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Discussion Starter · #1 ·
I have a 2015 Longhorn EcoDiesel Truck(I love this truck BTW) the the CP4 Pump failed on me due to contamination in the fuel. In lieu of taking it to the Dealer and paying $7500 for them to replace the entire fuel system by charging 2x for parts and having incompetent mechanics do the work I thought I would take a stab at it first.

The fuel tank was almost full when I came of the express way about 4 weeks ago and as soon as I got to the light it stalled. It did not turn on again. I had it towed to my house where I first checked the fuel filter which was replaced about 12-15K ago (148K miles currently). The filter was in good condition and the fuel was clean. I then moved to the fuel soleniod/regulator. Upon removing it I quickly I found crud and pump fragments, so I knew the CP4 had died. Prior to this, I had recently taken the truck into the Dealer for the Emissions recall because my regen system was broken. There they supposedly reprogrammed my ECU with the new EPA friendly software and replaced all bad Emission parts. They also told me that I had low Fuel Rail pressure and possible contamination in the fuel system. I left the dealer and not even 600 miles later I started to get the Regen Error again. The dealer now would not look at because they claimed that the contaminated fuel system is causing the Regen/Emissions system to fail. Well that made zero sense to me and I drove away.

I bought a new CP4 and installed it. I separated the pump return and the fuel rail return from each other because we know that the rail is contaminated with metal shrapnel and did not want to ruin a good pump. I checked the fuel pressure coming from the tank and it looks solid. I tried to start the engine and it would do nothing. Not even cough. Its as if the injectors are not firing because the Computer is not allowing it or perhaps that module is bad. I then cracked open all the injectors one at a time to make sure I am getting fuel and sure enough plenty of fuel is getting to each injector. I must of gone through the start cycle now like 20 times. I had to replace a week battery and all. Still I have witness Zero firing. I then purchase an ODM reader BlueDriver and read my codes. I first erased my codes and tried to start to engine to re generate them. I am now seeing P026D which is Fuel Injection Quantity Higher(gets to 4500psi) than expected and P0191 Fuel Pressure Sensor Circuit Range/Peformance Bank(says to replace sensor) . It also shows P2002 which is the fuel filter needs changing and I am going to do that ASAP, but there is good enough flow still.

I understand that I might have damaged injectors and some clogging in the fuel rail and I was expecting the engine to start and run really rough. However, as mentioned previously there are ZERO signs of combustion.

So my question is if there is too much fuel coming why would that prevent it from starting?
Is the Fuel Injection control module bad? how can I trouble shoot that? What controls the injectors from opening to allow fuel into the Cylinder?

Thanks in advance,

Ozzy
 

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@ozzyrom, how many miles do you have on your 2015?
 

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2015 Bighorn, CC, 6'4", 4x4, 3.55
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@biodiesel, it's kinda buried, but it's in his original post:
I read over it, but I didn't make the connection. 148,000 miles is still a fairly low mileage engine. I've often wondered what I might do if I had a CP4 pump failure. My insurance company said they would cover a CP4 pump failure as long as the fuel was contaminated. If there's no evidence of contamination, then I would probably opt to have a new engine installed. That's an easier decision on a high mileage truck, but not so easy on a 150,000 mile engine.
 
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Discussion Starter · #5 ·
A little more history about My Truck. I use to drive about 30K miles a year for the first three years and then my daughter became ill with Leukemia. I lived in the hospital for 2 years but she is fine now. Then Covid hit and I began working from home. So in the last 4 years I only put 30K miles on my truck. The fuel got contaminated because I forgot to change the filter and did so at 120K miles. It was pretty bad. Shortly after that I started to notice that engine was hard to start at a 1/4 tank. After reading other threads it turns out that the hose coming out of the pump inside the tank can dry up over time if you continuously run the tank down to almost empty. With Less fuel in the tank the hose heats up and eventually cracks. This is what I suspect. I continued to postpone fixing that and by simply keeping the tank always above 1/4 tank. Then the engine finally died about 5 weeks ago. I have not ruled out the Fuel Pump Drive module:

Automotive exterior Auto part Font Rectangle Automotive window part


However, the Imjection pump seems to be working pretty good. What I dont hear or feel are the injectors clicking. This is controlled by the ECM I believe. If so it may require some type of reset and or programming change. I am not sure. All I know is that the injectors are not making clicking noise.
 

