Driveability - Non-Dtc Based Diagnostics - Diesel: Diagnosis RAM Pickup 2500

PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE - 6.7L

For a complete wiring diagram, refer to appropriate SYSTEM WIRING DIAGRAMS article .

Diagnostic Test

1. NO RESPONSE Make sure the scan tool will communicate with the appropriate modules. Are you currently experiencing a NO RESPONSE condition? Yes The NO RESPONSE condition must be properly diagnosed before continuing. Perform the appropriate BUS Communication test . Refer to «COMMUNICATION - NON-DTC BASED DIAGNOSTICS - 3500 CAB & CHASSIS, 4500 & 5500 - DIAGNOSIS AND TESTING»(ref-457935) . No Go To 2 .
2. DTC PRESENT NOTE: Before continuing, complete the 6.7L Cummins Turbo Diesel Diagnostic Worksheet. Go to the TechConnect > submit the vehicle's VIN number > Search Tab > and Select Create Diagnostic Worksheet. Turn the ignition on. With the scan tool, view PCM for DTCs. Is there a DTC present? Yes Proceed to the MIL LIGHT ON PRETEST PROCEDURE. Refer to «MIL LIGHT ON PRETEST PROCEDURE»(ref-457925-S13962343332012030200000) . No Go To 3 .
3. CHECK FOR SYMPTOM BASED ISSUES Check the vehicle for one of the following conditions: Engine No Start / Hard Start Engine Misfires / Runs Rough / Poor Performance Engine Noise Excessive Smoke (Black/Blue/White) Do one of the following conditions exist? Yes Perform the appropriate symptom based diagnostic procedures below. No Verify the vehicles performance by performing the Diesel Fuel System Validation procedure. Refer to «DIESEL AFTERTREATMENT VALIDATION- 6.7L»(ref-457919-S26763156982012030200000) .

