:barf: need help with an 04 dodge 3500 5.9 ho. wont start no codes,fuel pressure is 10 psi to main injecthion pump? heater grids are working fine. batterys are new, transfer pump is working. run diagnostic test and no codes or help thier. one small shot of starting fluid and it runs fine, turn the key off and wont restart, hot or cold??? :pissed:

I don't know but mine is in the shop for what sounds to be the very same symptoms. It is 5 days today and they still can't figure it out? Replaced the number one injector, check valve in the fuel system as they thought fuel may be bypassing back to tank. I called yesterday and they still did not have it figured out. Based on what I have learned, I'm thinking it is the High Pressure fuel pump as I had a lift pump replaced with one in the tank and I have read that when the LP dies it starves the injector pump causing premature wear and will follow in 4-6 months depending on how much the truck is used.

Maybe someone with first hand knowledge will chime in here and I will update you when I get some answers on mine

ok i just had a post on this web site named 05wont start read them i replaced all my injectors over the weekend and it runs fine you have a sticking injector thats why it will start off of starting fluid. now the only way to can tell the correct injector is too have dodge test it and they can use a tool from cummins to block off an injector at a time to tell the one that is sticking open. i didnt get any trouble codes with mine either i replaced the cp3 pressure pump the flow tubes and it still wouldnt start i replaced the injectors and runs great. i would allmost bet anything this is your problem i hope it helps. keep one thing in mind cummins says you have to replace the flow tubes when replacing the injectors but dodge says you dont for 30.00 i would and did.

:thanks: guys. i had to send the truck to the dealer:evil: i am a ford mechanic and dont know alot about the cummins. really like it thow :Thumbup: i looked at it for a friend, my diagnostic machine will cut out an injector 1 at a time. i tried this and didnt find any injector sticking??? on a note the dealer still dosent know what is wrong. makes me feel better.:evil: my friend said they are whating for a enginier to come and look at it?????? please keep me posted on what you find out! i am more than willing to learn more about this. :thanks:

once you start it off starting fluid can you drive it. i could mine but the throttle response was crap. i replaced all the injectors and it runs great

once you start it off starting fluid can you drive it. i could mine but the throttle response was crap. i replaced all the injectors and it runs great
yes once its started its fine,no bad throttle response :shrug: felt like a strong good running truck. only has 49,000 miles two :shrug: taked to friend today truck still at dealer,the dc einginier was not thier yet??

What causes the injectors to go bad like that??? low fuel pressure,bad fuel,weak pump?? :shrug:

the thing is on the common rails you have too have the correct pressure in the rail or the ecm wont let it start i would run the dia. machine on it again and pay real close attention to rail pressure. if you have a good scan tool it will give you desired rail pressure and actual rail press. see if the desired is higher than the actual if so you dont have the required press. and either the injectors are returning all the fuel too the tank or the cp3 is not building the correct pressure.

As Too The Injectors It Could Be Any Thing Mine Went Bad In My Truck Because A Partical Passed Through The Filter And Hung The Injector Open. We Only Know That Because I Performed A Faluire Ana. On Them At Work. I Think The Filter In The Dodges Is 10 Micron And Cummins Wants A 2 Micron Filter Before The Injectors.

thanks for the replys :Thumbup: the truck is fixed, the dc enginier had them change all 6 injectors and the cp3 pump along with the flow tubes. twin-turbocummins you the man :Thumbup: :Thumbup: :Thumbup: :Thumbup: its wierd that the pcm or ecm in a dodge didnt set a code for the rail pressure being low or high??? i did check this and nothing out of ordanary??? im still learning about this awesome beast. :woot:

:Thumbup: :Thumbup: Iam Glad Its Fixed I Was Sure That Was The Problem

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 apparently tested as fine with only 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 replacement 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 the 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.

I don't know if they changed the flow tubes when they changed the injectors but I will check with them tomorrow and I will make sure that they do change them.

well if its the fuel preesure sensor the cp3 needs to be replaced that cant be fixed with out changing the cp3 pump.

also have the dealership check the actual rail pressure and the disered rail pressure i have seen where dirt or snad will stick the return ball open in the injector and aloww all the fuel to return to the tank. if your actual pressure doesnt equal the disered press or if its not highter the ecm wont allow the truck too start

also have the dealership check the actual rail pressure and the disered rail pressure i have seen where dirt or snad will stick the return ball open in the injector and aloww all the fuel to return to the tank. if your actual pressure doesnt equal the disered press or if its not highter the ecm wont allow the truck too start

Wasn't meaning to Hi-jack the thread but....I am desperate.

The Cp3 and all injectors have been replaced so I guess it can't be the fuel pressure sensor or the new injectors. Maybe the MAP sensor or pressure relief valve on the common rail. Will be going to the dealership to get FULL details on tests that have been done as well as the results of those tests. I have this feeling that people on this forum will help me figure this out before the dealer does.:thanks:

any new info on the test they have performed.

Got my truck back from the dealer on Day 21. Turns out that the first new CP3 was hooped (I showed them the rubbed wire on the AC Pump between the first new CP3 and the second so I don't know if the repair to the wire harness was the fix or the second ne CP3 but she is back home healthy and happy. I will be looking at installing a full set of gages in the near future. I also want to switch from a Bully Dog Power pup to an Edge Juice (hot or not) with attitude. So what gages will I need as the juice monitors a lot of the stuff as well.:shrug:

Now to fight with Dodge over the 21 days of rental charges as my warranty will only cover 5 days at $50/day.

Good Luck With That But At Least Its Fixed

Truck ran great for the 50 miles I drove it that weekend, now the injectors crapped out. Enging had a miss and something did nor sound right. Pulled over , the engine was running on and the truck was doing a break stand with no assistance from me other than me holding on the break for dear life as I shut the engine down. Towed back to dealer, six new injectors, got the truck back the next day and drove about 20 blocks and started the same thing over again. Now they have had the truck an additional seven days (5 weeks total) and the problem still has not been fixed.

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. [verymad]

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.