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Engine Controls - Basic Diagnostic Procedures - Diesel: Other Dodge Pickup R2500

Testing & Diagnostics 6 illustrations ~1436 words

CHECKING ENGINE MECHANICAL SYSTEMS

At this point in diagnostic test procedure, all engine control systems have been determined to be operating as designed and not causing a driveability problem. Following additional items should be checked as possible causes

  1. Check for malfunctioning fuel injection pump or incorrect fuel injection pump timing.
  2. Check for air in fuel system.
  3. Check for restricted or damaged fuel injector nozzle.
  4. Check for improper fuel.
  5. Check for restricted fuel filter.
  6. Check for restricted fuel injection lines.
  7. Check for leaking or damaged fuel injection lines or loose connections.
  8. Check for empty fuel tank or restricted fuel tank vent.
  9. Check for restricted air filter.
  10. Check for restricted or leaking intercooler.
  11. Check for low or uneven engine compression.

NO CRANK CONDITION

Note. For starter relay wiring diagram, see appropriate STARTERS article in ELECTRICAL. After completing any repair, perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.

For testing procedures (Scheme 1047)- (Scheme 1049).

Scheme 1047

Scheme 1047: NO CRANK CONDITION
Scheme 1047: NO CRANK CONDITION

Scheme 1048

Scheme 1048
Scheme 1048

Scheme 1049

Scheme 1049
Scheme 1049

ENGINE DIFFICULT TO START OR WILL NOT START (EXHAUST SMOKE)

Note. After completing any repair, perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.

  1. Check for any Technical Service Bulletins (TSB) or ECM calibration updates that may apply.
  2. Check for low fuel level.
  3. Check for low battery voltage.
  4. Check for plugged fuel filter.
  5. Check for poor quality or improper grade of fuel.
  6. Check for fuel tank venting malfunction.
  7. Check for low fuel pressure. See «CHECKING FUEL DELIVERY»(ref-157961-S20712108232003090400000) under FUEL SYSTEMS.
  8. Check for air in fuel system.
  9. Check for lift pump malfunction.
  10. Check for fuel inlet restriction. See «FUEL LINES & FUEL INJECTORS»(ref-157961-S03640751762003090400000) under FUEL SYSTEMS.
  11. Check fuel injection pump static timing. See «FUEL INJECTION PUMP TIMING»(ref-157961-S16031303392003090400000) under FUEL SYSTEMS.
  12. Check for kinked or restricted fuel inlet line.
  13. Check for kinked or restricted fuel return line.
  14. Check for incorrect injectors.
  15. Check for incorrect injector shim thickness.
  16. Check for malfunctioning injectors.
  17. Check for leaking fuel connection.
  18. Check for Crankshaft Position (CKP) sensor or Camshaft Position (CMP) sensor and/or circuit malfunction.
  19. Check for moisture in harness and/or connectors.
  20. Check for internal engine damage. See «PRELIMINARY INSPECTION & ADJUSTMENTS»(ref-157961-S32265046682003090400000) .
  21. Check for restricted air intake.
  22. Check for restricted exhaust.
  23. Check for fuel inlet temperature being too high.
  24. Check overhead adjustments.
  25. Check for ignition switch output voltage being low and/or open. For R2500, see «POWER DISTRIBUTION»(ref-154277-S13749694872003051200000) in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. For R3500, see «POWER DISTRIBUTION»(ref-154278-S09053572152003051200000) in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.
  26. Check for malfunctioning engine block or fuel line heaters (cold weather condition). See «FUEL HEATER»(ref-157961-S07252103862003090400000) under FUEL SYSTEMS.
  27. Check for malfunctioning fuel pump overflow valve. See «OVERFLOW VALVE»(ref-157961-S20377432112003090400000) under FUEL SYSTEMS.
  28. Check engine cranking speed for being too slow. See appropriate STARTERS article in ELECTRICAL.
  29. Check for electrical interference (noise).

ENGINE DIFFICULT TO START OR WILL NOT START (NO EXHAUST SMOKE WHEN CRANKING)

Note. After completing any repair, perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.

  1. Check for any Technical Service Bulletins (TSB) or ECM calibration updates that may apply.
  2. Check for low fuel level.
  3. Check for low battery voltage.
  4. Check for plugged fuel filter.
  5. Check for poor quality or improper grade of fuel.
  6. Check for fuel tank venting malfunction.
  7. Check for low fuel pressure. See «CHECKING FUEL DELIVERY»(ref-157961-S20712108232003090400000) under FUEL SYSTEMS.
  8. Check for air in fuel system.
  9. Check for lift pump malfunction.
  10. Check for fuel inlet restriction.
  11. Check for fuel injection pump supply voltage being open or low. See «FUEL SYSTEMS»(ref-157962-S03641520732003090400000) in SYSTEM & COMPONENT TESTING - RAM PICKUP - DIESEL article.
  12. Check fuel injection pump static timing. See «FUEL INJECTION PUMP TIMING»(ref-157961-S16031303392003090400000) under FUEL SYSTEMS.
  13. Check for kinked or restricted fuel inlet line.
  14. Check for kinked or restricted fuel return line.
  15. Check for incorrect injectors.
  16. Check for incorrect injector shim thickness.
  17. Check for malfunctioning injectors.
  18. Check for leaking fuel connection.
  19. Check for Crankshaft Position (CKP) sensor or Camshaft Position (CMP) sensor and/or circuit malfunction.
  20. Check for moisture in harness and/or connectors.
  21. Check for internal engine damage. See «PRELIMINARY INSPECTION & ADJUSTMENTS»(ref-157961-S32265046682003090400000) .
  22. Check for Sentry Key Immobilizer Module (SKIM) malfunction. See appropriate ANTI-THEFT SYSTEMS article in ACCESSORIES & EQUIPMENT.
  23. Check battery voltage to ECM for being open or low. See «DIAGNOSTIC CIRCUIT CHECK»(ref-157446-S03440214342003081400000) in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.
  24. Check fuel inlet temperature for being too high.
  25. Check overhead adjustments.
  26. Check ignition switch output voltage for being low and/or open. For R2500, see «POWER DISTRIBUTION»(ref-154277-S13749694872003051200000) in SYSTEM WIRING DIAGRAMS article in ELECTRICAL. For R3500, see «POWER DISTRIBUTION»(ref-154278-S09053572152003051200000) in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

