Problems starting

[05lly2500hd]

Couldn't find a better spot to post.

05 LLY built engine, stock cp3, stock injectors. Truck recently had a very long cranking time before it would start. I was running late one morning and low on fuel. After the day was finished truck would not start after adding fresh fuel from a container. Tow it home, changed filter, cleaned out tank..
After several attempts it started, and immediately after the twin kennedy lift pumps went south.
So now with the lift pumps disconnected, it's a booger to start.

I crank and crank but it runs the battery down pretty quick...so I leave the cables on the battery for 10 mins. or so, it takes a few attempts but it will start.
I drive the truck, it drives fine other than the fact it smokes super-ridiculous, mostly black, sometimes a greyish color.
I park it and kill the truck, and it will not start again for a few day, even with the battery on cables. I can kill the truck immediately after driving it, and immediately try and restart it to no avail...
But I can let it sit a few days, and it will start again, but the same process.

While cranking I'm only seeing 800psi cranking fuel pressure. Previously I've done individual return rate tests on each injector and one injector #6 was returning too much fuel. Checking the balance rates recently this injector was high while in drive. After adding FPPF balance rate dropped significantly. But still same smoke and problems starting.

Upon looking I may have an upper valve cover gasket leaking, also as I noticed what looked like fuel leaking from injector #8 directly beneath the hold down. So upon pulling number 8 the oring was damaged and the body was covered in engine oil.
Could be the reason it doesn't want to crank easily? maybe this injector is clogged or dirty? gonna have it cleaned, and possibly pull number 6 as well as it was the one returning too much fuel, and have it cleaned.

Also the primer button does not stay firm I can prime it and with in minutes i can pump it a dozen more times.

Any suggestions or similar stories?

 

[wes06dmax]

What all did you have built on the built engine

 

[05lly2500hd]

shortblock built by BMS Machine and All Season. LB7 block crank and cam, new stock LLY heads and sticks, Howard's rods, ARP head studs, DPR oil pump, Pistons cut to 16.1. Balanced and blueprinted.

I have MPI twin turbos, kennedy dual lift pumps, SCIII and an exhaust with Rob's tuning via efilive. stock cp3, shimmed fprv. new alternator, water pump and starter.
That should about do it huh?

 

[Leadfoot]

Have you logged rail pressure while driving as well? Wondering if you have a CP3 or fuel delivery problem.

 

[05lly2500hd]

rail pressure matches desired and actual until i stomp on it..the actual lags behind quite a bit.

 

[05lly2500hd]

Ok the only thing ive done was remove filter head from head. And replace inj #8. Now i cant get the hand pump to prime. All that is affected by hand pumpis from tank to cp3 correct? Anything after cp3 is up to the cp3?

 

[Colt]

Do your lines from the lift pumps taken to old age and softened to the point where the old supply line collapses when you call for hi fuel flows? Wondered if you have a pressure gauge to check flow from lifts regulator there.

 

[05lly2500hd]

Do your lines from the lift pumps taken to old age and softened to the point where the old supply line collapses when you call for hi fuel flows? Wondered if you have a pressure gauge to check flow from lifts regulator there.

I got a lil confused with this. But no I do not believe my hoses have or do collapse.

 

[05lly2500hd]

With the truck down and a broken hip....... I only have time to tinker....took all 4 passenger side injectors out, all but one covered in oil...(the lower valve cover bolts under injectors were hand tight only) Upon inspecting the injectors, just a look over, by looking down into the injector where the fuel return connects, 3 of them have what looked like a stainless pin or ball...the one injector that was returning too much fuel, did not have this....it was missing or hidden...


on another note.....until i get em checked or replaced....I tinkered some more...relocated my FICM, and removed the EGR canister, leaving the cast valve piece intact to support not only my intake but the second turbo's brace. Removed the BATT box(lil red box), and plan to somehow reroute the top rad. hose...as Ben had mentioned...
going to remove and bypass the stock filter head, while adding filtration elsewhere...relocating batteries to the back and adding a inverter in the driver's side batt. tray...the more i can remove from atop the valve covers the more... ok enough running on.....