Hi,
I am currently driving a 99' 3500 4x4 24v DRW w/140k. The Truck was my dad's dd a few years ago, but is now doing ranch duty where it only gets driven once a month. I started driving it regularly about a week ago and then on wed I noticed a sudden drop in power. The loss of power seemed to be spread evenly across the power range. It was so bad that I had to keep the pedal on the floor to maintain 55mph. I called my dad and he said it was just the fuel filter. So searched and found a thread describing in detail how to do this and followed the instructions exactly even filling the "filter holder cup" full of diesel before attempting to re-start the truck. I tried probably 20 times (giving the started plenty of time to cool) of cranking then waiting for the lp to cycle 30sec. before trying to restart to no avail. Like I said I can hear the lp cycling every time so I don't think its bad, buy when I loosen the brass "bolt" on top of the filter housing nothing comes out. Also how do I "crack" the injectors to bleed them, does this involve taking off the valve cover or do I just loosen the fitting going into the valvecover. Feedback will be greatly appreciated.

JR

 

To bleed a 99, you need to hit it like you are going to start it, but do not keep cranking, and just leave the key on. You just want the lift pump to cycle, so do that about six times, and then try to start it. If it does not start, then you need to do the same drill with the starter by just bumping it enough to trigger the lift pump and open the banjo bolt on the fuel feed side of the VP44 just a crack. That will allow the air to bubble out of the system.

Allow 25 seconds for the pump to cycle and watch for fuel leaking out of the banjo bolt.

With the cranking you have done, this may take a dozen or more times to get the fuel to start leaking out the banjo bolt. It is likely the truck will start and miss badly, and that is normal. Just let it run until it quits missing.

If you get clear fuel out of the banjo bolt, and it still will not start after a dozen tries it is time to bleed the high pressure side of the injection pump.

If you are not getting fuel out of the banjo do not go any farther, the lift pump is gone, so just get another before you try anything else. A shot lift pump will many times cycle, and make noise, but simply will not pump because it has lost its bypass valve.

Bleeding the pressure lines is really dangerous! Find the feed lines to cylinders #3, 4, and 5, (outside the valve cover) and crack them barely loose (I do mean barely). Do not let the engine run or be cranked while you are loosening the feed lines to those injectors. I cannot caution you enough as the fuel will come out with enough pressure it can blow right through your skin, and if that happens just bend over and kiss you a$$ goodby, because you have less than 9 minutes to get to an emergency room and receive treatment before you have a very terminal experience.

If you have the least bit of question about what to do here, just do not do it. Dead rig is much better than dead person.

Once the fittings are barely cracked loose, then do the start cycle in 30 second intervals until the engine fires and starts missing. Let it run a very short time, shut it down and then tighten those loose fuel line fittings. Do not let it get warm or run for an extended period with the lines open, and absolutely do not try to tighten them with the engine running.

 

It's gone.

Get a new Lift Pump (Tranfer pump) from Cummins. (Not Dodge)

If they ask for a serial number, you can use mine, 56471606. That is the engine serial #.

Even though the pump runs, it doesn't have to be pumping fuel.

Second option could be that injecion pump has taken a crap. Hopefully that hasn't happened.

I'm pretty well versed with the 24V Dodge Cummins. I've experianced 99% of the problems you can have with them. Including ruining 5 injection pumps in less than a year.

If you have questions drop me a pm.

Merrick

 

Since you were loosing power to begin with the chances are good the inj pump is bad caused by the bad lift pump. Better keep a few bucks on hand just in case.


Good Luck

Jason

 

Thanks for the advice,
The lp was definitely bad, however it was surprisingly easy to replace(maybe an hour). I got the new pump in and the truck fired right up after I bleed the fuel system. What is strange however is that I still have no power. The best way I can think of describing it is as if I am driving with out a turbo. The truck starts right up and has just as much power as before up to 1,000 rpm then it just barely accelerates regardless of throttle. It can now hold 60mph but that's about it. Thanks for the advice in advance.

--JR

 

Could be a bad MAP sensor, but, it sounds like a bad injection pump (unable to control it's timing, therefore won't allow heavier fueling).

Merrick

 

Have you checked for a restricted air filter? also a restricted exhaust will do the same. I had a dual wall exhaust pipe decide to delam and closed off the exhaust. Check your computer codes? Just a thought.

 

Well,
I finally tracked down Map Sensor at a Freightliner dealer and swaped it out. I was really surprised at how easy it was to change out, only took a minute. From the second I fired the ruck up with the new sensor I knew my problems were over. Its so nice to have a truck that can get up to 55mph in less than a minute. Anyways I just wanted to thank everyone for there help.


--JR

 

Good deal! You just saved yourself about $1000.00 (maybe more). The ******* would have no doubt put in a new injection pump, maybe turbo, plus fuel pump and map sensor. Glad it was not that painful for you. Good group of people here. Kevin

 

hello everyone.
i am new to your forum and a proud diesel owner. last night i was doing some maintenance on my '01 dodge turbo cummins. i replaced the fuel filter with a fram fuel filter from murrays. well it doesnt fit nearly as tight as the one i used before. i bumped the key several times to "prime" the system then started the truck. after 30 seconds it stalled. i am not a diesel mechanic but i am a "do it youselfer". after an hour of deliberation and beating myself i decided that google may help. did a search and found your site. logged on and found this thread. within an hour i had her purrin like a kitten and burnin rubber. a buddy of mine works at detroit diesel and he stopped by at 11:30 pm to give me a hand. turns out he is a member here.

THANKS EVERYONE! especially RCW and the thread starter pkdj83.

looks like i found another place to spend time online. a ton of very important info here.