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Diesel derated/power loss--NOT solved by Z96 Safety Recall

21JLURDG

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Update 4,000 miles later: The power loss with "Service ETC" re-occurred under near identical conditions as the last two times. Apparently the new HPFP had nothing to do with it. And since it only happens RANDOMLY when making prolonged climbs at highway speeds, I'm beginning to wonder how many others have the same problem that hasn't manifested since they don't live in mountainous areas.

BLUFF: I had multiple instances of power losses driving up steep highway grades, the "Service Electronic Throttle Control (ETC)" message and Check Engine Light (CEL) illuminated, and the vehicle remained drivable but with reduced power. After stopping and restarting the vehicle, power was restored to normal with a CEL that lasted a few key cycles. The final solution that seems to have fixed the problem was the dealer performing the Z96 Safety Recall: replacing the High Pressure Fuel Pump (HPFP) and a software update.

Long Version:
1. Sep 2023: I just had this happen to me twice in the last month. Both times I was accelerating on the highway going uphill, but indicated temps were all normal.... The dealer found p00af and performed TSB 18-001-22 (online search says this was superseded by a Rev. A) and STAR S2018000009. After getting home and looking those up, I'm not sure they're appropriate for my power loss. They also performed a forced DPF regeneration because they thought I was idling too much.

2. Oct 2023: A few weeks later I went on a road trip and it happened twice. After several incidents, I think I have nailed it down to when it specifically happens: going up a long steep hill at highway speeds, oil temp >230F, release throttle completely (e.g. slow trucks pulls out in front of you), a few seconds delay, and get back on throttle to start accelerating uphill (e.g. change lane to go around slow truck). A few seconds later I get service ETC warning with a few other warnings and a check engine light, and greatly diminished power. Pull of the highway and shut down, and after restarting the vehicle drives normal with the CEL on for a few key-cycles.

3. Nov 2023: Second time at the dealership, they insisted the Z96 Safety Recall specifically stated that it was to be performed for my vehicle symptoms. They changed the HPFP and made sure the latest PCM software was loaded. I went another road trip up the steepest highway I could find and really tried to push the engine oil temps with repeated accelerations and decelerations, but everything seems to be working perfect now. Parts installed: CSSMZ461AA (fuel injection pump), CSGNZ961AA EGR tube gasket), 4275086AE (label--probably the new B5 label on fuel door), CSGNZ965AA (fuel supply tube), CSFP01A1AA (owner's manual addendum limiting fuel to B5 with new restrictions to B20).

Hopefully this was the right solution, and it will be permanent. They could not tell me what was different about the new HPFP from the old model, but at least I have it installed now. Vehicle had ~35,000 miles when Z96 recall performed.

My recommendation to all of you: if you have any power loss and you're still under any warranty, get it documented. Don't just hope it never happens again.
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21JLURDG

21JLURDG

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The hpfp .. same brand ? Bosch ?
I have no idea, nor does the dealer. But I did find this MOPAR note (see attachment) on the HPFP. The way I read it, kit CSSMZ461AA includes the new HPFP 68631088AA.
 

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mtnmerlin

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I got the fuel pump replaced last week as per the recall. Then a few days later got the P00AF code, and derated power, twice. I was very heavily loaded and going up long hills. The ambient temperature was about 82F. The second occurrence was at about 8,000 feet above sea level, so cooling is more difficult due to the thin air. I believe that the turbocharger gets over-stressed causing the P00AF. The errors both cleared once the turbocharger got cooled down.
 

Ecorubi

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I did some moderate wheeling today with no issues then threw a P00AF code 30 minutes into my drive home. Cleared the code, restarted engine and it drove normal. Had the Service ETC message in addition to the CEL.
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