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Deleted. My reply was about an HO, forgot this is about an Eco
 

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my daughter became ill with Leukemia. I lived in the hospital for 2 years but she is fine now.
Praise God!

After reading other threads it turns out that the hose coming out of the pump inside the tank can dry up over time if you continuously run the tank down to almost empty. With Less fuel in the tank the hose heats up and eventually cracks.
Do you think your problem could be a bad lift pump?
 
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I have a 2015 Longhorn EcoDiesel Truck(I love this truck BTW) the the CP4 Pump failed on me due to contamination in the fuel. In lieu of taking it to the Dealer and paying $7500 for them to replace the entire fuel system by charging 2x for parts and having incompetent mechanics do the work I thought I would take a stab at it first.

The fuel tank was almost full when I came of the express way about 4 weeks ago and as soon as I got to the light it stalled. It did not turn on again. I had it towed to my house where I first checked the fuel filter which was replaced about 12-15K ago (148K miles currently). The filter was in good condition and the fuel was clean. I then moved to the fuel soleniod/regulator. Upon removing it I quickly I found crud and pump fragments, so I knew the CP4 had died. Prior to this, I had recently taken the truck into the Dealer for the Emissions recall because my regen system was broken. There they supposedly reprogrammed my ECU with the new EPA friendly software and replaced all bad Emission parts. They also told me that I had low Fuel Rail pressure and possible contamination in the fuel system. I left the dealer and not even 600 miles later I started to get the Regen Error again. The dealer now would not look at because they claimed that the contaminated fuel system is causing the Regen/Emissions system to fail. Well that made zero sense to me and I drove away.

I bought a new CP4 and installed it. I separated the pump return and the fuel rail return from each other because we know that the rail is contaminated with metal shrapnel and did not want to ruin a good pump. I checked the fuel pressure coming from the tank and it looks solid. I tried to start the engine and it would do nothing. Not even cough. Its as if the injectors are not firing because the Computer is not allowing it or perhaps that module is bad. I then cracked open all the injectors one at a time to make sure I am getting fuel and sure enough plenty of fuel is getting to each injector. I must of gone through the start cycle now like 20 times. I had to replace a week battery and all. Still I have witness Zero firing. I then purchase an ODM reader BlueDriver and read my codes. I first erased my codes and tried to start to engine to re generate them. I am now seeing P026D which is Fuel Injection Quantity Higher(gets to 4500psi) than expected and P0191 Fuel Pressure Sensor Circuit Range/Peformance Bank(says to replace sensor) . It also shows P2002 which is the fuel filter needs changing and I am going to do that ASAP, but there is good enough flow still.

I understand that I might have damaged injectors and some clogging in the fuel rail and I was expecting the engine to start and run really rough. However, as mentioned previously there are ZERO signs of combustion.

So my question is if there is too much fuel coming why would that prevent it from starting?
Is the Fuel Injection control module bad? how can I trouble shoot that? What controls the injectors from opening to allow fuel into the Cylinder?

Thanks in advance,

Ozzy
you have to replace all the injectors. That pump grenading will take out everything after the CP4. I'd replace all the lines and the rails as well. Just too hard to clean. You are talking about injectors where microns matter. Also, you just did a pump replacement... i highly recommend you replace the fuel filter prior to cranking on it anymore. No need to push crap through your new injection pump.

Check your fuel pressure sensor wiring. if the pcm doesn't get a reading there, i think its unlikely that it will fire the injectors because it can't adequately control injection quantity if it cant read the pressure.
 

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How do you know the lift pump is working well?
 

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you have to replace all the injectors. That pump grenading will take out everything after the CP4. I'd replace all the lines and the rails as well. Just too hard to clean. You are talking about injectors where microns matter. Also, you just did a pump replacement... i highly recommend you replace the fuel filter prior to cranking on it anymore. No need to push crap through your new injection pump.

