Approximately 18 Days ago, my truck would not start. Was running the night before, noticed increased Ping under load as well as a significant loss in power. Next morning engine turns over but would not fire.

Day 1 - Towed into DC and they replaced the #1 injector. Truck started and ran 10 blocks sat overnight and would not start again the following morning.

Day 2 - Back on the hook to DC.

Day 3 - DC says must be fuel contamination because now 4 additional injectors need to be replaced because they will not open (easy math tells me that I still have one good stock injector left) I said that if it was bad fuel them wouldn't all six injectors be equally impacted as same fuel flows through all injectors at the same time. Also why were these other injectors aparently tested as fine with nly one requiring to be replaced 10 blocks ago.

Day 4 - Collected fuel and oil samples from the truck at the dealership. Waiting on DC Techline to release the repplacement injectors. I asked if the injectors were leaking or stuck closed. The injectors were bypassing in the closed position (not opening) I suggested maybe an injection pump issue or electrical. DC said that standard practice was to test the entire injection system and the injection pump (CP3) tested good.

Day 5 - 9 Injectors installed (5 additional = 6 total) Truck still would not start. Now Dealer is telling me that they think it is the injection pump (CP3). Waiting on advise from techline. (Pump must have gone bad while sitting in their shop).

Day 12 - Tech line suggested further testing before they would release the CP3. Dealer conducted further testing and teh CP3 was released. Dealer installed the CP3 and attempted to start the truck. Still would not start.

Day 13 - 15 Tested transfer pump all OK. Electrical connections OK. Pressure on inlet side of CP3 is within spec. Pressure on outlet side of new CP3 is half what it should be. Pressure not registering high enough in the PCM to open the injectors.

Days 15 - 18 The technician is staring blankly into the engine compartment where he has all kinds of stuff tore apart and hanging loose. I took one look and shook my head in disgust.

On Monday I have the day off and plan on sitting in their shop all day to watch the performance. Anyone with similar past experience please advise me on what to do next. I’m thinking that it may be a fuel pressure sensor, pressure relief valve or MAP sensor issue.

 

Any codes?

 

None. That would make it too simple.

 

Pressure relief valve would be my first guess.

Defective New CP3 would be my second.

 

Have them check the AC pressure sensor wire that runs up behind the head. That rubs through and grounds the power and keeps the control voltage below solenoid actuation levels, makes for hard starting or no starting.

Then I would second the suggestion about the pressure relief valve for the common rail. I have seen more stumped Dodge mechanics when that valve sticks open than on anything else.

 

RCW might be onto something about the A/C wire. That sensor wire has been shorting out down underneath near the A/C pump. I don't remember reading about a short near the head but that may be another thread. Here is the thread that talks about the short near the A/C compressor:

https://www.dieseltruckresource.com/...ad.php?t=81936

That shorted wire throws all sorts of codes because that wire feeds voltage to a whole bunch of sensors. So either that isn't the problem OR the dealer isn't sharing the codes that they are finding.

 

You nailed it....First NEW CP3 was defective. Installed a second new CP3 and runs fine. Now to fight over the rental charges for past 21 days.

Now that you mention it I did read of this issue...Checked for rub through myself when it was in their shop and it was rubbed...Had them repair this before the second new CP3 but they already had the first new CP3 out so I can't verify that that was the fix. Worth a look for anyone else experiencing CP3 issues thought.

 

