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TSB 18-29-95 Rev. A

Diesel Low Power/ Poor Performance

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Date: Oct. 16, 1995

NOTE: THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 18-29-95 WITH AN EFFECTIVE DATE OF OCT. 16, 1995 WHICH SHOULD BE REMOVED FROM YOUR FILES

models: 1994 - 1995 (BR) Ram Truck

NOTE: THIS BULLETIN APPLIES TO VEHICLES EQUIPPED WITH A CUMMINS DIESEL ENGINE AND AUTOMATIC TRANSMISSION.

Symptoms:

Slow acceleration or lack of power with engine at operating temperature.  

Diagnosis:

1.    Scheduled maintenance of air filter, fuel filter & strainer and valve lash adjustment must be current prior to performing this Technical service Bulletin.

2.    Using the chart below, locate the appropriate time for the vehicle being tested.

 
AUTOMATIC TRANSMISSION
0 - 60 MPH TIME (SEC.)
0 - 60 MPH TIME (SEC.)
 
4x2
4x4
BR 2500 STD CAB
15.0
15.5
BR 2500 CLUB CAB
15.5
16.0
BR 3500 STD CAB
16.0
16.5
ER 3500 CLUB CAB
16.5
17.0
NOTE: PERFORMANCE VALUES LISTED ARE FOR THE SPECIFIED MODELS AT CURB WEIGHT

 3.    With the vehicle in Drive, on dry, flat straight - away of sufficient length. Run at least two 0 - 60 mph tests in opposite directions and record the time in seconds. Average the times and compare to the charted time for the vehicle.

4.    If the measured time exceeds the charted respective time listed for the vehicle, proceed to repair procedure.

5.    If the measured time is less than or equal to the charted time listed for the vehicle, performance is within specifications and no further diagnosis or repair is needed.

Repair:

This bulletin involves testing vehicle performance in three areas (wide open throttle, low pressure fuel system, injection pump timing). Adjustments or repairs will be made based on the results of the tests.

CHECK FOR WIDE OPEN THROTTLE:

1.    The key and engine should be off for this test.

2.    Two people are needed for this test. From inside of the vehicle, press the accelerator pedal to the floor. If throttle lever is operating correctly, the throttle lever to injection pump lever linkage rod should stop moving while the throttle lever continues to move towards the rear of the vehicle.

3.    If adjustment is needed, refer to the 1995 Ram Truck Service Manual (Publication Number 81-370-5108) Group 14, accelerator pedal and throttle rod section.

Additional Automatic Adjustments:

A.    Adjust the throttle valve cable to zero lash at zero throttle position. Refer to the 1995 Ram Truck Service Manual (Publication Number 81-370-5108) Group 21, 42RH/46RH/47RH Transmission in-vehicle service.

B.    With engine ignition on and engine NOT running, adjust throttle position sensor to read 1 volt at zero throttle position. Refer to Group 14, Component Removal/Installation for Diesel Engine.

4.    If adjustments were made, return to Diagnosis section of this Technical Service Bulletin and repeat steps 3 thru 5.

5.    If no adjustments were needed, proceed to low pressure fuel system check.

LOW PRESSURE FUEL SYSTEM CHECK:

1.    With engine off, install Diesel Low Pressure Gage (Miller Special Tools, Tool Number 6828) and the Fuel Feed Line Connection Adapter (Miller Special Tools, Tool Number 6976), at fuel feed line injection pump connection.

The tools can be obtained from Miller Special Tools at I- 800-801-5420 with the tool numbers given below.

a. The Diesel Low Pressure gage can be found in the Miller Special Tools Tool Kit number 6846.

b. Fuel Feed Line Connection Adapter (Miller Special Tools, Tool Number 6976)

c. A new kit that includes the gage and adapter, may be ordered by Miller Special Tools, tool number 6977.

2.    Start engine and let idle. If gage reads 12 psi or more proceed to injection pump timing adjustment section below.

3.    If gage reads less than 12 psi, turn engine off and replace overflow valve in injection pump.

4.    Start engine and let idle, if gage reads 12 psi or more, return to Diagnosis section of this Technical Service Bulletin and repeat steps 3 thru 5.

5.    If gage reading has not changed and is still less than 12 Psi, turn engine off and replace the fuel lift pump.

6.    Start engine and let idle, if gage reads 12 psi or more, return to Diagnosis section of this Technical service Bulletin and repeat steps 3 thru 5.

7.    if gage reading has not changed and is still less than 12 Psi, refer to Group 14, Diesel Engine - General Diagnosis for further assistance.

8.    If a copper sealing washer is used on the fuel feed line, it must be replaced before reassembly. The rubber sealing washers are reusable and do not need replacement.

INJECTION PUMP TIMING ADJUSTMENT:

To determine the proper timing specification for each vehicle, the CPL number should be referenced. The CPL number is located on the engine data tag, in the middle section, top line ( Figure 2).

1.    For 1995 1/2 M.Y. Engines equipped with Automatic transmission and a CPL number of 1968, set timing not to exceed 14.5 degrees BTDC static timing or 4.9 mm plunger lift at TDC.

2.    For all other 1994 and 1995 M.Y. engines, set timing not to exceed 13.5 degrees BTDC static timing or 5.9 mm plunger lift at TDC.

3.    Record as received timing. For further assistance with pump timing reference 1995 ram truck service manual (Publication Number 81-370-5108) Group 14, Diesel Engine - General Diagnosis.

4.    Return to Diagnosis section of this Technical Service Bulletin and repeat steps 3 thru 5. If test time still exceeds the value as listed for subject vehicle, proceed to remove and replace injection pump section below.

REMOVE AND REPLACE INJECTION PUMP:

1.    Remove injection pump and send to Bosch ADS Shop for Low Power fueling and timing adjustments.

2.    Install injection pump, check for leaks, road test and return to Diagnosis section of this Technical Service Bulletin and repeat steps 3 thru 5. Record final readings and return vehicle to customer.

Notes:

POLICY: Reimbursable within the provisions of the warranty.

TIME ALLOWANCE:

Labor Operation No:

14-00-01-90 . . . . 0.3 Hrs.

1994-1995 (BR) Diagnose and Road Test (Vehicle Passes Test)

14-00-01-91 . . . . . .0.9 Hrs.
1994-1995 (BR) Check and Adjust Throttle Linkage Road Test

FAILURE CODE: XX - Service Adjustment

Labor Operation No:

14-00-01-92 . . . . 1.1 Hrs.
1994-1995 (BR) Diagnose and Road Test, Check and Adjust Throttle Linkage Road Test, Test Low Pressure Fuel System Replace Overflow Valve (if necessary) Road Test

FAILURE CODE: P8 - New Part

Labor Operation No:

14-00-01-93 . . . . 3.3 Hrs.
1994-1995 (BR) check and Adjust Throttle Linkage Road Test, Test Low Pressure Fuel System Replace overflow Valve (if necessary) Check and Adjust Injection Pump Timing, Road Test

FAILURE CODE: XX - Service Adjustment

Labor Operation No:

14-00-01-94 . . . . 5.4 Hrs.
1994-1995 (BR) Check and Adjust Throttle Linkage Road Test, Test Low Pressure Fuel System Replace Overflow Valve (if necessary) Check and Adjust Injection Pump Timing, Road Test, Replace Injection Pump and Road Test

FAILURE CODE: P8 - New Part


Thanks to Barry Drodge for supplying this TSB information

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This page was edited on: May 3, 2004