i have just instaled a new lift pump got fuel now rail pressure is only geting 1200psi in the rail wile cranking if i spray A LITTLE eather in the intake AFTER unhooking the grid heater it will start and runs fine rail pressure at idle was 6200psi shut off and tried to start again still would not start

 

Guess number 1 would be your still drawing air somewhere. Start with the LP fittings that you messed with.

 

tried that blead system b/c had fuel tank out no change still no start. Did i damage my injectors or cp3 pump by trying to drive it home when the lift pump went out? why will my fuel pressure be so low when cranking but right up around ware snap-on scaner says truck is askin for btw the truck in question is a 2004.5 regular cab long bed with 160,000mi around 4900 hours

 

If the engine is a no start there should be almost no fuel from injector return after cranking 15 seconds. If injector fuel return flow is high the leaking injector or connector tube must be found. Do a injector isolation test with tool 9011. This will check the injector mechanically for internal leakage. A leaking injector may cause a no start. Remove the high-pressure line to the suspect injector. Use miller tool number 9011 to block off the fuel rail fitting to the high pressure line just removed. Crank the engine, if Actual Fuel Pressure increases to within 200 PSI of Set Fuel Pressure replace the injector and high pressure connector tube.
Miller tools are available here: http://www.millerspecialtools.spx.com/PaymentType.aspx

 

NOTE: Any injector contributing more than 40 mL (1.4 fl. oz.) is excessive (Example:
If total injector leakage is 200mL (6.7 fl. oz.) and blocking cylinder #1 reduces
the leakage to 160 mL (5.4 fl. oz.), cylinder #1 has excessive leakage test will tell you if injectors or HPC tubes have excessive leakage.

INJECTOR RETURN FLOW TEST
1 1. Operate the engine until the engine is at operating temperature.
2. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter
housing.
3. Install fuel system test fitting (9012) in place of the banjo connector.
4. Remove the vehicle fuel return line from the engine fuel drain tube.
5. Install a piece of fuel line onto the test fitting and into a fuel container or into the
fuel tank.
6. Install one end of a test hose onto the fuel drain tube. Place the other end of the
test hose into a graduated cylinder.
7. Start the engine and let it idle for one minute.
8. Measure the amount of fuel in the graduated cylinder.
9. If the flow is less than 180-ml/minute, the test has successfully passed.
10. If the flow is greater than 180 ml/minute, shut off the engine and remove all of the
fuel injector supply lines. Re torque all of the high-pressure connector nuts. Install all
of the fuel injector supply lines.
11. Start the engine and idle for one minute. Measure the amount of fuel in the
graduated cylinder.
12. If the flow is less than 180ml/minute, the condition has been fixed.
13. If the flow is greater than 180 ml/minute after step 12, shut off the engine and
remove the #1 fuel injector supply line. Re torque the high-pressure connector nut.
Cap the #1 fuel port on the fuel rail and the #1 high pressure connector.
14. Start the engine. Measure the amount of fuel in the graduated cylinder.
15. If the amount of fuel is less than 180 ml/minute, shut off the engine and remove
the #1 high pressure connector and the #1 fuel injector. Inspect for damage,
repair/replace as necessary.
16. If the amount of fuel is not less than 180-ml/minute, repeat steps 14-16 for
cylinders 2-6.
17. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines.
Repeat steps 1-8 to confirm repair.
SPECIFICATION:Less than 180 ml/minute total fuel return flow

Retaining nut #3 must be torqued to 37 Ftlbs.

 

codes?

 

I just went through this with my truck recently and leaking injector tubes or injectors will not usually set a code. I found #2 and #4 had excessive return flow. Replaced two injectors and fixed problem. Reman injectors and tubes from cummins around $340 each. Dodge wanted over $600 for one injector and $60 for tube.

 

thank you guys you have been a big help i will try these things and keep you posted

 

Looks good with what has been stated above... also, what about the rail pressure relief valve?

 

PRESSURE LIMITING VALVE
This can also give you long crank if it is leaking. Easy to check but need miller tool 9013 makes it easy to check. If you don't use tool you will get return flow from CP3 pump and will not be conclusive then.

