'03 starting problem

[JHenry]

My son has an '03 with 148,000 miles on it. He plugs it in at night in the winter, and never has any problem with starting. Last night it was 35 degrees and he did not plug in the heater. This morning it would not start. When he turns the ignition on, the wait to start light comes on and he can hear the heat cycle and turn off and the light goes out. But the truck won't start. We would appreciate any suggestions. Thanks. Jerry Henry

 

[Blue Ox1]

Is lift pump running?

 

[JHenry]

Is lift pump running?

I assume so. The truck starts fine when he plugs in the block heater, and any other time during the day after the initial morning startup.

 

[JJPage]

You cannot assume the lift pump is operating. If it has the stock lift pump, it is located on the back(next to firewall) of the fuel filter canister. When you turn on the key it should run for about 30 seconds, you should be able to hear it run, lift the hood if you have to.



This is a weak link on 03/04 models, not plugging the truck in is most likely a coincidence. If the pump is operating, next I would make sure the fuel filter is not plugged, then check all the connections on the injection harness.



Still will not start? Unplug the harness to the FCA (fuel control actuator) it is located on the rear of the CP3 injection pump. Now try and start it, if it starts it will rattle real loud, do not drive it this way. But if that does it, you found the culprit, you can get a new FCA at cummins for about $100. 00

 

[halfbean]

I'm having the same problem with my 03 with 210,000 miles. It won't start on mornings below 50 degrees w/o the block heater being plugged in. The dealer said it is a problem with the diesel return on the injectors being worn and not allowing the fuel pump to pressure up. After the first start of the day, it runs fine and starts easily for the rest of that day.



I'm thinking about getting new injectors but that is a lot of money to put in a truck wit over 200,000.

 

[HOBrian]

I'm having the same problem with my 03 with 210,000 miles. It won't start on mornings below 50 degrees w/o the block heater being plugged in. The dealer said it is a problem with the diesel return on the injectors being worn and not allowing the fuel pump to pressure up. After the first start of the day, it runs fine and starts easily for the rest of that day.



I'm thinking about getting new injectors but that is a lot of money to put in a truck wit over 200,000.

The injectors do not return any fuel! If you are having a pressure problem it might be your rail pressure relief vavle being worn, or it might be you FCA that is shot.



To test the FCA you can do what JJPage said to do. Just remember DO NOT RUN THE TRUCK LONG without the FCA. With no FCA the CP3 runs at full pressure!