I have an 03 dodge 2500 6spd with a cummins diesel that has been giving me trouble cranking on mornings when the temperature is below 50F. I took it to a mechanic in town and he diagnosed it as low fuel pressure on one of the injectors and recomended i take it to a dodge dealership because it should be covered by the warranty on the motor. The dodge dealership i took it to told me that wasn't the problem and that bad fuel was the problem. They said the tank needed to be drained and injector pump retrofitted. And wanted to charge me $2000 to fix it. When i found this out i tool the truck back to the original mechanic who looked at it b/c i would rather pay a mechanic i know than a dealership that i feel is trying to rip me off. He is in the process of checking the injectors now. Does anybody have any knowledge about this problem? i would really appreciate any comments you have about this

 

Unfortunatley we hear about the bad fuel excuse all to often.
There must be no good diesel anywhere.
You can pull most codes from you truck using the key and odometer.
Don't start the truck on any of these, key in, turn to on/off/on/off/on and leave it.

look at the odometer and write down the output. when it's done it will say DONE. Post that up for us.

 

O.k. , does it not crank? Crank slow? Cranks fine, but won't start? Have you changed the fuel filter recently? Any other work done recently? Need more info. Fill out your sig. with truck and any mods.

 

ok so when the truck has set over night and if it cranks it takes at least 10 sec turining the engine over b4 it starts, but after its been running you can turn it off and it'll crank right up within an hour or two being turned off. sometimes when its cold it won't even crank. The batteries have a full charge and turn the engine over fine when you turn the key. I change my fuel filter every 15,000 mile per the manual. My original mechanic said there was low fuel pressure when he checked it, like it leaks down overnight or something.

 

Now that I know what is going on......Need quite a few special tools to do these checks, but here is what Dodge say to check.......Check trouble codes first. Key - ON/OFF/ON/OFF/ON and read in the Odometer what it says. Should say P and 4 digits
example= P0104



