Fuel Delivery Issues

Approximately 18 Days ago, my truck would not start. Was running the night before, noticed increased Ping under load as well as a significant loss in power. Next morning engine turns over but would not fire.

Day 1 - Towed into DC and they replaced the #1 injector. Truck started and ran 10 blocks sat overnight and would not start again the following morning.

Day 2 - Back on the hook to DC.

Day 3 - DC says must be fuel contamination because now 4 additional injectors need to be replaced because they will not open (easy math tells me that I still have one good stock injector left) I said that if it was bad fuel them wouldn't all six injectors be equally impacted as same fuel flows through all injectors at the same time. Also why were these other injectors apparently tested as fine with only one requiring to be replaced 10 blocks ago.

Day 4 - Collected fuel and oil samples from the truck at the dealership. Waiting on DC Techline to release the replacement injectors. I asked if the injectors were leaking or stuck closed. The injectors were bypassing in the closed position (not opening) I suggested maybe an injection pump issue or electrical. DC said that standard practice was to test the entire injection system and the injection pump (CP3) tested good.

Day 5 - 9 Injectors installed (5 additional = 6 total) Truck still would not start. Now Dealer is telling me that they think it is the injection pump (CP3). Waiting on advise from techline. (Pump must have gone bad while sitting in their shop).

Day 12 - Tech line suggested further testing before they would release the CP3. Dealer conducted further testing and the CP3 was released. Dealer installed the CP3 and attempted to start the truck. Still would not start.

Day 13 - 15 Tested transfer pump all OK. Electrical connections OK. Pressure on inlet side of CP3 is within spec. Pressure on outlet side of new CP3 is half what it should be. Pressure not registering high enough in the PCM to open the injectors.

Days 15 - 18 The technician is staring blankly into the engine compartment where he has all kinds of stuff tore apart and hanging loose. I took one look and shook my head in disgust.

On Monday I have the day off and plan on sitting in their shop all day to watch the performance. Anyone with similar past experience please advise me on what to do next. I’m thinking that it may be a fuel pressure sensor, pressure relief valve or MAP sensor issue.

Problems Again

Truck ran great for the 50 miles I drove it that weekend, now the injectors crapped out. Engine had a miss and something did nor sound right. Pulled over , the engine was running on and the truck was doing a break stand with no assistance from me other than me holding on the break for dear life as I shut the engine down. Towed back to dealer, six new injectors, got the truck back the next day and drove about 20 blocks and started the same thing over again. Now they have had the truck an additional seven days (5 weeks total) and the problem still has not been fixed.

Went to the dealer yesterday to look at the paperwork and all diagnostics conducted on my truck in the past 5 weeks that they have been diddling with my truck. Seen the photos of all components and fuel samples sent to Daimler Chrysler. I did not see any obvious issues with anything. To go through three full sets of injectors in a period of less than 100 miles is just insane.

I told them it has to be something with the electronics opening the injector, ECM or PCM or some pressure relief valve issue or perhaps there has been a installation problem when they installed the injectors. I have contacted DC Customer care line to discuss the issue with my truck and they even seem to be dodging the issue. I feel like I'm beating my head against the wall.


FUEL FILTER

Just got a call from the dealer yesterday, he told me to come in as he wanted to show me something. Went into the shop and the he had my fuel filter out on the bench and showed me that the filter element had come apart from the housing. He suspected that the filter was allowing particulate to bypass into the injectors causing them to fail. I looked back on the work orders from day one and the work order from the first time in indicated that the entire fuel system had been inspected "FUEL AND AIR FILTER CHECKED - OK".

I asked them if this was the case and I had put less than 100 miles on since it had come in the first time, I find it hard to believe that the damaged filter was missed in the first place especially since the work order indicated that it was inspected. Also if contamination was suspect, the Dodge shop manual indicates that the entire fuel system is to be flushed and filter replaced. The tank was dropped (which I paid for) and the tank was emptied and fuel sample was collected. Fuel sample results indicate that there was 24ppm of sediment and water in the fuel sample. I called the lab and they indicated that the allowable limit is 500ppm, so my sample was way below the allowable limit.

I also asked why in gods name would they replace the old filter after inspection in the first place. It stands to reason that if you are looking at this as a possible issue, one would replace with a new filter ($10.00) which I would have gladly paid for if the dealer would not cover this cost under diagnostics. If Dodge will not cover this under warranty, my only other option would be to go after Luber-finer to cover the repair costs under their warranty.

On another note, when doing a diagnostic test on the fuel system, if the filter element is damaged and allowing fuel to free flow into the injection system, wouldn’t the flow volume be higher than expected causing the tech to question the increased flow volume and further investigate the cause of the increased flow.

Feels like I get this pain in my head but just can't figure out what is causing it.

 

I would find a new dealer if one is close by. I had a problem with my Intrepid I let my wife chew on them it came back fixed after that.

 

Do you think she would mind giving my dealer a call??

 

Just out of curiosity what brand Fuel Filter was it? P/N?

Any chance that the filter was materially defective or somehow mis-handled and damaged when it was changed out?

 

Which brand of filter? 7 or 10micron?

 

It was a Luber-finer Part # L1261F which is a 10 micron filter similar to that used by Dodge.

On your second question....all of the above are a posibility. I don't know what shape the filter was in the first time it was taken out and checked by the tech and replaced. So I can not say it was the filter or the techs fault.

 

Exactly why my fuel filter gets replaced at every oil change 5k miles!

The Common rail seems to be especially finiky in this respect!!

I also only use Fleet Guard filters!!

Rick

 

Here is the thing, I only had 1200 miles on the thing befor it let loose. How many people inspect their filter between filter changes? I would guess none!

I am very diligent on maintaining my vehicle......mostly because I hate to walk...and a happy truck is a happy owner. Some things are just out of our control. If DC will not warranty the work, I have 30 days to make a warranty claim againts the filter manufacturer.

 

X2 here......except every 7k to 8k miles with synthetic.

Greg

 

seems to me, if the dealers Mechanic took out the filter, and did an inspect, he put it back in wrong somehow,

and he's your huckleberry.

 

Thats the direction I'm hoping it goes. So far DC is not saying that I'm responsible but if the time comes, I will point the finger back in their direction.