04 Will not start

[ReelDuel]

Last week my truck would turn over but wouldn't start. Took it to the shop thinking the lift pump was bad as it seems to be a common problem. Replaced the pump and put a new filter in and truck was fixed. Drove it all week with no problem. Got home last night shut it off and this morning it turns over but doesnt start. I removed the + battery cable to reset the computer (not that this does anything) and still the truck doesn't start. I can hear what I guess is the lift pump pumping near the fuel tank and it runs for several seconds and stops. Then I try to start and it doesn't. I turn the key off for a few secs and back on and hear the pump do the same thing. I tried this several time and the pump acts the same. I never noticed this before. Any ideas what might be wrong now?? Thank you.

 

[p-Bar]

The lift pump is doing what it sounds like it is supposed to . Crack your water seperator and turn the key on and see if it's pumping . This will verify the lift pump is working . A gauge would be better .

 

[ReelDuel]

I'm pretty dumb when it comes to working on this diesel. Is that the yellow lever near the fuel filter? How far should I turn it? I think it turns towards the drivers side correct?

The lift pump is doing what it sounds like it is supposed to . Crack your water seperator and turn the key on and see if it's pumping . This will verify the lift pump is working . A gauge would be better .

 

[p-Bar]

Yes just turn it a bit till you see some fuel dribbling out below

 

[jhenderson]

Turn it till fuel dribbles. Bump the key to start the pump and fuel should flow stronger.

 

[Prairie Dog]

Just a note, if you get the latest SW update the pump will run continuously when ever the key is on.

 

[ReelDuel]

Ok I did this. I wasn't sure where to look for the dribble before I noticed it on the driveway. I then closed the lever and tried to start the truck and it started. Then shut it off. I cleaned up the spill then tried to start it again and now back to square one, it wouldn't start. I checked for errors with the Smarty and it showed P2509 Power down data lost error. I backed out the Smarty SW and put it back to stock. It still doesn't start. I noticed that the lift pump comes on and stops but the clicking in the engine compartment keeps on then stops. Then if I turn the key off and back on the same thing happens.

 

[ReelDuel]

I think the P2509 ECM/PCM Power Input Signal Intermittent error was caused by me disconnecting the battery earlier. I did this to maybe reset the ECM. Just trying things basically.

 

[cerberusiam]

The LP should cycle for 3-5 seconds then shutoff if the engine does not start. The clicking you hear is #1 and #6 injectors bleeding pressure off and purging the raill of any air.

Loosen the banjo bolt on the CP-3 where th eline comes from the bottom of the fuel filter housing and make sure when the LP runs you have fuel there. You might just have an air lock yet. Keep cycling the key on and off until you get solid fuel at the CP-3.

If it still doesn't start, pull the air filter and hit it with some starting fluid or carb cleaner to see if it will fire. If you are down south and the temps over 60 degrees the grid heaters won't fire but you could disconnect the feed wired for them on the passenger side battery.

If it starts and keeps starting just a vapor lock. If not, probably due for injectors or other pieces of the fuel system.

 

[ReelDuel]

cerberusiam, I do live in Alabama and it has been 70+ or so today. FYI the truck only has 144K miles. Not sure what you mean by "CP-3". The LP runs for 20+ seconds before it stops after I turn the key to the on position and the injectors run for 15+. I can't try anything else tonight because it is dark.

The LP should cycle for 3-5 seconds then shutoff if the engine does not start. The clicking you hear is #1 and #6 injectors bleeding pressure off and purging the raill of any air.

Loosen the banjo bolt on the CP-3 where th eline comes from the bottom of the fuel filter housing and make sure when the LP runs you have fuel there. You might just have an air lock yet. Keep cycling the key on and off until you get solid fuel at the CP-3.

If it still doesn't start, pull the air filter and hit it with some starting fluid or carb cleaner to see if it will fire. If you are down south and the temps over 60 degrees the grid heaters won't fire but you could disconnect the feed wired for them on the passenger side battery.

If it starts and keeps starting just a vapor lock. If not, probably due for injectors or other pieces of the fuel system.

 

[cerberusiam]

The CP-3 is the high pressure injection pump, it is on the left front of the engine right above the power steering pump. The CP-3 is what pressurizes th erail so the injectors will fire. Until the ECU sees 3000 psi rail pressur eit will not even fire the injectors and the engine will not start.

You will have 2 banjo bolts and one flare fitting on the CP-3, the lower outboard facing bolt should be the inlet that will have fuel flowing out when the banjo bolt is loosened.

 

[ReelDuel]

Thank you!! I will check that tomorrow AM. I have alot of Mechanic (mostly race cars) experience just not with Diesels. So hopefully with help from here I can save some money I am sure everyone can understand that. I just do not understand where it lost it's "prime" so to speak. I always thought the Cummins was self priming mainly because I have never had to do much of anything when changing the fuel filter.

The CP-3 is the high pressure injection pump, it is on the left front of the engine right above the power steering pump. The CP-3 is what pressurizes th erail so the injectors will fire. Until the ECU sees 3000 psi rail pressur eit will not even fire the injectors and the engine will not start.

You will have 2 banjo bolts and one flare fitting on the CP-3, the lower outboard facing bolt should be the inlet that will have fuel flowing out when the banjo bolt is loosened.

 

[cerberusiam]

You are correct, the system is self priming. If everything works correctly. That said, it sounds like you have the LP on the filter housing, that is a suction pump so any cracks or breaks will casue it not to pump fuel correctly. The sock on the pickup in the tnak can plug, the stand pipe get a hole or come loose. If you have an in-tank pump lines bad or just a bad pump will leave oyu no pressure.

Verify you have good fuel pressure to the CP-3 then go from there.

 

[ReelDuel]

Thank you, I do have an in tank LP and it was replaced 2 weeks ago (I was wrong earlier) with one from NAPA (Life time Warranty). I will check the CP-3 pressure tomorrow. I am guessing that when I loosen the banjo fitting it should be spraying fuel almost is this correct? When you refer to the "outboard fitting" is this on the left when facing towards the front of the truck?

You are correct, the system is self priming. If everything works correctly. That said, it sounds like you have the LP on the filter housing, that is a suction pump so any cracks or breaks will casue it not to pump fuel correctly. The sock on the pickup in the tnak can plug, the stand pipe get a hole or come loose. If you have an in-tank pump lines bad or just a bad pump will leave oyu no pressure.

Verify you have good fuel pressure to the CP-3 then go from there.

 

[cerberusiam]

Yes, fuel will spray out around that bolt whne it is loosened. Sitting in the drivers seat, the CP-3 is on the mid left front of the engine and the inlet port is the lower left facing port that has a line coming from the bottom of the filter housing.

 

[ReelDuel]

I got fuel from this fitting. It is closest to the front of the pump but it was not alot. I just had the key in the start position

Yes, fuel will spray out around that bolt whne it is loosened. Sitting in the drivers seat, the CP-3 is on the mid left front of the engine and the inlet port is the lower left facing port that has a line coming from the bottom of the filter housing.

 

[ReelDuel]

Lets see if I can post a picture of the banjo fittings. It was the fitting on the left facing kinda upwards

 

[ReelDuel]

Ok I tried the starting fluid and it started right up. And I am letting it run. I wonder what is going on and how long I should let it run.

 

[ReelDuel]

I let the truck run for about 10 minutes and shut it off. I let it sit for another 10 and it started right back up. Just wish I knew why it did what it did? cerberusiam thank you for ALL of your help.

 

[cerberusiam]

That is the CP-3 inlet. If it started right off on starting fluid now shut it off and see of you have any long cranks or no starts.