Engine/Transmission (1998.5 - 2002) Hard Starting...Fixed

[Bratton]

My 2002 ETH with 15000 miles has been hard to start for the last 3 months or so. I was certain that the IAT sensor was bad as the grid heaters never stayed on very long. The diesel tech couldn't find anything obvious and they ended up replacing the VP-44 as a few codes had been set. The problem got better for about a week and then it got as bad as ever with some starts taking as long as 45 seconds of cranking.

Yesterday I took it back in, and it appeared that the IAT sensor was indeed bad as it was showing a reading of 140 degrees fahrenheit in the shop where the actual temperature was 60. Chrysler would not allow the tech to order a new IAT sensor and had him keep looking. He pulled all of the injectors and found the real cause of the problems, a faulty injector O-ring. This bad o-ring caused fuel drain down and soot and carbon buildup on the injectors. Somehow it also affected the readings of the IAT sensor. This part I don't quite understand. But it works perfectly now.

I'd like to give credit to Jim Harmon, the diesel service manager at Billion Dodge. Through a very frustrating diagnosis and repair process, he always kept me abreast of where they were and when they thought they could get me the truck back. When it was finished he had the truck driven to my office so I didn't have to take time off of work to get it. Not all dealers are bad!



I share this because if there is one bad injector o-ring, there is probably another out there.

 

[TPlasek]

Where exactly is this injector O-ring you are talking about. I too am having a hard start problem... Sometimes

 

[illflem]

Billion does excellent service work, but watch your bill if it isn't under warranty, they also have an excellent reputation for double charging on parts and charging for work not performed.

 

[sag2]

There are several places it could leak. There is a connector tube that carries the fuel from the line to the injector, an O ring around the injector, and a copper sealing washer that seals the injector to the combustion chamber.

 

[Bratton]

I'll second what Sag2 said. They replaced the copper washers too.

It is night and day now to then. This engine starts with half a revolution just like my '93CTD did.



With regards to Billion overcharging, I don't know anything about that as my truck has a long way to go on warranty. They have been courteous, prompt and communicate really well.

My '93 was out of warranty when I bought it so I always used private shops or did the work myself.

 

[TPlasek]

So, when it finally started, did it stumble and hesitate, or did it just fire off and run right????



I put 275 injectors in 10k ago. I am courious if it could be related...

 

[Bratton]

I'm assuming you mean when it was still having trouble. After it finally started, it seemed to run fine. The mileage seemed a bit low and the power was not as good as it is now with the repair.



I won't know if the mileage is back where it should be for a couple weeks.