INTAKE MANIFOLD AIR HEATER SYSTEM

Intake manifold air heater is used to heat incoming air before entering each cylinder. Warming of incoming air aids in engine starting and improved driveability during cold ambient temperatures. Engine Control Module (ECM) uses input signals from various sensors for controlling intake manifold air heater relays. For testing of intake manifold air heater, see FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - RAM PICKUP - DIESEL article.

AIR IN FUEL SYSTEM

Note. Air in the fuel system may cause hard starting, rough running, excessive smoke, poor engine performance, engine misfire, poor fuel economy and fuel knock. Air may enter fuel system whenever fuel supply lines, fuel filter/water separator, fuel injection pump, fuel injectors or high-pressure fuel lines are removed or disconnected.

Inspect all low-pressure fuel lines from fuel tank to fuel transfer pump, fuel heater and fuel filter/water separator for signs of leakage. Inspect all high-pressure fuel lines for signs of leakage. See FUEL INJECTOR & HIGH-PRESSURE FUEL LINES .

CHECKING FUEL DELIVERY

Note. Due to very small vacuum specifications, use a scan tool and Peripheral Expansion Port (PEP) module with 0-15 psi transducer to perform following test. For circuit identification, see WIRING DIAGRAMS . After completing any repairs, perform POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.

For testing procedures (Scheme 1050)and (Scheme 1051).

Scheme 1050

Scheme 1050: CHECKING FUEL DELIVERY
Scheme 1050: CHECKING FUEL DELIVERY

Scheme 1051

Scheme 1051
Scheme 1051

Scheme 1052

Scheme 1052
Scheme 1052

FUEL FILTER/WATER SEPARATOR

Note. A blocked or restricted fuel filter/water separator may cause starting problems, prevent engine from accelerating, low power or White smoke. If an excessive amount of water collects in filter/separator in a short period of time, it may be necessary to drain and clean fuel tank. This procedure does not diagnose fuel filter/water separator, only operation and servicing procedures.

  1. When ignition switch is first turned to ON position, Water-In-Fuel (WIF) warning light should come on for 2 seconds to perform bulb and wiring circuit test and then go off. WIF warning light is located on instrument panel, just below the tachometer. If WIF light does not operate properly, perform appropriate WIF sensor related diagnostic test. See «DIAGNOSTIC TROUBLE CODE DEFINITIONS»(ref-157446-S28685869512003081400000) in SELF-DIAGNOSTICS - RAM PICKUP - DIESEL article.
  2. If WIF warning light stays on, water should be drained from fuel filter/water separator. To drain water from fuel filter/water separator, ensure engine is not running. Place drain pan below drain tube at fuel filter/water separator. see scheme 1
  3. Rotate handle on drain valve upward, to OPEN (DRAIN) position. Drain valve is located near top of fuel filter/water separator. see scheme 3 Drain water from fuel filter/water separator.
  4. Allow water to drain until clean flow of diesel fuel exists. Rotate handle on drain valve downward, to CLOSE position.

FUEL HEATER

Note. Fuel heater is located in fuel filter/water separator. see scheme 3 Fuel heater uses a fuel heater temperature sensor for controlling operation of the fuel heater. A defective fuel heater may cause excessive wax build-up in the fuel filter/water separator during cold ambient temperatures. Wax build-up may cause hard starting, prevent engine from accelerating, low power, Blue smoke or White smoke.

For testing of fuel heater, see FUEL HEATER under FUEL CONTROL under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - RAM PICKUP - DIESEL article.

FUEL HEATER RELAY

Ensure fuel heater relay, located in power distribution center is installed correctly and that terminals are not corroded. For fuel heater relay testing, see appropriate test under RELAYS & SOLENOIDS in SYSTEM & COMPONENT TESTING - RAM PICKUP - DIESEL article.

FUEL INJECTION PUMP TIMING

With the Bosch injection pump, there are no mechanical adjustments needed or necessary to accomplish fuel injection timing. All timing and fuel adjustments are electrically made by the engine mounted Engine Control Module (ECM).

OVERFLOW VALVE

See FUEL DELIVERY under FUEL SYSTEMS in SYSTEM & COMPONENT TESTING - RAM PICKUP - DIESEL article.

RAM PICKUP R2500

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

RAM PICKUP R3500

See ENGINE PERFORMANCE in SYSTEM WIRING DIAGRAMS article in ELECTRICAL.

More articles — Engine Controls - Basic Diagnostic Procedures - Diesel