I have a 94 dodge 3500, 5 speed, it chugs at an idle sometimes, also when i drive it and take off it chugs, plus when i slow down for a stop sign and let it idle then take back off, it chugs like it has air in the fuel. Sometimes it gets bad enough it stalls out on me and will not restart unless i snuff it with ether. I have already have put on an injection pump, injectors, new lift pump, new fuel filter, and new sending unit in the tank. Also, i pressurized the fuel lines and no leak found there either. I am out of ideas! Need help please!!!!

 

Still have the fuel heater? What is fuel pressure at idle? What is it at wot?

 

Yes it still has the heater. We looked at it when it first started acting up, when we replaced the fuel filter. Did not see any thing abnormal. We have not checked fuel pressure yet. Will do and see what she's doin! Thanks for the reply!!

 

That's the starting point, fuel pressure. I would go ahead and eliminate the heater. Chances are it doesn't even function. Was the overflow valve replaced when the pump was replaced?

 

Alright, we will get rid of it or at least bypass it. The pump was off a good running engine that we just bought for my sisters project truck. It was last run about a month ago, so it should still be good. It just is not brand new.

 

How did you time the pump when you put it on?
Just pull the fuel strainer off, remove the heater and put the strainer back on.

 

Hey, sorry about taking a bit to get with you. Dad runs a full fledge heavy duty diesel repair shop and I work for him during the day, so I work on our stuff in my spare time. But anyways. We put the engine at #1 TDC before pulling the pump, and the pump was set with the alignment pin in the side under the plug. The pump shaft and gear was cleaned and dry, then torqued to 150 ft. lbs. Yesterday I got a wild hair and looked at the shut-off solenoid. I was wondering if it was not allowing the rack to travel all the way. So I removed the solenoid and manually held it open all the way with mechanics wire. It ran great yesterday, except for a small flutter on initial fire up, but other than that, it was fine. I stalled it to shut it off,so there was no variables. Dad drove it this morning, same start up as yesterday but went back to its spitting and spuddering and stalled twice. So today I will try to work on it and get some pressure readings and delete the fuel heater. Ill get back with ya. Thanks for the help!

 

Good morning. I believe that we have our problem solved! Our shop has been swamped, so we haven't had much time to work on it. 2 days ago we bypassed the fuel heater/ sump screen and so far it has been working great. Fires up within 2-3 revolutions and runs smooth. so as of now she is all good. I just wanted to say Thanks for your guidence on this fix! I appreciate it!