Along with some other issues that is...
New guy here, and I wish I had surfed the diesel forums alot sooner.
I've done alot of reading on this and the other main forums and have learned alot in the last 2 weeks. Now on to the l o n g story:

Early July I took my truck in to the dealer for a turbo speed sensor code and they replaced the sensor. I also complained of a diesel smell from the exhaust. Dealer had no comment on this. Oil and filter changed at that time due to a killer price I couldn't pass on.
I replaced the fuel filter a day or 2 later as it was time (56k miles).

Fast forward 2 weeks later. Towing my trailer (8k# loaded) up hwy 395 to the sierra's when I noticed a loss of power, tranny downshifting to climb up some easy hills into the Little Lake area.
Got into Coso Junction and looked things over but didn't find anything, no codes and it seemed it was running ok so I continued on.
Got about 3 miles out of the rest stop and had a severe power loss/piston slap and all and had to pull over.
No CEL, nothing... Checked what I could and while I was outside (in 100 deg heat) the CEL finally came on.
I let it idle for a while and pulled out to find a turnaround. It seemed to be running well so we nursed it into Lone Pine for the night. On the way there I got the DPF full message on the ovhd and checked the codes at the campground. Found P200C DPF over temp bank 1, P242F DPF restriction, ash accumulation, P1451 DPF performance and P2267 H2O in fuel. The last one from when I changed the fuel filter and forgot to connect the sensor wires.
Sorry, I dont (didn't until now) have gauges so I can't give any info temps or boost.
I took it out the next morning to see if it would regen with no luck. (I know better know) I found an ex ford diesel mechanic that looked at the truck and clued me in on the no regen mode it was in. He suggested clearing the codes and seeing if it would regen. If so then I could carry on from there. If not then it was 200 mile tow time. (yeah, I lost all the data)
Long story short, it went into regen and cleared the ovhd console message and limp mode.

We test drove it up to Mammoth Lakes and back with no codes. (230 miles or so) I lucked out and found a friend that towed the trailer up the hill for me so we finished our vacation a little late, but finished it all the same.
Since we didn't have any issues we towed the trailer down the hill and left it in Lone Pine until the DPF/engine issues were ironed out. (too many hills going home and didn't want to get stranded w/a dog, 2 grandkids, wife and trailer in the desert)
Checked for codes again before leaving and got a pending P0489 EGR control circuit low.

Took it to the dealer and they cleaned the EGR valve, did the Cummins worksheet, did a stationary desoot, test drove and gave it back saying I needed to replace the air filter and fuel filter.
Did the Air filter when I got it home and since the fuel filter only has 2k on it, I figure it doesn't need to be done(?) May still do it if the forum feels it should be done again and since the tech didn't say why, not in records or low fuel rail pressure...
Ordered and installed the Edge Insight gauge setup to keep an eye on things alittle better. Didn't have time to install the EGT sensor but watched the DOC temp and a general indicator.

Went out and picked up the trailer last Tuesday. No real issues coming home, no codes or pending codes. DPF regen'd twice on the 200 mile drive home. Still smell diesel in the exhaust and now have a nice coating of soot in the tailpipe. I still feel it lacks power as it's downshifting to pull easy hills at 65mph (for the socal folks its the hills coming out of Little Lake to Mojave. I don't remember it downshifting to pull those hills, or climbing Sherwin grade at 65+ for that matter) and I've gone from 10.9 to 9.7 mpg towing. The 10.9 mpg has been constant since I bought the truck in Jan 2008.

So here I sit, lack of power, diesel smell in exhaust, DPF probably cracked and still no idea of what caused it all. I read the TSB on the codes I got, but as far as I know the dealer didn't do it as it wasn't on the repair paperwork.

In all the reading, I found that a bad injector could cause it, or air filter, or ECU, or turbo or..... Don't know what all they checked as they only said they completed the "Cummins Worksheet". Anyone know what all is checked on it?

