DodgeRam.info > TSB's > 14-003-05

TSB 14-003-05

Superseded by TSB 14-003-06 - Left for reference only

Visit Geno's Garage
for Truck accessories.

Date: July 8, 2005 Cummins Diesel Diagnostics

Models: 2003 - 2005 (DR/DH) Ram Truck

Overview:
This bulletin provides diagnostic procedures for the fuel injection system.

Symptom/Condition:
Revised diagnostic procedures are available for the following Symptom/Conditions:

Engine cranks for a long time or will not start.
White smoke and/or misfire after starting when the engine temperature is below 66° C (150° F).
Engine surges at idle
Engine sounds

Special Tools/Equipment Required:

CH6000A	Scan Tool (DRBIII)
CH7000A	J1962 Cable with red DRBIII connector
9011	Adapter, Fuel Pressure Test
9012	Fitting, Fuel System Test

Discussion:

NOTE: Do not use the “Cylinder Performance Test” on the DRBIIIT. This test may
result in unnecessary injector replacement.

CAUTION: Do NOT disconnect the Electronic Fuel Control (EFC) actuator or the Fuel
Rail Pressure Sensor while the engine is running. Damage to the rail
pressure relief valve may occur.

Diagnosis:

PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE

For the engine circuit diagram, refer to the detailed service information available in
TechCONNECT, under: Service Info, 9 - Engine, Schematics and Diagrams. For a complete
wiring diagram, refer to the detailed wiring diagrams available in TechCONNECT under: Wiring,
14 - Fuel System, Fuel Injection, (component)

Perform the existing “Pre-diagnostic Troubleshooting Procedures” available in TechCONNECT
under: Service Info, 9 - Engine, Diagnosis & Testing.

WHITE SMOKE AND/OR MISFIRE AFTER COLD START

Possible Causes

Air in fuel supply
Coolant leaking into combustion chamber
Active DTC’s
In very cold ambient temperatures, engine block heater is malfunctioning (if equipped)
Engine Coolant Temperature sensor malfunctioning
Engine Control Module (ECM) incorrect calibration
Fuel filter restricted
Fuel grade not correct or fuel quality is poor
Fuel heater element or fuel heater temperature sensor malfunctioning
Fuel Injector malfunctioning
Fuel injector hold-downs loose
Fuel injector protrusion not correct
Fuel injection pump malfunctioning
Intake/Exhaust valve adjustment not correct (too tight)
Intake manifold air temperature sensor malfunctioning
Intake manifold heater circuit not functioning correctly in cold weather
Internal engine damage
Restricted fuel supply side of fuel system

Preliminary checks:

Repair active DTC’s before proceeding.
Check for normal white smoke at cold start-up that stops within one minute and is
more noticeable when cold.
Ensure the customer’s concern is not related to situations which may increase normal
white smoke; idle time, engine temperature, fuel source, cold ambient temperature,
high altitude.

NOTE: Steps 1 through 4 should be performed BEFORE the engine is started.

1.   Temperature sensors: Using the DRBIII, before starting engine after an overnight
soak, verify that the Intake Air Temperature (IAT), Engine Coolant Temperature (ECT),
Inlet Air Temperature, and the Battery Temperature sensors are showing similar and
appropriate temperatures. - Are the sensors showing similar and appropriate
temperatures?
   a. Yes >> Go to (Step #2).
   b. No >> Repair the appropriate sensor or circuit. Refer to the diagnostic procedures
       available in TechCONNECT under: Service  Info, 9 - Engine, Diagnosis & Testing. -
       Go to (Step #12).

2.   Pressure sensors: Using the DRBIII, before starting engine after an overnight soak,
verify that the Intake Manifold Pressure and Inlet Air Pressure sensors are showing
similar and appropriate pressure. - Are the sensors showing similar and appropriate
pressures?
   a. Yes >> Go to (Step #3).
   b. No >> Repair the appropriate sensor or circuit. Refer to the diagnostic procedures
       available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing. -
       Go to (Step #12).

