I have a 2007 5.9 3500 ctd. When it sits overnight and is cool it starts up fine. Truck runs fine while driving. Once the truck is warmed up and driving around it gets real hard to restart. This started this summer and has been getting worse and worse, til yesterday. Truck started fine, drove 4 miles and stopped for lunch. Came out and truck would not start. Took about 5 minutes of cranking off and on to keep the starter cool til it finally started up. Only things I have done are basic service, changed fuel filter and o ring and also changed out the FCA.

From searching I have found it could be injector pump, injector or the in tank pump.

I am thinking it is the in tank fuel pump.As the only time I have a propblem is while starting. I am going to order a banjo bolt from Ginos garage to test the fuel pressure at the fuel filter housing. Any ideas or how to test is appreciated. Thanks for the help.

The truck dies have an AFE intake,shneid elbow, edge CTS and 4 inch turbo back with no cat.

 

There are some interesting Youtube videos available with loads of info on your CTD. It may not be exact to your year, but fuel flow test should be fairly accurate. The series begins with but the fuel flow test is . You won't need the DRB3 tool to activate your lift pump. Just turn the key on or bump the engine.

Good luck, hope it is your lift pump vs the $$$$$ pump.
Back to morning brew . . .

 

I ran some tests to check the injection pump and the injectors. I used tool 9012 and checked return for the pump. Test allows for 1000ml in one minute, and I am at 800-850 in one minute. Then checked the return from the injectors. Test allows for 180ml in one minute and I am at 125 in one minute. These test were done with the engine warmed up. Also cracked the line at the relief valve on the rail and I don't have flow.

I did check the torque on all my lines and they seemed to be good. Since the weather has cooled the warmed engine starts are a little better but still cranks a little bit. Anyone have any ideas for me to check next I will appreciate it.

 

Injectors

 

What are the results from your lift pump fuel pressure test? Probably normal, I'm guessing. I agree with Eat Beef on your injectors probably being the issue, especially if you have decent mileage on them (you didn't say how many miles/hours on your truck).

If it were me (and it was several years ago), I would pull the injectors and send them to a reputable shop for testing. I sent mine to F1 but you may have a closer shop. My '03 had the the symptoms you have before I sent them out. When I got them back, rebuilt, the engine started like it was brand new.

Someone on DTR started a very well documented thread on pulling and replacing the injectors. Not real hard to do.
Back to morning brew . . .