adambray

This past February the cranking problems started so I took it to my mechanic and he tightened the High Pressure Connectors and the truck cranked w/i a few seconds of turning the key. In June the problem came back, but it seemed different this time. The truck would crank after holding the starter for 10 seconds, turning the key off, then turning the starter for another 5-10 seconds. It would only do this after sitting for over an hour. If the truck was running then turned off for about 30 minutes it would crank right up. My mechanic spent 10 hours researching and testing pressures, but couldn't find a problem and gave up. This past weekend I put a BD OEM lift pump replacement on the truck, cleaned the tank out and replaced the fuel filter. After the install the truck would crank right up every time, even after sitting over night. Yesterday I went to get in the truck and the long crank started again as described above, only this time it happens every time you crank the truck whether its 30 minutes after it has been running or all night. Any help would be greatly appreciated.

vzdude

This is a revised diagnostic procedure for hard starts ect. I would follow it to a T and see what you can find. It sounds like a cascade valve is leaking down or something. I'd even try a piece of clear line between your fuel pump and filter to see if there are any bubbles. All of these things are listed below though.


This bulletin is supplied as technical information only and is not an authorization for repair. No part of this publication may be reproduced, stored in a retrieval system,
or transmitted, in any form or by any means, electronic, mechanical, photocopying, or otherwise, without written permission of DaimlerChrysler Corporation.
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-003-06, DATED
MAY 5, 2006, WHICH SHOULD BE REMOVED FROM YOUR FILES. THIS IS A
COMPLETE REVISION AND NO ASTERISKS HAVE BEEN USED TO HIGHLIGHT
REVISIONS.
SUBJECT:
Cummins Diesel Diagnostics
OVERVIEW:
This bulletin provides diagnostic procedures for the fuel injection system.
MODELS:
2003 - 2007 (DR/DH/D1/DC) Ram Truck (2500 / 3500)
NOTE: This bulletin applies to vehicles equipped with a 5.9L Cummins 24-valve
diesel engine (sales code ETH or ETC).
SYMPTOM/CONDITION:
Revised diagnostic procedures are available for the following Symptom/Conditions:
· White smoke and/or misfire after starting when the engine temperature is below 66°
C (150° F).
· Engine surges at idle
· Engine sounds
· Engine cranks for a long time or will not start.
SPECIAL TOOLS / EQUIPMENT REQUIRED:
CH6000A Scan Tool (DRBIII®)
CH7000A J1962 Cable with red DRBIII® connector
CH9401 StarSCAN® Tool
CH9404 StarSCAN® Vehicle Cable
9007 Adapter, Compression Test
9011 Adapter, Fuel Pressure Test
9012 Fitting, Fuel System Test
9013 Adapter, Fuel Pressure Test
NUMBER: 14-003-06 REV. A
GROUP: Vehicle Performance
DATE: October 27, 2006
9014 Adapter, Fuel Pressure Test
9022 Adapter, Turbo Test
DIAGNOSIS:
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.
PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE:
1. Check TechCONNECT for any Service Bulletins related to the customer concern.
2. Verify that the ECM software is at the latest level.
3. Perform the existing “Pre-diagnostic Troubleshooting Procedures” available in
TechCONNECT under: Service Info tab > 9 - Engine > Diagnosis & Testing.
4. For the engine circuit diagram, refer to the detailed service information available in
TechCONNECT under: Service Info tab > 9 - Engine > Schematics and Diagrams.
5. For a complete wiring diagram, refer to the detailed wiring diagrams available in
TechCONNECT under: Service Info tab > Wiring > 14 - Fuel System > Fuel Injection >
(component).
NOTE: Refer to the appropriate section below (A, B, C, or D) to diagnose the
customer specific symptom / condition.
SECTION A - WHITE SMOKE AND/OR MISFIRE AFTER COLD START:
Possible Causes
Air in fuel supply
Coolant leaking into combustion chamber
Active Diagnostic Trouble Codes (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
High pressure fuel 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
14-003-06 REV. A -2-
Perform the Pre-Diagnostic Troubleshooting Procedure before proceeding.
