Sprinter diesel ran on gas

Luke Mobile Technician California Posted   Latest  
Resolved
Driveability
2009 Dodge Sprinter 2500 3.0L (5 EXM) 5-spd (W5A380)
Extended Crank/Start

Hi everyone, This is my first post so please bear with me. I have a sprinter that was run on gas for less than 5 minutes. When it started to run rough customer pulled off the road and towed it to a shop knowing right away what he did. Other shop drain tank and changed filter. After that work was done it started and ran but had a lack of power and extended crank always. Customer droved it to our shop about 40 miles to have us figure out the new problems that started when he got the van back.

We have changed low pressure fuel pump (had a bad winding), fuel filter, drivers fuel rail with quantity valve, high pressure fuel sensor, high pressure fuel pump. Now the van starts normal every time but after 10 minutes hot soak it will crank for 10 seconds before starting. I have scoped the 

We're looking for a good way to condemn the injectors. Kinda the last part in the fuel system but would like to feel better before putting im just because of that. 

I have scoped injectors and high pressure fuel sensors and would like to compare it to a know good if someone has that file. 

Let me know what you guys think. Thank you for your time.

File has Y crank R cam G inj 1 B inj 1 current. The capture is only a little extra crank time. It has actually been running rough when it first get running to now. Thats what happen in this capture. But when its bad it cranks for 5-10 seconds then stops before starting. Then next time cranking it will usually start. 

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Dave Owner/Technician
California
Dave
   

Suggest you do injector bleed test. Remove bleed line from all injectors, put clear plastic tubing on all, gather tubes together ang hang from hood safety latch. Start engine for about a minute and see if all injectors bleed off same. If lets significantly more fuel out it is defective. oregonfuelinjection​.​com/services-repai… diag​.​net/msg/m42gozknib…

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Luke Mobile Technician
California
Luke
 

I didnt think about checking the bleed lines. I'll give that a try soon as possible. Thank you Dave

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Luke Mobile Technician
California
Luke
 

I drove the sprinter to duplicate the hot extended crank. Put on the clear lines while I waited the 10ish minutes it normally takes after the drive to have the extended cranking. Looks like we have 3 bad injectors 1,2,4. The pics are from the initial 5 seconds of cranking. I didn't get to ambitious about measuring the amount of fuel coming out to see if it was over 2.5ml per oregonsdiesel's…

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Marvin Mechanic
Mississippi
Marvin
 

I wouldnt change just 3

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Luke Mobile Technician
California
Luke
 

I agree but its my my vehicle

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Marvin Mechanic
Mississippi
Marvin
 

Pull the injectors and take to a good diesel fuel injections shop, and have them tested on a bosch test stand and see what steps they fail,probably have excessive return…..question why did you change rail sensor ?/

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Luke Mobile Technician
California
Luke
 

We will look for a injection shop. Last one we used closed down. Rail sensor was replaced because shot gun had an extra barrel round in it. haha. And we had low rail pressure before low and high pumps were replaced so we thought it was worth a try, easy swap, and no way to verify 50K psi. At least with equipment we have.

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Ryan Owner/Technician
British Columbia
Ryan
 

We ran into this same scenario a few years ago with another shop. A Sprinter van filled with gasoline and driven for some distance. It had a slight starting issue and rough running concern. We received the injectors for testing. All six injectors passed on our Bosch EPS205. The customer requested new injectors anyways but after the shop installed them, there was no change to the issue. The fix…

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Interesting
Richard Technician
New York
Richard
 

Great tip!

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Luke Mobile Technician
California
Luke
 

We have reset the adaptive values for the injectors with no change. With Xentry it has connection errors when we try to watch current adaptive values when its extended cranking. maybe we need to connect while cranking and it will not error out.

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Dave Owner/Technician
California
Dave
 

Look in one of those guides, from Oregon I think. We had extended crank once and it turned out to be pressure control valve on rail. We found it was bleeding off while cranking. Didn't cause problem once running.

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Michael Technician
British Columbia
Michael
 

Was there any evidence of failure leading to metal in the system? The Ford 6.7L often has high pressure pump failure fairly quickly when run with gas and although I am no diesel tech, my former co-workers have done several $15k CAD fuel system overhauls for running gas. That's the entire system due to metallic contamination.

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Luke Mobile Technician
California
Luke
 

We didn't see any indication of metal in the fuel system.

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Jason Technician
Georgia
Jason
 

Gasoline is a solvent, diesel is a lubricant. The lubrication qualities of the diesel lubricates the many moving parts inside the fuel system. Not to mention seals and everything else, many internal that are now leaking. So no doubt the high pressure pump and injectors are probably not operating correctly as they got hundreds of thousands of miles of wear in a matter of minutes. Sure, you can…

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Luke Mobile Technician
California
Luke Resolution
 

Sorry for the late replay. We replaced the 3 injectors that had fuel coming from the leak oil lines. still same problem, extended crank. then we swapped the three we took out with the other original 3 and that took car of %80 of the extended cranking. Customer didnt want to replace the other 3 with new at this time. But it is significantly better to we will take that for now. Thank you…

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