03 Cummins No Start, Need serious help

[alexk2552]

Hey guys, my 2003 Dodge 5.9 Cummins does not start after I did some work on it.

The history of the truck isn't really known. When I purchased the truck, it had a FASS fuel system installed as well as 100hp injectors.

It was throwing two codes:
P0088 Maximum Fuel Rail Pressure
P0341 Open/Short Circuit Left Front Sensor

It would run but of course it sounded like a badly running tractor. So I began work.

• Firstly, I replaced all 6 injectors with brand new Bosch stock injectors.
• Completely drained the fuel tank (Appeared to have a LOT of water in the tank).
• Replaced both filters on Fass.
• Replaced the FCA.
• Replaced the Rail pressure sensor.
• Replaced the pressure relief valve.

Started up the truck and it appeared to be running better. Drove it to O'Reilly's the next day to scan and it still was throwing the same two codes. Listened to it run again and sure enough it sounded bad. I started it late at night so maybe I was very tired.

Thinking maybe the FCA was bad, I ordered a new one. Before installing it, I went through all of the injectors again making sure they were properly installed. Put in the new FCA. Now the truck does not even start.

I bought a new injector tube and replaced one that looked a little damaged. That did not fix it.
Then I bought a new pig tail connector for the FCA. That did not fix it. I then tried to put the old FCA back in, that did nothing. I unbolted the fuel line that goes into the back of the CP3, and cranked the engine and a bunch of fuel shot out. So the fuel system is working.

I also did valve lash a couple of times.

I then went to reinstall the old 100hp injectors. As I was removing the new injectors, I was noticing that everything was dry. The lines, the injectors, everything seemed completely dry. Like there was absolutely no fuel.

Ensuring everything was properly torqued, the truck still would not start. I opened the banjo bolt on top of the pressure relief valve. There was a little bit of fuel. I wiped as much as I could out, took note of the level, and cranked the engine. The level did not rise.

Out of sheer frustration, I went and completely unbolted a fuel line at the rail. Taking cover in the cab (no one was around me), I cranked for a couple of seconds. I went to check and there was absolutely no fuel anywhere.

So it appears that my rail isn't even getting fuel now. I tried unplugging the FCA and cranking for 30 full seconds. Nothing. I purchased my own scanner, it does not show any codes. But of course, the truck doesn't start.

I've had this truck for several months now. It's the most expensive lawn ornament I've ever owned! Please help me!

 

[Ozymandias]

Stupid question - but the Fass is running and fuel is up to the CP3?

The Anti-Theft is off? No red little light is blinking while you crank?

 

[alexk2552]

Stupid question - but the Fass is running and fuel is up to the CP3?

The Anti-Theft is off? No red little light is blinking while you crank?

Yes I mentioned in the post that I removed the line that goes from the FASS to the CP3 and fuel came out during cranking.

There is no blinking light when I crank.

 

[cerberusiam]

Hit it with some starting fluid and see if that will boost it up to start. If there was ANY chance of FOD in the fuel system replace all the cross over tubes. They have filters in them and they will plug. Since you have ZERO idea what they went thru before they need replaced. If it won't keep running after starting fluid you have a pressure issue and the ECM isn't firing them.

 

[sag2]

According to the fault code it should only monitor it when the engine is running. Are you sure the code is active? You are probably going to need a scanner that shows actual and desired fuel pressure. Either the pressure is actually high, or the sensor is reporting too high pressure. The other possibility is if it did have lots of water in it the CP3 is done. But that does not jive with the P0088.

 

[alexk2552]

Hit it with some starting fluid and see if that will boost it up to start. If there was ANY chance of FOD in the fuel system replace all the cross over tubes. They have filters in them and they will plug. Since you have ZERO idea what they went thru before they need replaced. If it won't keep running after starting fluid you have a pressure issue and the ECM isn't firing them.

I forgot to mention I did attempt using ether. It would only run while spraying and as soon as I'd stop it would shut off. It also sounded terrible.

 

[alexk2552]

According to the fault code it should only monitor it when the engine is running. Are you sure the code is active? You are probably going to need a scanner that shows actual and desired fuel pressure. Either the pressure is actually high, or the sensor is reporting too high pressure. The other possibility is if it did have lots of water in it the CP3 is done. But that does not jive with the P0088.

Yes that's my next thing, I'm going to buy a bluetooth scanner that can show fuel pressure

 

[p-Bar]

always use WD-40 for starting fluid