Scheme 114

Scheme 115

1. RELATED TSBs NOTE: If there are DTCs present in the PCM, TCM, or ABS Modules, repair the DTCs before proceeding. Check for any TSBs or, PCM or CCN software updates that may relate to customer's complaint. Follow the appropriate diagnostic procedure in the TSB. Is vehicle repaired? Yes Repair complete. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 2 .
2. VISUAL INSPECTION Perform an inspection of the following: Verify there are no external fuel or coolant leaks. Verify the oil level. An excessively high or low oil level may cause a performance issue. Visually inspect the air filter for a restriction. Verify that the battery voltage is between 12.5 and 14.0 Volts when running. Verify that there are no Non-OEM engine modifications installed on the vehicle. Verify proper fuel level. Listen for any obvious intake or exhaust leaks. Were any of the above conditions found? Yes Repair as necessary and verify repair. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 3 .
3. CHECKING THE AIR FILTER Visually inspect the Air Filter for modifications, or excessive dirt or debris causing a restriction. Were any issues found? Yes Replace the Air Filter. Go To 4 . No Go To 4 .
4. CHECKING FUEL QUALITY/CONTAMINATION Check the quality of the fuel using the DIESEL FUEL CONTAMINATION TEST PROCEDURE. Refer to «DIESEL FUEL CONTAMINATION TESTING PROCEDURE»(ref-457834-S16021765672012030200000) . Was any contamination detected? Yes Perform the appropriate repair according to the testing and cleaning procedure. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 5 .
5. CHECKING CYLINDER CONTRIBUTION Using the scan tool, navigate to Miscellaneous Functions and perform the Injector Kill test procedure. Do the results indicate that a cylinder is low? Yes Go To 6 . No Go To 11 .
6. INJECTOR RETURN FLOW TEST Perform the INJECTOR RETURN FLOW TEST diagnostic procedure. Refer to «INJECTOR RETURN FLOW TEST»(ref-457849-S39570439482012030200000) . Did the INJECTOR RETURN FLOW TEST pass? Yes Go To 7 . No Repair as necessary and verify repair. Inspect and clean any soot fouling in the Air Handling and Exhaust systems as needed. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
7. CHECKING FUEL INJECTOR AND VALVE COVER HARNESS TERMINALS Turn the ignition off. Visually check the valve cover connectors and Fuel Injector terminals for loose connections or damaged threads. Check the torque of the Fuel injector nuts. NOTE: The Fuel injector nuts should be torqued to 8.8 in/lbs. Are the Fuel injector nuts torqued correctly and the connections and terminals good? Yes Go To 8 . No Repair the connections as necessary. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
8. CHECKING VALVE LASH Check the valve lash adjustment on the suspect cylinder or cylinders. Is the valve lash within specification? Yes Go To 9 . No Adjust the valve lash to specifications. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
9. COMPRESSION CHECK Perform a manual compression check of the cylinder. Refer to «CYLINDER COMPRESSION/LEAKAGE TESTS»(ref-457798-S06017113402012030200000) . Is the compression within specification? Yes Go To 10 . No Perform a cylinder leak down test to determine if the low compression is caused a by piston or cylinder head/valve condition and repair as necessary. Inspect and clean any soot fouling in the Air Handling and Exhaust systems as needed. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
10. FUEL INJECTORS Change the Fuel Injector with a Fuel Injector from another good cylinder. With the scan tool, perform the Cylinder Cut-Out test. Did the performance issue follow the Fuel Injector? Yes Replace the Fuel Injector and check for fuel contamination. If fuel is found to be contaminated determine the point of entry of the contamination and repair. Inspect and clean any soot fouling in the Air Handling and Exhaust systems as needed. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 15 .
11. CHECK THE FUEL DELIVERY SYSTEM Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. Refer to «CHECKING THE FUEL DELIVERY SYSTEM»(ref-457849-S04686286802012030200000) . Were any fuel system issues found? Yes Repair the Fuel Delivery System. Inspect and clean any soot fouling in the Air Handling and Exhaust systems as needed. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 12 .
12. CHECK THE ENGINE PRESSURE SENSORS NOTE: Perform steps 5, 6, and 7 of the 6.7L Cummins Diagnostic Worksheet. Star Center must be contacted before worksheet steps 5, 6, and 7 can be completed. Turn the engine off, ignition on. With the scan tool, compare the Barometric Sensor reading and the Exhaust Pressure Sensor reading. Are the two readings equal? Yes Go To 13 . No Compare the two readings to the Inlet Air Pressure Sensor reading. Replace the sensor that does not match the Inlet Air Pressure Sensor. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
13. CHECKING MASS AIR FLOW SENSOR OPERATION Turn the ignition on, engine not running. With the scan tool, read the MAF Sensor value: The MAF Sensor shoulf be reading close to 0.01lb/min. Start the engine, allow it to reach operating temperature and then idle for five minutes. NOTE: This is how long it takes for the EGR Valve to close. With the scan tool in Data Display, verify that the EGR Valve is at 0%. With the scan tool, read the MAF Sensor value: For an automatic transmission the MAF Sensor should read 3.0 - 6.75 lb/min at idle. For a manual transmission the MAF Sensor should read 3.5 - 7.5 lb/min at idle. Is the MAF Sensor reading within specification? Yes Go To 14 . No Replace the MAF Sensor in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
14. CHECK CRANKCASE FILTER Verify proper Crankcase Filter operation. Were any problems found? Yes Repair as necessary. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 15 .
15. CHECKING THE INTAKE SYSTEM Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted. Perform the CHECKING THE INTAKE AIR SYSTEM PRESSURE diagnostic procedure. Refer to «INTAKE AIR SYSTEM PRESSURE TEST»(ref-457849-S41730497842012030200000) . Inspect Turbocharger for wheel clearance and proper wastegate operation. Were any problems found? Yes Repair as necessary. Inspect and clean any soot fouling in the Air Handling and Exhaust systems as needed. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 16 .
16. CHECKING THE EGR SYSTEM Perform the following EGR system checks: Look for visible signs (soot streaks) of an external EGR system leak. Remove the EGR Outlet Temperature Sensor from the thermostat outlet. Check the outlet for blockage or debris. Remove EGR Crossover Tube from EGR Cooler and EGR Valve. Inspect the tube for a restriction. Verify EGR Cooler is not leaking. Check for coolant in EGR plumbing, engine overheat fault codes, and low coolant level. Check the Air Intake Grid Heater for excessive soot build up or restriction. Were any problems found? Yes If the soot inside the EGR Crossover Tube is oily, inspect the Turbocharger for leaking oil into the intake system. If Turbo is leaking, replace the Turbo. If Turbo is not leaking, clean the Crossover Tube, remove and clean the EGR Valve and EGR Cooler. Go To 17 . No Go To 17 .
17. CHECK THE EXHAUST AFTERTREATMENT SYSTEM FOR A RESTRICTION Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . Were any problems found during the inspection? Yes Perform the appropriate repair. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Perform the DIESEL FUEL VALIDATION procedure. Refer to «DIESEL AFTERTREATMENT VALIDATION- 6.7L»(ref-457919-S26763156982012030200000) . If the vehicles passes the validation, the vehicle is operating properly. If the vehicle fails the validation, the issue was missed during diagnostics. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .

