2005 5.9L Cummins No Start

[wreck62]

I have a 2005 Dodge 2500 4WD, Cummins 4wd.
100 HP injectors
Smarty programmer
Air Dog 150 lift pump
190,000 miles
48RE
Lift pump pressure gauge
Fuel rail pressure gauge
Turbo boost gauge
P codes
P0107
P0108
P0480
P0643
P0868
P1750
I just bought the truck and it ran great for two weeks and I went out the other day and it will not start.
It turns over fine but is not getting any fuel pressure
When I turn the key on:
The fuel gauge does not come on
The tach does not come
The voltmeter does not come up
So basically the gauges do not work

I have checked fuses and they are good
I removed the fuel pump relay and fed 12V into the fuel pump(Air Dog) and it comes up to 20 to 25 PSI. But the fuel rail pressure is not coming up.
At the fuel pump relay socket there is no 12V feed that would energize the relay.
So I believe the relay to be good.
I am thinking that the P0480 might be the culprit. That is the Vistronic fan clutch and maybe shutting down the ECM.

I have been working on this and researching it for about 4 days. It did start 3 or 4 times and had 20 to 25 PSI lift pump pressure and 10,000 to 25,000 PSI on the fuel rail depending on the engine RPM. When I shut it off and tried to start it again it would not start again so back to square one. I did not do anything that would make it start. Just tried starting it and the gauges came up and fuel pressure came up and it started. So why???

I am looking for input from other members that have experienced a problem like this or someone can steer me the correct path. So what would be a good direction to start on or what do you think might be the problem? I appreciate any help.

 

[p-Bar]

2005's have problems with cold solder joints on the instrument cluster yours sounds like other problems though. What are you getting for rail pressure while cranking? you are probably on the right track about that one code screwing up the ECM . We have some good troubleshooters on the forum guess they are sleeping in today

 

[p-Bar]

http://www.cumminsforum.com/forum/3rd-gen-powertrain/533756-p0480-p0243-help.html. Read into this . Sure fuse 36 and 6 are good ? Your truck should be in LIMP mode check the wires under the air conditioning compressor for chaffing and shorting out the 5v signal

 

[wreck62]

2005's have problems with cold solder joints on the instrument cluster yours sounds like other problems though. What are you getting for rail pressure while cranking? you are probably on the right track about that one code screwing up the ECM . We have some good troubleshooters on the forum guess they are sleeping in today

Thanks for the reply. When I am cranking the engine I do not have lift pump pressure and of course no rail pressure. In addition, the fuel gauge does not work or any of the other gauges which leads me to believe the ECM is not signaling a start condition. I think the starter itself is a separate circuit. I have read the P0480 code(cooling fan) can shut down the ECM but I haven't pulled the plug on the cooling fan yet to see if the ECM will then signal the fuel pump relay and the gauges. The 3 or 4 times it would start the lift pump pressure came up to 20 to 25 PSI and the fuel rail pressure was between 10K and 25K depending on the engine RPM. So I am looking for the guys on the website that have some experience with this kind of problem to give me some ideas. I mayu be way off base and if so then maybe someone can steer me in the right direction. I will get it but I could use some help. Thanks again.

 

[p-Bar]

Long shot pull the battery cables and let sit 15 min or so could reset the gauges .I had the 480 and all it was , was a blown fuse 36

 

[jkidd]

do you have high mileage on the injectors?

 

[Prairie Dog]

Don't underestimate the Fan code. If the signal wire going to it is shorted then it pulls down the entire bus. Unplug the fan and see what happens.

 

[cerberusiam]

My guess is you have a bad ground to the ECM. All those codes indicate high voltage on the sensors which is usally a bad connection and back feeding power form somewhere. Time to pull all the battery cables and check \clean all the grounding points under the hood.

While you are cleaning, tie the battery ground cables together to disharge and volative memory or sensor routines. The last time I has something similar the truck would start but all the codes came uop like that and maxed the rail pressure. Ended up being a ground cable loose and corroded.

The gauges not responding is the ECU just not putting the data on the bus which could be a short, like the fan, or a bad gorund and it went to fail over mode and did not fully come on line.

 

[wreck62]

Don't underestimate the Fan code. If the signal wire going to it is shorted then it pulls down the entire bus. Unplug the fan and see what happens.

I did unplug the fan and now it starts. Gauges come on. Lift pump pressure is around 18 to 22 PSI and Rail pressure is 10,000 to 24,000 PSI depending on the engine RPM. I am going to troubleshoot the circuit. I have All Data for this 2005 Dodge so I will try to through all the codes and make sure there is nothing else wrong. Don't want to get stranded. In the meantime probably going to order a new fan. Thanks for you help.

 

[wreck62]

Thanks for your help. I unplugged the fan and it now will start and the gauges power up. I will go through all the grounds to make sure there is not a problem there also. My lift pump pressure is 18 to 22 PSI and fuel rail pressure is 10,000 to 24,000 PSI. I have started it 4 times since I unplugged the fan and it has started every time so I am hopeful I only have to replace the fan. I will follow your advice and clean all the grounds and check the circuits that are involved in the other codes. I have All Data with a 2005 Dodge Cummins pickup. Thanks again for your help. I will post when I get everything sorted out.

 

[Prairie Dog]

Glad it's running. Now the bad news, after market fan clutches are junk and the only ones that last are the stockers - which are crazy expensive.

Scott

 

[wreck62]

Yeah, I saw that it is close to 400.00 through Geno's garage. Would you consider that to be a good choice?

 

[wreck62]

do you have high mileage on the injectors?

The injectors have only about 50,000 miles. The guy who had it before me did a lot of highway traveling and changed the filters and oil change about every 2500 miles.

 

[Prairie Dog]

I haven't priced a clutch lately but Geno's is usually very competitive.

 

[cerberusiam]

MoparParts Online and AllMoparParts sells the clutch for around $320 plus shipping. You save a little. Either one should be good.

 

[Cummins10]

MoparParts Online and AllMoparParts sells the clutch for around $320 plus shipping. You save a little. Either one should be good.

Did you find out your exact problem?

 

[Cummins10]

Any results to issue

Having same issue but not sure if it's ecm or something else. I've checked all ground and wires

 

[wreck62]

Having same issue but not sure if it's ecm or something else. I've checked all ground and wires

Engine

Yes, i did it get my issue resolved. I don't remember exactly what codes I had but one was for the clutch fan. That fan is electronic and as the engine warms up it locks up and runs faster. Well my fan was bad. The engine would
turn over


but the start circuit was not engaged. My fuel pump would not turn on and all of my gauges did not work. They are part of the start/run circuit. Not the starter circuit but the run/start circuit. Since the fan was bad it shut down the ECM. I crawled under the truck and unplugged the fan and it started right up. So if your symptoms are like mine try unplugging engine cooling fan and see if that works. Good luck.