3.   Fuel Rail Pressure sensor: Using the DRBIIIT, before starting engine after an overnight
soak, verify that the fuel rail pressure reads 0 (+/- 500 PSI). - Does the fuel rail
pressure read 0 (+/- 500 PSI)?
   a. Yes >> Go to (Step #4).
   b. No >> Repair the fuel rail pressure sensor or circuit. Refer to the diagnostic procedures
       available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing. -
       Go to (Step #12).

4.   Intake Air Heater: Verify the intake air heater is operating properly. Refer to the detailed
service information available in TechCONNECT, under: Service Info, 14 - Fuel System,
Fuel Injection, Intake Air Heater, Operation. - Is the intake air heater operating
properly?
   a. Yes >> Go to (Step #5).
   b. No >> Repair the intake air heater or intake air heater circuit. Refer to the
       diagnostic procedures available in TechCONNECT under: Service Info, 9 - Engine,
       Diagnosis & Testing. - Go to (Step #12).

5. Start the engine: Start the engine following normal starting procedures and allow to run
at idle. Determine when the white smoke disappears. If the white smoke disappears
within one minute, it is normal. If the engine is operated in cold ambient conditions
and/or at altitude, white smoke at start-up is expected.

6.   Test for injector misfire: Using the DRBIIIT, perform a “Cylinder Kill” test. Cancel each
cylinder one-at-a-time. Note any change in smoke and/or misfire. Does a single
cylinder show a difference in smoke or misfire?
   a. Yes >> Go to (Step #7).
   b. No >> Go to (Step #8).

7.   Diagnose single cylinder white smoke/misfire:
   a. Remove the valve cover.
   b. Inspect the valve lash.
   c. Remove the injector.
   d. Inspect the injector seal washer and High Pressure Connector (HPC). Replace the HPC if it is damaged.
   e. Install the injector. Refer to the detailed service information available in
      TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, Fuel
      Injector, Installation.
   f. Repeat test for injector misfire. Go to (Step #6).

NOTE: If the same single cylinder is still the cause of the miss or white smoke, replace
that single injector and HPC.

NOTE: Perform the following test if a single cylinder was not identified by the cylinder
cutout test to be causing the white smoke.

8.   Test for injector leaking fuel into the cylinder. - Using Miller Special Tool, 9011, block
the high pressure fuel line at the rail, one injector at a time. Is a single injector the
cause of the white smoke and/or miss?
   a. Yes >> Replace that injector and HPC. - Go to (Step #12).
   b. No >> Go to (Step #9).

9. Test for high injector return flow. Perform the “Injector Return Flow Test”. Refer to the
detailed diagnostic information available in TechCONNECT under: Service Info, 9 -
Engine, Diagnosis & Testing. Do the injectors pass the “Injector Return Flow Test”?

NOTE: Maximum leakage allowable for all injectors combined is 180 mL (6.1 fl. oz.) (At
idle pressure).

NOTE: It is critical that all HPC nuts are tightened to the correct torque. Refer to the
detailed tightening information available in TechCONNECT under: Service Info,
14 - Fuel System, Fuel Injection, Fuel Injector, Installation. Retest when all HPC
nuts are properly torqued.

NOTE: Any injector contributing more than 40 mL (1.4 fl. oz.) is excessive (Example: If
total injector leakage is 200mL (6.7 fl. oz.) and blocking cylinder #1 reduces the
leakage to 160 mL (5.4 fl. oz.), cylinder #1 has excessive leakage).

NOTE: Test should be repeated to confirm measurements.
a. Yes >> Go to (Step #11).
b. No >> Go to (Step #10).

10. If any cylinders are deemed excessive
   a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
       information available in TechCONNECT under: Service Info, 14 - Fuel System,
       Fuel Injection, Fuel Injector, Removal/Installation. - Go to (Step #12).
   b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed
       service information available in TechCONNECT under: Service Info, 14 - Fuel
       System, Fuel Injection, Fuel Injector, Removal/Installation. - Go to (Step #12).
   c. If total injector return flow is high and individual cylinders cannot be identified as
       the source, replace all injectors and HPC’s. Refer to the detailed service
       information available in TechCONNECT under: Service Info, 14 - Fuel System,
       Fuel Injection, Fuel Injector, Removal/Installation.Verify that a quality fuel filter is
       used. - Go to (Step #12).