1. Preliminary checks:
a. Repair active DTC's before proceeding.
b. 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.
2. 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 #14.
b. No >> Go to Step #3.
3. Temperature sensors: Using the appropriate scan tool, 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 #4.
b. No >> Repair the appropriate sensor or circuit as necessary. Refer to the diagnostic
procedures available in TechCONNECT under: Service Info tab > 9 - Engine >
Diagnosis & Testing. >> Go to Step #14.
4. Pressure sensors: Using the appropriate scan tool, 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 #5.
b. No >> Repair the appropriate sensor or circuit as necessary. Refer to the diagnostic
procedures available in TechCONNECT under: Service Info tab > 9 - Engine >
Diagnosis & Testing. >> Go to Step #14.
NOTE: The Inlet and Baro sensors will read in Inches of Mercury (Hg) while the
Intake and Boost sensors will read Pounds per Square Inch (PSI). The values
displayed on the scan tool will not be the same, 2 in. Hg = 1 PSI.
5. Fuel Rail Pressure sensor: Using the appropriate scan tool, 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 #6.
b. No >> Repair the fuel rail pressure sensor or circuit as necessary. Refer to the
diagnostic procedures available in TechCONNECT under: Service Info tab > 9 -
Engine > Diagnosis & Testing. >> Go to Step #14.
6. Intake Air Heater: Verify the intake air heater is operating properly. Refer to the
detailed service information available in TechCONNECT under: Service Info tab > 14 -
Fuel System > Fuel Injection > Intake Air Heater > Operation. Is the intake air heater
operating properly?
a. Yes >> Go to Step #7.
b. No >> Repair the intake air heater or intake air heater circuit as necessary. Refer to
the diagnostic procedures available in TechCONNECT under: Service Info tab > 9 -
Engine > Diagnosis & Testing. >> Go to Step #14.
-3- 14-003-06 REV. A
7. Start the engine: Start the engine following normal starting procedures and allow the
engine 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.
8. Test for injector misfire: Using the appropriate scan tool, 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 #9.
b. No >> Go to Step #10.
9. 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 Miller Special Tool 9007 (Compression Test Adapter) and perform a cylinder
compression test. Cylinder pressure should be 350 PSI minimum.
f. Install the injector. Refer to the detailed service information available in
TechCONNECT under: Service Info tab > 14 - Fuel System > Fuel Injection > Fuel
Injector > Installation.
g. Repeat test for injector misfire. >> Go to Step #8.
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.
10. 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 #14.
b. No >> Go to Step #11.
11. Test for high injector return flow: Perform the “Injector Return Flow Test”. Refer to
the detailed diagnostic information available in TechCONNECT under: Service Info tab
> 9 - Engine > Diagnosis & Testing. Do the injectors pass the “Injector Return Flow
Test”?
a. Yes >> Go to Step #13.
b. No >> Go to Step #12.
NOTE: Maximum leakage allowable for all injectors combined is 160 mL (5.4 fl. oz.):
taken when engine coolant temperature is greater than 82°C (180°F), engine
speed is equal to 1,200 RPM's, and fuel rail pressure is equal to 1400 bar
(20,305 psi.).
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 tab > 14 - Fuel System > Fuel Injection > Fuel Injector > Installation.
Retest when all HPC nuts are properly torqued.
14-003-06 REV. A -4-
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.
12. If the injector return from any cylinder(s) is deemed excessive:
a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Go to Step #14.
b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Verify that a quality fuel
filter is used. >> Go to Step #14.
13. 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 tab > 9 - Engine > Diagnosis & Testing >
Smoke Diagnosis Charts > Excessive White Smoke. >> Go to Step #14.
