separator cap and start the truck again. I read and cleared the codes, but “No Luck” as the code simply would not go away...
I then bought a Fuel Pressure Tester and designed a Tee I could connect to tester to and used Clear Tube on either side so I could see if any obvious air bubbles were being pulled from the lift pump to the injector pump. (I temporarily replaced the existing rubber hose that joined the two steal lines between the Lift Pump and the Injector Pump with my T-Connector.)
I turned the key to the on position and observed the pressure reading to be 10 psi. I pushed the bleeder button, but it remained at a constant 10 psi, while the Lift Pump was running.
I turned the key off and bled the pressure down to 0 and repeated the test indicated above. (Same Result, 10 psi.)
Although I am very concerned about damaging the Injector pump, I figured that 10 psi was double the minimum, of 5 psi, so I started the truck and checked it while idling. (Same result 10 psi.)
I took the truck for a test drive and to be honest, it has plenty of power and does not show signs of any problems.
I realize that the P0148 code could be caused by anything starting from the fuel tank all the way to the injectors, but my mind is telling me the issue has to be coming from something before the injector pump and may be electrical in nature, with the following considerations:
1. The Code “Never” clears and continues to occur without ever starting the truck. (i.e. Turn the key to the On position, with the Lift Pump running only. Clear the code, Check Engine Light Flashes, but will not go out. I have used two different tools, one of which was a Snap-On brand with the same result..)
2. The High Pressure Line did fail and caused the engine to die. However the code was not present prior to this issue.
3. The Filter was changed and the Lift Pump holds a constant 10 psi, for the 25 - 30 seconds that it runs in the ON position as well as while the engine is running.
4. I realize that an unplugged sensor could cause an error to be thrown, so I have checked to see if I inadvertently disconnected any plugs near the Fuel Rail System or the injectors and they all look to be connected.
5. I have unplugged and re-plugged the three connectors I found on the Lift Pump and Fuel Water Separator housing. I have also visually looked at the wires going to the Injector Pump, but they all appear to be fine.
Although I may be wrong and my logic might be flawed, but it seems to me that Injector Pump Pressure and Injector issues should throw a code after the engine starts or at least allow me to clear the codes before reoccurring after the engine has started. Although I would not expect getting diesel on any of the plugs, found in this area, should cause an error code of this nature, I am still trying to determine the timing of the code since it only occurred after the fuel line let go.
Is there any chance I could have caused this code when I removed and replaced the Fuel Filter? I do not see how, but check engine light was not on prior to the line letting go...
Anything constructive would be greatly appreciated.
Thank you in advance for your time.
Thanks Brother, Looks like I can now justify a F.A.S.S system without risking a divorce.
Linear Mode
