Need your expertise! 5.9 Cummins won't start
 

Ok, starting at the beginning...2003 Dodge Ram 3500 5.9 diesel got to where it didn't want to start. It would crank but not fire. It was cold weather then (yeah, we've been working on this thing for that long!) so we thought it needed to be plugged in. This worked fine but didn't make since why we were having to plug it in once it got to 75 degrees outside! But we went along with it. Until plugging it in quit helping it start. Now, we know this is not a good thing, but if we give it a small squirt of ether in the air intake, it'll fire right up and runs great! No smoke. No hesitation. But once you cut the truck off, it won't crank without a little 'squirt'.
1. We have installed fuel pump relocation kit (fuel pump was relocated from the motor to the fuel tank). Truck started and ran fine for a few days. Then same deal with cranking but not starting.
2. New fuel filter. Truck started and ran fine again for a few days. Then same thing...
3. Took out the fuel filter and truck started fine for few days. Then quit starting...
4. Installed new Raptor High Performance fuel pump with adjustments from 15 psi to 45 psi. Didn't fix a darn thing!
4. Took out the fuel filter. Truck started for a few turnovers. Then quit starting...
It'll only start with a 'squirt' and runs fine.

Mechanic told us it was the glow plugs but according to Dodge, this truck doesn't have any (?) (Heater accuator maybe?) Checked heater relay. Then mechanic said injector pump, then someone said it doesn't have an injector pump so we called Dodge and they said there is an injector pump. Problem with this is it runs great once started with ether. All the injectors have been tested. Replaced all fuel.

From fuel tank to incoming fuel filter housing, more than enough pressure. Problem seems to be from the fuel leaving the fuel filter housing to the fuel rail.

PLEASE HELP!

Dodge don't have glow plugs
03 has a cp3 fuel pump.
I seen this before on and 03 might not be the same deal with yours but it turned out to be a cracked fuel line. the truck would not start on its own unless we give it a shot of starter fluid. than it would run fine turn it off would not start on it own.

Sounds to me like a dead CP3. Bout the only way to tell is with a rail pressure gauge, or someone that has a computer that reads signals from all the sensors.

I have heard of similar problems when the FCA on the CP3 goes bad. The FCA is the little silver cylinder with a dlack cap and a harness plug on the side of the CP3. Try swapping it out with one out of a running truck. New ones run around $150 if i remember correctly.

Great! We've been out of town but we are gonna try these things out this week. If y'all come up with anything else to try in the mean time, please, don't hesitate to make suggestions. We'll keep you posted and Thanks so much!

What did ya get figured out??

Same problem
 

I have an 03' Dodge Cummins Diesel also that is doing the same thing. It has been into the dealer only to have cost me $1400 this far and problem not solved. I took it back to the dealer when I received a notification for the steering recall and told him that the starting problem continues. They came back to me claiming that because I have the EDGE system, it fried the injectors and they all needed to be replaced at $2900. Some major BS!!! :madd:So I told them not to touch it and I am going to take it to a diesel mechanic near my Mack Dealer. I am curious to find out if you guys were able to figure out what's going on with yours since mine only starts with a couple of hits of starting fluid. Thanks!!!

i have a buddy that has a 03 that replaced all his injectors. i sold him a rail gauge but he works all the time. i would also like to here if yours gets fixed.

We replaced the injector pump. It started a couple of times and we got excited...but then the same thing. Only starts with starter fluid...it's going to another mechanic Tues.

---AutoMerged DoublePost---

Keep coming with y'all's suggestions...need all the help we can get...and help others as well!

---AutoMerged DoublePost---

Keep coming with y'all's suggestions...need all the help we can get...and help others as well!

This is crazy man... can't figure out the problem. It seems almost as if the diesel returns back to the fuel filter housing and air fills the void in the line, and the reason why it will start with a hit of ethel is because that initial explosion will suck the diesel in to the injectors.

Dig4h2o - Do you have the EDGE installed on your truck? I read your thread and you have already replaced and tested so many things... it's a mystery. Keep me posted with your progress, I have the same problem and can't seem to figure out.:argh: