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TSB 14-004-05

Electronic Fuel Control (EFC) Actuator Available For Service

Visit Geno's Garage for Truck accessories.

Date: July 8, 2005  

Models: 2003 - 2005 DR/DH Ram Truck

NOTE: This bulletin applies to vehicles equipped with a Cummins Turbo Diesel (sales
code ETC or ETH).

Overview:
This bulletin involves replacing the EFC Actuator.

Symptom/Condition:
Engine surges at idle.

Diagnosis:

ENGINE SURGES AT IDLE

Possible Causes

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

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.

1.   DTC’s - Check for any Diagnostic Trouble Codes (DTC’s) present. - Are there any
DTC’s stored or active?
   a. Yes >> Repair as necessary before proceeding further with this bulletin.
   b. No >> Go to (Step #2).

2.   Verify complaint - Verify proper fuel quality, grade, and level in the vehicle. Using the
DRBIII, 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 #3).
   b. No >> Go to (Step #7).

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.

3.   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 #4).
   b. No >> Repair the low pressure fuel supply system. Refer to the detailed diagnostic
       information available in TechCONNEC under: Service Info, 9 - Engine, Diagnosis
       & Testing, Fuel Lift Pump - Diesel. - This bulletin does not apply.

4.   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 #6).
   b. No >> Go to (Step #5).

5.   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 #8).
   b. No >> (Step #6).

6.    This bulletin does not apply. Replace the fuel injection pump. Check for source of
water to prevent future complaints. Refer to the detailed service information available in
TechCONNEC under: Service Info, 14 - Fuel System, Fuel Injection, Fuel Injection
Pump.

7.   Further diagnosis is necessary. This bulletin does not apply. Refer to SB 14-003-05.

8.   Perform the Repair Procedure.

Parts Required:

Qty.	Part No.	Description
1	05183245AA	Actuator

Special Tools/Equipment Required:

Repair Procedure: 

1.

Replace the EFC as follows, if the high pressure fuel pump is discharging the correct amount of fuel.    a. Remove the cap screws (3).    b. Using a (Clockwise/Counterclockwise) twisting motion, remove the EFC.    c. Using a (Clockwise/Counterclockwise) twisting motion, install the EFC.    d. Install the cap screws (3). Torque the cap screws in two steps. Step 1 - Torque all        cap screws to 3 N·m (27 in. lbs.). Step 2 - Torque all cap screws to 7 N·m (62 in. lbs.).    e. Start the engine to remove air from the fuel system. >> Go to (Step #2).

2.

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.

Time Allowance:

Failure Code:

This page was edited on: May 3, 2004