3rd Gen Engine and Drivetrain -> 2003-2007 5.9 liter Engine and drivetrain discussion only. PLEASE, NO HIGH PERFORMANCE DISCUSSION!

5.9 INJECTOR / PCM white smoke and miss

Old Aug 23, 2021 | 10:57 AM
  #1  
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From: Fort Campbell Kentucky
5.9 INJECTOR / PCM white smoke and miss

It’s a long story but I’m just gonna give u the whole rundown
Bought the truck private party about 2 months ago it’s a 2006 dodge 2500 5.9 Cummins 24 valve common rail. Has 216k miles on it now, I replaced the turbo with an exact oem replacement holset turbo and new exhaust manifold. Truck ran great for a month and drove it to work and back one day but I whent to the store after work one day and it started missfiring and throwing some light white smoke, instantly turned around and stopped, ran #3 injector codes, ended up swapping #1 and #3 injectors due to a electrical lead breaking on the no 1 injector cylenoid. Also put a new electrical valve cover gasket on. But it still is misfiring and rough idle with white smoke to reiterate There hasn’t been any white smoke for a month of daily driving with the new turbo only just recently it started and the white smoke started instantly it didn’t progressively get worse. It came all at once with the rough idle and miss. I don’t know how to set valves but I’m fairly certain the rings are fine because I have no blowby and my compression test came out to 500psi on the #3

im looking for suggestions on what to look at next I don’t have a shop only a the basics and a few special tools. I’m going to swap out my FCA this week but I doubt that’s the main issue because I only have a miss on the #3

it does not get better will hot or driving
Attached Thumbnails 5.9 INJECTOR / PCM white smoke and miss-6533bbf1-beff-48b7-9d7d-145b1ec2cfac.jpeg  
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Old Aug 24, 2021 | 10:06 AM
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From: Old Norte Mexico
Originally Posted by Billy 5.9
. . . ran #3 injector codes, ended up swapping #1 and #3 injectors due to a electrical lead breaking on the no 1 injector cylenoid. Also put a new electrical valve cover gasket on. But it still is misfiring and rough idle with white smoke . . .
It sounds like you ran the codes and the code showed up for #3 injector. It then sounds like you swapped #1 and #3 injectors. If both of those are true, did you run the codes again, and if so, did the code follow the injector to #1 cylinder or stay at #3 cylinder?
Back to morning brew . . .
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Old Aug 24, 2021 | 03:36 PM
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From: Fort Campbell Kentucky
Originally Posted by FMB
It sounds like you ran the codes and the code showed up for #3 injector. It then sounds like you swapped #1 and #3 injectors. If both of those are true, did you run the codes again, and if so, did the code follow the injector to #1 cylinder or stay at #3 cylinder?
Back to morning brew . . .

sorry I realized my poor wording by swapped I meant replaced I replaced the #1 and #3 injectors with new injectors. The issue is still present and I have recently re calibrated my valve lashing as well and the issue is the same
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Old Aug 25, 2021 | 08:36 AM
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From: Old Norte Mexico
What codes do you have now? P????
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Old Aug 25, 2021 | 03:24 PM
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From: Fort Campbell Kentucky
Originally Posted by FMB
What codes do you have now? P????
I have P0303
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Old Aug 26, 2021 | 09:14 AM
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From: Old Norte Mexico
Originally Posted by Billy 5.9
I have P0303
I would;
  1. recheck the wiring going through the valve cover to insure it wasn't damaged during installation.
  2. Clear codes and start engine.
  3. If the misfire is still there, I would recheck the torque on the high pressure connector retainer nut.
  4. Clear codes and start engine.
  5. If the misfire is still there, I would pull #3 and #4 injectors.
    1. When pulling the injectors, compare the two as you pull them out.
  6. Reinstall, but swap injectors to see if the P0303 returns for the cylinder or P0304 comes up following the injector. Use new washers (shims).
  7. Clear codes and start engine.
  8. If P0304 shows up, you probably have a bad injector. If P0303 shows up, it may be your harness.
I don't have a shop either, not a mechanic by trade, worked on my '03 when needed. I had my injectors rebuilt by F1, now called FDI. I was very happy with them. Be careful with torque settings.

If I missed something, hopefully someone with more experience will chime in.
Back to morning brew . . .
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Old Feb 20, 2022 | 04:40 PM
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From: Fort Campbell Kentucky
Issue resolved unusual culprit

Originally Posted by Billy 5.9
It’s a long story but I’m just gonna give u the whole rundown
Bought the truck private party about 2 months ago it’s a 2006 dodge 2500 5.9 Cummins 24 valve common rail. Has 216k miles on it now, I replaced the turbo with an exact oem replacement holset turbo and new exhaust manifold. Truck ran great for a month and drove it to work and back one day but I whent to the store after work one day and it started missfiring and throwing some light white smoke, instantly turned around and stopped, ran #3 injector codes, ended up swapping #1 and #3 injectors due to a electrical lead breaking on the no 1 injector cylenoid. Also put a new electrical valve cover gasket on. But it still is misfiring and rough idle with white smoke to reiterate There hasn’t been any white smoke for a month of daily driving with the new turbo only just recently it started and the white smoke started instantly it didn’t progressively get worse. It came all at once with the rough idle and miss. I don’t know how to set valves but I’m fairly certain the rings are fine because I have no blowby and my compression test came out to 500psi on the #3

im looking for suggestions on what to look at next I don’t have a shop only a the basics and a few special tools. I’m going to swap out my FCA this week but I doubt that’s the main issue because I only have a miss on the #3

it does not get better will hot or driving

I gave in and took it to a reputable Engine shop around town and the tech there found my #3 cylender had a broken exhaust rocker and stuck the valve open or it was not sealing all the way, he replaced it and boom no more misfire and runs good as new, also a good idea to check your valve rocker spacing next time your under the valve cover. Intake is .10 and exhaust should be .20 if I remember correctly. Happy troubleshooting gents back to morning brew
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Old Feb 21, 2022 | 07:36 AM
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From: Old Norte Mexico
Originally Posted by Billy 5.9
I gave in and took it to a reputable Engine shop around town and the tech there found my #3 cylender had a broken exhaust rocker and stuck the valve open or it was not sealing all the way, he replaced it and boom no more misfire and runs good as new, also a good idea to check your valve rocker spacing next time your under the valve cover. Intake is .10 and exhaust should be .20 if I remember correctly. Happy troubleshooting gents back to morning brew
Glad it is fixed and thanks for the update.
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