Early 04 cummins no start or hard start

[05chumminss]

I have an early 04 which is mostly stock. I bought it knowing it had a hard start issue. Has 173K on it but engine was replaced at 113K. Sometimes it will start fine, sometimes it cranks awhile and starts, sometimes it won/t start at all. I hooked fuel pressure gauge on inlet of CP3 and have 7-10 psi at all times lift pump is running. Hooked scan tool up to truck and rail pressure reads 4800-5500 while idling. When it won't start or cranks before starting rail pressure seems low like around 800 to 1000, as soon as it gets to 1600 it fires right up. I unhooked the FCA and it shoots to 26K, and I tapped a cap into the Rail pressure relief valve and it still operates the same. Where should I start looking for my problem? I have no smoke and it seems to idle and drive really good. only problem is the hard start or no start.

 

[MMeier]

Check to make sure your connector tubes are properly tightened . Oh, and welcome to the fam !!!

 

[Prairie Dog]

I agree, torque the cross-over tubes. If that doesn't do it then your probably looking at injectors - it's getting close to that time at your mileage and no extra filtering.

 

[p-Bar]

injectors , when you change them add some extra fuel filtration

 

[HHhuntitall]

Injectors are usually the culprit from what you describe. Try the crossover retorque, then you'll probably find a bad injector or two.... Good luck....

 

[05chumminss]

Thanks for the info. I will try to get back to it this week and retorque to see what happens.

 

[BDaugherty]

On my 03, the injectors were so worn out that it wouldn't start unless the engine was warm. This was due to excessive return flow from the injectors not allowing the truck to build enough rail psi to start. I would get 850 or so, but the computer would't turn on the injectors until about 1000. With brand new injectors, mine fires right up in single digit temps with no block heat.

 

[HHhuntitall]

.... and as an afterthought, there is a TSB on hard or long starts on the 03-04 trucks, which requires a reflash, but usually fixes the hard/long crank starts.... Jus' sayin'.....

 

[STEVEBROOKS]

.... and as an afterthought, there is a TSB on hard or long starts on the 03-04 trucks, which requires a reflash, but usually fixes the hard/long crank starts.... Jus' sayin'.....

I haven't heard or read anything about this before. What is the reference number for this TSB?

Steve

 

[MattKeller]

My '03 had two bad injectors and had a hard start then eventually wouldn't start but cranked and once started up it ran like it should. This happened at 94,000 miles and caught me by surprise but once that was fixed it starts almost instantly. When it wouldn't start I would use just a touch of ether or starting fluid and it would fire right up, if you try the ether or starting fluid make sure to use just a tiny bit. A little goes a long way with that stuff

 

[STEVEBROOKS]

I haven't heard or read anything about this before. What is the reference number for this TSB?

Steve

My local dealer said there is a software reflash TSB out there on the subject, but it references hard-start problems when the temp is below freezing only.

Steve

 

[HHhuntitall]

Your dealer only read the first half of the TSB.... The one I referred to was TSB 14-003-05, which has since been updated to TSB14-003-06. Cold starts are the first subject. Scrolling down, you will find Hard Start/No Start.....

Try this website, they have a LOT of VERY USEFUL information... I'm not sure who maintains/owns this website, but my hat's off to ya.... I know several of the contributors, and all know their individual subjects well..... http://dodgeram.info/tsb/2006/14-003-06.htm

As a side note, it appears I was wrong about the reflash.... perhaps.... I need to check my '03, because I distinctly remember them reflashing it at one point to alleviate the long cranks....

Ok, so I checked out my '03, it has had TSB 18-017-05 performed on it, which is the ECM reflash, and is directed at cold weather starts.... but it helped warm weather starts when the engine is cold, too.... Hope this helps...

 

[05chumminss]

I torqued crossover tubes today. Got at least quarter to half turn out off all them except 1, it was closer to a full turn. I thought I had it. Hit the key and it fired right up as soon as I got the air out. Started it several times and everything seemed to be better. Drove down the road about 3 miles shut it off and I'm back to the long cranking and no start again. Time for injectors or can i check something else?

 

[BDaugherty]

You can check individual injector return flow to see if you have one that is worse than the rest that may be causing the problem. Some people buy a rail cap and just cap one off at a time until they narrow it down to one pr two causing hard starts. Mine were evenly wore out and I ran every test I could trying to narrow it down. I finally took all six out of the truck and had Jeff Garmon run them on his test stand. Return flow was off the charts. A new set of Bosch Motorsports 50 hp injectors changed everything about my truck. Cold starting to power and idle quality, it felt like a different truck.

 

[HHhuntitall]

Well, in re-reading the thread, I see the truck has 173k on it, and I'd presume the stock injectors.... if so, I'd suggest replacing the set. Expensive, yes, but I'd wager you have one sticking when hot, and typically, others will follow suit shortly, if not already starting to...

My '03 started having misses under load at 135k.... I replaced the set with aftermarket, and while I haven't had any problems with function, fuel mileage has been sucky.... 120hp nozzles are a bit much.... she runs pretty good, though....

 

[05chumminss]

update: I've been busy but finally got into troubleshooting some more. Number 3 injector was the culprit. I assume the others will go soon, but for now I just put number 3 in and it fires right up. Thanks for everyones input