SECTION D - ENGINE WILL NOT START / HARD TO START:
Possible Causes
Battery voltage
Starting Accessories
Fuel Supply (Low Pressure) System
Fuel Injection (High Pressure) System
Fuel Return
Air Intake System
Other Vehicle Systems
Base Engine
14-003-06 REV. A -8-
Perform the Pre-Diagnostic Troubleshooting Procedure before proceeding.
1. DTC / Product Improvement: Check for any service bulletins related to the
customer's concern or Diagnostic Trouble Codes (DTC's) present. Follow appropriate
guidelines in the diagnostic procedures outlined in TechCONNECT. Is the vehicle
repaired?
a. Yes >> Go to Step #17.
b. No >> Go to Step #2.
2. Verify Battery Voltage: Measure the battery voltage and load capability. Is the
battery voltage sufficient?
a. Yes >> Go to Step #3.
b. No >> Repair low battery voltage condition. Go to Step #17.
3. Verify Starting Accessories: Verify the ignition switch, vehicle theft system, starter,
intake manifold grid heater, and fuel heater are functioning properly. Are all starting
accessories functioning properly?
a. Yes >> Go to Step #4.
b. No >> Repair or replace accessories as necessary >> Go to Step #17.
4. Check the supply fuel in the vehicle: Verify fuel level in the fuel tank. Also verify fuel
quality. Remove, inspect and replace the fuel filter (if necessary). Investigate for
evidence of fuel contamination and improper fuel type. Refer to the vehicle owners
manual fuel requirements section. Is the fuel quality within specification?
a. Yes >> Go to Step #5.
b. No >> Follow fuel contamination process (drain contaminated fuel, replace
damaged components, fill with proper fuel). >> Go to Step #17.
5. Verify complaint: Using the appropriate scan tool log the fuel pressure set point and
actual fuel pressure. Verify the rail pressure versus set point, this can be done while
cranking or with the engine idling. A good system will have actual fuel pressure that is
+/- 500 PSI from the set pressure. (Example: If the fuel pressure set point at idle is
6500 PSI, the actual fuel pressure on a good system is expected to be between 6000 -
7000 PSI). Does the actual fuel rail pressure meet the set fuel pressure +/- 500
PSI?
a. Yes >> Go to Step #6.
b. No >> Go to Step #9.
6. Check the engine oil level: Check the engine oil level. Is the engine oil level over
filled?
a. Yes >> Go to Step #7.
b. No >> Go to Step #8.
7. Remove the engine valve cover: Inspect for injectors leaking fuel into the valve train
area while cranking the engine. If the engine will start and idle, actuate the Fuel
Pressure Override Test on the appropriate scan tool NOTE: This feature is not
available on 2003 MY vehicles. Use the fuel manifold blocking tool, Miller special tool
#9011, to isolate suspected leaking injectors. If the leak is still present with the
suspected injector isolated, remove the injector and inspect the O-ring on the body of
the injector for cuts or damage. Inspect the injector bore for burrs or other cause for a
cut O-ring. Correct the cause of the damaged O-ring and replace the O-ring. Use
copper sealing gasket when reinstalling the injector. Refer to the detailed removal and
installation procedures available in TechCONNECT under: Service Info tab > 14 - Fuel
System > Fuel Injection > Fuel Injector. Are there any leaking injectors?
a. Yes >> Replace the leaky injector(s). Refer to the detailed removal and installation
procedures available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector. >> Go to Step #17.
b. No >> Determine the source of fuel/coolant/other substance in the crankcase
causing the system to be over full. Repair as necessary. >> Go to Step #17.
-9- 14-003-06 REV. A
8. Check the fuel pressure limiting valve: Perform the “Checking Pressure Limiting
Valve On The Fuel Rail For Internal Leaks” test. Perform the existing diagnostic
procedure available in TechCONNECT under: Service Info tab > 9 - Engine >
Diagnosis and Testing. No leakage is expected while cranking or while at idle speed.
Does the pressure limiting valve leak internally?
a. Yes >> Replace the fuel pressure limiting valve. - Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Delivery > Fuel Pressure Regulator. >> Go to Step #17.
b. No >> Go to Step #9.
9. Test for high injector return flow: Refer to the detailed diagnostic information
available in TechCONNECT under: Service Info tab > 9 - Engine, Diagnosis and
Testing > Injector Return Flow Test. Do the injectors pass the “Injector Return
Flow Test”?
a. Yes >> Go to Step #11.
b. No >> Go to Step #10.
NOTE: Torque all High Pressure Connector (HPC) nuts to the correct torque and
retest. Refer to the detailed service information available in TechCONNECT
under: Service Info tab > 14 - Fuel System > Fuel Injection > Fuel Injector.
NOTE: Test should be repeated to confirm measurements.
10. If the injector return from any cylinder(s) is deemed excessive:
a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Go to Step #17.
b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Verify that a quality fuel
filter is used. >> Go to Step #17.
11. Verify proper low pressure fuel supply to the high pressure pump: Perform the
appropriate fuel supply system flow test. NOTE: This procedure can be slightly
different depending on if the vehicle has an engine-mounted transfer pump or
the in-tank transfer pump. In a good low pressure fuel system, fuel flow of 560 mL in
10 seconds or better is expected for model year 2003 and early 2004 vehicles. In a
good low pressure fuel system, fuel flow of 590 mL in 10 seconds or better is expected
for model year late 2004 through 2007 vehicles. Be sure there is no air in the system.
Is the low pressure fuel supply volume sufficient?
a. Yes >> Go to Step #12.
b. No >> Repair the low pressure fuel supply system. Vehicles equipped with an in
tank fuel pump: Refer to the detailed diagnostic information available in
TechCONNECT under: Service Info tab > 9 - Engine > Diagnosis & Testing >
In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure. Vehicles equipped with
an engine mounted fuel transfer pump: Refer to the detailed diagnostic
information available in TechCONNECT under: Service Info tab > Diagnostics tab,
Powertrain Gas, Driveability Diesel, Fuel Lift Pump Flow And Inlet Restriction Test
>> Go to Step #17.
14-003-06 REV. A -10-
12. Verify high pressure pump output volume: Remove the high pressure fuel line from
the high pressure pump outlet port to the fuel rail. Connect a suitable hose to the high
pressure outlet port of the high pressure pump and route it to a graduated container.
Disconnect the Electronic Fuel Control Actuator. Crank the engine until fuel exits the
hose. NOTE: With the discharge line routed to atmosphere, fuel will discharge at
0 PSI. Crank the engine for three 10 second intervals, pausing to allow the starter to
cool between each crank event. High pressure pump output volume must be greater
than 70 mL in 30 seconds. Is the high pressure pump output flow sufficient?
a. Yes >> Go to Step #13.
b. No >> Replace the high pressure pump. Refer to the detailed service information
available in TechCONNECT under: Service Info tab > 14 - Fuel System > Fuel
Injection > Fuel Injection Pump. >> Go to Step #17.
13. Fuel Return: Check for kinked or restricted fuel return lines. Check the fuel tank
venting. Where any problems found in the Fuel Return system?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #14.
14. Intake/Exhaust Systems: Check for inlet restriction, inspect air filter for excessive
dirt/debris. Verify air intake tubes and hoses are not kinked or restricted. Check for
charge air cooler air system leaks. Perform the “INTAKE AIR SYSTEM PRESSURE
TEST - DIESEL”. Refer to the detailed service information available in TechCONNECT
under: Service Info tab > 11 - Exhaust System > Turbocharger System > Turbocharger
> Inspection. Inspect the Turbocharger for excessive compressor wheel movement
and proper waste gate operation. Check for exhaust restriction. Check for kinked or
blocked exhaust pipes. Verify proper exhaust brake operation (if equipped). Were any
issues found with the Intake/Exhaust Systems?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #15.
15. Other Vehicle Systems: Verify proper operation of the Transmission Clutch. Verify
proper operation of the Transmission. Verify proper operation of the Vehicle brakes
(check for dragging). Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories. Were any issues found
with the Other Vehicle Systems?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #16.
16. Base Engine: Check for internal engine damage. Valve lash settings, engine
compression, cylinder leak down, etc. Were any issues found with the Base
Engine?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #17.
17. Repair Complete: Perform Powertrain Verification Test VER - 1 (Diesel). Refer to the
detailed service information available in TechCONNECT under: Service Info tab > 8 -
Electrical/Electronic Control Modules/Engine Control Module > Diagnosis And Testing.
POLICY:
Reimbursable within the provisions of the warranty.
-11- 14-003-06 REV. A
GOOD LUCK!

