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Yours don't sound like the classic symptoms of CPS going bad. You haven't done something like a 10K mod, have you?
An intermittant "stumbling" can be a CPS, the Camshaft Position Sensor, but yours isn't intermittant, is it?
It could be the sensor on the high-pressure oil rail that senses the pressure of the high pressure oil that is used to "fire" the diesel fuel through the injectors. It's a regulated pressure that varies according to engine RPM and fuel demands. There is a regulator valve that is driven by the signal produced by this sensor, too. The sensor is called the ICP (Injection Control Pressure) sensor, and the regulator valve is the IPR (Injection Pressure Regulator).
Engine "roughness" (if that's what you meant by 'stumbling'), especially at idle, can be caused by either the sensor going bad, or the regulator valve getting dirty or leaky.
Do a search for both ICP and IPR and you'll get a bunch of diagnostic information. You'll even get a link to a site that has rebuild information on the IPR.
Also, when's the last time the oil was changed, and what weight for what outside air temperature? Too-thick oil will cause rough running.
Pop
Last edited by SpringerPop; Mar 24, 2006 at 12:02 PM.
The problem may not completely be water incursion. There may be components of vibration and dust involved, too.
There are less-hassle ways of improving the reliability of this connector. They involve the VERY judicious use of both conductive silver (or copper) paste and non-conductive (dielectric) greases.
I am just thinking that if you can hard wire at the point where it mounts to the motor, you could loose the chance of 1) vibration. 2) dust. 3) water. And move the "plug" to a mount on the ...say fender well. And I could have a spare hard wired CPS with pig tail ready incase it goes out.
Springer - you may be right. I just figured the CPS was cheap enough just to throw the new part in there, and hope it corrected the problem. I can perform diagnostics easy enough, but I'm a business owner, and spare "daylight" time is hard to come by! Maybe I'll replace those sensors you mentioned as well. The truck has 198K miles on it, so it probably doesn't hurt to replace at least the "easy" sensors if they are known to cause problems. I live in Virginia Beach, VA so the temps don't stay in the frozen zone for very long here. I haven't had the truck long, but the previous owner used 15W 40 - so you may be right. It may be a little thick - any suggestions? I appreciate all of your advice, and I'll let you know how it goes. Just to give you a description - when the problem occurs, it feels like a gas engine does when it's running on two cylinders. Very rough, no power, barely running. If I just let it idle - it will eventually smooth out, but press the accelerator during this time, and the problem gets worse. Anyhow (??). When it has warmed up - it runs fine, so maybe it is an oil problem - thinning as it warms up.
Weather.com says you're in the 40's, so 15W-40 should be the correct weight oil.
Any evidence of "hissing" while it's warming up? You might have a stuck-closed EBPV (Exhaust Back-Pressure Valve). It's a valve that closes when very cold to cause the engine to warm up faster, but if the exhaust can't get out, it may run rough.
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