******THIS IS YOUR PROBLEM*********If you have an 04.5 look on top of your fuel tank about 11:00 from your axle, you'll find an air inlet in a resovoir. I'll bet it was raining when you drove it last. That inlet pulls water in and will burn up every injector in the truck. Dodge would'nt warranty mine because they said my lift caused it. Thats bull, I don't have a body lift so it does'nt effect the location of this inlet. The inlet is a 90 degree angle and is below the water level. A peice of .25cent hose will fix it after you replace about $4500.00 in injectors and clean out your tank. This problem may exist in other years as well. Personally I'd like to start a class action law suit for all the people that have been screwed by this. The fuel is contaminated from this air inlet NOT YOUR FUEL! DON'T LET THEM WIN THIS ARGUMENT! I WILL TESTIFY FOR YOU! I'm so ****** about this F^&F up I could scream. By the time I was done it cost $5275.00 bucks. THIS IS 100% DODGES FAULT DON'T LET THEM TELL YOU OTHERWISE! MOST LIKELY YOUR INJECTORS ARE ALL BAD, YOUR FUEL PUMP IS BAD AND ANYTHING IN LINE WITH IT. THEY MUST CLEAN THE TANK SPOTLESS BEFORE FIRING IT UP. MAKE SURE THEY DON'T DAMMAGE YOUR STARTER AS WELL. My name is Bill, I can be contacted at 520-624-2000 tuesday-friday 9:00 to 6:00, 10:00 to 4:00 saturday pacific coast time. Please call me, I'll help any way I can.

 

Well Bill, I'm sorry to here the troubles that you had experienced with your truck. As soon as dodge mentioned the possibility of contamination, I asked them to drop my tank (cost me $120) and I was to be there when they did so I could collect my own sample. At the same time I asked them for a new oil filter. Pulled the old filter off the truck with oil in it and replaced with new filter (cost me $20) Cut appart the oil filter to inspect for metal particles or filings. Filter looks good magnet did not pick anything up and no evidence of aluminum. Sent oil and fuel samples to a lab for contamination analysis (cost me $60 for both) and both show no issues. Rental truck for 21 days (cost me $1900) and my warranty only covers 5 days at $50/day (-$250).

Drop tank $120
Oil Filter $ 20
Lab work $ 60
Rental $1900
DC Credit -$250
TOTAL $1850.00

I got six new injectors and tubes, new Injection pump and every other aspect of the engine has been gone over with a fine tooth comb.

Injectors 6 @ $910/ea $5460
Injection pump (approx) $3000
TOTAL NEW PARTS $8460

So I think I am ahead of the game. But still going after Dodge to ponny up some more towards the rental cost.

 

Even if they determine that that is not the problem I'd check for that inlet on top of the tank. It was definatly the cause of my problem. Just curious, had it rained recently before this happened. Also if they sampled the fuel off the top of the tank you would'nt pick up the water contamination. The dealer had dropped my tank 3 times and did'nt figure it out until I pointed it out to them the 3rd time. Once again, thank you very much for your help. If any of you ever need car audio I'll take good care of you all.

 

Sandtazam,

Sorry it took me so long to reply. My trucks back in the shop again (now the third time) this time the injectors started leaking into the cylinder causing the engine to run on and fuel to enter the crank case. Drove the truck approximately 50 miles before it crapped out this time. Was running good and strong like the day it was new.....then my happiness was dashed when on one rainy morning I was driving to work (had the truck home for four whole days) and what strange noise was that I was hearing, increased rattle, strange exhaust noise and I hit the brakes to investigate. Started doing a brake stand (on its own) in a vacant parking lot. Scared the jeepers out of me and I immediately shut the engine off. It then failed to re-start. Due to my past experience I made sure the truck was stopped in a towable position before I shut it down. Dealer called me the next evening and told me that the injectors were washed out and had to be replaced (they said that it is uncommon but not impossible that they got a bad batch of all six injectors) must think I am a fool.....Picked up the truck the next morning, drove 20 blocks to work and same thing.....again. Now DC is telling me it is fuel contamination but the dealer tells me that the fuel looks fine. Isn't the filter supposed to filter out water and the water in fuel indicator light should let a guy know before it becomes an issue.

 

Went to the dealer yesterday to look at the paperwork and all diagnostics conducted on my truck in the past 5 weeks that they have been diddling with my truck. Seen the photos of all components and fuel samples sent to Daimler Chrysler. I did not see any obvious issues with anything. To go through three full sets of injectors in a period of less than 100 miles is just insane.

I told them it has to be something with the electronics opening the injector, ECM or PCM or some pressure relief valve issue or perhaps there has been a installation problem when they installed the injectors. I have contacted DC Customer care line to discuss the issue with my truck and they even seem to be dodging the issue. I feel like I'm beating my head against the wall.