Scheme 116

1. VISUALLY CHECK THE FUEL DELIVERY SYSTEM FOR LEAKS AND DAMAGE NOTE: Make sure that both Batteries are fully charged before proceeding. A weak battery can cause inaccurate fuel volume readings. Turn the ignition off. Visually inspect the Fuel Delivery System for external leaks and damage. Visually inspect the Fuel tank vents and hoses for any signs of a possible restriction or plugging. Is the system leaking, plugged, or damaged? Yes Repair/replace as necessary. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 2 .
2. CHECKING FUEL QUALITY/CONTAMINATION Check the quality of the fuel using the DIESEL FUEL CONTAMINATION TEST PROCEDURE. Refer to «DIESEL FUEL CONTAMINATION TESTING PROCEDURE»(ref-457834-S16021765672012030200000) . Were any signs of contamination detected? Yes Perform the appropriate repair according to the testing and cleaning procedure. Go To 3 . No Go To 3 .
3. IN-TANK FUEL LIFT PUMP FLOW TEST WITH DECAY TESTER NOTE: Before performing the IN-TANK FUEL LIFT PUMP FLOW test, verify that the fuel level in the fuel tank is above 1/4 full. If fuel tank is not above 1/4 full the pump will take in air causing the test results to be inaccurate. Disconnect the low pressure fuel supply line from the High Pressure Fuel Pump. Connect the (special tool #8978A, Decay Tool, Fuel) to the low pressure fuel supply line. WARNING: To reduce the risk of fire and serious possible serious or fatal injury, place the Reservoir Assembly 534960 (3) on the floor and out of the way so that it is not a trip hazard. Perform the following to purge air from the system: With the scan tool, actuate the In-Tank Fuel Lift Pump Module. Open the Flow Test Valve and allow the fuel to flow into the Reservoir for 10 seconds, then close the Flow Test Valve. Turn the ignition off. Disconnect, empty, and then reconnect the Reservoir Assembly. Perform the following three times to find the average flow rate: With the scan tool, actuate the In-Tank Fuel Lift Pump Module. Open the Flow Test Valve (1) for 10 seconds, then close the Valve. Turn the ignition off. Measure and record the amount of fuel in the Reservoir Assembly. Disconnect, empty, and then reconnect the Reservoir Assembly. Add the three recorded measurements and then divide the total by three to calculate the average flow rate. The flow rate is 500 ml in 10 seconds. Does the average flow rate meet or exceed the specification? Yes - Vehicle starts and runs: Go To 5 . Yes - Vehicle is a no start: Go To 10 . No Leave the Fuel Decay Tester installed. Replace the Fuel Filter/Water Separator in accordance with the service information. During Fuel Filter replacement, be sure to check and clean the secondary filter screen in the filter head outlet. Go To 4 .
4. RECHECK IN-TANK FUEL LIFT PUMP FLOW Perform the following to purge air from the system: With the scan tool, actuate the In-Tank Fuel Lift Pump Module. Open the Flow Test Valve (1) for 10 seconds, then close the Valve. Turn the ignition off. Disconnect, empty, and then reconnect the Reservoir Assembly (2). Perform the following three times to find the average flow rate: With the scan tool, actuate the In-Tank Fuel Lift Pump Module. Open the Flow Test Valve (1) for 10 seconds, then close the valve. Turn the ignition off. Measure and record the amount of fuel in the Reservoir Assembly (2). Disconnect, empty, and then reconnect the Reservoir Assembly (2). Add the three recorded measurements and then divide the total by three to calculate the average flow rate. The flow rate is 500 ml in 10 seconds. Does the average flow rate meet or exceed the specification? Yes Repair complete. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Use the wiring diagram as a guide to check the In-Tank Fuel Lift Pump wiring for an open, high resistance, or short to ground. If the In-Tank Fuel Lift Pump wiring is okay, remove the fuel tank and replace the In-Tank Fuel Lift Pump Module in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
5. PRESSURE LIMITING VALVE NOTE: In the illustration provided, the pressure-limiting valve location is indicated by the number (1). Reconnect the fuel supply hose. Remove the banjo bolt from the Pressure Limiting Valve on the fuel rail. Install the (special tool #9012, Fitting, Fuel System Test)into the Pressure Limiting Valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container. NOTE: NOTE: Do not drive the vehicle with any portion of this test kit installed. Start the engine and operate the engine at idle. Watch for fuel flow into the fuel container. NOTE: There should be no fuel flow into the container. While the engine is at idle, actuate the Fuel Pressure Override Test with the scan tool. Watch for fuel flow into the fuel container. NOTE: You may observe a few dribbles of fuel from Pressure Limiting Valve during Fuel Pressure Override Test. One drop per second or 8 ml in 30 seconds is considered normal. Do not replace this valve unless you can see continuous leak. Is fuel flowing into the container? Yes Replace the Pressure Limiting Valve in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 6 .