14. Repair Complete: Perform Powertrain Verification Test VER - 1 (Diesel). Refer to the
detailed service information available in TechCONNECT under: Service Info tab > 8 -
Electrical/Electronic Control Modules/Engine Control Module > Diagnosis And Testing.

vzdude

Next Third! Dang large TSB's!

SECTION B - ENGINE SURGES AT IDLE:
Possible Causes
Fuel Supply (Low Pressure) System
Fuel Injection (High Pressure) System
Fuel Return
Air Intake System
Other Vehicle Systems
Base Engine
Perform the Pre-Diagnostic Troubleshooting procedure before proceeding.
1. 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 #15.
b. No >> Go to Step #2.
-5- 14-003-06 REV. A
2. Verify complaint: Verify proper fuel quality, grade, and level in the fuel tank. Operate
the engine at idle speed. Using the appropriate scan tool, log the fuel pressure set
point and actual fuel pressure. A good system will have actual fuel pressure that is +/-
500 PSI from the set pressure. (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
actual fuel rail pressure fluctuate more than +/- 500 PSI?
a. Yes >> Go to Step #3.
b. No >> Go to Step #8.
NOTE: A loud “knock” and black smoke that exists with an actual fuel pressure drop
may be an injector issue and should be identified using the single cylinder
cut out test.
3. Verify proper low pressure fuel supply to the injection pump: Perform the
appropriate fuel supply system flow test. NOTE: This procedure may be slightly
different depending on if the vehicle has an engine mounted transfer pump or
the in-tank transfer pump. In a good low pressure fuel system, fuel flow of 560 mL in
10 seconds or better is expected for model years 2003 and early 2004. The fuel
volume for the model years late 2004 through 2007 is 590mL in 10 seconds. 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 TechCONNECT under: Service Info tab > 9 - Engine >
Diagnosis & Testing > Fuel Lift Pump - Diesel. >> Go to Step #15.
4. Test for high injector return flow: Refer to the detailed diagnostic information
available in TechCONNECT under: Service Info tab > 9 - Engine > Diagnosis and
Testing > Injector Return Flow Test. Do the injectors pass the “Injector Return
Flow Test”?
a. Yes >> go to Step #6.
b. No >> go to Step #5.
5. If the injector return from any cylinder(s) is deemed excessive:
a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Go to Step #15.
b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Verify that a quality fuel
filter is used. >> Go to Step #15.
6. Verify high pressure pump output volume: Remove the high pressure fuel line from
the high pressure pump outlet port to the fuel rail. Connect a suitable hose to the high
pressure outlet port of the high pressure pump and route it to a graduated container.
Disconnect the Electronic Fuel Control Actuator. Crank the engine until fuel exits the
hose. NOTE: 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. High pressure pump output volume must be greater
than 70 mL in 30 seconds. Is the high pressure pump output flow sufficient?
a. Yes >> go to Step #7.
b. No >> Replace the high pressure pump. Refer to the detailed service information
available in TechCONNECT under: Service Info tab > 14 - Fuel System > Fuel
Injection > Fuel Injection Pump. >> Go to Step #15.
14-003-06 REV. A -6-
7. Electronic Fuel Control Actuator (FCA): Replace the Electronic Fuel Control
Actuator. Refer to the detailed service information available in TechCONNECT under:
Service Info tab > 14 - Fuel System > Fuel Injection > Fuel Injection Pump. >> Go to
Step #15.
8. Verify High Pressure System Is Functioning Normally: Using the appropriate scan
tool watch the fuel rail pressure set point. Does the fuel rail pressure set point
fluctuate at idle?
a. Yes >> Check the vehicle for signs of parasitic load causing the ECM to adjust fuel
pressure set point.
b. b. No >> Go to Step #9.
9. Idle speed fluctuation: Using the appropriate scan tool watch idle speed. Compare
the idle speed shown on the scan tool to the reading on the tachometer. Does the idle
speed on the scan tool fluctuate more than 20 RPM while the engine is at idle?
a. Yes >> Go to Step #10.
b. No >> Investigate fuel quality. Look for evidence of fuel contamination. Investigate
for aftermarket performance devices.
