Hi Guys,

I’m new to the forum and the list below was typed up for a different group of people but it explains my problem and thanks ahead of time for any help that you can possibly provide.

I have a 06 3500 Dodge with a 5.9, it has 150,000 and I have owned it since it was new. I got a code P0148 so I took the truck into Lithia Dodge. They could not find anything wrong with it so I took it home and waited for things to get worse and in a couple of weeks they did. I got code P0148, PO192, and PO237 and the truck went into limp or protect mode and had to be taken back to the Dodge service center with a tow truck.

They put a new software flash in and the truck ran like a champ and the fuel mileage was back like it used to be. I was headed home and the mat sensor light came and chimed 10 times and put code P1223 and PO633. The problem lies with code P1223. I pulled all the injectors and had them tested three came back from OFI bad they could not hold the necessary pressure. So I replaced them with new one's and still I have the light and the chime so the Dodge service representative said it could be the high pressure tubes. I went to the local Cummins store and bought 6 new tubes and put those in paying very close attention to the torque specs. Unfortunately, still have the light so I had the mechanical flow test done they measured the flow from the back of the block. There is no leakage and or excessive fuel return from the injectors at an idle but once you run it up to around 1800 rpm the flow goes to 520 ml in 30 seconds way above the 160ml that is spec. Not one cylinder was under 80ml and three of the injectors are new rebuilt from Bosch that according to the specs should only put out 22ml in a minute, now we are checking to see what that should be a higher rpms.

The question I have is can we take the new code in the software off the truck somehow as it runs great. The only problem it really had was that it started a little rough when it was cold till I gave it fuel and then it was fine. The three new injectors put an end to that and it runs like a champ, with good mileage, starts great also. I also need to know if the new flash they put on the truck could be asking the injectors to do something that is causing the problem. It only happens going uphill in the 1800 plus rpm area I mean a very slight hill and you have to hang there for a while.

At this point we are going to pull out the injector tubes and injectors send them off and have them tested. Right now it looks like the new injectors are not making spec not even close but I suspect that the program has more to do with it than the injectors as I have never know Bosch to turn out crap but things change. Today I was pulling my trailer and noticed that when the light came on I had a dead pedal. It seems to hold speed, but I can put it to the floor and it I can't gain any speed.

This is a rough but detailed description of my problem. I would be happy to answer any additional questions if it might help resolve my issue.

Thanks,
Kerry

 

After a ton of research and effort I have finally been able to iron down the issue(s) and I figured that I would share the knowledge that I've gained with anyone who has experienced these issues. I own a 2006 Dodge one ton with a 5.9 cummins engine.

As mentioned in the first post we planned to have the Injectors and injector tubes tested. Mark at Southern Oregon Fuel Injector Eugene Oregon said he figured that the tubes were leaking as he had never seen a case of that many injectors leaking. OFI Eugene phone 1-800-452-5055 if you have this problem he is the guy to talk to. I still thought that the running program was the problem but if I was wrong there was something going on that could do real damage so I agreed to the test. Cost for the test was $50.00 a cylinder or $300.00. I pulled the injectors and tubes out and sent them and the old injector tubes up to Mark at OFI. He called me in a couple of days they had done a pressure test and a physical inspection he said all the original injector tubes were bad. (If you replace the injector replace the injector tube with a Bosch injector tube) Mark sent the injectors and the new improved tubes up to be tested and got back to me in a few days. The test showed that one of the new injectors failed by the thinnest of margins and 5 out of the 6 brand new injector tubes failed.

As it turns out Per Bosch, they have not approved the use of the 6.7L fuel injector tube for use in the 5.9L injectors. The 6.7L fuel connector tube is a higher Rockwell hardness. If the customer is using the 6.7L fuel connector tubes and has excess fuel return issue, advise them to contact Cummins for a solution.

Mark said the only way to get rid of the problem was to use the original injector tubes recommended by Bosch. (I was told by Cummins that they didn’t make them anymore and or have them can’t remember for sure but getting them was impossible) I was still skeptical as this problem has never changed even a little with all the work we have done and all the expense we have gone to. I agreed to purchase the new and original injector tubes as recommended by Mark at OFI. The cost was $40.00 each for the tubes. I received them a few days later and installed everything figuring that I would have the same problem as before. I still thought the program was at fault. I installed the injectors and the tubes same as before. We fired up fine no problem but it always did that. Remember my truck ran fine with the other tubes the problem was code 1223 would not stop going off. I took it for a long drive over all the places it would normally set the code and nothing happened we seemed to be good. That weekend I loaded up one of my work trailers 10,000 LBs give or take and headed to Cave Junction a trip that would set of the code for sure if I still had the problem.
The trip was a total success I have not had the code trigger even once since we installed the correct and recommended tubes from Bosch.