Any ideas? Is the DPF covered under the catalyst warranty or is it my cost? I'm at 58k now, still have 6 months on the California long term emissions warranty and 18 months on the Cummins warranty. And gotta hook up the EGT sensor this week if it gets below 105 outside.

Again, sorry for the really long post, but more info is usually more good'er.
thx, dan
2007.5 Dodge 2500 Mega cab auto trans (cant remember the diff ratio, but it's the lower of the two)

 

do all the deletes as soon as possible

 

I wonder if you bought my old truck? I had same problem w/ my 2007.5 mega 4x4 w/ the EGR that went to limp mode (filter was full and wouldn't regen cause of it being faulty, it was replace for free by the dealership) out in west Texas coming home to Dallas towing my T.T. I knew something was wrong when I was towing up a very long hill and had it floored going 55mph and a Toyota Camery pulling a small U-Haul passed me up like I was standing still!

 

I'll do the deletes when the warrantees expire.

I bought the truck new in Jan of '08 so I don't think it's yours.

So a few questions.
Is the DPF covered under my Cal long term emissions warranty or the Cummins warranty?
Am I correct in assuming that I shouldn't smell diesel out the tail pipe even in active regen mode?
Anyone know what's on the Cummins Worksheet they use to check out problems?

Just a few things I need to know to decide where to go from here.
thx, dan

 

I thought so. Just joking w/ ya.

 

The delete answer is always a forum favorite here! So take no offense xcc...

I would check with Dodge about that. I had some surging issues etc with my 07.5 and it did come from DPF/EGR stuff but Dodge took care of it all under the Cummins warranty...

 

I found the Cummins Diagnostics Worksheet on the web. Looks like it's pretty indepth. I just need to get a copy of the one they filled out to see what they found. (it gets attached to the dealer paperwork and filed)

I guess I'll find out about the DPF when I take it in next week.

One thing I'd really like to know before I take it in,
has anyone smelled raw diesel out the tailpipe on a 2007.5 and newer Cummins 6.7? It's real important to me as it may lead to an underlaying condition that was not addressed at the dealer in June, before the DPF issue in July.

thx, dan

 

There should never be any raw diesel smell from the tailpipe on a 2007.5 or newer. There can be some weird smells and sounds, but never diesel.

 

thx, it's good to know I'm not crazy.
Now off to the dealership.
thx again, dan

 

First, I'm no expert but you shouldn't smell the fuel in the exhaust and the tailpipe should be pretty clean. Just a guess but I'd bet that DPF is getting clogged and the Regen cleans it just enough to keep the codes away but they're probably happening more often than normal and that's causing the mileage to suffer. If you're considering deleting the emissions you'll need to get the system working well first since you'll have to put the stuff back on every 2 years for the California emissions test. I think the warranty that's going to cover you is the one for the emissions system so you should keep on the dealer to make it right.

One other thing, I was curious about the P2267 and it came up as "P-2267-Water In Fuel Sensor Circuit High" and not Water in Fuel. Just make sure the dealer doesn't try to blame problems on "bad fuel". Since you recently changed the fuel filter most likely the connector is causing this one or the sensor is bad.

 

Yeah, the tailpipe is black with soot so the DPF is cracked for sure.
While towing the trailer home from Lone Pine (178 miles) it went into regen twice. I don't know if two regens in that mileage is normal or not but will keep an eye on it with the new gauges.
I abbreviated the P2267 message on the note pad. It was the correct message and I didn't give that one to the dealer as I know it was my mistake for not connecting the sensor after the filter change.
I just ordered another fuel filter and am going to change it prior to taking it back to the dealer. They recommended changing the air and fuel filters when it was at the dealer. I did the air but since I just changed it, wavered on the fuel. I just figure they had to have a reason to recommend it so I'm doing it just in case.
You're right, I've been doing some research and the Cali long term emissions warranty should cover it.
And no I'm not considering the deletes, I've already decided to do them. Gonna get all the smog crap working perfectly before the warranty expires. Then do the Cali version DPF/EGR delete. Then I start the every 2 year shuffle.
thx, dan

