[E55 Bulldog]

I have a 2005 2500....
Drove the truck yesterday for about 30miles with no issues.
Started the truck today and drove it about 1 mile down the road and the engine cut off, dead. No signs or symptoms, no sputter, no smoke, nothing. Tried to restart and it would just crank and crank and crank but no start. Pushed the truck off the road checked for trouble codes with CTS3 and there were no codes. Walked back to the house to grap tools and laptop. Here is what I have checked so far.

Batteries are good
Airdog Lift pump is pumping fuel, had new filter, I checked that by disconnecting fuel line at the CP3 and cranked engine, plenty of fuel came out.
Bled injector lines at injector by opening line, cranking, and closing, did the same thing with the pressure relief valve
Hooked OBD up to laptop and scanned with HP Tuner...... red flag that I can see is while cranking im only getting 80-90psi fuel rail pressure

What should my next steps be to diagnose this.

Would FCA cause this? Or another sensor that im not thinking of.

 

[E55 Bulldog]

Also, Im not getting any smoke out of exhaust while trying to crank for 10-15 seconds so it seems Im not getting fuel into the cylinders

 

[E55 Bulldog]

I have also tried to unplug the FCA and still got no pressure on crank. Im order a new pressure relief valve and try that since I was getting fuel out of that while cranking

 

[rghavana]

Dont need to bleed CR fuel system they are self bleeding actually make things worse and can cause serious injury.
So where is fuel going?
pull dipstick check oil level?
Check return fuel on CP3?
Check return fuel on injectors?

 

[E55 Bulldog]

Dont need to bleed CR fuel system they are self bleeding actually make things worse and can cause serious injury.
So where is fuel going?
pull dipstick check oil level?
Check return fuel on CP3?
Check return fuel on injectors?

I’m about to start testing these, just check oil and it’s a little above full but truck has been sitting for a few days with no start, would that be oil draining out of motor ?

 

[E55 Bulldog]

Took return off at CP3 and I have fuel coming out during crank. That’s shouldn’t happen right? Pressure valve should be preventing that. So PV might be stuck open?

 

[rghavana]

Oil should really not be over mark unless overfilled when you changed it .
As far as Cp3 return, How much fuel ?
certain amount will come out of return need to isolate and measure
info here GGTech-Fuel Return Flow Test.indd

 

[E55 Bulldog]

Oil should really not be over mark unless overfilled when you changed it .
As far as Cp3 return, How much fuel ?
certain amount will come out of return need to isolate and measure
info here GGTech-Fuel Return Flow Test.indd

First off, I really appreciate your help.

in regards to the oil, There could be a slight overfill but in not sure, Im usually pretty good about that so that lead me to next question... if an injector shi*t the bed, would it increase my oil capacity?

I don't have these fittings to do a proper test so ill have to estimate fuel amounts. I guess its best to test that valve by removing banjo fitting on top of it and crank motor to see if any fuel comes out. There was a good amount of fuel that came out but it also came out of the CP3 hole from where that line was attached.

Would a bad injector have that much return to build no pressure. Its really odd that im only seeing around 80 PSI, would there be more pressure even it one of these items failed? Do the pressure sensor commonly go bad, I would think id get a code if that was bad though. Still confused about the truck just dying with no signs, like someone turned the key off. I would think it would buck or spudder before turning off.

 

[rghavana]

Injector that is cracked or has a bad copper oring will leak fuel into oil really not that common.
injector internal issue will leak out return chamber in head then out return line, very common.
That is very low pressure, unless you have multiple failed injectors I would concentrate on lift pump /CP3.

With out those fittings gonna be heard to know if CP3 is bad or just cascade overflow valve.
can field test volume of lift pump, should get about a quart of fuel in 10 second crank.
Then can try test volume of Cp3, Remove the discharge line from the CP3 pump to test output, just be careful.
Good volume test the CP3 pump should discharge 70 ml (at 150 rpm or 90 ml at 200 rpm), from the CP3 to rail manifold fuel line, in 3 10 second cranking intervals (total of 30 seconds cranking).

 

[E55 Bulldog]

Injector that is cracked or has a bad copper oring will leak fuel into oil really not that common.
injector internal issue will leak out return chamber in head then out return line, very common.
That is very low pressure, unless you have multiple failed injectors I would concentrate on lift pump /CP3.

With out those fittings gonna be heard to know if CP3 is bad or just cascade overflow valve.
can field test volume of lift pump, should get about a quart of fuel in 10 second crank.
Then can try test volume of Cp3, Remove the discharge line from the CP3 pump to test output, just be careful.
Good volume test the CP3 pump should discharge 70 ml (at 150 rpm or 90 ml at 200 rpm), from the CP3 to rail manifold fuel line, in 3 10 second cranking intervals (total of 30 seconds cranking).

Okay I’ll check CP3 next. I popped the banjo off the relief valve and cranked motor and fuel flowed out, not like a few drips but a heavy flow .

 

[rghavana]

thats not good can make or buy plug for testing.
tuner on truck?

 

[E55 Bulldog]

Well…. Pulled the line off CP3 (the one from CO3 to underside of rail…. Cranked for 3 10 sec intervals and got a little over 100ml

 

[rghavana]

If volume measured 100 ml then Cp3 seems to be supplying adequate fuel.
To rule out electrical with scanner try and read demanded/actual rail psi.
For pressure to build need to plug or replace PRV.
Then verify connector tubes torqued to 40ft/lbs on injectors.
Double check injector bodies/install in head, by removing valve cover and look for fuel leaking from injectors/head, made easier if using bright led light .
Get a couple of rail caps start capping off injector(s).

 

[E55 Bulldog]

I ordered a new PRV and it should be here on Wed. Figures crossed that is the issue and its not injectors.