Old & Injecting

About two years after I bought my 2002 new, the engine required sometimes two 10-15 second crank cycles to start with the truck positioned nose up on our sloped driveway. The engine never failed to start: it was just the unusual initial starting behavior first thing in the morning. This behavior only occurred in the winter and only on the initial start in the morning. Use of the block heater did not significantly change the behavior. If the truck was parked level or nose down, it fired right away. The Dodge dealer said all was OK. As time went on the truck exhibited the same behavior year round if it was parked nose up, but still fired right away if level or nose down. We just completed a 5000 mile trip towing a 23 foot travel trailer and towards the end of the trip, especially pulling a grade, power would surge down …. I would shift down and then in a few minutes power surge back. In the shop at home, the verdict was a failed lift pump and a failed injection pump. The mechanic had a failed lift pump on his 2002 at nearly the identical mileage (67K). He recommended and I had him install a Dodge lift pump conversion package that places the lift pump in the tank rather than on the block. The next modification soon will be the installation of a set of instruments that includes fuel pressure, boost pressure, and engine exhaust gas temperature. After the new injection pump was installed, the engine runs noticeably quieter. And there are no nose up issues.

mishkaya

As long as you have gauges you should be OK, the in-tank pumps don't seem to be that much better than the engine mounted ones though. You probably would have been better off with an aftermarket solution IMO. Either way, glad you got the problem fixed.
mishkaya

j-fox

Every VP equiped Cummins needs a fuel pressure guage. It should be factory installed. It is no guarantee to keep that pump alive, but without fuel surplus to cool and lube, it is an easy failure.
I have a friend with a 02 ( so do I) and he refuses to spend the money for a simple fuel pressure guage. I won't work on it anymore. He won't listen to me, but thinks I should be able to keep it running.

Tate

Your initial issue sounds like an air leak in your fuel system. Seems to be fairly common. The lift pump in the tank is an expensive retro fit, considering you can get better aftermarket setups for less. Not sure if you ever plan on turning the truck up, but the in-tank setup will make upgrading the fuel system harder.