6. ENGINE RUNNING INJECTOR RETURN FLOW TEST NOTE: The purpose of this test is to determine if the Fuel Injectors are leaking internally into the fuel return. Turn the engine off. Remove the (special tool #9012, Fitting, Fuel System Test) from the Pressure Limiting Valve. Operate the engine until the coolant temperature is above 82.2°C (180°F). Turn the engine off. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. Install the (special tool #9012, Fitting, Fuel System Test) in place of the banjo connector. NOTE: Do not use fitting 9014. This fitting will block return flow from the High Pressure Delivery Pump and damage the seal and could potentially damage the engine. Install a 5/16 diameter rubber fuel hose (Hose A) onto the test fitting and into a fuel container. NOTE: This hose will be used to measure the High Pressure Pump return flow in the next test procedure. Remove the vehicle fuel return line (Quick connect) from the engine fuel drain tube. Install a 5/16 diameter rubber fuel hose (Hose B) onto the engine fuel drain tube and into the fuel container. NOTE: This hose will be used to measure the Injector return flow for this procedure. Start engine and allow to idle for 30 seconds. This step allows the flows to stabilize. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure Override Test. Select Start, then press Next. NOTE: While the test is running, record the FCA duty cycle % and actual rail pressure. Press the Run button to start the Fuel Pressure Override Test. The engine speed will elevate rapidly to 1200 RPM and the rail pressure will increase to 26107 psi (1800 bar). At this point, move (Hose B) from the bucket and insert it into a graduated cylinder. Collect the fuel until the Fuel Pressure Override Test times out (30 seconds). Measure and record the amount of fuel collected in the graduated cylinder. Repeat this three times and take the average of the three results. NOTE: Flow should be less than 210 ml for 30 seconds. If the flow is less than 210 ml/30 seconds, the test has successfully passed. If the flow is greater than 210 ml/30 seconds, turn off the engine and remove all 6 high pressure fuel lines. Re-torque the high-pressure connector nut for each injector. Inspect for damage, repair/replace as necessary. Reinstall the high pressure fuel lines. Re-measure the injector return flow using steps 10 through 13 as a guide. Continue on to next step. If the amount of fuel is still greater than 210 ml/30 seconds after re-torquing the high-pressure connector nuts, turn the engine off and remove the #1 high pressure fuel line. Cap the #1 fuel port using tool(special tool #9864, Cap, Fuel Rail) for the 6.7L engine on the fuel rail and re-measure the injector return flow using steps 10 through 13 as a guide. Repeat this procedure for injectors 2-6. Continue on to next step. Replace the Fuel Injector and High pressure connector of the injector that shows the largest amount of change when capped off. Did the vehicle pass the Injector Return Flow test at step 12 without any repairs needed? Yes Go To 7 . No Perform the necessary repairs and verify fuel system operation. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
7. HIGH PRESSURE DELIVERY PUMP RETURN FLOW TEST Move (Hose B) back into the fuel container. Empty the graduated cylinder. Move (Hose A) into the graduated cylinder. Allow the engine to idle for one minute while collecting the fuel from (Hose A) . Measure the amount of fuel collected from (Hose A) in the graduated cylinder. NOTE: The fuel flow should be less than 1,150 ml/minute at idle. Is the flow less than 1,150 ml/minute at idle? Yes Go To 8 . No Replace the High Pressure Delivery Pump in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
8. HIGH PRESSURE DELIVERY PUMP PERFORMANCE TEST Turn the engine off. Remove the (special tool #9012, Fitting, Fuel System Test) and reinstall the banjo connector. Disconnect the Fuel Control Actuator harness connector. Disconnect high pressure fuel line from the fuel rail and route the high pressure fuel line into a graduated cylinder. Crank the engine until fuel exits this line. This will not be high pressure fuel. Crank the engine for three 10 second intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into three separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 RPM cranking speed is 70mL. Minimum fuel pump flow at 200 RPM cranking speed is 90mL. Does the fuel flow exceed the minimum specification? Yes Go To 9 . No Replace the High Pressure Delivery Pump in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
