Hi all,
got an 03 2500 4x4 6 speed. Had it two months. It seems to take a second longer to "catch" when starting compared to my 98.5. but it always starts.
This morning, 34 degrees outside, it failed to start. Cranks strong, batteries and cables all good. Glow plug light cycles for an appropriate amount of time. Lift pump runs and makes good pressure when tested by opening the filter drain and bumping the starter.
It doesn't even attempt to catch or run.
I put it on a cord and plugged in the block heater, but 34 just isn't that cold. Not sure what to do next. Waiting for the block to warm up.
Matt

 

OK- after soaking on the block heater for about 90 minutes it started. No longer an emergency, but what gives?

 

I think those have a temp sensor in the fuel heater. Maybe the block warmer fooled it into starting. Look into that and see if it is a possibility. And maybe the air heater really wasn't heating the elements. These heat the intake air, not glow plugs.

 

A free flow test of the lift pump isn't really telling you much, other than fuel ran out the end of the hose. It very well may do that without the lift pump on. You really need the system closed and a fuel pressure gauge put on it. Test it three ways. 1-key on, not running, 2-at idle, and 3-at wide open (for a short time). None of these should ever be 0. You should have about 15 or so psi at test 1 and 2. Maybe 5 or so at test 3. I'm not aware of a fuel temp sensor.

Have you looked at the fuel filter? I change mine every other oil change. If you have no knowledge of when it was last changed, then change it. It very well may be your issue.

At 34, it shouldn't have any cranking issues. Maybe a little slower but it still ought fire right up.

And once you do have it running, with it in neutral, turn on the cruise control, then press the set button. If it has high idle enabled, it will raise the idle to 1500, You can adjust the idle speed with the increase/decrease speed buttons. You can disable the high idle by turning the cruise off, pressing the cancel button, or stepping on the brake.

 

Thanks for the advice. I went ahead a bought a high pressure guage and an injector line block off plug from Geno's Garage. I plugged each line and tested the rail. It came up 6k at idle and 8k at 1200 RPM every time. The thought was that I have a leaking injector. Now I am wondering if I have more than one leaking injector. where to go from here?

 

This sounds exactly like you have an injector going south on you. The block heater trick will get you by until you figure out what you want to do.

 

Went through the same issues twice with mine, about a year apart. It was an injector each time that was leaky.

I was lucky that the injectors just returned fuel and didn't dump into the crankcase.

When this happened the second time, I figured I had 5 original injectors and 1 new one. Didn't want to go through this again, went ahead and replaced all 6 with 60hp upgrades.

 

So who do you all recommend for a rebuilder? I don't have a lot of cash, but I want it done right. The rest of the truck is bone stock so HP upgrades aren't necessary, but if the upgrade is the same price I might as well do it.
Do the HP upgrades hurt fuel economy?

 

F1 diesel, get in touch with one of his distributors for prices. Do a search on Don M on here.

www.f1diesel.com