2005 5.9 common rail, rebuilt motor and no start
 

Hey Guys,

I need any advise possible and appreciate it all. Here goes, First I'm going to mention I am a mechanic by profession, I work on VW's so I have slight knowledge of diesels, mainly on one's the size of a pea shooter. I have a 05 2500 4x4 with a 5.9 common rail. Actually my brother's. He bought the truck at 146k and at 152k by by motor. Cyl #1 cracked ring ate oil and took out Cyl # 6 rod bearing. So out came the motor, sleeved block, new crank, new pistons and one new rod, rebuilt cyl head. Put it all together, finally in the truck. Hit the key and it won't start. It's definetly a fuel problem, Yes I did the no no and started it on starting fluid just to make sure. Drained the old fuel and put in fresh, used the in tank pump to empty the tank, Had a p0251 fault so replaced the FCA, still no fire. Injectors and tubes torqued down correctly, I have the factory service manual so it went back together per cummins specs. I have a gst and don't have any faults, I can't read live data with it cranking but with the key on I haven't seen fuel pressure over 45psi. Will it loose pressure that fast?

I guess my biggest question, is there some type of priming procedure like on an old injection pump setup. Or did the cp3 die sitting in the garage? The fuel system was fine before we tore it down, but it was down for a while.


Sorry so long, just wanted to get the info out there. Thank you so much for any advise.

Did you replace your cross over tubes? And while the engine was out did you happen to have the injectors tested? Id look at replacing the crossover tubes before you determine the CP3 as faulty.

Didn't replace the cross tubes, inspected and no signs of cracks or deformation. Didn't have the injectors tested or replaced, thinking that is something that is in the near future. The truck ran good as far as driveability when it went down, just ate alot of oil and devoloped a serious knock. I didn't have any reason to condemn the fuel system at that time. Just trying to figure out where I'm losing fuel pressure or not building it. Is it possible to test the high pressure pump besides monitering fuel pressure through a scan tool?

Crossovers can be damaged on reinstall and look good. Cummins recommends replacing crossover tubes everytime you pull the injectors on a Common Rail.

I'll rip it tomorrow and let you know what I found. Thank you very much, I hope it's just cross over tubes.

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Ripped it apart, a couple tubes have the ever slightest marks on the ends, had a guy call and say to add a couple of inch pounds to the injectors and a couple foot pounds to the tubes. Put it back together just to try and got exactly where I figured. He was more inclined to think it was going to be injectors and tubes. He also said it should attempt to fire with little pressure as long as there was fuel. After it was running the pressure would come.

did it fire? because the one that i had this issue with would just crank and crank and crank. When we replaced the tubes and put her back together she fired right up.

Got it to fire today, ran smooth as could be at 2k rpms, bellowing more white smoke than ten freight trains, found the fuel pressure in the range of 35-3800psi at this rpm, found number 5 and 6 about 15 degrees cooler than the other 4 cylinders. Thiking stuck open injectors. Going to price them out now, any good places to get some?

Quotem on here Get some good prices!