 

Well Dan, Like Mark said in the above post,I hope they don't tell you it's contaminated fuel. I am dealing with the same problem you had posted and my
2007.5 that I bought new in Jan of 2008 did the same thing with the same codes except for the water in fuel code. But I took it back to the dealer and he said I had gotten bad fuel and it was contaminated and it got past the fuel filter and now the injectors have to come out and sent away to be tested and cleaned which they said would be covered by Dodge. The other half is that I have to spend $1400.00 to have the fuel tank dropped and cleaned also the lines going to and back from the engine have to be cleaned, then another severe duty fuel filter has to be added in conjuction with the already replaced fuel filter assembly (replacement of orignal fuel filter) that cost me $281.30 . The worst thing about this is that I had taken it back to the dealer for it's scheduled maintenance since day one.
So I hope your dealer takes care of you and doesn't blame it on contaminated fuel because it's an easy out for Dodge.
Enjoy the Day, Mark

 

Hokie,

I think I would request a fuel sample and have it tested. It's possible there's nothing wrong with the fuel and that's probably why they're willing to take care of the injectors under warranty. Either that or they're just passing on the warranty cost to Cummins but they want you to pony up some money for a better fuel filter. Taking the fuel tank down and draining it and then flushing the lines should be a pretty simple task for the dealer and $1,400 seems extremely high. The Dodge severe duty filter kit could be a big chunk of the cost but I don't see how they could require that as part of the fix. For that price you could get a replacement tank, pump and better filters.

 

MLRey,
That is my whole point. evidently Dodge is saying that contaminated fuel got past the fuel filter that they had replaced the original with and to me it seems that the engineering of the fuel filter system was not designed to do it's purpose of filtering the fuel. They said they took a sample of fuel from my truck, they brought out a Pyrex 2 quart bowl placed it on the counter and said there's your problem,I looked at it and I could see contamination floating in the fuel. Now if I can see contamination with my eyes I know that the fuel filter isn't doing it's job protecting the injectors,because they said the sample was taken after the fuel filter. As you stated they want me to kick in some bucks and who knows what is really wrong with the truck? I even have the extended service contract and that won't cover cleaning the system as well as the replacement of the original fuel filter and the new severe duty fuel filter. So it seems that they are placing the blame on Cummins and don't want to cover the cost of their poor fuel filter design,if that is really the problem,or is the fuel filter design a Cummins design?

Have a nice day,hokie

 

Just an update, been back to the dealer twice this month.
First visit they replaced the EGR valve due to it not sealing correctly. Said it was fixed again.

Verified they tested the injectors when they completed the Cummins Worksheet. Found they tested out good, and found no other fuel related problems.

Last saturday as I was merging onto a freeway I punched it and left a soot cloud as big as a house! No kidding! My wife told me to look in the rear view mirrow and I saw an 18 wheeler driving through it. It was higher than his cab and longer than his rig.

Back to the dealer again. This time armed with a full page write up documenting the problems since the diesel smell in May. Had an intelligent discussion with the service manager and set some expectations.
They finally checked the DPF and it had a huge crack in the substrate. Replaced it and I picked it up again.

I had found a TSB that outlined my exact problem, codes etc, but couldn't see what the diagnostic and repair info was on it so I didn't know what they were looking at. Yesterday I found a way to access the DC TSB documents that have that info in them and found they followed the TSB to the letter, except for the part about replacing the DPF.
If they would have followed it completely in July, all this would have been done with.
Well, now off on another trip next friday. I guess we'll see if it's really fixed and if the turbo/boost lag I documented for the dealer is still there.

I think they're getting tired of seeing me...
thx for all the input, dan