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TSB 14-01-89

Injection Pump Diagnosis Procedure Chart

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Date: October 2, 1989

models: 1989 AD With 5.9L Dodge/Cummins Diesel Engine

Body Code: AD - DODGE RAM PICKUP/RAMCHARGER SPORT UTILITY (RWD, 4WD)

Discussion:    INJECTION PUMP REPLACEMENT

To make diesel engine diagnosis easier and more accurate, the following injection pump troubleshooting procedure has been established. Prior to replacing the injection pump, this procedure should be used to make sure the problem is in fact caused by the injection pump.

Troubleshooting Injection Pump Related Problems
on the Dodge Ram/Cummins 5.9 Liter Turbo Diesel Engine
Injection Pump Removal Causes, Symptoms and Troubleshooting
**Justifiable Injection
Pump Removal Causes
Complaint/Symptom **Required
Diagnostic Check
A. Fuel leaks (1) Visible leaks #1
(2) Contaminated lubricating oil #8
B. Engine startup problems (1) Will not start - no smoke #2, 3, 4c, & 5a
(2) Excessive white smoke #6
C. Idle problems (1) Engine surges at idle #1, 3, 4, 5, 6, 7, & 8
D. Power problems (1) Engine will not reach rated speed - no load #2d, 3, 4, 5, 7, & 8
(2) Low power #2d, 3, 4, 5, 7, & 8
(3) Excessive exhaust smoke #8, & 9

**If the performance concern still exists after completion of the required diagnostic check chart, replace the injection pump. Note: Warranty claims for the injection pump will not be accepted unless all tamper-resistant seals are intact.

 
(#)
Procedure
SVC
Manual
Page
1.   Document fuel leak(s):
 

a. Describe magnitude of the leak (seep, weep, drip, stream, etc.)
b. Describe location of fuel leak(s):

14-11
2.   Verify the injection pump is delivering fuel:
  a. Loosen a high pressure line at the 'injector and check for fuel delivery while cranking the engine. FUEL DELIVERED?     * NO; go to 2b      * YES; go to check #3 14-16
b. Measure and record power to the fuel solenoid volts. BATTERY VOLTAGE PRESENT ?
* NO: troubleshoot wiring      * YES; go to 2c
14-8
c. Remove the solenoid plunger and spring and repeat step 2a.
FUEL DELIVERED? *NO; go to 2d.     *YES; replace the solenoid.
14-8
d. Bleed air from the supply line and measure the pressure at the filter head outlet through the bleed screw with the engine running at low idle and at full speed.
IS THE PRESSURE ABOVE 0.5 PSI IN BOTH CASES?
* YES; remove the injection pump. *NO; troubleshoot the fuel supply system.
14-15
3.  Determine fuel quality:
  a. Check for air in the fuel by bleeding the system AIR IN THE FUEL)
*YES: troubleshoot the fuel supply system for leaks      *NO; go to 3b.
14-15
b. Check type of Diesel Fuel No. 2, No. 1, Climatized No. 2, Other (verify) OE-4
c. Check for fuel contamination: -  Water, Gasoline, Other: (specify if possible)
NOTE: If incorrect fuel was used (#3b) or fuel is contaminated (#3c), drain and flush the fuel system, change the filter and check for proper engine operation.
 
4.  Check injection pump control levers:
  a. THROTTLE LINKAGE ADJUSTED TO PROVIDE STOP-TO-STOP TRAVEL?
* YES; go to 4B     *NO; adjust throttle travel
14-38
b. IS LOW IDLE SETTING CORRECT?
*YES; go to 4C      *NO; adjust setting
14-38
c. SHUTDOWN LEVER SPRING LOADED IN THE RUN POSITION?
* YES               *NO;, connect spring.
14-7
5.   Verify pump timing:
  a. Visually check the timing mark on the pump flange. 14-11
b. Measure and record the plunger lift mm. 14-35
6.   Verify operation of cold starting aids:
  a. INTAKE AIR HEATER OPERATING?
* YES; check KSB.       *NO; troubleshoot heater and electrical power source.
14-8
b. KSB FUNCTIONING?
* YES           *NO; troubleshoot electrical power source
14-9
7.   Check for excessive restriction or loss of air flow through the engine.
  Of the answer to all of the following questions is NO;, the air intake flow is acceptable): OC-9/11-3
a. EXHAUST VISUALLY DAMAGED AND RESTRICTED?       *NO  
b. AIR FILTER VISUALLY DIRTY?                                              *NO  
c. AIR LEAKS FROM THE PIPE CONNECTIONS BETWEEN TURBO- CHARGER AND INTAKE MANIFOLD?               *NO 14-4
d. LEAK IN LINE CONNECTIONS BETWEEN INTAKE MANIFOLD AND THE INJECTION PUMP?            *NO 11-24
e. TURBOCHARGER MALFUNCTIONING?          * NO
Note- If the answer to any of the above questions is YES, inadequate air intake flow may be the cause for the engine performance problem and should be corrected before removing the injection pump.
11-5
8.   Verify injector performance:
 
 
Cylinder No.
 1   2   3   4   5   6 
a. Operating Pressure            
b. Spray Pattern OK?            
c. Leakdown OK?            
14-41
9.   Perform smoke analysis*:
  a. Classify the color of the smoke.    *Blue     *White    *Black  
b. Blue - Not injection pump related. Troubleshoot cylinder sealing for oil consumption or turbocharger seal leakage.
c. White - Verify the pump timing (check #5) and troubleshoot the cold starting aids (check #6). Not injection pump related.
d. Black - Verify the pump timing (check #5) and troubleshoot the air flow through the engine (check #7). Remove the pump for calibration or repair.

Notes:

POLICY: Information only.


Thanks to Barry Drodge for supplying the TSB information

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This page was edited on: May 3, 2004