The nozzle is basicly the same as on a regular mechanical injecter. The electrical siglnals are only operating a small ball bearing about the size of a grain of sand.This relieces a small ammount of pressure from the top of the spring pack to create a difference in pressure from the bottom,to the top causing the pressure on the needle to overcome the spring,& fire the injecter.When the bearing is closeing the bleed port the pressure is equal.When it's open it's higher @ the needle,& the injecter fires.There still has to be enough pressure there to open the nozzle.Also,even if you do get an out of spec readsing from a leak test,you need some more special equipment to isolate which injecter is the one leaking.This you should leave to a Cummins tech.Cheating on equipment for this could get you hurt.Like I said.If you're in the Washington area,I can help you out.I am a certified Cummins tech. @ a Cummins dealer.Good luck.

 

Thanks for offering me to help,I wish I lived near to you,but I live in the Netherlands (Europe)

The problem is there is no warranty from Dodge /crysler,because the pickups are not been selling here through our Dodge /crysler dealers ,so we have to import them ourself ,and have no warranty at all,even when bought new there is no warranty.( I think there is when I bring it back to the U.S,but thats expensive too)

We have a few companies here that have new pickups which they did import themselves ,but they offer a year warranty from theirself ,thats why a pickup is roughly 15000$ more expensive than importing yourself.

We have a cummins dealer here ,I believe it cummins marine europe,I could give them a call to ask if they can help.

thanks sterling

 

Bigwheels do you think that the injectors are at fault in the no start situation? I am thinking that the truck would not run so good if th injector pump was no good? Mine will not start unless plugged in . Will start all day after initial start.

 

Sterling.If I were you I would definitly take it to a
cummins Marine dealer for proper diagnosis.(I'm a
Cummins Marine tech.)They should have all the right test equipment to help you out.The only difficulty they will encounter is there are some differences that Dodge did to the systems.Insite(The diagnostic software) will not efficiently communicate with the dodge ECM.It can do some things,but not others.But With some support from Cummins they should be able to get around that.
Longbed. There are a multitude of things it COULD be.The only way to properly diagnose a problem is to go through the steps to isolate YOUR problem.For instance,if it's cold,& your grid heaters aren't working,then it will be hard to start,but with the block heater on all night there is sufficient temp. in the cylinders to light up.These engines are VERRY COMPLEX,& need to be treated as such.Guessing,&/or throwing parts at a problem will be verry expensive,& long. If you can describe your problems in as minute detail as you can,I may be able to point you in the rightdirection,but I'll need to know when the problem started,if it ever happened before,what the temp. is,how long it has sat,etc.I'll do what I can with the info,I have to work with.Good Luck.

 

hey if you figure it out let me know i have the some problem. it is getting crazy

 

My first advice would be to varify that it still does it without any box's/programers.They are the easyest things to eliminate.If it still does it,then give me as much info as you can,& I'll see what I can do.

 

My truck is an 03 so engine it has no box never has. This started when it got cold . It would start but only on second crank. Became no start unless it was plugged in. Other day it was 60 out and would not start . Plugged it in 1 hour starts right up first time. If you look in help section it a post 20 F no start. Another member brought his truck in for same problem to a cummins not dodge dealer and after a injection pump then 6 new lifters got it to start in any conditions. He spent 1700 on a ip then 1700 on injectors . Sounds like they just threw parts at it to fix. Thats not what i want to happen. If i need injectors i will put in performance ones or an ip i will put in performance parts.If i go to dealer they will charge more for stock parts than performance.It is not the grid heater i went through that allready. Truck is perfect after initial start up.

 

If you can work on it yourself, I might be able to help you figure it out. PM me

 

Is there any smoke when it's cranking,& not starting?Pure white smoke is raw fuel.No smoke is NO fuel.After it starts,does it smoke at all?Stumble,etc.? Have you tryed checking the MAP sensor for dirt,etc.? Also,check the signal voltage to the rail pressure sensor.Does it crank at the same speed,or slower/faster? PM me with as much detail as you can,& I'll go over the symptoms in my manual,& see where it leads.

 

Longbed

You and I have exactly the same problem,only mine gets worser,and will not start at all.
When starting with a little etherit will run perfect,unless i shut it down ,then she will never fire up .

Bigwheels We have a truckbrand here in the Netherlands (DAF trucks)that belongs to a US company,and they use cummins diesels 5,9 commonrail in 3 configuratios,150 hp-180-250 hp I saw that the cp3 pump is mounted on the other side of the engine,and a few other things are different ,I ,m going to let my truck check there,and see what they come up with .

thanks Sterling

 

Try unplugging the FCA and see if that makes a difference in starting.

Try blocking the rail return line and see if that helps.

Good luck.

 

Whatever you do. DO NOT unplug,the FCA,& plug the rail return line at the same time. You could try them seperatly.I'm not positive but I'm thinking that the engine won't start with the FCA unplugged anyway.I know it will run that way if it's failed,etc. when it's allready running,but if the ECU finds it unpluged, during prestart,it may triger a no start.It will definatly set a code.
The return line being pluged,by itself won't hurt anything,& if the no start problem goes away there's your problem(leaking pressure relief valve)Not unheard of.The way the Cummins manual says to check for this condition,is to crank the engine for 30sec. continuosly,& check for a code 2615?(I think that was it.)I would recomend unpluging the grid heaters first,& doing that 1st. thing so the starter has time to cool down.If rail pressure hasn't reached aprox. the comanded level,it will set the code after 30 seconds.As this is real hard on starters,I'd recomend doing flow testing first,to find the problem.Good Luck.

 

I do not get smoke before or after a start. I have cranked the engine a number of times with no start than after i plug it in foor an hour it starts no smoke. The map sensor being dirty i will check. When i took off my grid heater the inside of the intake was like new inside. It always cranks a little slower in the morning i guess oil viscosity. I have two new batteries and a new grid heater. Crank the engine for 30 seconds that does sound long . I have no codes now with 3 x key cycle. I will try this saturday see if i get the code. Pressure sensor at the rail i do not know how to check and blocking off the return line sounds like a good test . I will have to look into that as well.

 

If you don't have an afterarket rail pressure gauge,you can not check rail pressure.That would have to be done with a scanner like the one the dealer uses.Have you changed your fuel filter recently? Check the voltage while cranking?Air filter? I know this stuff is basic,but sometimes you have to back up,& start over from scratch.Are you sure the lift pump is working? Off the top of my head,it sounds like you're loseing prime overnight,& the lift pump isn't pushing fuel to the CP-3.If you have a bad lift pump the engine would be hard to start,till it was primed.There is another pump inside the CP-3 that will draw fuel through a weak lift pump,& run fine once it's got fuel.The lift pumps are notorious for doing this on the early 3rd. gen's.One thing is for sure. NO SMOKE=NO FUEL.

 

Have changed fuel filter. Air cleaner is almost new. I did get a used lift pump that i want to install. I will see if i have time this weekend to get it done. The reason i did not do it yet was because when i changed the fuel filter it primed the filter empty and started right up . The truck had already been started for the day. I think that a weak pump would have made me key on a number of times to get prime.