Question about 2004 Dodge Ram 2500

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2004 cummins diesel intermittent no start

Hot and cold starting problem.fuel and pressure good

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  • brian calhoon
    brian calhoon May 11, 2010

    what about injector return flow

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GLOW PLUGS ?

Posted on Feb 14, 2009

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Just bought. 5.9 cummins Can`t get it to start without pushing gas pedal slightly. Runs good after warms up. Still have to give it fuel to start.


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97 mpv cold start fuel injector location


If it is a diesel then the cold start injector will be in the manifold . There will be a pipe connected to it and a wire as the injector normally squirts on a hot element which creates a fire that is drawn into the combustion chambers.. Check that the element is operational. If petrol then run the fault codes to find out the problem. I would be having a pressure test done on the fuel manifold to check the pressure regulator and pump operation

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FIRST CHECK YOUR FUEL PUMP TO ENSURE IT IS WORKING PROPERLY, THEN DO A FUEL PRESSURE TEST. AN AVERAGE READING WILL READ BETWEEN 15 AND 30 LBS. THEN YOU NEED TO BE MORE SPECIFIC IS IT GAS OR DIESEL IF IT IS A DIESEL THEN YOU NEED TO LOOK INTO INJECTOR PRESSURE THE AVERAGE CUMMINS COMMON RAIL PRESSURE AVERAGES AROUND 5,000 TO 8,000 PSI ANYTHING LESS THAN 5,000 PSI THE TRUCK WILL NOT START OR WILL BE HARD TO START.

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Will not start only backfires and start dieseling.5.7 automatic. hear fuel pump running. ran fine last trip and parked overnight. few times in past week or two. little trouble starting. rough idle for few...


You need 3 things.
Compression
Good hot blue spark to all plugs.
Good gasoline and proper fuel pressure. 63-64 lbs.
If you have all 3 then move on to injector pulse to all injectors.
I think each injector is on a separate driver on that one.
Check for pulse to all of them.

You may be weak on fuel pressure . Even a couple of lbs low on a cold start will cause a no start. Double check cold start cranking fuel pressure. If under 63-62 lbs you have problems.one test is to give it a squirt of carb cleaner not starting fluid. If you get a intake or engine full of starting fluid it can blow things. Carb cleaner will start it if it is a fuel problem and lot safer. Also in the good old days when i was a kid, i used to get a couple of cans of starting fluid and get in the back and have a good starting fluid spraying contest. Good for a big blast if someone lights a match. If it starts then you have a fuel pressure problem. Run the full fuel pressure test and post back pressures.

Here is the guide lines on testing.
Hard to start cold.
Check cold start fuel pressure.
Check engine running fuel pressure.
Check engine running on the road fuel pressure.
Then shut it off and watch for fast leak down.
Pinch off at rubber part or block off return line and check full pressure.
V8 gm engines should have 60-66 fuel pressure.
Cold start should be 64-65 lbs of pressure.
If you do not have full fuel pressure on a cold start the injectors will not squirt fuel. Do not leave home without it.
Engine running should be 60-66 lbs pressure depending on engine load.
Full pressure with return pinched off should be 75-85 or more.
And if it has a fast leak down after shut off you have a leak.


The 75-85 is only a check on the capable full pressure of fuel pump.
If you can not find the rubber return line check full pressure by plugging return line or just or the true full pressure can be taken direct at the end fuel filter.
What are the pressure readings that you have done.
What are your cold start pressure readings?



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The lift pump is bad Check the fuel pressure with a test gauge.

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may be a check valve letting warm expanded fuel to slowly leak back to the tank causing hard start. When starting cold its harder to move the cold thick fluid. Check into it. Good luck..

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I had a similar problem with my 06 cummins 5.9, I had to replace the lift pump.

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