11. If the engine passes the previous tests and still exhibits white smoke that clears with a
warm engine, check the following:
   a. Idle Time >> More than 20% is excessive.
   b. Engine Temperature >> Verify that the thermostat allows the engine to reach
       operating temperature.
   c. Fuel Source (Cetane) >> Check with fuel supplier or try another source.
   d. Fuel Quality (lubricants/detergents) >> May benefit by using a fuel detergent with
       a lubricity additive.
   e. Winter Fuels >> No. 2 diesel not blended for winter conditions.
   f. Cold Ambient >> Use block heater where appropriate, limit warm-up time in winter.
   g. High Altitude >> Effect will be worse with altitude and cold ambient temperatures.
   h. Refer to Service Information >> Refer to the detailed diagnostic information
       available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing,
       Smoke Diagnosis Charts, Excessive White Smoke. - Go to (Step #12).

12. Repair Complete. - Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL
MODULE - DIAGNOSIS AND TESTING.

ENGINE SURGES AT IDLE

Fuel Supply System
Injection System
Fuel Return
Intake System
Other Vehicle Systems
Base Engine

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.

13. DTC/PRODUCT IMPROVEMENT - Check for any service bulletins related to the
customer’s concern or Diagnostic Trouble Codes (DTC’s) present. Follow appropriate
guidelines in the diagnostic procedures outlined in TechCONNECT. - Is the vehicle
repaired?
a. Yes >> Go to (Step #20).
b. No >> Go to (Step #14).

14. Verify complaint - Verify proper fuel quality, grade, and level in the vehicle. Using the
DRBIIIT, log the fuel pressure set point and fuel pressure. Operate the engine at idle
speed. A good system will have actual fuel pressure that is +/- 500 PSI from the set
point. (Example: If the fuel pressure set point at idle is 6500 PSI, the actual fuel pressure
on a good system is expected to be between 6000 - 7000 PSI). If fuel pressure variation
is excessive, an audible surge will be present. If the variation is severe, a slight engine
speed variation may also be noticed. - Does the fuel rail pressure fluctuate more
than +/- 500 PSI?
a. Yes >> Go to (Step #15).
b. No >> Go to (Step #19).

NOTE: A loud “knock” and black smoke that exists with a pressure drop may be an
injector issue and should be identified using single cylinder cut-out test.

15. Verify proper low pressure fuel supply to the injection pump. Perform the “In Tank
Fuel Lift Pump Flow Test - Diesel”. In a good system fuel flow of 430 mL in 10 seconds
or better is expected. Be sure there is no air in the system. Is the low pressure fuel
supply sufficient?
   a. Yes >> Go to (Step #16).
   b. No >> Repair the low pressure fuel supply system. Refer to the detailed diagnostic
       information available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis
    & Testing, Fuel Lift Pump - Diesel. - Go to (Step #20).

16. Verify High Pressure Fuel Pump Performance. - Remove the fuel pump to rail high
pressure fuel line. Inspect the fuel pump outlet port for rust, debris, or other sign of
contamination. - Is contamination present?
a. Yes >> Go to (Step #18).
b. No >> Go to (Step #17).

17. Verify fuel injection pump flow. - Route the high pressure fuel line to a graduated
container. Crank the engine until fuel exits the line (with the discharge line routed to
atmosphere, fuel will discharge at 0 PSI). Crank the engine for three 10 second
intervals, pausing to allow the starter to cool between each crank event. Fuel flow
specification is based on engine cranking speed. 1. Minimum fuel pump flow at 150
RPM; 70 mL in 30 seconds. 2. Minimum fuel pump flow at 200 RPM; 90 mL in 30
seconds. Is the fuel flow sufficient?
a. Yes >> Go to (Step #19).
b. No >> (Step #18).

18. Replace the fuel injection pump. Check for source of water to prevent future complaints.
Refer to the detailed service information available in TechCONNECT under: Service Info,
14 - Fuel System, Fuel Injection, Fuel Injection Pump. Go to (Step #20).

19. Electronic Fuel Control Actuator (EFC) - Replace the EFC if the high pressure fuel
pump is discharging the correct amount of fuel. - Go to (Step #20).

20. Repair Complete. - Perform Powertrain Verification Test VER - 1 (Diesel). Refer to 8 -
Electrical/Electronic Control Modules/Engine Control Module - Diagnosis And Testing.

