My truck recently stalled out due to a blown fuel rail, fuel leaking everywhere. I have changed out the fuel rail, but have since had an issue starting the vehicle. It will crank over, but will not start. Either something else went bad via a HUGE coincidence or something else went wrong during installation. Here is the sequence of events and what I have done and tested so far:

V8, 4.7 liter Flex Fuel...

1) Replaced fuel rail. During this process the rail was not seated properly on all the injectors. Basically, I cranked the vehicle and it started right up, but I had a leak at one or two of the injectors. I went through this process about 5 times, the engine cranked and the vehicle started every time.

2) About the 5th time I finally sealed all the injectors. Went to start the truck, it cranked, but would not start. Checked all electrical connections and cannot finad anything that was unplugged.

3) I checked all of the fuses and they are all good.
4) Can hear the fuel pump, so that seems to be fine.
5) Tested for a spark and I am getting spark to the plugs.
6) While cranking the engine, hit the fuel rail release valve and gas comes flying out endlessly, so gas appears to be getting through the entire rail.
7) tested fuel pressure to be sure and it is reading correctly, at least while we are cranking the engine over.
8) Battery was only seven months old, but had it tested and recharged, it is fine.
9) replaced idle air valve.
10) Replaced cam shaft sensor.
11) Replaced crank sensor.
12) tried about three different computer resets from this forum, from pulling PCM fuse to removing negative cable, waiting, chiming the ignition, combinations of a few of these, etc. etc. etc....

I am at a complete loss as to what is going on. Why was the truck firing right up when one of the injectors had a slight leak and then once I got them all sealed, it will crank, but won't start? Thanks for any advice anyone can provide, feel like I am living in the twilight zone here....

 

Will it start if you give a shot of starter fluid. Alittle shot. Just enough to see if it will fire. Only thing I could think of is air in the injector.

 

I have not tried starter fluid, but I did throw some some gas at it and that did not do it. I am mechanically inclined, but not a mechanic, so I have to ask if it would be better I use the starter fluid. If there is air in the injector, how would I go about clearing it? Thanks

 

Fuel should have worked. Have you got a fuel pressure reading at the rail? The fuel pump may run, but not supply enough pressure to open the injectors.

 

Yes, we did a fuel pressure test at the rail. Of course the engine was only cranking but the guage was bouncing from around 50-60psi which I was told was correct, should be around 55-60psi.. I also went out today and cranked it and bleed fuel from the rail, roughly a pint of fuel (couple 10-15 second cranks) to see if I could bleed out any air. I did not notice any air coming out and after this attempt the truck still will not start.

 

I think going back and forth with the fuel rail.. you disturbed something electrical.... connector, sensor, broke a wire.... something. recheck., tug on connectors... etc.

 

Thanks Chuck. I have checked wires and did some wire wiggling here and there, but will do it again. I have to wonder if there is a possibility something is tripped in the computer system from all the battery disconnects and reconnects during the fuel rail replacement. What I would like to know is if say one injector was clogged from say a small piece of debri dropping down in it, would this cause the issue. I would think it would still start, but would not run well. Anyway, I'll play with the wires some more and report back. Thanks again!

 

yes it would start.. just have a misfire ...

 

Well, I finally got the truck to start, but still have issues. When we pulled the used fuel rail from another truck (2002 Dodge Rame 1500 4.7L) we also pulled a few other parts. One of them was the MAP sensor. During all of these issues, this is one thing we changed out. I decided to put back in my original MAP sensor and the truck started, blue smoke everywhere!!!!. However, The truck will stall below 1000 RPM's and when I start the vehicle I have to keep the pedal down. I have reset the PCM and that got the check engine light to go away, but the vehicle still stalls. I have code P0113 which appears to be the the IAT or MAP sensor issue. My understanding is this truck does not have an IAT, but a MAP. I guess I can just go buy a new one and replace it, but I have a feeling that may not resolve my issue and I am just throwing parts at it. I see I can do some throttle body cleaning as well, but not sure if that will help. The whole reason the truck broke down in the first place was because the fuel rail blew a hole in it, before that it was running perfectly fine. Not sure why all these other issues are coming up after merely replacing the fuel rail. Any other ideas before I replace another part would be appreciated. Thanks

 

Another Update. Went out to mess around with the truck this morning. Got it started up with the usual pressing of the gas peddle. Was able to slowly let off the gas peddle to finally get it to idle correctly (this was not working yesterday, tried it many times). Drove it around for a few miles, did not have any issue with stalling when switching to reverse, drive or coming to any stops, idled at proper RPMs, no bouncing around. Once it is parked and turned off, I have to go through the same scenario to get it to idle. It is running a little rough (slight shaking) when idling as if there is a misfire, some clicking seems to be coming from maybe the injectors or plugs on the passenger side. Can hear my fuel pump at all times and a little hissing from the throttle body, not sure if either of those sounds are right, don't recall them before, but never paid any attention. Think I am going to pull all the plugs as it is possible some small debri may be caught up in one or more of them, who knows. Will just pull everything and blow it all out with the compressor, do some throttle body cleaning and anything else that seems gummed up and will see what happens. I have read many times that after driving them for awhile, a tripped up computer will fix itself. Also think their could be an issue with bank one 02 sensor as that code came up with engine light on about a month before the truck broke down. However, that code was not showing after the fuel rail replacement, just P0113. Engine light is on again but cannot get a code reading with the three key turn in the ignition, so will also take it to autozone for a code reading after I clean it up. Any other ideas from anyone will be appreciated, will provide an update after all of this is done!