Hi everyone. Back again with this same truck im trying to work on.

Bought 2005 5.9l cummins
had major issues
rebuilt motor. Had head machined and block bored to 0.20 over
Cylinder 6 was in bad shape, bored to 0.40 over and sleeved back to 0.20
Just installed brand new BBI stage 0.5 injectors today as well as new fuel feed tubes
Was having trouble getting truck to fire. Would crank but no fire.
Checked all connections and I am 100% sure injectors and feed tubes were done right to spec.
Cranked for a total of maybe 2 minutes in 20-30 second intervals throughout the morning.
Unplugged FCA just to see if rail pressure was the issue.
Truck fired right away. Lots of white smoke and knock.
Shut truck off after maybe 3-5 seconds of idle.
Plugged FCA back in. Truck fired.
Same result - lots of white smoke and what sounds to me like a feint knock.
Also, Fuel rail pressure sensor is new.

I'm sure the injectors are not the problem I think its electrical which I'm terrible with, so hoping someone can treat me like a 5 year old to get through troubleshooting.

Also, when I bought this truck, the FCA it had on it was melted. The receiver end that attaches to the CP3. Plastic part was melted. So I replaced that. The FCA in it now is about 12 months old but has almost 0 hours on it. Just been sitting.

Codes I pulled after borrowing buddies scanner.
P0088 - Fuel Rail pressure too high - maybe the FCA is not working. I plugged it back in but it wouldnt fire before only after I took it off and still fires after I put it back on.
P0107 - MAP sensor circuit low
P0073 - Ambient Air Temperature Sensor Circuit High
P2121 - APPS 1 performance
P2509 - ECM/PCM power input signal intermittent - batteries are older I think just need to replace but not causing the problem I have
P0517 - battery temp sensor circuit high
P0251 - Injection Pump Fuel Valve Feedback - this one I think is important

Video of symptoms:

You Tube

Any help is greatly appreciated. I really dont want to take it to a shop. I feel like ive done so much I want to be the one to bring it home.

Only response I've gotten from other forum is batteries, which I will try but don't think will take away a knock and white smoke. Maybe I need a new wiring harness.

 

I think I have a grounding/wiring Issue as from what I understand the APPS, MAP sensor, and AATS are all controlled by same part of the PCM. I think they share the same ground.

If anyone is able to explain how I can test that connection please share.

Thanks

 

Based on your description, it appears that there is a fuel delivery issue with your 2005 2500 truck. Your next steps could be to:

• Check the fuel pressure regulator and replace it if necessary
• Check the fuel pressure sensor and replace it if necessary
• Check the injectors for clogs or leaks and replace as necessary
• Check the fuel pump and replace it if necessary
• Check the fuel lines for leaks or clogs

It's also a good idea to consult a mechanic or a diesel specialist for a proper diagnosis and repair. They will be able to perform tests and inspect the system in detail to determine the root cause of the issue and ensure that your vehicle is running smoothly.

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