6.5l disel. engine completly rebuilt 20,000 miles ago. new lift pump installed yesterday. all fuel lines are good. starts fine but will skip and sputter from time to time, even stall, but will start again. fuel and filter are good. Injection pump is original. Love the truck, please help.
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How many miles do you have on the new engine? Did you install it yourself? Was it a long or short block install? Was the timing belt on the replacement engine new? Does the engine crank over faster than what would seem normal? If your engine has more than 80K miles on it, you may have a broken timing belt.
I notice my 94 pathfinder runs rough and cuts-off acting as if it is fuel starved or it has a bad coil (spark not hot enough). When I jump statrted the car with a 200 amp Battery charger /booster the engine smoothed out perfectly. So, I assumed it is the coil or the wires since I have just replaced the distributor cap and the rotor, replaced the fuel pump and fuel filter less than 200 miles ago, and the car has been sitting most of the summer without being driven. Im checking the vacuum lines and need to consider that the fuel pump, although a brand new Bosch unit could have a problem or somehow the filter is clogged. Miles on this vehicle are unknown but could be 200k judging from the wear and tear , but engine has good compression . It could be the catalytic convertor is clogged, as I have seen cars run this way before (car had a carburetor though) when the convertor clogged to the point of not running at all- could not start it and run for more than 10 seconds at a shot. The last couple of times I have started the car to diagnose the problem, the engine developed a rattle that is audible at low speed(idle and off idle) thru 1500 rpm. Thinking it could be the tensioner on the timiing chain has loosened-up and jumped timing. Lots of things to check- may as well run down every possibility and get it over with.
Check if there isn't any blown "engine control" fuse. It looks like the computer isn't adjusting the timing as the engine accelerates. I assume you've already checked for open circuits at the ignition system. If not, do so, making sure all your connections are tight.
Have you ever had the mechanical lift pump go out on these vehicles? If the fuel pressure drops under 5psi on the VP44 injection pump for any length of time, the diaphrams get weakened and especailly when the warmer seasons come back, you will notice fuel delivery problems. A new/rebuilt pressure pump is required! Sorry for the bad news, if indeed this is the case. One solution/prevention is to replace the lift pump with the upgraded Mopar (goes into the tank now) or an aftermarket pump like the FASS pump or the like. Anyone that has the VP44 injection pump should upgrade ASAP! This is a common problem on the OEM mechanical lift pump on this particular run of Rams. Need to do it before you run up a costly repair bill later on down the road. The stock/OEM lift pumps WILL go out, sometimes as little as 12k miles, sometimes 50k miles.....I had 3 go out, Stock at 43k, Mopar replacement lasted 31k and the 3rd (aftermarket OEM) lasted 14k. I had a fuel pressure guage installed a very long time ago to alert me of failures. The 4th go around I installed the FASS and now it maintains 21 to 27psi even with chip mods switched to extreme! I am still on original VP44 pump (knock on wood!)