Help! all info appreciated. Have '03 dodge 2500 5.9L Cummins turbo diesel that started out not starting when hot,cold started fine. Changed filtres would start a few times then back to not starting. ether started it.when started ran great. Took to shop and they changed the cross over valves,started great for about a week now back to not starting hot or cold. Will always start on ether and run great. Has Bully Dog chip and shop suggested the I take it out as it will take out tranny. Already had to change the torque. I have done some research and found that these chips can pop the pressure relief valve. Shop suggested that my injectors need replacing. Truck has 236000km. Any troubleshooting ideas before I empty my bank account on this truck. Thanks

 

If it runs fine after getting it started, then I would lean towards one or more leaky injectors. You can have an injector be leaky without it affecting your oil level. It happened to mine twice. There is a injector cap you can buy that you use to block off one injector at a time until it starts. (only good if you have one bad injector)

 

Thanks so much for the advice. I'll give it a try.

 

Injector issue. Get all 6 rebuilt or replaced with F1 diesel or Exergy injectors. I used Tim at TRE diesel as my F1 dealer.

 

you have the old style injector bodies. do not rebuild, get new from f1 or ddp. install a 2 micron filter to prevent future wear and be very careful to follow the torque setting on the wire nuts.

 

I've been fighting similar proeblems since I put on a chip two months ago. Occasional long crank times and LP not coming on. I put a fuel pressure test gauge on and that has helped a lot to see the irratic LP operation. I've been reading about all sorts of electric glemlins on 03s lately and they all have chips. That looks like the common denominator. Try returning it to stock and see what happens. ALL my problems go away when it's back to stock so I know it's chip related. The ground paths of all the aftermaket gadgets is/can be the killer. I've been experimenting with grounds and have been making some headway. Was yours OK before the chip? Be sure to check out all the obvious and basic stuff before bleeding yourself dry on injectors and big ticket items. Craig

 

Same problem you had bub, buy the block off tool from genos. Start with the easiest injector line. My number four was bad. I did not have enough money to replace all six, but just the one made my truck work better than ever. I should have bought that tool a long time ago. I had the exact same symtoms as you, save yourself the trouble and just buy the tool. Denial is what caused me so much headache.

 

patti, pm sent to your box.