9. CHECKING THE FUEL CONTROL ACTUATOR Reconnect the Fuel Control Actuator harness connector. Reconnect all fuel lines and hoses. Start the engine. With the scan tool, navigate to Systems Tests and select the Fuel Pressure Override Test. Allow the engine speed and fuel pressure to ramp up and stabilize and then stop actuation. Does the engine speed and fuel pressure ramp up and stabilize when actuated and then come back to rest at idle and stabilize when actuation is stopped? Yes The fuel system is operating normally. Check for any Service Bulletins that may apply. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Replace the Fuel Control Actuator in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
10. PRESSURE LIMITING VALVE (NO START) NOTE: In the illustration provided, the pressure-limiting valve location is indicated by the number (1). Reconnect the fuel supply hose. Remove the banjo bolt from the Pressure Limiting Valve on the fuel rail. Install the (special tool #9012, Fitting, Fuel System Test) into the Pressure Limiting Valve. Attach one end of a fuel hose to the fuel fitting and put the other end of the fuel hose into a container. Crank the engine and look for fuel leaking from the Pressure Limiting Valve. NOTE: There should be no fuel flow into the container. Is fuel flowing into the container? Yes Replace the Pressure Limiting Valve in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 11 .
11. INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @ 200 RPM (NO START) Remove the (special tool #9012, Fitting, Fuel System Test) from the Pressure Limiting Valve. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. Install the (special tool #9012, Fitting, Fuel System Test) in place of the banjo connector. NOTE: Do not use fitting 9014. This fitting will block return flow from the High Pressure Delivery Pump and damage the seal and could potentially damage the engine. Install a 5/16 diameter rubber fuel hose (Hose A) onto the test fitting and into a fuel container. Remove the vehicle fuel return line (Quick connect) from the engine fuel drain tube. Install a 5/16 diameter rubber fuel hose (Hose B) onto the engine fuel drain tube and into the fuel container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing. NOTE: This will be used to measure the Injector return flow for this procedure. Unplug the injector harnesses at the valve cover, unplug the harness connector to the FCA. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished. Let all the fuel drain out of each line before continuing. Place (Hose B) into a graduated cylinder. Crank the engine for 10 seconds (Go from Key off to Crank back to Key off). Do not leave the ignition on between tests. Let all of the fuel drain out of the injector hose. Record the amount of injector return flow for a 10 second crank. NOTE: Flow should be less than 40 ml for 10 seconds of cranking. If the flow is less than 40 ml, the test has successfully passed. If the flow is greater than 40 ml, remove all 6 high pressure fuel lines and re-torque the high-pressure connector nut for each injector. Inspect for damage, repair/replace as necessary. Reinstall the high pressure fuel lines. Re-measure the injector return flow using steps 7 through 12 as a guide. Continue on to next step. If the amount collected is still greater than 40 ml, remove the #1 high pressure fuel line. Cap the #1 fuel port using tool(special tool #9864, Cap, Fuel Rail) for the 6.7L engine on the fuel rail and re-measure the injector return flow using steps 7 through 12 as a guide. Continue on to next step. If the amount collected is less than 40 ml for 10 seconds after capping the #1 fuel port, remove and replace the #1 Fuel Injector and #1 High pressure connector. If the amount of fuel collected is still greater than 40 ml after capping the #1 fuel port, repeat step 14 for injectors 2-6. Did the vehicle pass the Injector Return Flow test at step 13 without any repairs needed? Yes Go To 12 . No Perform the necessary repair. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
12. HIGH PRESSURE FUEL PUMP PERFORMANCE TEST (NO START) Turn the engine off. Disconnect the (special tool #9012, Fitting, Fuel System Test). Reconnect the banjo connector to the drain tube. Disconnect the FCA harness connector. Disconnect high pressure fuel line from the fuel rail and route the high pressure fuel line into a graduated cylinder. Crank the engine until fuel exits this line. This will not be high pressure fuel. Crank the engine for three 10 second intervals. NOTE: This will give you 30 total seconds of flow time. These are broken into three separate intervals to prevent damage to the starter. Fuel flow specification's based on engine cranking speed. If you do not collect the stated amount of fuel in 30 seconds, replace the pump: Minimum fuel pump flow at 150 RPM cranking speed is 70mL. Minimum fuel pump flow at 200 RPM cranking speed is 90mL. Does the fuel flow exceed the minimum specification? Yes The fuel system is operating normally. Check for any Service Bulletins that may apply. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Replace the High Pressure Delivery Pump in accordance with the service information. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .

