590ml in 10 sec is the spec. you're half way there, transfer pump, leaking fuel lines, air in lines, or restrictions have to be the prob

 

Checked all of the above. Starting to think its a issue with the tank module.

 

is your pump in the tank module or mounted to the filter? 04.5 may be in tank

 

It's a intank. I dont know if you guys have trouble like we used to in the VP trucks with cracking modules or not ?

 

tank module is transfer pump. if you don't have 590ml@ 10sec without restrictions you need a tank module

 

I agree, however he stated he was seeing 10 psi from the lift pump. This raises another question in regards to volume. 10 psi with 250ml leads me to believe there is a fuel line restriction. volume goes up, pressure goes down.

 

Exactly,
And I know that the tank module is the pump...been doin this a long time.
I was asking is the tank module (tank module and pump are two peices) prone to cracking? I would expect to see more air in the fuel but anything is possible!

 

there is no psi spec for this engine, there is only one feed line from fuel module, easy to ck for restrictions or air leaks, restrictions definatly raise pressure and lower flow. i repeat if you have no restrictions you need a pump

 

Sorry not the case, Just found my bosch Common rail spec book. Minimum of 10 PSI with 1060mL of flow in 10 Seconds.

 

dodge specs are 560ml in 10 sec, no spec for pressure if you have the volume i guess pressure doesn't matter

 

This is test for CP3 pump.
HIGH PRESSURE FUEL PUMP PERFORMANCE TEST

no start test of fuel system
6. 5. Disconnect the FCA harness
7. 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder.
8. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel.
9. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump:
10. Minimum fuel pump flow at 150 rpm cranking speed is 70mL
11. Minimum fuel pump flow at 200 rpm cranking speed is 90mL
12. If the engine is a no start do the following:
13. 1. Remove fuel pump to railhigh pressure fuel line.
14. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination.
15. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4.
16. 4. Disconnect the Fuel Control Actuator (FCA).
17. 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder.
18. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel.
19. 7. Crank the engine for three (3) 10 seconds intervals.


NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter.
20. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump:
21.
22.
23. Minimum fuel pump flow at 150 rpm cranking speed is 70mL
24. Minimum fuel pump flow at 200 rpm cranking speed is 90mL
25.

This is test for excessive fuel injector return flow.
INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM WHEN THE VEHICLE WILL NOT START


--------------------------------------------------------------------------------
1. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing.
2. Install fuel system test fitting 9012 in place of the banjo connector.
3. Install a 5/16 diameter rubber fuel hose (Hose A) onto the test fitting and into a fuel container.


NOTE: This will be measuring the High Pressure return flow for this procedure.
4. Remove the vehicle fuel return line (Quick connect) from the engine fuel drain tube.
5. Install a 5/16 diameter rubber fuel hose (Hose B) onto the engine fuel drain tube and into the fuel container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing.

NOTE: This will be measuring the Injector return flow for this procedure.
6. Unplug the injector harnesses at the valve cover, unplug the harness connector to the FCA.
7. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished.
8. Let all the fuel drain out of each line before continuing.
9. Place (Hose B) into a graduated cylinder.
10. Crank the engine for 10 seconds (Go from Key off to Crank back to Key off). Do not leave the ignition on between tests.
11. Let all of the fuel drain out of the injector hose.
12. Record the amount of injector return flow for a 10 second crank.

NOTE: Flow should be less than 40 ml for 10 seconds of cranking.
13. If the flow is less than 40 ml, the test has successfully passed. If the flow is greater than 40 ml, remove all 6 high pressure fuel lines and re-torque the high-pressure connector nut for each injector. Inspect for damage, repair/replace as necessary. Reinstall the high pressure fuel lines. Re-measure the injector return flow using steps 7 through 12 as a guide. Go To .
14. If the amount collected is still greater than 40 ml, remove the #1 high pressure fuel line. Cap the #1 fuel port using tool 9864 for the 6.7L engine on the fuel rail and re-measure the injector return flow using steps 7 through 12 as a guide. Go To .
15. If the amount collected is less than 40 ml for 10 seconds after capping the #1 fuel port, remove and replace the #1 Fuel Injector and #1 High pressure connector. If the amount of fuel collected is still greater than 40 ml after capping the #1 fuel port, repeat step 14 for injectors 2-6.


SPECIFICATION: Less than 40 ml total fuel return flow for 10 seconds.

 

let me know what you figure out. Im having hte same issues but i got diesel in my oil so I pointed at the injectors, pulled em and had em tested and they passed. Actually in really good shape. Truck ran after I put em in but without improvement. Shut it down and now it wont start. Dont feel like using ether on it yet. good luck.

 

You had fuel in your oil you have an injector problem or connecting tube that was not seated.

 

You've got a connector tube thats not seated in the injector or a damaged connector tube. I'll help anyway I can, Give me a call monday (828)773-6625


Been through this one twice now lol, I've got alldata and mitchell too
Thanks though!! I really appreciate the help guys.
The bosch common rail system tech book shows that the actual correct flow is 1060mL on systems built after 06/04. And a pressure no lower than 10PSI, While the 03-04 trucks were lower flow and no pressure spec. I'll start back on this monday and let ya'll know how it goes.
It's getting a new FCA, RPR Block, and a LP.

My real concern and the reason for this post is customers. With the changing economy and changing people they dont understand the cost of repairs when you charge them $5.00 to patch a tire. This guys already trying to get me to use used parts. I'm more concerned with putting parts on and not solving the problem than i used to be! I guess the reality is that the lift pumps out of spec and should be replaced according to all the data we have available. Before I can diagnose the truck and determine if theres another issue, It's got to have a pump on it that produces the required volume!

Thanks guys!
Lucas

 

I was afraid of that. I followed the procedures seating the injectors then backing them off and bottoming the connector tubes, torquing the injectors and then doing the final torque on the tubes. I reused the tubes but i marked both the injectors and tubes for location. Kind of wondering if reusing the tubes was a mistake.
I checked each tube over and didnt see any cracks and they were all tight in the first place. The tubes wouldnt just start leaking out of the blue to cause my initial trouble would they?