RAM 3500 Truck 2WD L6-5.9L DSL Turbo VIN C (2003)
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.
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.).