ENGINE NOISE

When standing in front of the truck with engine running, several distinct noises may be heard.
These noises may vary depending on listener location, 2WD vs. 4WD, engine temperature and
miles on the vehicle.

21. Gear Train Noise Evaluation
   a. Normal: Gear noises noticeable when standing in front of the engine, may vary
       from engine to engine.
   b. Abnormal: Gears are visually damaged or have backlash or end clearance out of
       specification. The cause should be identified and corrected.

22. Fuel Pump Noise Evaluation
   a. Normal: Pumping noise may vary - the fuel pump is producing between 5,000 and
       20,000 psi depending on operating conditions.
   b. Abnormal: A fuel pump with excessive pressure variation (+/- 500 psi from set
       point) is abnormal. The cause should be identified and corrected, refer to Engine
       Surge or Engine Difficult to Start symptoms.

23. Injector Noise Evaluation
   a. Normal: Combustion noise may vary at different operating conditions. May be
       more noticeable on throttle tip-in and vary from engine to engine.
   b. Abnormal: Loud knock with smoke and vibration. Cylinder cut out test or
       mechanical blocking of injectors (tool #9011) should be used to identify failed
       injectors.

24. Valve Train Noise Evaluation
   a. Normal: Valve settings are correct and no visual damage to parts.
   b. Abnormal: If valve settings are out of specification, they should be reset. Also,
       correct for any damage to rocker levers, push rods, or cross heads.
       25. Refer to the detailed diagnostic information available in TechCONNECT under: Service
       Info, 9 - Engine, Diagnosis & Testing. Engine Diagnosis - Mechanical.

ENGINE WILL NOT START/HARD TO START

Possible Causes

Battery voltage
Starting Accessories
Engine Timing
Fuel Supply System
Injection System
Fuel Return
Air System
Other Vehicle Systems
Base Engine

26. DTC/PRODUCT IMPROVEMENT - Check for any service bulletins related to the
customer’s concern or Diagnostic Trouble Codes (DTC’s) present. Follow appropriate
guidelines in the diagnostic procedures outlined in TechCONNECT. - Is the vehicle
repaired?
a. Yes >> Go to (Step #40).
b. No >> Go to (Step #27).

27. Verify complaint - Using the DRBIIIT, log the fuel pressure set point and fuel pressure.
Crank the engine for a maximum of 30 seconds. A good system will have actual fuel
pressure that is within 500 PSI of the set point. (Example: If the fuel pressure set point
during cranking is 6500 PSI, the actual fuel pressure on a good system is expected to
be above 6000 PSI). - Is the fuel rail pressure within 500 PSI of the fuel pressure
set point?
a. Yes >> The fuel system is functioning correctly - return to the appropriate symptom list.
b. No >> Go to (Step #28).

28. Verify proper low pressure fuel supply to the injection pump. - Perform the “In Tank
Fuel Lift Pump Flow Test - Diesel”. In a good system fuel flow of 430 mL in 10 seconds
or better is expected. Be sure there is no air in the system. Is the low pressure fuel
supply sufficient?
   a. Yes >> Go to (Step #29).
   b. No >> Repair the low pressure fuel supply system. Refer to the detailed diagnostic
       information available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis
       & Testing, Fuel Lift Pump - Diesel. >> Go to (Step #40).

29. Check oil level. - Check the oil level for evidence of fuel in the crankcase oil. If there is
fuel in the oil, suspect a cracked fuel injector - Is there evidence of fuel in the oil?
a. Yes >> Go to (Step #30).
b. No >> Go to (Step #32).

30. Remove the valve cover - Inspect for cracked injectors. Use the rail blocking tool (tool
#9011) to isolate cracked injectors Are there any cracked injectors?.(Step #40).
a. Yes >> Go to (Step #31).
b. No >> Go to (Step #32).

31. Replace the cracked injector(s). Refer to the detailed removal and installation
procedures available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel
Injection, Fuel Injector. >> Go to (Step #39).

32. Verify High Pressure Fuel Pump Performance. - Remove the fuel pump to rail high
pressure fuel line. Inspect the fuel pump outlet port for rust, debris, or other sign of
contamination. - Is contamination present?
a. Yes >> Check for source of contamination to prevent future complaints. Go to (Step #39).
b. No >> Go to (Step #33).