10. Verify proper low pressure fuel supply to the high pressure pump: Perform the
appropriate fuel supply system flow test. NOTE: This procedure can be slightly
different depending on if the vehicle has an engine-mounted transfer pump or
the in-tank transfer pump. In a good low pressure fuel system, fuel flow of 560 mL in
10 seconds or better is expected for model year 2003 and early 2004 vehicles. In a
good low pressure fuel system, fuel flow of 590 mL in 10 seconds or better is expected
for late model year 2004 through 2007 vehicles. Be sure there is no air in the system.
Is the low pressure fuel supply volume sufficient?
a. Yes >> Go to Step #11.
b. No >> Repair the low pressure fuel supply system as necessary. Vehicles
equipped with an in tank fuel pump: Refer to the detailed diagnostic information
available in TechCONNECT under: Service Info tab > 9 - Engine > Diagnosis &
Testing > In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure . Vehicles
equipped with an engine mounted fuel transfer pump: Refer to the detailed
diagnostic information available in TechCONNECT under: Service Info tab >
Diagnostics tab, Powertrain Gas, Driveability Diesel, Fuel Lift Pump Flow And Inlet
Restriction Test >> Go to Step #15.
11. Fuel Return: Check for kinked or restricted fuel return lines. Check the fuel tank
venting. Does a fuel return system restrictions exist?
a. Yes >> Repair as necessary. Go to Step #15.
b. No >> go to Step #12.
12. Intake / Exhaust Systems: Check for inlet restriction, inspect air filter for excessive
dirt/debris. Verify air intake tubes and hoses are not kinked or restricted. Check for
charge air cooler air system leaks. Perform “INTAKE AIR SYSTEM PRESSURE TEST
- DIESEL”. Refer to the detailed service information available in TechCONNECT
under: Service Info tab > 11 - Exhaust System > Turbocharger System > Turbocharger
> Inspection. Inspect Turbocharger for excessive compressor wheel movement and
proper waste gate operation. Check for exhaust restriction. Check for kinked or
blocked exhaust pipes. Verify proper exhaust brake operation (if equipped). Were any
issues found with the Intake/Exhaust Systems?
a. Yes >> Repair as necessary - Go to Step #15.
b. No >> Go to Step #13.
13. Other Vehicle Systems: Verify proper operation of the Transmission Clutch. Verify
proper operation of the Transmission. Verify proper operation of the Vehicle brakes
(check for dragging). Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories. Were any issues found
with the Vehicle System?
-7- 14-003-06 REV. A
a. Yes >> Repair as necessary. Go to Step #15.
b. No >> Go to Step #14.
14. Base Engine: Check for internal engine damage. Valve lash settings, engine
compression, cylinder leak down, etc. Were any issues found with the Base
Engine?
a. Yes >> Repair as necessary. Go to Step #15.
b. No >> Go to Step #15.
15. Repair Complete: Perform Powertrain Verification Test VER - 1 (Diesel). Refer to the
detailed service information available in TechCONNECT under: Service Info tab > 8 -
Electrical/Electronic Control Modules/Engine Control Module > Diagnosis And Testing.
SECTION C - ENGINE NOISE:
Perform the Pre-Diagnostic Troubleshooting Procedure before proceeding.
When standing in front of the vehicle 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.
1. 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.
2. 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.
3. Injector Noise Evaluation
a. Normal: Combustion noise may vary at different operating conditions. Maybe 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 (Special Tool #9011) should be used to identify
failed injectors.
4. 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 any damage to rocker levers, push rods, or cross heads.
5. Refer to the detailed diagnostic information available in TechCONNECT under:
Service Info tab > 9 - Engine > Diagnosis & Testing > Engine Diagnosis - Mechanical.
