RAM 3500 Truck 2WD L6-5.9L DSL Turbo VIN C (2003)
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.
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 0-ring on the body of the injector for cuts or damage. Inspect the injector bore for burrs or other cause
for a cut 0-ring. Correct the cause of the damaged 0-ring and replace the 0-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.
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.