No matter what don’t use the new tubes from Cummins demand the use of the original tubes that Bosch recommends. I’m putting this on every forum I can so you folks don’t have to go thought this to fix your trucks.

Cost to fix the truck came in at close to $4000.00

First three new injectors from OFI at $1400 give or take.

Second 6 new and improved injector tubes from Cummins at $240.00

Third a mechanical fuel flow test at Lithia Dodge in Medford OR at $300.00 which they did for free as it made no sense given the parts that were in the truck. I have to say that Lithia was as good to work with as could be expected.

Fourth send the injectors and injector tubes to OFI to be sent out for testing at $300.00

Fifth purchase two more injectors from OFI and a new set of injector tubes. The Bosch tubes recommended for the 5.9L at a cost of $1400 give or take.

The total cost as mentioned above is close to $4000.00 with miscellaneous expenses. Keep in mind that this does not include any labor for the mechanic work. The cost of the down time. The time it took to do the research on the problem.


I took the new and improved injector tubes back to Cummins Northwest and asked for a refund of the $240.00 dollars as they had sold me injector tubes for a 5.7L and not for a 5.9L rather they want to admit it or not they are the wrong tubes. Now we knew this was going to be an uphill battle as they have been selling the wrong tubes to people for some time. If the new code had not been put on my truck I would be running the 5.7L tubes now and the truck would be running fine but not right. Also keep in mind that I have not asked to be reimbursed for the time and expense that selling me the wrong injector tubes truly cost only the original cost. I really want them to send the injector tubes back to operations or whomever makes these decisions with the information I have so the problem can be fixed. Either the code is set to tight or the injector tubes do not seal properly through the entire rpm range. We have a flow test that proves without question that the 5.7L tubes failed in the midrange setting off code 1223

As of now Cummins Northwest has refused to refund my money. I have a meeting I think with the General Manager on Thursday it is my hope that the injectors can be returned to Cummins and they can find a solution to the problem. I have given thought to taking them to small claims court as I’m sure I can win the case if I have to it will be for all my incurred cost. That is however not what I want to do. I will keep you informed on the outcome.

Remember never use the new tubes from Cummins in a 5.9L they are for the 5.7L Cummins they are not designed for the 5.9L engine. The mechanics at the Cummins service centers do not have to deal with the new code 1223 they have a totally different set of codes as Cummins has a deal with Dodge. Cummins cannot work on any of Vehicles that Dodge sells only Dodge can. If there is no code there is no problem as they see it. Cummins cannot hook there machines up to a Dodge product totally different code system. Cummins has not made a final decision at this time. I will let the forum know what their solution to this problem will be when I find out.

Have a great day

 

Kerry1

While I don't drive a Diesel, Really great write up!!!!

 

Thanks for posting this.. I have an 06 2500 5.9, so far no problems of this nature, but only 50K on the truck. Will definitely keep this in mind.

I am also in Meford Oregon... small world!

 

Well as I said before I would post some updates in regards to how this is all playing out and this is where it is at currently. Never ending problem!

Rick at Cummins Northwest asked me to return the parts they had sold me (Some months back) and the original parts taken out of the 5.9 the injector tubes which I did. I called the company ricks cell a number of times and Rick never returned my calls and has kept the parts which are obviously different from the original parts. It would seem that the company is going to keep my money and the parts they sold me plus the parts that came out of the 5.9L Cummins.

At this time 9-12-13 I have made a claim with Capital One Credit Card to have my money returned just the original purchase price not the cost incurred. Cummins Northwest has refused to return the money at this time. Nobody has given me a call to pick up my parts. Today I will make another effort to get my money back with this letter and all the rec and cost this has generated. I will keep you informed to my progress but as of now I would highly recommend a different supplier such as OFI for your parts and possibly just a different brand of engine all together.

 

Kerry,

This is looking like it might be a better case for a small claims court. If they haven't resolved these issues by now, they most likely aren't. You might want to consider your time involved and other expenses they have caused also.

 

what was the torque spec on the tubes you used , found SB on cummins from 2012 they should be 41 lb

 

Had same code p1223 on a 2005 5.9 and was able to fix it by just retorqueing the injector tubes to 41lb , lines to 22lb . found SB from 2012 from cummins.
cost me 1 hr of my time