hard starting 03

[BGoodale]

I've got a buddy with an 03 2500 Cummins with about 100,000 miles on it. When it was cold last winter the truck would not start unless it was plugged in and then the engine would start but with a long cranking time. After it started it ran fine. This summer the engine starts but takes atleast 10 to 15 seconds to start. Then when he shuts engine down and then restarts it when it is still warm he has to crank it for several seconds before it starts. I ruled out the fuel delivery pump because it runs fine after he gets it started. Any ideas? Thanks , B gOODALE

 

[GDMRTN]

Just got done replacing injectors in a friends 03 truck for the same reason. Took care of the problem.

 

[SWithrow]

I had the same problem, (150k) then one morning it quit running, the lift pump quit working. I replaced it with a frame mounted pump and the long crank times went away. I would check into a replacement pump before pulling the injectors. Mine are stock and have 150k on them.

 

[BGoodale]

Thanks for the info. We'll probably start with the fuel transfer pump but if that doesn't work the we'll go the injectors route.

 

[BGoodale]

Thanks for the info. I've ordered the fuel transfer pump from Geno's . And will help my buddy install it. Hopefully that takes care of the problem.

 

[BGoodale]

Good idea about the starter. If the fuel transfer pump doesn't help then we'll go to the starter. Thanks

 

[DGoodwin]

I have been having similar issues with my 03 2500. If the ambient temp is cold the engine will start within 2-3 seconds of crank time. If the ambient temp is hot or the engine is hot, it may not start at all…. like today (97 F). If and when it does start there is no cloud of black smoke which suggests that there is no to little fuel getting to the combustion chamber. If I am parked on a grade and let it roll, it will start easily by just popping the clutch! I have changed the fuel filter numerous times thinking that I picked up some shotty fuel, this will help for about a tank or two and then back to the same issues.

I have heard and discussed numerous suspected problems with local mechanics…. all have different answers. Crankcase position sensor, lift pump, high pressure fuel pump, oil pressure relay?, injectors, starter motor, (I have changed batteries…. . thinking they were weak and would not crank the starter fast enough (they were on their way out anyhow).

Any suggestions? Much appreciated!

 

[Huff N Puff]

Before you spend big money on a set of injectors or a CP3

Check the nuts that press the transfere tubes against the injectors. They do loosen over time which will cause the CP3 to over come the leaks into the return fuel before starting pressure will be acheived. Caution do not over tighten.

 

[cschlaps]

DGoodwin,



I am in exactly the same boat as you describe, and am on the verge of taking it to the local Cummins dealer after the Dodge dealer assured me they had fixed the problem. I've got 160k miles on mine, and over the last year, it has taken longer and longer to start... to the point now where the ONLY way it will start is by rolling it and popping the clutch. Runs great as soon as it starts.



Cummins dealer suggested I check the battery voltage to make sure it's not dropping too low during crank, but I've got 11. 1 volts while cranking. Lift pump seems to be running fine (replaced it around 130k).



I'll check the nuts on the transfer tube tonight. Any other ideas out there?

 

[DGoodwin]

Cschlaps,



My truck has been hang’n out at the employee parking lot since I originally posted a comment/question in the middle of June. I haven’t had much ambition to do anything about it……I have other transportation…. . and its been HOT!



Huff N Puff mentioned ” Check the nuts that press the transfer tubes against the injectors”. I’m a little unsure as to what “NUTS” you are all talking about. Any help…pics, directions etc…. would be great!



I have recently installed two new batteries…. . thinking my crank rpm wasn’t being met. I can guarantee if I install a new fuel filter it will start right away……but give it a week and I will be right back to the same old problem. This has been a slow progression over the past 6 months…. actually started last summer, but I haven’t but many miles on since because I have a Co. truck. It is also related to temperature……the hotter the ambient temp the more unpredictable it becomes. The weather is supposed to cool off to low 90’s on the w’end, maybe I will crawl up under the hood and have a peek.



Please post any progress.

 

[cschlaps]

Fortunately (or unfortunately) for me, regular fuel filter changes have had absolutely no effect on the situation.

 

[cschlaps]

To update:



Got mine back from the Cummins shop yesterday after 9 days. We started by replacing the FCA because I had already picked one up because it sounded like a possibility. That didn't do it.



Then they went through all of the fuel line fittings and tightened some loose ones. Thought that would fix it, but no. Still not making enough pressure to start without assistance.



Then they noticed a small leak at the relief valve and replaced that. Still not making enough pressure.



Then they found a hairline crack in a fuel line on the back side of the head. Thought for sure that was the culprit... replaced it, but still not making enough pressure.



Finally had them cap each injector and check the fuel pressure each time. The #4 injector was found to be leaking fuel back to the return. Replaced it, and bingo.



Runs like a million bucks now, for about $1600 invested. Ugh. What a pain.