SECTION D - ENGINE WILL NOT START / HARD TO START:
Possible Causes
Battery voltage
Starting Accessories
Fuel Supply (Low Pressure) System
Fuel Injection (High Pressure) System
Fuel Return
Air Intake System
Other Vehicle Systems
Base Engine
14-003-06 REV. A -8-
Perform the Pre-Diagnostic Troubleshooting Procedure before proceeding.
1. 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 #17.
b. No >> Go to Step #2.
2. Verify Battery Voltage: Measure the battery voltage and load capability. Is the
battery voltage sufficient?
a. Yes >> Go to Step #3.
b. No >> Repair low battery voltage condition. Go to Step #17.
3. Verify Starting Accessories: Verify the ignition switch, vehicle theft system, starter,
intake manifold grid heater, and fuel heater are functioning properly. Are all starting
accessories functioning properly?
a. Yes >> Go to Step #4.
b. No >> Repair or replace accessories as necessary >> Go to Step #17.
4- 1 (Diesel).

vzdude

This is it! The end of the TSB!


Check the supply fuel in the vehicle: Verify fuel level in the fuel tank. Also verify fuel
quality. Remove, inspect and replace the fuel filter (if necessary). Investigate for
evidence of fuel contamination and improper fuel type. Refer to the vehicle owners
manual fuel requirements section. Is the fuel quality within specification?
a. Yes >> Go to Step #5.
b. No >> Follow fuel contamination process (drain contaminated fuel, replace
damaged components, fill with proper fuel). >> Go to Step #17.
5. Verify complaint: Using the appropriate scan tool log the fuel pressure set point and
actual fuel pressure. Verify the rail pressure versus set point, this can be done while
cranking or with the engine idling. A good system will have actual fuel pressure that is
+/- 500 PSI from the set pressure. (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). Does the actual fuel rail pressure meet the set fuel pressure +/- 500
PSI?
a. Yes >> Go to Step #6.
b. No >> Go to Step #9.
6. Check the engine oil level: Check the engine oil level. Is the engine oil level over
filled?
a. Yes >> Go to Step #7.
b. No >> Go to Step #8.
7. Remove the engine valve cover: Inspect for injectors leaking fuel into the valve train
area while cranking the engine. If the engine will start and idle, actuate the Fuel
Pressure Override Test on the appropriate scan tool NOTE: This feature is not
available on 2003 MY vehicles. Use the fuel manifold blocking tool, Miller special tool
#9011, to isolate suspected leaking injectors. If the leak is still present with the
suspected injector isolated, remove the injector and inspect the O-ring on the body of
the injector for cuts or damage. Inspect the injector bore for burrs or other cause for a
cut O-ring. Correct the cause of the damaged O-ring and replace the O-ring. Use
copper sealing gasket when reinstalling the injector. Refer to the detailed removal and
installation procedures available in TechCONNECT under: Service Info tab > 14 - Fuel
System > Fuel Injection > Fuel Injector. Are there any leaking injectors?
a. Yes >> Replace the leaky injector(s). Refer to the detailed removal and installation
procedures available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector. >> Go to Step #17.
b. No >> Determine the source of fuel/coolant/other substance in the crankcase
causing the system to be over full. Repair as necessary. >> Go to Step #17.
-9- 14-003-06 REV. A
8. Check the fuel pressure limiting valve: 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 tab > 9 - Engine >
Diagnosis and Testing. No leakage is expected while cranking or while at idle speed.
Does the pressure limiting valve leak internally?
a. Yes >> Replace the fuel pressure limiting valve. - Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Delivery > Fuel Pressure Regulator. >> Go to Step #17.
b. No >> Go to Step #9.
9. Test for high injector return flow: Refer to the detailed diagnostic information
available in TechCONNECT under: Service Info tab > 9 - Engine, Diagnosis and
Testing > Injector Return Flow Test. Do the injectors pass the “Injector Return
Flow Test”?
a. Yes >> Go to Step #11.
b. No >> Go to Step #10.
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 tab > 14 - Fuel System > Fuel Injection > Fuel Injector.
