I have a 2003 Ram 3500 5.9 that just had an engine install but having an issue running need help! It is a 4x4 automatic with a 47re transmission. The engine was originally a 305 block with a Bullydog. The engine I had installed is a 325 with coated pistons and 12 valve rods for strength. I put a new Industrial Injection Turbo on it new TDM 80HP injectors with Bosch OEM connecting tubes. I hooked up the bully dog to make sure it is in stock mode only. The truck starts right up but has black smoke at idle and dies after about 3 minutes. If I hold the throttle above 1500RPM it will stay running. In the video it looks like white smoke but its black. I have also attached a video of a data stream from my Actron OBDII just in case that helps. The current codes are (6: Driver Squib Open/ this code was there before the engine install) (25: Left Front Circuit Malfunction) (21: Right Front Circuit Malfunction) (84: Mismatched Vehicle Identification Number) (P0107: Manifold Absolute Pressure Sensor Voltage Low) This is the only one that I think is related to the issue. Things that have been done to test. 1. New lift pump with sump installed and does not lose low fuel pressure. 2. FCA swapped out. 3. Rail pressure sensor swapped out 4. Map sensor swapped out.(the one on the manifold not the IAT sensor on the intake tube by the air filter) 5. Injectors and connector tubes removed and re-torqued according to the ft lb's in service manual.

Will put the links to the videos on as soon as the website will let me. it is on Youtube if you search
2003 Ram 3500 5.9 cummins stalling diagnoses issue HELP

 

Lots of different parts mentioned in your post...

Which ECM are you using? The 2003 305HP ECM originally in your 2003 truck is very different than the 2004.5+ 325Hp ECM.

Which style pistons and injector nozzles are you using?
The 2003 305HP pistons and injector nozzles are different than the 2004.5+ 325Hp pistons and injector nozzles.

The pistons, injector nozzles and the ECM program have to be compatible.

What are your low side and high side fuel pressure readings with the engine running? If your don't already have these 2 gauges, plus several others, you are going to need them.


If your truck originally had was a 2003 with a 305HP HO Cummins, I'm sure it should have had the 48RE auto trans not the 47RE you mentioned.
This is not really a factor but I will mention it.

 

I posted this exact post on three other forums and Youtube have got no good replies so far maybe you can help.

I have read too much misinformation on what deciphers as an HO vs SO engine. I used to think the 305 was the SO and 325 was the HO, but have come to the conclusion that I had the SO 250hp. I was told the 48RE wasn't available in 2003 the HO would have only came with a Manual transmission so I'm pretty sure I had an SO just wasn't sure on the HP (250,305,325) till now. But definitely has the 47RE but it has been completely rebuilt and upgraded.

The engine I got was a brand new long block 325 and ONLY long block no sensors, no turbo, no electronics just the block and head. Everything from my truck was transferred to the new block and head including electronics and harness. EXCEPT turbo, injectors, and connecting tubes. I bought an industrial injection turbo specifically for a 2003 and injectors for a 04.5-07 to match the piston bowls in the 325 block.

When I started this engine replacement I got a CTS2 Edge with EGT, and Trans Temp sensor. I was told I can read rail pressure through the ECU via the Edge and plan to order the low pressure sensor also. But for now I have a Fuel system test kit coming that will let me read low pressure but the guy I Had install the engine did test the low pressure and said it was good he had to install a new Titanium Fass system with sump so it's definitely good. Rail pressure I haven't been able to test but Assume as of now it is alright considering the truck starts up almost right away.

 

So you are using the 2003 SO ECM with 2004.5 pistons and 2004.5 80HP injector nozzles with a larger turbo.
This is quite the mismatch.

The program in the 2003 ECM is not correct for the 2004.5 pistons and injectors.
Specifically the injector timing. Plus your aftermarket upgrades.

I do not recommend loading your Bully Dog programmer on your ECM or any other 2003 programmer.
Aftermarket programmers will be completely incorrect for your current engine combination.

What you really need is a custom ECM program for your 2004.5 pistons and injector nozzles plus your larger turbo and 80HP injectors.
Either HP Tuners or Smarty UDC Pro.

And you need to accurately monitor low side and high side fuel pressures.


Don't get hung up on the SO and HO terminology. Those are marketing terms that can change year to year.