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