33. Verify fuel injection pump flow. - Route the high pressure fuel line to a graduated
container. Crank the engine until fuel exits the line (with the discharge line routed to
atmosphere, fuel will discharge at 0 PSI). Crank the engine for three 10 second
intervals, pausing to allow the starter to cool between each crank event. Fuel flow
specification is based on engine cranking speed. 1. Minimum fuel pump flow at 150
RPM; 70 mL in 30 seconds. 2. Minimum fuel pump flow at 200 RPM; 90 mL in 30
seconds. Is the fuel flow sufficient?
a. Yes >> Go to (Step #34).
b. No >> Go to (Step #39).

34. Test for high injector return flow. - Refer to the detailed diagnostic information
available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis and Testing, Fuel
Pump Return Flow Test. - The worn injector set limit is 180 mL/minute (at idle pressure).

NOTE: Maximum leakage allowable for all injectors combined is 180 mL (6.1 fl. oz.) (At
idle pressure).

NOTE: Torque all High Pressure Connector (HPC) nuts to the correct torque and
retest. Refer to the detailed service information available in TechCONNECT
under: Service Info, 14 - Fuel System, Fuel Injection, Fuel Injector.

NOTE: Any injector contributing more than 40 mL (1.4 fl. oz.) is excessive (Example: If
total injector leakage is 200 mL (6.7 fl. oz.) and blocking cylinder #1 reduces
the leakage to 160 mL (5.4 fl. oz.), cylinder #1 has excessive leakage).

NOTE: Test should be repeated to confirm measurements.Do the injectors pass the “Injector Return Flow Test”?
a. Yes >> Go to (Step #35).
b. No >> Go to (Step #36).

35. Fuel Return - Check for kinked or restricted fuel return lines. Check the fuel tank
venting. Repair as necessary. >> Go to (Step #40).

36. If any cylinders are deemed excessive:
   a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
       information available in TechCONNECT under: Service Info, 14 - Fuel System,
       Fuel Injection, Fuel Injector, Removal/Installation. - Go to (Step #40).
   b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed
       service information available in TechCONNECT under: Service Info, 14 - Fuel
       System, Fuel Injection, Fuel Injector, Removal/Installation. - Go to (Step #40).
   c. If total injector return flow is high and individual cylinders cannot be identified as
       the source, replace all injectors and HPC’s. Refer to the detailed service
       information available in TechCONNECT under: Service Info, 14 - Fuel System,
       Fuel Injection, Fuel Injector, Removal/Installation.Verify that a quality fuel filter is
       used. - Go to (Step #37).

37. Check the fuel pressure regulator. - Perform the “Checking Pressure Limiting Valve
On The Fuel Rail For Internal Leaks” test. Perform the existing diagnostic procedure
available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis and Testing. - No
leakage is expected while cranking or while at idle speed. Does the pressure regulator
leak internally?
a. Yes >> Go to (Step #38).
b. No >> The fuel system is functioning properly. Return to the symptom list.

38. Replace the fuel pressure regulator. - Refer to the detailed service information
available in TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Delivery, Fuel
Pressure Regulator. >> Go to (Step #40).

39. Replace the fuel injection pump. Refer to the detailed service information available in
TechCONNECT under: Service Info, 14 - Fuel System, Fuel Injection, Fuel Injection
Pump. >> Go to (Step #40).

40. Repair Complete. - Perform Powertrain Verification Test VER - 1 (Diesel). Refer to 8 -
Electrical/Electronic Control Modules/Engine Control Module - Diagnosis And Testing.

Policy:
Reimbursable within the provisions of the warranty using diagnostic labor operations for actual
labor time. The Operation Diagnostic labor operations can be located in the 80/90 – Special
Services tab in the Labor Operations Manual. Usage of these operations must follow the
guidelines outlined in the Global Warranty Administration Manual.

I would like to thank Bob Bergevin, Arthur Cantrall, Barry Drodge, David Lovell, Bill Maurits, and Steve for supplying the information for these bulletins. And a big thank you goes to Geno's Garage for making DodgeRam.info possible.

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This page was edited on: May 3, 2004