bday

This is going to sound like the same old song. By now you guys must be getting good at answering it though.

Last winter my truck would only start when warm. The dealer thought it might be the lift pump. so I installed an Air dog 100 to no avail.

It ran fine all summer and then when it got just a little cool got hard to start and quickly went to not starting even while warm.

I connected a code reader and was graphing cranking speed, not expecting the truck to start because it was cool and it started. I turned it off to remove the reader and the truck would not start. Making me think it was maybe not temp related.

One day I had to crank it a while then drove it, got home and park and it has not started since.

There where never any drive-ability issues, smoke at all, when running.

I took a guess, based on reading here and replaced the FCA. I also added a low pressure waring light to the Air Dog, which shows good pressure.

Now I am looking at the HPCR with an analyzer and I am seeing a set point of about 5000 and pressure of about 950.

What other information should I gather, or tests to preform, to help determine the problem?

Thanks in advance for the help!

Spooler

Sounds like you have a leaky injector. Your rail pressure she be around 5000psi when starting. Sounds like you have a bad injector or three. Send them all off to be repaired and upgraded by F1. Very common on the 03/04 trucks with the 305/555 engine.

no_6_oh_no

Rail pressure needs to about 3000 psi to start normally, what you have is way to low.

If you verified good fuel pressure to the IP inlet, unplug the FCA and see if that helps. That will throw full fuel to the high pressure circuit and build rail pressure faster.

The COV could be the issue. You could replace with aftermarket that boosts the case pressures. Doesn't really point out the problem but its a start.

Low rail pressure could be CP-3, injectors, or crossover tubes. Injector return flow test and cylinder contribution test would probably give some good info.

Need it running to do that though. See if it will start with some kind of starting fluid so you can run the tests. Disconnect your grid heaters first so you don't have an expensive "incident".

bday

I guess it's time I got the manual for this truck. I bought a Chilton's which is about useless.

What's the best way to buy the shop manual?

Thanks!

SuperGewl

Dodge or E-bay

bday

It does start on ether, and after that started with out. I had it plugged in all night.

So I hooked up the analyzer and graphed the rail pressure.

The pressure (with out ether) rises quickly to 10000 then falls back to match the set point of 5000 rising to 20000 briefly while shutting down.

Then I thought I would try with the FCA disconnected. The truck would not start without ether. It showed the same pressure data as other non-starts, pressure did not reach 1000. With ether it started, pressure to 26000.

Subsequently it started again several times with FCA and with out ether. Something sticking?

Any thought?

How are these test preformed?:
Injector return flow test and cylinder contribution test would probably give some good info.

Is this something I should be able to do?

Thanks!

bday

I ordered the manual from TechAuthority; how can they chage $20 to ship a CD?