Remove the banjo bolt from the pressure-limiting valve on the fuel rail.
Install fuel system test fitting 9013 into the pressure-limiting valve.
Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container.
Perform the tests listed below to determine if the pressure-limiting valve is leaking.
a. Operate the engine at idle and watch for fuel flow into the fuel container.
b. Operate the engine at idle and actuate the high pressure safety valve test with the scan tool. Watch for fuel flow into the fuel container.
If fuel flows into the fuel container, replace the pressure-limiting valve. If fuel does not leak from the pressure-limiting valve, the test is complete.

NOTE: Do not drive the vehicle with any portion of this test kit installed.

 

one of the local shops around me told me to try clamping off the return line and see if the pressure goes up i tried that and it did go up but only to 1310psi so i removed the injector lines and torqued the tubes to 37 ft lbs the all turned about 1/8 turn but no more than 1/4 still have to put back together and see what happens do you think i could have hurt the cp3 when limping the truck home?

 

You can test CP3 pump,hook up battery charger so you have consistant cranking rpm when testing.
HIGH PRESSURE FUEL PUMP PERFORMANCE TEST

1. If the engine will run do the following:
2. 1. Monitor rail pressure with scan tool while the engine is at idle.
3. 2. Compare the fuel pressure set point with the actual fuel pressure reading.
4. 3. If actual fuel pressure reading fluctuates more than +/- 500 psi from the set point, then replace the Fuel Conrol Actuator (FCA). NOTE: After the acutator is removed, check for debris or corrosion on the FCA. If debris or corrosion is found, replace the entire Fuel Injection Pump.
5. 4. Turn off engine.
6. 5. Disconnect the FCA harness
7. 6. Disconnect high pressure fuel line from fuel rail and route the high pressure fuel line into a graduated cylinder.
8. 7. Crank the engine until fuel exits this line. This will not be high pressure fuel.
9. 8. Crank the engine for three (3) 10 second intervals (Note: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter). Fuel flow specification s based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump:
10. Minimum fuel pump flow at 150 rpm cranking speed is 70mL
11. Minimum fuel pump flow at 200 rpm cranking speed is 90mL
12. If the engine is a no start do the following:
13. 1. Remove fuel pump to railhigh pressure fuel line.
14. 2. Inspect the fuel pump outlet port for rust, debris, or other signs of contamination.
15. 3. Replace pump if any contamination is found. Check for source of water in fuel or debris in fuel to prevent future complaints. If no contamination is found continue to step 4.
16. 4. Disconnect the Fuel Control Actuator (FCA).
17. 5. Disconnect the high pressure fuel line from the fuel rail and route the high pressure fuel line to a graduated cylinder.
18. 6. Crank the engine until fuel exits this line. This will not be high pressure fuel.
19. 7. Crank the engine for three (3) 10 seconds intervals.


NOTE: This will give you 30 total seconds of flow time. These are broken into 3 separate intervals to prevent damage to the starter.
20. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump:
21.
22.
23. Minimum fuel pump flow at 150 rpm cranking speed is 70mL
24. Minimum fuel pump flow at 200 rpm cranking speed is 90mL

 

ok after torquing crossover tubes fuel pressure wile cranking 150rpm went up to 1380psi a woping 60 psi raise still no start

codes that are present are
1) p0483 cooling fan speed
2) p0480 cooling fan 1 control circuit open (low speed fan relay)
3) p0148 high pressure common rail error
4) p0628 fuel lift pump circuit low voltage
5) p0243 waste gate solenoid circuit
6) p2509 ecm/pcm power suply intermittent
7) p0541 intake heater relay 1 circuit low
8) p2607 intake heater relay 2 circuit low

 

That is a lot of electrical gripes... What do your battery cables look like?

Could be an ECM problem...

 

This is a shot in the dark but open the water drain on the fuel canister and let it drain empty. Leave the drain valve open. Then turn the key to run, you should here the lift pump run and in very short order should have fuel comming out. If you do not bump the starter and see if you hear it run and have fuel. If not your new lift pump has and issue an isn't priming the system. I think the system is designed to get rid of any air in the prime. These pumps will draw fluid from the tank when running. That is how the DMAX's work. The problem is the inline pump restrict flow when it dies causing the pump failure and it won't allow the IP to draw fuel and prime the system. That is if you find the batteries and connectors are good. Make sure both batteries have over 12.5 volts at rest and closer to 13+ if disconnected.