 

I would start with the basics 1st , from your 2nd post my 1st thought was a bad ground , positive connection , fusable links , fuses , relays ,
It sound like some sort of lose of power with the fuel [ electric ] & no crank -starter - electric , 2 problems from different systems make me go back to a main lose or power/ground .

 

Look at post in 3rd gen "rail pressure at start" Sterling got his to start after a walpro kit install and tightend the fuel lines. I finally changed my lift pump last night and it started this morning 37 f outside. I am going to start without plugging it in again tommorrow i hope that fixed the problem. I think it is your lift pump. Your man said low pressure. My truck ran perfect all the time but would not start without being pluged in the morrning. I could hear lift pump run and when i changed filter it would fill the filter with fuel. Why would you put the fuel pump in the tank where you cannot service it go with the walpro kit. Let your mechanic know. Start with the cheapest thing first and the upgrade should be done anyway. I was waiting to post after tommorrow on the other post just to make sure it didnt start for some other reason. Good luck.

 

thanks for the input, i will post when i figure it out

 

If the truck starts after 10 seconds in below 50deg weather and when cut off starts right back up, could it be that you need to cycle the glow plugs a second time?

 

Glow plugs do not exist on a 5.9 cummins they use a manifold heating element!
Between 30 and 50 degrees one cycle of the preheat should be plenty. If you do not have the proper fuel pressure from the lift or high pressure pumps you will get a longer crank or a no start. The same thing will apply if you have a slow cranking (rpm) due to a bad starter, cables,batterys,etc
If you do not have a fuel pressure gauge add one right away and eliminate the guessing. If you need a lift pump upgrade with an aftermarket pump (not an in the tank) and also larger lines.

 

my mechanic says all he had to do was tighten up the HPC and its cranking fine, thanks for everyones input!

 

What is the HPC?

 

it is the high pressure connector that connects the fuel system to the injector i believe. Look at VZDUDE's post and you can read more about it.

 

problem returned a few months later. I replaced the lift pump with a BD replacement pump. Truck cranks right up.