Well, I just installed the XZT on my "06 today and immediately had problems. As soon as I turned the truck on the rattle was pretty loud. Then I noticed that the check engine light was on, checked for codes and saw P0192 was the only one displayed. This truck is 100% stock with the exception of the XZT.

Turned the truck off and uplugged harness from the MAP sensor and Fuel snesor and the truck sounded fine but check engine light still on.

Has anyone had this problem before?? I bought the box from an authorized Quad dealer in a sealed box so no issues with 2nd or 3rd person owner.

I did call Quad and spoke to a woman there, however, she was getting off of work and I did not have the trouble code yet to give her so I got nothing yet over the phone.

The box gave the proper LED flash test and I know that the connectors gave an audible "click" at each point so I cannot see how this could be the problem.

Any ideas would be much appreciated. With my pesonnality and the $$$ for this truck I know that this will bug me all night wondering if I somehow screwed up my truck.

 

Try reconnecting all the connections again and make sure they are all good a tight. I had the same problem back when I installed mine and I had a connection that was not really tight. The check engine light cleared after I started the truck three or four times.

 

Check the fuel rail pressure sensor connector. Add some dielectric grease to the pins and also make sure it's plugged in the right way.
I had a very similar issue with the Edge EZ.

MikeyB

 

Ok, I'll triple check the connections but like I said I heard (and felt) the click into place for each point. Are you guys continuing to push on the connections after they lock into place? I did not use dielectric grease but will definately get some and give that a shot.

Hunter11 that is encouraging that the check engine light cleared itself. I didn't know that that happened.

 

MikeyB, on a side note, what kind of mods did you do to your airbox before you threw the Amsoil filter in there?

 

P0192-FUEL PRESSURE SENSOR VOLTAGE TOO LOW

WHEN MONITORED
With the ignition on and battery voltage greater than 10.4 volts .

SET CONDITION
The circuit voltage to the ECM falls below a calibrated threshold for a certain period of time.

POSSIBLE CAUSES

• Other DTC's
• Fuel pressure sensor
• (F855) 5-volt supply circuit shorted to (F855) return circuit
• (K181) signal circuit shorted to (F855) return circuit
• (K181) signal circuit open
• (F855) 5-volt supply circuit open
• (K181) signal circuit shorted to ground
• (F855) 5-volt supply circuit shorted to ground
• ECM
• Intermittent condition

Check the fuel pressure sensor plug, make sure it is pluged in tight.


Mark

 

Ok, I will definately recheck the connections tomorrow...would this also cause the loud rattle? Or is the noise a by-product of the XZT's timing?

 

sounds like you have some timing rattle.
I don't know much about the XZT
is the timing adjustable on XZT???

 

I don't think the timing is adjustable it is just a set module.

Contact Quad on here PM him. I've allways gotten an answer from him.. Sound like your wiring harness might be bad. Pretty much had the same problem with mine but on an 05 and it would kill the truck. Can't remember the code it would always throw.

Shane

 

Sounds good...I am should be receiving a call from one of the tech support people in the morning. With Quad's reputation I'm sure this will be resolved. Maybe it is the harness?? I just don't believe that I could get those connections any tighter. But like I said I will give it a go again in the morning with the dielectic grease.

Your right, this box is non adjustable.

And if the rattle is a normal issue with the box I'm OK with that, I've just never heard anyone with one of these hooked up so I have no idea what to expect.

 

Most llikey the sensor was plugged in good but, backwards. Typically this happens on the factory sensor into our molded plug.

Make certain that the locking tab goes over the ramp side of the plug. It should plug in without you having to press on the locking tab at all, it should slide up. If you plug it in backwards you will have to press teh tab so that it goes over the guide for the other side of the plug but, they will plug in backwards.

Now this can be done on the stock sensor as well so make certain you got them in the right direction.

There are about 6 different configurations of this same plug that are used on all of the Bosch fuel systems and I have seen at least 3 of them on the 5.9 so that is why they can be turned different ways.

What happens is that the 5v supply gets shorted to ground if it gets turned around. When this happens you get the 0192 code followed by the truck running at a constant pressure which is much higher than idle. This will cause the truck to idle rough and be pretty loud. You are not hearing timing or anything else you are simply hearing about 15k of pressure at idle. It does not hurt anything and the truck is programmed to fall in this safe mode but, it certainly will rattle some!

Check it again and report back to us.

 

Thanks....for the reply and for the hour. I don't think many folks would take the time at 9:30pm to respond to this. I will check that out first thing in the morning.

 

Hmmm, you are lucky you are out west. It is actually Wednesday here! 12:45am right now!

I just realised it took 1.5 hrs to respond to pm's and posts! I gotta get a different job!

Let me know if you get it in right. I am pretty positive that is what it is. I have seen it ohhh a few times!

 

I removed the silencer ring, replaced the baffle tube with a piece of 5.5" thick wall aluminum tubing and installed a 4" drain pipe elbow at the bottom of the airbox. Cheap effective mod for less than $25.

MikeyB

 

Well, I checked the connections again for the 20th time and they were solid. I did use the dielectric grease and confirmed that none of the sensors were plugged in backwards. So I called Quad support again and spoke to a customer support rep. who is going to send me out a new harness today. Hopefully, I will get that in the next couple of days and the problem will be fixed.