Help: No crank after turbo, CP3, and EGR delete install

Dozerboy

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Jun 23, 2009
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Well I installed Marks 3794 Stg2, new cp3, deleted the EGR and my truck aint happy. After I got everything installed I loaded a tune that had a no start tune in one of the DSPs(zeroed out inj. quantities). So I could crank the engine over to prime the turbo with oil and get some fuel through the CP3. I had also removed the maxfuse for the Grid Heater.

When I tried to turn the engine over it wouldn't crank. It just clicked and the headlights, dash lights (CEL, Glow Plug), RV mirror light, and radio all started flashing. The ABS pump under the cab started pulsing and other things too. I got 4 codes P0540(Grid Heater), P0405(EGR Low Voltage), U1026(Lost Com. Tcase), U1041(Lost Com. Brake/Traction Controller). I've had the EGR blocked and haven't gotten an EGR code ever.

I thought maybe pulling the maxfuse was the problem and reinstalled. Never got the 2 Lost of Communication codes again, but still no crank and all the flashing. Still getting the other 2 codes. (Edit looks like when I switched off the Grid Heater CEL it didn't save in the tune so I still need to reload the tune to see if that fixed that code). I looked over all the plugs I could see without tearing anything off and everything looks ok. I tried plugging back in the grid heater (not the big power wire) and EGR and that didn't change anything.

I'll pull a few thing off in the morning to get a better look at all the wiring harnesses. I can't see that any of the plugs could be in the wrong place they all looked to be unique. Never did messed with anything from the Tcase or Brake controllers, so I'm not sure whats going on there. The only ground I removed was the one to the hood and its still off, but I doubt that's the problem.

The ECM is flashing fine, so I didn't brick it. I guess it could be the no start tune. Its been so long since I built it I don't recall if the engine cranked or not. I pretty sure it did. I might load another tune what do you unplug to get the truck crank and not start? Crank sensor? Any other ideas?
 
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Dozerboy

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Jun 23, 2009
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Well no luck finding anything. Charging the batteries now even though they showed 12v. Once they are done Im going to flash the tune with the grid heater shut off, check the power to the starter, and reprogram my Astro Start since its acting up. Might jump the starter off but I hate doing that.

The electrical going crazy after hitting the key to start is whats got me scratching my head.
 

Dozerboy

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Jun 23, 2009
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One battery was bad, but only the side post not the top post where they load tested it the first time. Truck still wont start with just the good battery in. Even when I ran jumper cables from another vehicle to boost the power. Starter is fine. Not getting high resistance from from any of the ground or power wires. But when I hit the key the power to the starter is dropping from 12v to 7v.
 

Awenta

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Sep 28, 2014
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Sounds like you have a bad wire maybe. Try making a new lead or jumping the starter. Or ohm out the wires.

Jumping usually isn't enough juice. Have a jump box you could use? It sounds like low power.

Sent from my SM-N910V using Tapatalk
 

Dozerboy

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Jun 23, 2009
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I ohm them out all of the power and grounds all of them where less then 1ohm.

I used 1 good battery in the truck and jumped it on top of that.

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Dozerboy

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Jun 23, 2009
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Where exactly does the ground strap that goes from the firewall to the back of the block connect? Its seems connected, but maybe its just pinched between the block and up pipe. It ohmed out good.

New batteries coming tomorrow I only had a few days left on the full replacement warranty. Lucked out.
 

Dozerboy

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Jun 23, 2009
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Thanks

Its runs! Not sure if it was a bad connection or just the one bad battery. Don't know how yall are starting trucks with one battery. I had one good battery and a booster hooked to the starter and the damn thing still wouldn't turn over.

Not happy about the POS Cat batteries, but thats what I ended up with again.