dcoll1957

Pulled grid apart and jumped power to heaters they got hot to the touch my jumpers started smoking to small guage wire and pulled top off of fuel filter housing level was kinda low bumped key to run and filled up canister

Mexstan

Not exactly sure what you are saying or asking here, so could you please clarify? What kind of vehicle is this?

dcoll1957

I have 2003 Cummins no mods bone stock having starting problems when it is cold 35 degrees here pulled intake off of grid heaters jumped two wires to heaters they got hot to touch my jumpers started smoking to small wire also factory second fuel lift pump runs at least 30 seconds after I turned key on to run position it starts and runs fine when it is warmer outside

Mexstan

Sounds like your grid heaters are working. Please explain what you mean by starting problems. Does it just crank for a long time and then start? Or does it not start at all? Have you load checked your batteries? Does it crank fast or slow?

dcoll1957

Most of time I try not to crank on it to much I don't want to run batteries down or grind on starter to much I have strong batteries it cranks it over pretty fast I did crank on it one time batteries started getting weak still no start and run

Mexstan

Do you have a fuel pressure gauge and if so, what is the fuel pressure?
How long did you crank it before the batteries started to run down? How do you know that you have "strong" batteries? What makes you so sure about this?

dcoll1957

I cranked for 4-5 minutes off and on batteries have 12.6 volts no I do not have a fuel pressure guage

Mexstan

Will let someone with more knowledge than me respond.

dcoll1957

Thanks mexstan

cLAYH

You are not really clear in your post but I'll take a shot at it.
So what you are saying is there truck is hard to start when cold even though it cranks good. You jumpered the grid heater and then the truck started well.

If that's all correct then I'd say your grid heater is ok but not coming on. Most likely due to a failed relay which is located below the passenger side battery. Use a multimeter or test light to see if it is sending power to the grid heater when the key is turned on. Be quick as it only runs 5-20secs if its not really cold out. Have a friend key on while you watch the meter.

FMB

I disconnected my grid heaters at the relay a good 8 years before I sold it (at 295k miles). I never had starting issues, even down to the teen* F. I doubt very much your grid heaters are your issue.

Your injectors may be getting old and leaking by. Might be wise to send them out to be tested and rebuild as necessary. I used F1Diesel for mine and was very happy with the results. YMMV
Back to morning brew . . .