1. PCM GROUND CIRCUIT(S) OPEN Turn the ignition off. Disconnect the PCM C2 harness connector. Using a 12-volt test light connected to 12 volts, probe each of the PCM ground circuit (terminals 4 and 6) at PCM C2 harness connector. Did the test light illuminate for each cavity? Yes Go To 2 . No Repair the PCM Ground circuit(s) for an open. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
2. CHECK THE (F202) FUSED IGNITION SWITCH OUTPUT CIRCUIT Using a 12-volt test light connected to ground, probe the (F202) Fused Ignition Switch Output circuit (terminal 71) at PCM C2 harness connector. Turn the ignition on. Is the test light on? Yes Go To 3 . No Repair the (F202) Fused Ignition Switch Output circuit for an open or short to ground. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
3. CHECK THE (A209) FUSED B+ CIRCUIT Using a 12-volt test light connected to ground, probe the (A209) Fused B+ circuit (terminals 3 and 5) at PCM C2 harness connector. Does the test light illuminate brightly for each circuit? Yes Test Complete. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Repair the Fused B+ Output circuit for an open or short to ground. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .

1. CHECKING THE EXHAUST SYSTEM FOR LEAKS Turn the ignition off. Raise the vehicle in accordance with the service information. WARNING: The normal operating temperature of the exhaust system is very high. Never work around or attempt to service any part of the exhaust system until it has cooled. Special care should be taken when working near the catalytic converter. The temperature of the converter rises to a high level after a short period of engine operating time. Connect the (special tool #8404-ECT, Exhaust Cone, Truck) to the Air Pressure Regulator (with hose) W-18-MIL-1146AS. CAUTION: The air pressure must not exceed 4 psi, otherwise engine damage can occur. Attach shop air to the air pressure regulator. Adjust the Air Pressure Regulator to 4.0 psi. Insert the exhaust cone into the vehicle tail pipe. If the vehicle is equipped with dual exhaust. Use the (special tool #8404-ECT, Exhaust Cone, Truck) with equipped attached plug, plug one side of the dual exhaust pipe. Pressurize the other as described above. Apply Mopar Air Leak Detector or Equivalent to the following areas: All welded joints from 6 inches rearward of the Downstream O2 Sensor forward. O2 sensor seal points. O2 sensor boss welds. Flange/joint connection(s). Exhaust Manifold to Cylinder Head connection(s). EGR Solenoid gasket base and tube seal points (if equipped). Watch for the liquid/soapy water to bubble. Use the following definitions to help determine if system or component repair/replacement is necessary: Type 1 Leak is defined as a leak where very small foam like bubbles (1.0 mm or less) appear. Any Type 1 or greater leaks found in welded joints, O2 Sensor seal points or O2 Sensor boss welds must be repaired or the component must be replaced. Type 2 Leak is defined as a leak where larger bubbles (pea size, 8.0 mm or greater) appear. Any Type 2 or greater leaks found in welded joints, O2 Sensor seal points or O2 Sensor boss welds must be repaired or the component must be replaced. Leak Location Repair required if results at 4 psi reveal bubble size: Welded joints Type 1 (1.0 mm) or greater O2 Sensor seal points Type 1 (1.0 mm) or greater O2 Sensor boss welds Type 1 (1.0 mm) or greater Flange / joint connections Type 2 (8.0 mm) or greater Exhaust Manifold to cylinder head connections Type 2 (8.0 mm) or greater EGR gasket and tube seal points Type 2 (8.0 mm) or greater If a leak is found that matches the above definition, repair or replace the component as necessary. Once the repair is complete, repeat the procedure to verify that all leaks have been repaired. Were any exhaust leaks found? Yes Repair or replace the leaking exhaust parts as necessary. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Test complete.

1. CHECK TSBs NOTE: This vehicle is equipped with a Diesel Particulate Filter (DPF) which should trap most particles that would appear out of the tail pipe in the form of black or blue smoke. If black or blue smoke is coming from the tail pipe, the DPF should be inspected for damage after the root cause of the problem is diagnosed and corrected. With the scan tool, check for any TSBs that may apply. Were there any TSBs that applied to and repaired the condition? Yes Perform the appropriate repair. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 2 .
2. CHECK FUEL FOR CONTAMINATION Perform the DIESEL FUEL CONTAMINATION AND CLEANING PROCEDURE. Refer to «DIESEL FUEL CONTAMINATION TESTING PROCEDURE»(ref-457834-S16021765672012030200000) , and «DIESEL FUEL SYSTEM CLEANING PROCEDURE»(ref-457834-S22549319022012030200000) . Is the fuel contaminated with debris? Yes Follow step three of the DIESEL FUEL CONTAMINATION AND CLEANING PROCEDURE and clean the diesel fuel system and Fuel Injectors. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 3 .
3. CHECKING CYLINDER CONTRIBUTION Using the scan tool, navigate to Miscellaneous Functions perform the Fuel System Run Up test procedure. NOTE: This test will take approximately 270 seconds to complete. The PCM will cut out each individual Fuel Injector three times and calculate the delta RPM change. Based on the delta RPM change, the test will indicate a bad cylinder based on the limits that have been set. When the test is complete, the engine will return to idle. Do the results indicate that a cylinder is out of spec? Yes Refer to the CHECKING ENGINE MISFIRE / RUNS ROUGH / PERFORMANCE TEST and begin at 5 for diagnosing a single cylinder issue. No Go To 4 .
4. CHECK THE FUEL DELIVERY SYSTEM Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to «CHECKING THE FUEL DELIVERY SYSTEM»(ref-457849-S04686286802012030200000) . Were any problems found? Yes Perform the appropriate repair. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Refer to the CHECKING ENGINE MISFIRE / RUNS ROUGH / PERFORMANCE TEST and begin at test step 8 .

