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Old 06-14-2013, 06:30 PM
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rough running but no codes.

So my truck crapped out the other day running really rough. I just converted the truck to run on efuel and boosted the pressure to about 65psi. Don't ask me why; just did; some folks say a little more power. The truck was running GREAT. All the sudden it started acting like it was missing. Fuel pressure is good. All I get is P1111 (system pass) code. Still rough as hell. Are my injectors just shot, but still firing??
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Old 06-14-2013, 06:35 PM
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Possibly cps

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Old 06-14-2013, 06:40 PM
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Already changed out the CPS. The IPR is brand new this winter, IPC sensor new this winter as well.
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Old 06-14-2013, 06:46 PM
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Forgot to add, I replaced the pigtail on the IPR at the same time as the valve, and the UVCH's are new on both heads. I've also checked all four connectors to see if there was any loose connection. No change. I'm stumped.
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Old 06-14-2013, 07:01 PM
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Is the IPR coil nut snug? Have you rechecked your fuel pressure? If it is still at 65 psi, have you tried backing down to 60 (although 65 should not be an issue)? How's the oil level? Cheers!
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Old 06-15-2013, 05:54 AM
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I checked the coil nut when I checked the ipr connector--it's snug. I have a fuel pressure gauge--it's still 65. Oil level is good. Fuel pressure shouldn't affect it--it was running better than ever for a couple weeks at 65psi.
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Old 06-15-2013, 06:00 AM
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MORE INFO

I just remembered something. When I was running up a hill or hard on the throttle, the fuel pressure never dropped much, BUT when I let off the accelerator, it would sometimes surge up for a split second, up over 80 psi. That's why I'm suspecting the o-rings. ALSO; I had just filled up the tanks about 10 mins. before the problem. Big rig station; I get diesel there all the time; I don't think it's bad diesel. Point is, I let it idle while I was filling up. There was a bit of smoke at idle, which usually doesn't happen when the engine is up to temp. This also makes me think rings--burning oil?



If one or more of the injector o-rings were bad, it would keep pressurized fuel from entering the injector, right? I know the o-rings could explain the smoke.
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Old 06-15-2013, 11:13 AM
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PROBLEM GONE!!! WTF!!!?

Well, I don't know what the @#$K is going on with this truck, but it is running fine at the moment. So I tapped the fuel pressure gauge, and realized it wasn't getting power. The harness was loose, and when it re-connected, the pressure reading climbed to about 75psi. I backed it off to about 50psi, and PRESTO-CHANGE-O. The rough running disappeared. Turns out, the truck does NOT like to have the psi that high. I don't know whether the fuel was bypassing one or more of the injector nozzles because of the added pressure and (VERY) old injectors, but in any case, it is running great right now. I even set the EVO-CTS to "extreme" and cranked it up. The truck runs awesome.


I still believe I need to replace the injectors with new rebuilds, but now the problem is a little bit more back-burner than immediate.

The other possible scenario is that by getting up onto/into the engine bay to get to the pressure sender and FPR to change the pressure, I might have re-connected something that was loose. I seriously doubt that took place, because i checked and re-checked all the harnesses by unplugging and re-plugging them all back in with the engine running, with no change in smoothness until I backed down the fuel pressure to just over 50 psi.

Because I changed the mechanical pump to electric, the water-in-fuel sensor, fuel heater plug, and low pressure indicator are not being used, and are cable-tied together, out of the way. There was no easy way to utilize them without re-using part of the old pressure regulator, which I did not want to do. Maybe the stock pressure sender, which I thought only indicated too low of pressure, triggering the "fuel filter" light, also would have indicated a DTC for high pressure? Whatever, it's running.
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Old 07-29-2013, 08:58 AM
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Little update:

So the same problem happened again, and I had to get towed home....again. The tow truck driver happened to be a diesel mechanic. Problem isolated in about 2 minutes. One of the injector harnesses WAS bad. I thought I'd tried all 4 of them pulling out and plugging back in, but apparently not. I pulled the harness and sure enough, one of the pins was loose and intermittently losing contact. New harness spliced in, happy diesel.


And, I bumped the fuel pressure back up to about 65-67psi. I must have been touching the harness while adjusting the fuel pressure before.
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