My new(to me) truck has been giving me issues the past two days. First, the specs of my truck:

2003 CTD 2500 4x4 6spd 305/555. Industrial Injection SPS 62/80 turbo, DDP 90hp nozzles, Edge EZ, Smarty Revo, FASS 150, Fluiddampr, Diprocol RP gauge

Ive been changing around the levels on the Smarty, just learning what it does. Before, it was on SW2, tim0, tqm 3, rp0. Truck ran great and had awesome power. Changed to SW4 for a couple hours, ran awesome as well.

The next day I was back on SW2, but added tim3 just to see if my MPG would increase. Truck ran great, mileage increase slightly, black smoke decreased significantly. Did not notice any injector rattle or abnormal noises

Problems started on Sunday. Truck was still programmed to SW2 with tim3 and was running great. Stopped and got fuel at a local store that I have been going to for 2+ years occasionally and never had a problem with bad fuel. Its a BP station with diesel FWIW.

Fast forward 30min later, driving down the interstate at between 60 and 70mph I started noticing that my truck was surging, RP on my gauge kept jumping past 25Kpsi. Got to my destination 10min later, and put timing back to stock. Got back on the road and the surging continued. Felt as if the truck was trying to accelerate on its own without much throttle input. Pulled over, and redid the programming again. After this, it ran perfect all the way home.

Couple hours later, went to the store. Leaving the store, at startup, i noticed a noise that I would call injector rattle for about 2 seconds. I pulled out onto the road, drove about a quarter mile then the surging came back. I saw my RP gauge almost peg itself and the truck took off. I had to depress the clutch to slow down, barking the turbo as the truck seemed to be at WOT. Got alot of injector rattle and weird throttle responses.

Put the Smarty back to 0 and restarted. Truck lopes real bad and I shut it down. Disconnected batteries for 10min. Restarted, and truck idled fine. Pulled out for a test drive and the surging was still there. Pulled over and truck was shaking and idling very rough. Everytime the RP gauge would spike, the truck would almost go to WOT. Figured it might be something with the Edge EZ pressure module. Got back to the house and removed Edge, so now there is no programmer on the truck. Started truck and it lopes real bad again. Takes a little longer to start as well, but not more than maybe 4 cranks more than normal. Disco'd batteries again, started it up again, and loping is still there.

So now, I have the following codes thrown says my Smarty. ***There were no codes showing whatsoever before I pulled the Edge off.

P0237- map sensor voltage too low
P0251- CP3 pump regulator control
P2269- Water in fuel condition
P0652- sensor reference voltage 2 circuit low

Being that I have a FASS, I dont think the WIF sensor is even in use right? Before I pulled the Edge and it started and idled fine, everything sounded normal, so I wouldnt think it would be something mechanical, more electrical, like a sensor or something. Not seeing anything but black smoke

Sorry this is so long, but this truck is my daily driver and I need it to be running. If ANYBODY has an idea whats up with this thing, I am all ears!

Thanks, Peter

 

Fuel control actuator could be sticking. It has a two wire plug and is mounted on the back of the CP3. It controls the rail pressure. They are only about a 100 bucks and it only has 3 torx heads holding it on, but they are normally tight and you want to make sure the torx is fully engaged. Cummins is the best place to buy one since they are twice as much from dodge. You should just need your engine serial number tell them you need a Fuel Control Actuator.
What is your rail pressure as it lopes at idle? There is a chance that it may have damaged an injector or two from excessive rail pressure. Since you just bought this truck you might check to see if the rail pressure relief valve is still functional. They might have blocked it off if it went bad. Just so you know the EZ runs a lot of rail pressure and can be pretty hard on injectors. Good luck with your problems.

 

The seller has an FCA on the way to me from Cummins, so ill have to see if that fixes it. If I had a damaged injector wouldn't there typically be some white smoke? Not sure, just what ive read?

Now I am getting a Camshaft Position Sensor Signal Lost code, and my tach is not working. RP is around 4-5K at idle. While it is loping, if I give it the slightest bit of throttle, the truck revs up much more than what is requested of it, for a longer duration.

The EZ was always on level one, so hopefully it hasnt been too hard on the injectors. I never got a RP too high code or anything.

thanks for the help

 

And I still dont know where the water in fuel light and code came from. Im running a FASS, so no WIF sensor should be involved

 

When you play big you will lose! Where is your fuel pump ?

 

isn't there some posts about rubbing wires on 03's, that cause all kinds of problems?

here it is

https://www.dieseltruckresource.com/...=rubbing+wires


Joe

 

What did you find with your problem? FCA?

I've got a similar problem.

 

It ended up being both the Crankshaft and Camshaft position sensors. Dealer also said my Diprocol RP gauge was causing high RP, but I dunno how correct that was. Reconnected and truck has been running great since.

 

Wow, thats not what I expected.

I have changed my crank sensor already but I wonder if maybe I should do the cam as well....

Thanks for the update.

 

Dipricol rail press gauge harness is crap, at least the first ones released.