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Old 09-04-2011, 01:09 PM   #1
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National RV Owners Club
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Engine lacks power....2004 Cat. 7.2

Severe power loss, can't operate on road. Check engine light is on and I found 2 codes stored in memory. First code if for fuel injection circuit, Second code is for fuel injection sensor circuit. My gut feeling is that the sensor is malfunctioning. Will probably need to find a mobile mechanic to troubleshoot it.

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Old 09-04-2011, 08:24 PM   #2
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First thing you do is change fuel filters. It is the cheapest thing you can do and will solve most fuel/power issues. I always carry 2 extra filters and all the tools to change it. You never know if the last place you got fuel gave you a bunch of dirt or water. Those engine codes are best taken with a grain of salt. They can indicate a problem, but seldom really nail down what is going on. It is up to you or the repairman to interpret what is really going on. Remember a diesel engine really only needs 2 things, air and fuel. Air doesn't change much, but fuel is the real variable.

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Old 09-04-2011, 09:22 PM   #3
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X2 on what mike said. fuel filters are cheap and it might even be the first thing someone you call wants to do.
I'd almost bet money they will ask you when the last fuel filter change was.
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Old 09-05-2011, 01:07 PM   #4
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Thanks for the reply Mike. I experienced fuel contamination twice in the past year and had to repl the fuel filter (I believe my vehicle only has one) before I could operate on the highway. I have since bought the required tools to replace the filter. The difference between this experience and the previous 2 is the addition of the check engine light and 2 fuel related fault codes. I did drain fuel from the filter and there doesn't appear to be water contamination. Not sure exactly how to replace the filter, apparently I will drop the filter unit and then unscrew the lower part which has the drain. Install it onto the new filter, fill with fresh fuel and reinstall on engine. I have my fingers crossed on this, thanks.
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Old 09-05-2011, 06:55 PM   #5
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Hey Mekanic, thanks for your reply. I'm going to replace the fuel filter (am pretty sure I only have one), cross my fingers and let'r rip! I've already disconnected the batteries in attempt to reset the computer (to eliminate the fault codes, I realize many restarts are required to remove codes from memory). We'll see what happens, thanks.
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Old 09-06-2011, 06:18 PM   #6
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Cut the casing off the old filter and see what it looks like. Mine recently had a biological growth problem in the tank and have turned the filter element solid black. A fuel additive eliminated the bio growth, but I would never have known it without cutting the casing off the old filter. Fill the new filter from the holes on the perimeter. Call Cat with your engine serial number and ask them if your motor was shipped with a fuel filter mounted to it. If so, you'll probably want to replace and check both the rail and the block mounted filters. Good luck.
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Old 09-06-2011, 07:54 PM   #7
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Thanks for the info BDStinson. I replaced the filters twice in the past year (about 8,000 miles), but will do what you suggest with the filter inspection. I'll give Cat. a call too about a rail mounted filter. A trucker suggested to me that a fuel tank contamination might be the issue, and the tank may need to be removed and cleaned.

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