2004 Dodge Ram 2500 5.9 Cummins fuel rail pressure sensor replacement

[@FeralLifeofTroyandMe]

Thank you!! This video is perfectly detailed! Appreciate it greatly!! 💯

[@jtdiffen]

Thanks Greg. Got a code for this item a few times so it’s getting replaced. 👍😎

[@racefabwrench]

Yes sir, glad I could be helpful

[@jameshicks5256]

appreciate the helpful video. Thanks

[@racefabwrench]

You’re welcome sir, I appreciate the comment

[@ericjaquez4347]

Great video! the only thing I would do different is stick with OEM parts, diesel's are finiky.

[@rambler8870]

I have a 2007 with the 5.9 Cummins. Haven't been long replaced the Fuel Control Actuator/Fuel Pressure Regulator since it decided to eat crap on me. Truck runs fine, but I've recently noticed on my Edge monitor that my fuel rail pressure kinda fluctuates a little bit. And, when I have it on high-idle, I don't want to say it has a lope to it, but it's not a steady idle either like it is when it's at normal idle. I actually ordered a Bosch Fuel-Rail pressure sensor, but just curious if that being bad could cause that. Truck just tripped 160,000 miles. And, thanks for the how to video.

[@racefabwrench]

The fuel rail pressure sensor will definitely show a fluctuation of the fuel pressure on a gauge or a tuner readout when it starts to fail. As for the rougher idle on high idle, it’s my experience that all these trucks do this if they’re on a tuner. This truck began doing a rough/lopey idle if it automatically went in to high idle during cold weather once the Smarty was installed. If you manually put it in high idle using the cruise control it will idle smoothly. I reached out to Smarty and was told the smarty and possibly other tuners juggle the main injection events on each cylinder to help with warm up, but I haven’t uninstalled the Smarty to test that.

[@rambler8870]

@@racefabwrench, I guess I should have clarified. The Edge I have is the Edge Insight. It's nothing more than a monitor so I can keep an eye on everything. Truck has never had a tuner/ programmer on it, and I don't plan on ever putting one on it. It was an older guy that owned it before me, and I'm just the 2nd owner. He had it all original. The only thing I've added is an AirDog, transmission cooler, a DPS exhaust manifold, and the Edge Insight. The weird part is it doesn't do the weird idling on high-idle when it's cold. It only does it when the engine is warned, like if I've been driving it and I parked for a bit, but wasn't cutting the truck off for whatever reason. I'd just turn the high idle on to keep the oil and coolant flowing good, and it'll do a little weird. Hopefully that sensor will fix it. Might just be me being OCD. 🤣

[@Frankstgeorge88]

Mine is doing that same thing. At cold weather idle my 04 jumped between 4900-5700. At high idle its 6100. While driving down the road at 60mph some times it will read 10000 or it will fluctuate and read as high as 16000. I'm baffled...

[@corneliolucas1766]

Question: I have the same truck and when I press the accelerator it doesn't work and suddenly it returns to normal.

[@corneliolucas1766]

And also when the speed goes to about 70 and I release the accelerator, the revolution increases and I give it and give it until it grabs diesel, what will it be?

[@CheltonMondlane-ps5zl]

Hi I need your help On a dogde that won't start and combu pressure

[@gloglo1275]

Hello, I have a 2005 Cummins. Recently I was driving and when I opened it up on the highway the WTS light started beeping. I have the code p1222. Any thoughts on how you would proceed to troubleshoot? Thanks In advance.

[@racefabwrench]

P1222 is for excessive fuel return which is a leak detected in the fuel system causing more fuel to be supplied than is used and then being returned to the tank. It could be a couple things, a bad PRV on the fuel rail or FCA on the back of the injection pump can cause the code and WTS light. Most commonly however is caused by a failing or failed injector or injectors. That’s a little hard to self diagnose without the proper test equipment to block off the fuel supply to each injector and monitor the fuel return flow. My first suggestion would be to take it to a shop, the second would be throw parts at it, the PRV and FCA are relatively inexpensive next to replacing injectors

[@gloglo1275]

@@racefabwrench Thanks I will try the FCA and PRV. Then take it from there. Is there an odb2 tool that can better assist in the diagnosis? I’ve been trying to research but don’t want to spend money on one unless I know it can give me the necessary information to help and guide me. Thanks

[@racefabwrench]

The Dodge’s scan tool, the DRB3 of course would be the best thing to have as it allows access to all the factory information, they are also expensive. Also the Snap on Modis but there again with out the special testing tools to use in conjunction they won’t help much. You maybe able to find some procedures online to test the FCA without the use of a scan tool. There is also a PRV block off made for racing purposes that could be used to eliminate whether the PRV is failing. Beyond that you get stuck in a deep hole having to buy a lot of special equipment for diagnostics

[@gloglo1275]

@@racefabwrench I just removed the FCA, and it does not rattle at all. I just ordered a new one. Thanks for your help. I do appreciate it.

