Help,
We have been working on a 04 Dodge Cummins for too long. Problem originated with a no start condition. Tests showed lift pump bad. Action: replaced lift pump and filter. No help. After talking to the customer he explained the problem started with a hard starting problem. More testing and scanning. Found the inj. pump not producing enough rail pressure. (100-125PSI). Replaced the inj. pump. Now it starts, but only after about 30-45 seconds. Reading a thread somewhere we retorqued the injector heads to 40 ftlbs. Startup was much improved, 2-3 seconds crank time. Runs strong and good today (Thursday). Customer calls today (Sunday) now it won't start again. The truck will start when pulled. It lights up as soon as the strap gets tight, we pull it in 3rd. for only 10-20 feet before it lights. So, what the heck is up???
Truck has 134685 miles, no codes. batteries good, intake heater good, lift pump pressure 4 psi, rail pressure cranking 550-600psi.
Any help is greatly needed and appreciated.

 

What are the codes?

 

what is your oil pressure looking like after about 15 sec of cranking?

 

Does it start ok if its runs everyday back to back? Or does it still have starting issues if it runs everyday?

 

sounds like high injector return to me