2005 lost power, died while decelerating, and now will not start

[avantidude]

Got off work late at night, truck was running great, I looked at my Snow control and noticed that it was fueling at 40 %, normal would be 8 to 12% on the same hill. I shut the water meth off (I run 48% meth), the truck seemed a little sluggish, but I was real tired. As soon as I started to decelerate, the truck shut off. I coasted around the corner into my subdivision, that woke me up. The truck would not restart. Turns over like it wants to, but nothing. Called AAA, and waited 1 1/2 hours to get towed a 1/4 mile.


Used Smarty no codes at all.
Reset to stock all the relays clicked and fuel pump ran, sounded like always, but no start.


Did not get to work on it for 4 days, two weeks prior, my Air Dog had quit, called and got a replacement motor, so I thought look there. It seemes to work fine I can here it run and build pressure, and shut off. I opened the line at the back of the CP3, turned it over, fuel went everywhere. Opened line at the fuel log turned it over it again fuel.


Checked all the fuses all looked good.
Clean battery terminals charged the batteries, 7 amps ran them down trying to start. Did not run the starter more than a few seconds at the time.


Read a bunch of posts on hear.


Replaced Crank position sensor
Replaced fuel rail relief valve, with a plug. Turned it over, got a code HIGH FUEL Rail pressure.


Put the Fuel Rail relief valve back in.
Broke rail pressure sensor, replaced with new.


I had ordered the bag of parts from Industrial injection, so I put the Fuel Control in.


Turned over acts like it wants to start, seems faster after Fuel control, but no start.


Today I will put the rest of the Bag of parts in. And pull the valve cover and check the injectors to see if they are within speck. Less than .05 if I remember. I replaced all the injectors two years ago with remains from Diesel logic, in Florida two years ago, maybe 18000 miles. Two already went bad, and were replaced. The injector harness were replaced as well.


As soon as I can I will replace the injectors with new, but it pisses me off that everyone but BBI wants core charges for new injectors, that's not right.


Could use some knowledge laid on me starting to get frustrated [duhhh][duhhh]


I should add that all the gauges work, and no codes are showing. I am stumped

tested injectors .6, .6, .6, .6, .6, .6-7

Getting a lot of looks, no advice yet, just took the drimel tool and cleaned the grounds. Got thinking about bad fuel, I got fuel that morning. Took 15 gal out, will and new fuel.

 

[p-Bar]

I think we are all stumped too. No codes is odd. Did you disconnect both batteries to reset the ECM? It would still run some what if you had crappy fuel . sounds like injectors aren't getting signal to open/close?

 

[avantidude]

I think we are all stumped too. No codes is odd. Did you disconnect both batteries to reset the ECM? It would still run some what if you had crappy fuel . sounds like injectors aren't getting signal to open/close?

I did get a trail pressure to high, when I put the fuel rail relief valve back in. And then a p2607 code, when I put the fuel rail plug in, but checked the conectioins on the grid heater and that went away.

 

[avantidude]

Took the batteries out and had them tested they tested fine.

 

[p-Bar]

I'm stumped

 

[avantidude]

Cam Position Sensor not the problem.

 

[p-Bar]

Yes that would have popped a code same with crank sensor

 

[cerberusiam]

Replaced fuel rail relief valve, with a plug. Turned it over, got a code HIGH FUEL Rail pressure.

Not recommended to replace the PRV with a plug as it won't seal correctly. You need to test rather than plug the PRV then replace if it is bad. The code indicates you had other issues it tells you nothing. Now, test the PRV for leakage.

I replaced all the injectors two years ago with remains from Diesel logic, in Florida two years ago, maybe 18000 miles. Two already went bad, and were replaced

Quite likely the source of the problem, injector(s) are junk. Diesel Logic remans are considered on a par with Dealer remans, pure junk. You could try and cap off each injector and test but hard to tell how many are actually bad.

Get a good set of NEW injectors to eliminate them. Cores charges are there for a reason, they are rebuildable. Without the core you pay more. Your choice but I would nto have an issue sending the junk you have back for a core.

 

[avantidude]

I agree and a rail protege sure relief valve, is on the way, however at least two guys I work with have been using the BD rail plug no issues, the seal is just fine. I don't know how comfortable I would be running with it. The goal was to get the truck running. As for the injectors, 3600, is a lot for most people to swallow, going to take a few months to do that. As far as sending in old injectors, I don't care, but if I pay a premium for new, then they should buy my injectors, junk or not. Maya be I am wrong, but I don't think so. If your buy remans ok, I get that. BBI has no core charge.

Thanks for your advice, at least you replied. Anything Iyou can think of at this time, keep it coming. I am down to checking for broken, damaged wires. What do you think about the ignition switch itself?

 

[avantidude]

Also I have been trying to get my signature working, I paste it in save it and it's gone.

 

[cerberusiam]

The signature may not show on subsequent posts, only the first. If you have entered it in the User CP and saved it will show next time the first post is made.

BBI does business a bit differently with Bosch so it is not the same as other wholesalers. You also pay a bit more for the BBI injectors to cover that core charge and other things.

Electrical issues are always possible, and royal pain to identify. Have you hit it with some starting fluid to see if it will light off and run? Since the injectors were replaced re-torqueing the cross over tubes may be worth the effort, one loose one it will not build enough rail pressure to start,

 

[avantidude]

Do you know the torc specks on the crossover tubes off hand?

 

[cerberusiam]

The spec on the 5.9 tubes is 37 ft lbs, I have put them in at 41 ft lbs with no issues. If you have new tubes with the injectors 37-41 should be fine. If you did not replace them I would not go over 37-38 ft lbs. Entirely possible it split the end of one also if they were not barnd new.

 

[avantidude]

They were new. I replaced every fuse related to ignition, disconnected the batteries, reconnected them then tried to start, got a new code P2509.

 

[cerberusiam]

The 2509 is from disconnecting the batteries, just means power was lost to the ECU.

Have you tried starting fluid?

 

[avantidude]

Been swamped at work, 4 double shifts this week. I have not gave up, just waiting for it to cool down a bit. Been hot out here this week.

 

[WalterJ]

They were new. I replaced every fuse related to ignition, disconnected the batteries, reconnected them then tried to start, got a new code P2509.

...but did you short/touch together one pair of battery leads to 'kill' all stored electrical energy in your system, including ECM? Just disconnecting power does not accomplish what you need.

I can't imagine all injectors 'failed' to operate simultaneously. Sure seems to point to a loose/broken ground or common wiring issue as Cerberusiam mentioned. Best of luck.

 

[avantidude]

What about that fuseable link?

 

[sag2]

Have you checked the fuel to make sure it's good? Could you have picked up a bad load of fuel? From the rail pressure high code it sounds like the system is building pressure but without having a scan tool to look at actual pressure you are kind of at a disadvantage. My neighbor has the $125 HF scanner and it reads pressure. Might be worth a try.

 

[CrewCabDiesel]

be careful with the starting fluid, seen a guy destroy a 5.9 with similar problems. It seems you have hit all the trouble shooting options, have you verified all the basic mechanics are functioning? I have seen a cam break and other timing and compression issues. its rare but it does happen. check for top dead center and where your rockers are. A broken cam will not throw a code.
Kyle