NOTE: Test should be repeated to confirm measurements.
10. If the injector return from any cylinder(s) is deemed excessive:
a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Go to Step #17.
b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed service
information available in TechCONNECT under: Service Info tab > 14 - Fuel System
> Fuel Injection > Fuel Injector > Removal/Installation. >> Verify that a quality fuel
filter is used. >> Go to Step #17.
11. Verify proper low pressure fuel supply to the high pressure pump: Perform the
appropriate fuel supply system flow test. NOTE: This procedure can be slightly
different depending on if the vehicle has an engine-mounted transfer pump or
the in-tank transfer pump. In a good low pressure fuel system, fuel flow of 560 mL in
10 seconds or better is expected for model year 2003 and early 2004 vehicles. In a
good low pressure fuel system, fuel flow of 590 mL in 10 seconds or better is expected
for model year late 2004 through 2007 vehicles. Be sure there is no air in the system.
Is the low pressure fuel supply volume sufficient?
a. Yes >> Go to Step #12.
b. No >> Repair the low pressure fuel supply system. Vehicles equipped with an in
tank fuel pump: Refer to the detailed diagnostic information available in
TechCONNECT under: Service Info tab > 9 - Engine > Diagnosis & Testing >
In-Tank Fuel Lift Pump Flow/Diagnostic Test Procedure. Vehicles equipped with
an engine mounted fuel transfer pump: Refer to the detailed diagnostic
information available in TechCONNECT under: Service Info tab > Diagnostics tab,
Powertrain Gas, Driveability Diesel, Fuel Lift Pump Flow And Inlet Restriction Test
>> Go to Step #17.
14-003-06 REV. A -10-
12. Verify high pressure pump output volume: Remove the high pressure fuel line from
the high pressure pump outlet port to the fuel rail. Connect a suitable hose to the high
pressure outlet port of the high pressure pump and route it to a graduated container.
Disconnect the Electronic Fuel Control Actuator. Crank the engine until fuel exits the
hose. NOTE: 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. High pressure pump output volume must be greater
than 70 mL in 30 seconds. Is the high pressure pump output flow sufficient?
a. Yes >> Go to Step #13.
b. No >> Replace the high pressure pump. Refer to the detailed service information
available in TechCONNECT under: Service Info tab > 14 - Fuel System > Fuel
Injection > Fuel Injection Pump. >> Go to Step #17.
13. Fuel Return: Check for kinked or restricted fuel return lines. Check the fuel tank
venting. Where any problems found in the Fuel Return system?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #14.
14. Intake/Exhaust Systems: Check for inlet restriction, inspect air filter for excessive
dirt/debris. Verify air intake tubes and hoses are not kinked or restricted. Check for
charge air cooler air system leaks. Perform the “INTAKE AIR SYSTEM PRESSURE
TEST - DIESEL”. Refer to the detailed service information available in TechCONNECT
under: Service Info tab > 11 - Exhaust System > Turbocharger System > Turbocharger
> Inspection. Inspect the Turbocharger for excessive compressor wheel movement
and proper waste gate operation. Check for exhaust restriction. Check for kinked or
blocked exhaust pipes. Verify proper exhaust brake operation (if equipped). Were any
issues found with the Intake/Exhaust Systems?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #15.
15. Other Vehicle Systems: Verify proper operation of the Transmission Clutch. Verify
proper operation of the Transmission. Verify proper operation of the Vehicle brakes
(check for dragging). Verify proper operation of the Cooling fan operation cycle time.
Verify proper operation of the Engine driven accessories. Were any issues found
with the Other Vehicle Systems?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #16.
16. Base Engine: Check for internal engine damage. Valve lash settings, engine
compression, cylinder leak down, etc. Were any issues found with the Base
Engine?
a. Yes >> Repair as necessary. >> Go to Step #17.
b. No >> Go to Step #17.
17. Repair Complete: Perform Powertrain Verification Test VER