 

It's sounds like Lemon Law Time.

 

Just got a call from the dealer yesterday, he told me to come in as he wanted to show me something. Went into the shop and the he had my fuel filter out on the bench and showed me that the filter element had come apart from the housing. He suspected that the filter was allowing particulate to bypass into the injectors causing them to fail. I looked back on the work orders from day one and the work order from the first time in indicated that the entire fuel system had been inspected "FUEL AND AIR FILTER CHECKED - OK". I asked them if this was the case and I had put less than 100 miles on since it had come in the first time, I find it hard to believe that the damaged filter was missed in the first place especially since the work order indicated that it was inspected. Also if contamination was suspect, the Dodge shop manual indicates that the entire fuel system is to be flushed and filter replaced.

The tank was dropped (which I paid for) and the tank was emptied and fuel sample was collected. Fuel sample results indicate that there was 24ppm of sediment and water in the fuel sample. I called the lab and they indicated that the allowable limit is 500ppm, so my sample was way below the allowable limit.

I also asked why in gods name would they replace the old filter after inspection in the first place. It stands to reason that if you are looking at this as a possible issue, one would replace with a new filter ($10.00) which I would have gladly paid for if the dealer would not cover this cost under diagnostics. If Dodge will not cover this under warranty, my only other option would be to go after Luber-finer to cover the repair costs under their warranty.

On another note, when doing a diagnostic test on the fuel system, if the filter element is damaged and allowing fuel to free flow into the injection system, wouldn’t the flow volume be higher than expected causing the tech to question the increased flow volume and further investigate the cause of the increased flow.

 

Wow, I am currently having a similar problem. I bought a 2003 3500 HO 4x4 6 sp. from a guy on ebay. Picked it up on 29th of April. I have never owned a diesel before but since we have decided to sell our class C motorhome in favor of a 5th wheel and also plan on making biodiesel, the decision to buy the truck was the only way to go. Everybody with any experience owning a diesel said buy Cummins........I beginning to believe the old adage "misery loves company". I did the "look around" with the previous owner and descovered a can of starting fluid in the compartment between the two front seats and when I asked what it was for he told me that I might have to use it if the vehicle sat for a month or so. Long story short: I noticed the truck took a seemingly long time to start, ie it cranked for 5 to 10 seconds before firing up, but I thought it was normal for diesels, seeing that I had never owned one before. The problem got worse and worse until finally we couldn't get the truck started the next day. I asked a friend who owns a 2002, who is coincidentally, a mechanic on gas motor vehicles and he suggested I take it to the guy he trusts to work on his vehicle, who would then put it on the computer and diagnose it. That guy was 35 miles away and there was a dealer a couple of blocks away from where I work so I took it there. They first told me it was flagging a clutch fan. That may have been bad, but I could not equate that part being bad with my scenario so I was going to pull the truck out of their dealership and bring it to the other guy farther away. When I went to pick the truck up it wouldn't start so they told me it was now able to be fully troubleshot and a problem found. The call came in later the next day that my lift pump was shorting out and needed to be replaced. I made it clear that I didn't want to "throw" parts at this vehicle just hoping it would be fixed. They assured me the part was bad and that this would fix it. Put it in I said. The later call confirmed my fear.....the part didn't fix it and now they want to replace the fuel control actuator and pressure relief valve to the tune of an additional $800 on top of the $575 I have already authorized. I paid the $575 and now it's in the shop farther away and so far they believe my injectors need to be replaced....all of them. You may be under warranty, but I am not so unless the service tech can convince the district manager to give me the parts under warranty, I will be out a lot more money here soon. The previous owner didn't tell me that in Alaska he got bad gas and after two injectors, a pressure relief valve, and two lift pumps were replaced, the dealership/ DC restricted the vehicle from ever receiving any parts under warranty again. My truck is still in the shop today and I am hoping to hear from them by mid next week. Please let me know what you find out and I'll do the same. George sonocareinc@juno.com