[@racefabwrench]

You’re welcome

[@joemiller2020]

I just replaced my fuel injectors in my 06 5.9, lift pump and a few fuel filters. I’m throwing a p0148 low fuel pressure code. Any ideas? My code reader is showing 6800 at idle

[@racefabwrench]

Give me some context of why you replaced your injectors etc? Also do you have any aftermarket parts in your fuel system? Were you getting the code before you replaced your parts? P0148 is fuel pressure delivery. Usually the supplied pressure and the requested pressure doesn’t match. A good place to start since you did replace the injectors would be to make sure your connector tubes nuts got torqued properly. Dodge had problems with these loosening in the past and sometimes if the connector tube doesn’t seat in the injector it can cause a false torque reading which will cause a leak between the connector tubes and injector. Factory spec is 35 ft lbs but I usually go 45 ft lbs. other possibilities are a bad PRV (pressure relief valve), a failing off the shelf lift pump, bad FCA (fuel control actuator), bad fuel pressure sensor, blocked return lines. The most common cause is lift pump flow and pressure. If you’re able you should check your lift pump pressure. You should have around 10-15psi at the fuel filter. Get back to me and let me know. Thanks!

[@joemiller2020]

It turned out to be the fuel tube nuts, I believe that’s what you said. I was getting about 16,000 PSI while driving, went through and made sure they were all torqued down properly and now back up to the original psi and truck is running good! Just have some squeaky noise coming from the rear pumpkin area now I have to figure out.. thanks again for the advice! It saved me a lot of time and energy!

[@racefabwrench]

@@joemiller2020 You’re welcome, glad things worked out for you!

[@johnchaney1472]

Hey Greg. I have a 2004 dodge as well with a manual transmission. It will sit and crank but won't make it past that. I have good fuel flow to the injection pump. Any thoughts?

[@racefabwrench]

Well, there’s a lot there to unpack there… for starters does it make any smoke as it’s cranking over? Are there any codes present? What lead up to the no start as in did it run the day before and then the next day wouldn’t start or did you notice any issues leading up to it not starting? Could be a hard failed CP3 inj pump but that is pretty rare. I would determine (safely) if there’s any fuel pressure in the fuel rail. If pressurized fuel is making it to the injectors I’d check all your fuses just to cover your bases, check your injector harness connections outside the valve cover and check your injector harness under the valve cover going to the injectors. The harness is very prone to failure from riding in oil it’s whole life.

[@johnchaney1472]

@@racefabwrench This truck has been sitting for probably two years. When it cranks I don't notice any smoke, but will have to check again. As far codes have not seen any on the dash yet, but I don't have a scanner to plug into it. I will check the rail pressure next probably.

[@luisuranga9212]

Very good video. Do you know something about code p0069 Cummins 3500 2005 ?? I will precísate

[@racefabwrench]

Code P0069 sets if the PCM is getting contradictory readings from the MAP (boost) sensor and the barometric pressure sensor in the air box. Either sensor could be bad or have a bad connection. Check your connections are plugged in and tight and that either sensor isn't dirty. Possibly a bad sensor if all else checks ok.

[@luisuranga9212]

@@racefabwrench thank you so much, i was worried about something expensive, this job only toke me about 10 min to cleaned it

[@luisuranga9212]

@@racefabwrench thanks man I fixed drives like new again and is a old truck 👍👍

[@geraldinegranado3386]

What did u say about be sure to release pressure ?

[@racefabwrench]

It’s extremely important to let the fuel pressure alleviate itself by sitting for a couple hours to avoid any injury from fuel spray.

[@frxghtz6991]

If it sits for let’s say 6 hours will all the fuel pressure be released? Basically if I just let it sit then I can start removing the fuel rail pressure sensor?

[@kurt8986]

Sensor price?

[@racefabwrench]

It will run you $400-$700 depending on where you buy. From NAPA is $550

[@kurt8986]

@@racefabwrench thx for the vid

[@racefabwrench]

@@kurt8986 yes sir you’re welcome thanks for the question and comment

[@dylandurand8151]

@@racefabwrench Amazon cheap

[@patrickbeatty3444]

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