I have a 2005 Dodge 3500 2x4 with a 5.9 Cummins Vin C and 230,000 miles. It will not start without a shot of starting fluid cold or hot but once started will run well until shut off. It had a miss 30,000 miles ago but still started on its own. Dodge dealer installed a new set of injectors and fixed the miss. The hard start started about 25,000 miles after the new injectors. When the truck starts after a shot of starting fluid it starts and runs smooth. The heater grids are working ok. Any suggestions? Thanks Fred

 

Hard start or no start at all w/o ether?

 

No start. Just cranks over and never starts up. Fred

 

I heard on these the injection pressure needs to be at least 3500psi while cranking to start. Mine is 1500psi while cranking. Testing with a OTC tester.

 

So far, it sounds like the in-tank lift pump died and won't feed the CP3 during crank; after you fire it off with ether, the high-pressure CP3 is able to pull fuel through the stock lift pump.

Open the water drain on your fuel filter housing (yellow lever), let it empty and bump the starter... should have diesel pouring out on the ground.

No gauges, huh?

If the LP is shot, don't wait too long to R & R it, since it could shorten the CP3's life.

p.s. why don't you take a moment and fill out your truck's signature?

 

I was told it might be a fuel pressure regulator returning too much fuel back to the tank. The regulator would be arround a $500.00 guess. Kind of an expencive guess. If I was positive that would fix it I would buy one.

 

Thanks for the information. I will try that tomorrow and see if the intank pump is working. I will let you know what I find out.

 

i would also check the pressure relief valve on the common valve sometimes this gets crap in it and gets stuck open i had a hard start for a while then i pulled that off and found the retainer screw for the spring cracked.

 

PSI relief does not open UNLESS rail psi has gone beyond a designed threshold therefore it will not "get crap in it and get stuck open". Matter of fact IF the rail psi gets high enough to allow the relief valve to open the high psi will often cut small grooves in the seat (think waterjet cutter) and ruin the valve. It's made as a last ditch effort to relieve excessive psi if something goes wrong to save other componants.

 

I would also check you lift pump first like XLR8R stated.

The other option could be the injectors again. They might be leaking back to the fuel return system. I cylinder cut-out test would help to determine this.

Otherwise I read that someone else was able to use a IR heat gun to find out which cylinder exhaust temp was lower than the rest to find the bad injector.

We're all assuming that you change your filters

 

i havent done this but it might be worth trying

https://www.dieseltruckresource.com/...=177547&page=2

post 27

Cascade Overflow Valve

also check post 34

 

I checked in-tank fuel pump today and it was ok. While I was at it I changed the fuel filter as well. It still wouldnt start without a ether assist. This was as far as I tested because I had to go to the emergency room with my mother and ended up spending the rest of the day there. But I am sure the problem will be there for tororrow. I looked at some of the other hints posted and I will look into them as well. Thanks for all of your hints!

 

How's your Mom doing, Fred?

 

I checked out the truck a little while today. I took out the Cascade Overflow Valve and it looked to be seated but when I tryed blowing through it it leaked. So I cleaned it with penetrating fluid and blew it out a few times. When I tried blowing through it the second time it was sealed. Installed and after a few revolutions it started. I let it idle for a little while then shut it off. Tried a restart and wouldn't fire off. Removed the Cascade Overflow Valve and tried blowing through it again. Like before it could be blown through. Blew it out out with air pressure and reinstalled it and the truck started again. I parked it out side and ordered a new Cascade Overflow Valve.

p.s. my mother is doing better but still in the hospital. Thanks for asking. Fred