1. CHECK TSBs NOTE: This vehicle is equipped with a Diesel Particulate Filter (DPF) which should trap most particles that would appear out of the tail pipe in the form of black or blue smoke. If black or blue smoke is coming from the tail pipe, the DPF should be inspected for damage after the root cause of the problem is diagnosed and corrected. With the scan tool, check for any TSBs that may apply. Were there any TSBs that applied to and repaired the condition? Yes Perform the appropriate repair. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 2 .
2. CHECK THE AIR FILTER Perform an inspection of the Air Filter. Check for an improper filter or signs of a restriction such as excessive debris or a filter that is out of shape. Does the Air Filter system appear in good shape? Yes Go To 3 . No Replace the Air Filter assembly. Go To 3 .
3. CHECK THE CCV FILTER AND SYSTEM Perform an inspection of the CCV system. Are there signs of a restriction in the system. Are there signs of a restriction in the CCV system? Yes Replace CCV Filter and determine root cause. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 4 .
4. CHECK THE TURBOCHARGER FOR OIL LEAK INTO THE INTAKE SYSTEM Remove the inlet to the Turbocharger assembly. Inspect the Turbocharger inlet compressor for oil leaking into the Air Handling system. Was oil leaking into the Air Handling system from the Turbocharger? Yes Check the Turbocharger oil drain for a restriction. If restricted, clean or replace the oil drain tube. If not restricted, replace the Turbocharger assembly. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 5 .
5. CHECK THE TURBOCHARGER FOR OIL LEAK INTO THE EXHAUST SYSTEM Inspect the Turbocharger turbine for oil leaking into the exhaust system. Was oil leaking into the exhaust system from the Turbocharger? Yes Go To 6 . No Go To 7 .
6. CHECK FOR OIL LEAKING INTO THE EXHAUST MANIFOLD Remove the Turbocharger and inspect for oil leaking into the Exhaust Manifold. Was oil leaking into the Exhaust Manifold from the Turbocharger? Yes Go To 8 . No Replace the Turbocharger assembly. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) .
7. CHECK THE INTAKE SYSTEM FOR LEAKS Perform the INTAKE AIR SYSTEM PRESSURE TEST procedure. Refer to «INTAKE AIR SYSTEM PRESSURE TEST»(ref-457849-S41730497842012030200000) . Were any leaks found? Yes Perform the appropriate reapairs. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 8 .
8. CHECK THE VAVLE TRAIN Remove the Vavle Cover. Inspect the Valve seals. Look for any broken, brittle, or improperly installed seals. Were problems found? Yes Perform the appropriate reapairs. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Remove the Cylinder Head. Inspect for any worn or damaged pistons, piston rings, or cylinder walls. Check for excessive clearance/wear in the valve guides. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) .

1. CHECK THE COOLING SYSTEM FOR LEAKS Pressure test the cooling system. Is the cooling system holding pressure? Yes Go To 2 . No Diagnose and repair the coolant leak. We are looking for coolant leaking into the combustion chamber. Check EGR Cooler for internal cracks. If the cooler is not leaking then check the engine internally for faulty cylinder head gasket, or cracks to the cylinder head or block.
2. VERIFY CONDITION NOTE: Some white smoke from the tail pipe during initial start up is normal, especially during cold ambient temperatures. If the white smoke is excessive, continue with this test. Allow the engine to cool to ambient temperature if possible. Start the engine and allow it to idle monitoring smoke during warm up. Is the white smoke occuring during cold ambient temperatures at initial start up ONLY? Yes Condition is normal. Verify proper operation of of the Intake and Fuel Heaters. No Go To 3 .
3. CHECK THE ENGINE COOLANT THERMOSTAT Verify the operation of the cooling system Thermostat. Does the engine heat up properly to operating temperature? Yes Go To 4 . No Replace the cooling system Thermostat.
4. CHECK THE FUEL HEATER OPERATION Verify that the Fuel Heater and temperature sensor is operating properly. Is the fuel heater system operating normal? Yes Go To 5 . No Diagnose and repair the Fuel Heater system as necessary.
5. CHECK FOR IMPROPER FUEL OR CONTAMINATION Perform the DIESEL FUEL CONTAMINATION AND CLEANING PROCEDURE. Refer to «DIESEL FUEL CONTAMINATION TESTING PROCEDURE»(ref-457834-S16021765672012030200000) , and «DIESEL FUEL SYSTEM CLEANING PROCEDURE»(ref-457834-S22549319022012030200000) . Is the fuel improper or contaminated with debris? Yes Follow step three of the DIESEL FUEL CONTAMINATION AND CLEANING PROCEDURE and clean the diesel fuel system and Fuel Injectors. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Go To 6 .
6. CHECKING CYLINDER CONTRIBUTION Using the scan tool, navigate to Miscellaneous Functions perform the Fuel System Run Up test procedure. NOTE: This test will take approximately 270 seconds to complete. The PCM will cut out each individual Fuel Injector three times and calculate the delta RPM change. Based on the delta RPM change, the test will indicate a bad cylinder based on the limits that have been set. When the test is complete, the engine will return to idle. Do the results indicate that a cylinder is out of spec? Yes Refer to the CHECKING ENGINE MISFIRE / RUNS ROUGH / PERFORMANCE TEST and begin at step 5 for diagnosing a single cylinder issue. No Go To 7 .
7. CHECK THE FUEL DELIVERY SYSTEM Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to «CHECKING THE FUEL DELIVERY SYSTEM»(ref-457849-S04686286802012030200000) . Were any problems found? Yes Perform the appropriate repair. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . No Refer to the CHECKING ENGINE MISFIRE / RUNS ROUGH / PERFORMANCE TEST and begin at test step 8 .

Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding. Refer to PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE - 6.7L .