Check your fuel pressure sensor wiring. if the pcm doesn't get a reading there, i think its unlikely that it will fire the injectors because it can't adequately control injection quantity if it cant read the pressure.
I agree what everything you said. But you would think that at least one or two injectors would still work enough to get some kind of "Action" ? Maybe not....
 

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I agree what everything you said. But you would think that at least one or two injectors would still work enough to get some kind of "Action" ? Maybe not....
Correct. The engine would still fire. He would run the risk of destroying an injector, but that's another discussion. Somehow, he's not getting fuel to the injectors, which is why I questioned the lift pump.
 

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Discussion Starter · #13 ·
you have to replace all the injectors. That pump grenading will take out everything after the CP4. I'd replace all the lines and the rails as well. Just too hard to clean. You are talking about injectors where microns matter. Also, you just did a pump replacement... i highly recommend you replace the fuel filter prior to cranking on it anymore. No need to push crap through your new injection pump.

Check your fuel pressure sensor wiring. if the pcm doesn't get a reading there, i think its unlikely that it will fire the injectors because it can't adequately control injection quantity if it cant read the pressure.
 

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Discussion Starter · #14 ·
Shaggn85,
I will check to see if the ODB will detect the bad fuel pressure sensor. Currently Im getting a bad Fuel Rail Pressure sensor reading. I will test again. Also I ordered new filter for the fuel , I will install before cranking anything further. It seem like if what you are saying is true that the Fuel Pressure sensor is broken, then this would prevent the PCM from sending pulses to the Injectors preventing engine from firing. I will take a look at the signal with an Oscilloscope to verify that there is no pulse being sent to injectors... Thanks for your input
 

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Discussion Starter · #15 ·
How do you know the lift pump is working well?
I havent put a fuel pressure gauge on it but it pumps a lot a fuel when I turn on the pump. Of course I lot might be a relative term. I might have to put a fuel gauge in line. But the fact that the enigne just died on fine day tells me that it was something that turned off the firing.
 

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I havent put a fuel pressure gauge on it but it pumps a lot a fuel when I turn on the pump. Of course I lot might be a relative term. I might have to put a fuel gauge in line.
One of my goals is to put a fuel pressure sensor on my truck. Maybe I'll add that to my to-do list for 2022.

Here's a post by @Haul N Grass:

I installed my fuel pressure sender in the fuel line in between the fuel tank and def tank seemed to come out nice.
To my surprise our trucks fuel pressure runs between 58-85.6 PSI with 53 gph flow the normal pressure is between 79-83 psi and when I initially installed it I
Thought it was inaccurate so I called my Ram dealer to verify the readings .
So I ran the truck for 1 more month then replaced the fuel filter to see any deference of psi and there was none and the old filter had about 10,000 miles on it

 
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Shaggn85,
I will check to see if the ODB will detect the bad fuel pressure sensor. Currently Im getting a bad Fuel Rail Pressure sensor reading. I will test again. Also I ordered new filter for the fuel , I will install before cranking anything further. It seem like if what you are saying is true that the Fuel Pressure sensor is broken, then this would prevent the PCM from sending pulses to the Injectors preventing engine from firing. I will take a look at the signal with an Oscilloscope to verify that there is no pulse being sent to injectors... Thanks for your input
This could be keeping your truck from firing. Like i said before, if it cant tell how much pressure is being generated by the high pressure pump, the PCM will likely not allow the injectors to fire. I'd fix this first. your shredded CP4 probably took out this sensor on its way out.
 

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Discussion Starter · #18 ·
Praise God!



Do you think your problem could be a bad lift pump?
The lift pump is working as long as I have more than a 1/4 tank of fuel. I have not tested the pressure but there is plenty of fuel being pumped. Engine just died out of the blue and never tried to start again. It has to be something digital. Bad sensor, etc.
 

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Discussion Starter · #19 ·
I changed my fuel Filter and I am still getting P2002. ODB App software recommends reprogramming Engine Control Module (ECM). How do I perform a reprogram? The Fuel filter is not like oil filter that you must reset the clock with the computer , right?
 

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I changed my fuel Filter and I am still getting P2002. ODB App software recommends reprogramming Engine Control Module (ECM). How do I perform a reprogram? The Fuel filter is not like oil filter that you must reset the clock with the computer , right?
Are you sure on that code?
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