Engine Controls - System & Component Testing - Diesel: Diagnosis Dodge Pickup R2500

INTAKE AIR SYSTEM PRESSURE TEST

For testing procedures (Scheme 1054)

Scheme 1054

Turbocharger Boost Pressure Test (Using Scan Tool)

1. Loosen clamps holding air inlet duct rubber sleeve to intake manifold and air inlet duct. (Scheme 1055) Remove air inlet duct rubber sleeve.
2. Position Boost Pressure Sleeve Tool (8462) onto air inlet duct and intake manifold using existing clamps. Tighten clamps.
3. Install Pressure Transducer from Pressure Transducer Kit (OT-CH8520)( into Boost Pressure Sleeve Tool.
4. Connect scan tool to Pressure Transducer following instructions supplied with scan tool.
5. Using scan tool, enter PRESSURE READING mode and test drive vehicle.
6. Turbocharger boost pressure should be 16-20 psi (110-138 kPa). If turbocharger boost pressure is less than 16 psi (110 kPa), check for turbocharger wastegate malfunction. See «TURBOCHARGER WASTEGATE»(ref-157962-S00117322372003090400000). Check for restricted air inlet system, leak in the charge air cooler system or turbocharger malfunction.

Scheme 1055

Brake Switch Test

1. Remove lower panel for access to brake switch. Brake switch is located on bracket, near top of brake pedal. Disconnect electrical connector from brake switch.
2. Ensure plunger on brake switch is in fully outward position. (Scheme 1056)Check for continuity between terminals No. 1 and 2 on brake switch. Continuity should exist. If continuity exists, go to next step. If continuity does not exist, replace brake switch.
3. Push plunger on brake switch fully inward. Check for continuity between terminals No. 3 and 4 on brake switch. Check for continuity between terminals No. 5 and 6. Continuity should exist. If continuity does not exist, replace brake switch.

Scheme 1056

Scheme 1057

Fuel Transfer Pump Preliminary Inspection

1. Check for restricted or leaking fuel supply line to fuel transfer pump or fuel return line located on driver's side of engine. Repair fuel supply line or fuel return line if restricted or leaking.
2. Check for fuel leaking from weep hole on housing of fuel transfer pump. Replace fuel transfer pump if fuel is leaking from weep hole. Check fuel transfer pump for output pressure, pressure drop, supply restriction, and air leaks. For diagnosing fuel transfer pump output pressure, pressure drop, supply restriction, and air leaks, see «BASIC DIAGNOSTIC PROCEDURES - RAM PICKUP - DIESEL»(ref-157961) article.

FUEL HEATER THERMOSTAT TEST

After the test procedure, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - PICKUP - DIESEL article. For testing procedures (Scheme 1058)

Scheme 1058

FUEL LIFT PUMP LOW & INLET RESTRICTION TEST

For testing procedures (Scheme 1059)

Scheme 1059

FUEL SYSTEM VACUUM TEST

After the test procedure, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - PICKUP - DIESEL article. For testing procedures (Scheme 1060)

Scheme 1060

HIGH PRESSURE FUEL PUMP PERFORMANCE TEST

After the test procedure, see POWERTRAIN VERIFICATION TEST VER-1 under VERIFICATION TESTS in SELF-DIAGNOSTICS - PICKUP - DIESEL article. For testing procedures (Scheme 1061)

Scheme 1061

INJECTOR RETURN FLOW TEST

For testing procedures (Scheme 1062)

Scheme 1062