1. DTC/PRODUCT IMPROVEMENT Check for any TSBs related to customer's complaint or DTCs present. Follow appropriate guidelines in DTC troubleshooting tree or instructions in TSB. Is vehicle repaired? Yes Repair complete. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 2 .
2. NO CRANK CONDITION Does the engine crank? Yes Go To 6 . No Go To 3 .
3. BATTERY VOLTAGE Check for low battery voltage. Is battery voltage okay? No Repair low battery voltage. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . Yes Go To 4 .
4. OTHER VEHICLE SYSTEMS Verify proper operation of the Transmission Clutch. Verify proper operation of the Transmission. Verify proper operation of the Engine driven accessories. Were any issues found? Yes Perform the appropriate repairs. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 5 .
5. STARTING ACCESSORIES Inspect the Ignition switch (check for proper output voltage and/or open circuit). Inspect the Starter operation. Inspect the Grid Heater operation. Inspect the Fuel Heater operation. Were any problems found? Yes Perform the appropriate repairs. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Check for internal engine damage.
6. ENGINE TIMING Inspect speed indicator ring for damaged/missing teeth. Inspect for dirty or damaged pins at Crankshaft position sensor (CKP) or Camshaft position sensor (CMP). Verify proper overhead adjustments. Were any problems found? Yes Perform the appropriate repairs. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 7 .
7. CHECK THE FUEL PRESSURE ACTUAL -VS- SETPOINT Using a scan tool, compare the fuel pressure actual reading to the set point while cranking the engine. Does the actual fuel pressure fluctuate more then +/- 500 psi of set point? Yes Go To 8 . No Perform the CHECKING THE FUEL DELIVERY SYSTEM test procedure. Refer to «CHECKING THE FUEL DELIVERY SYSTEM»(ref-457849-S04686286802012030200000) .
8. CHECK THE EGR AIRFLOW CONTROL VALVE OPERATION Turn the ignition off. Remove the inlet hose to the EGR Airflow Control Valve. Use a mirror to inspect the valve while and assistant cycles the ignition on and off several times. Does the EGR Airflow Control Valve cycle open and closed without sticking when the ignition is cycled on and off? Yes Go To 9 . No Check the electrical circuits for the EGR Airflow Control Valve. If the wiring is good, replace the EGR Airflow Control Valve. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
9. CHECK FOR A PLUGGED EXHAUST SYSTEM Separate the exhaust system and attempt to start the engine. Does the engine start? Yes Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to «AFTERTREATMENT INSPECTION GUIDELINE»(ref-457849-S31366167062012030200000) . NOTE: It is imperative to determine root cause of excessive soot build up. After repair perform the DIESEL FUEL VALIDATION TEST. Refer to «DIESEL AFTERTREATMENT VALIDATION- 6.7L»(ref-457919-S26763156982012030200000) . No Go To 10 .
10. CHECKING FUEL QUALITY/CONTAMINATION Check the quality of the fuel using the DIESEL FUEL CONTAMINATION AND CLEANING PROCEDURE. Refer to «DIESEL FUEL CONTAMINATION TESTING PROCEDURE»(ref-457834-S16021765672012030200000) , and «DIESEL FUEL SYSTEM CLEANING PROCEDURE»(ref-457834-S22549319022012030200000) . Was any contamination detected? Yes Perform the appropriate repair according to the testing and cleaning procedure. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Go To 11 .
11. CHECK THE INTAKE SYSTEM Check for inlet restriction, inspect the Air Filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted. Inspect Turbocharger for wheel clearance and proper wastegate operation. Check for air system leaks. Perform INTAKE AIR SYSTEM PRESSURE TEST procedure. Refer to «INTAKE AIR SYSTEM PRESSURE TEST»(ref-457849-S41730497842012030200000) . Were any issues found? Yes Perform the appropriate repairs. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) . No Check for an engine mechanical problem such as low compression due to damaged pistons, cylinder walls, or valve train. Perform the PCM VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .

Note. When diagnosing engine noise problems, make sure that noises caused by accessories, such as the A/C Compressor and power takeoff, are not mistaken for engine noises. Remove the accessory drive belts to eliminate noise caused by these units. Noise will also travel to other metal parts not related to the problem.

Note. The use of a stethoscope can help locate an engine noise.

Engine noises heard that are at Crankshaft speed (engine RPM), are noises related to the Crankshaft, Pistons, Connecting Rods, and piston pins. Noises heard that are at Camshaft speed (one-half of the engine RPM), are related to the valve train. A handheld digital tachometer can help to determine if the noise is related to components operating at crankshaft or camshaft speed. Engine noise can sometimes be isolated by performing a cylinder cutout test. If the volume of the noise decreases or the noise disappears, it is related to that particular engine cylinder. There is not a definite rule or test that will positively determine the source of a noise complaint. Engine driven components and accessories, such as gear-driven fan clutches, hydraulic pumps, belt-driven Alternators, A/C Compressors, and Turbochargers can contribute to engine noise. Use the following information as a guide to diagnosing engine noises.

1. ENGINE RUNS NOTE: Review Warranty bulletin D-05-24. Does the engine run? Yes Go To 2 . No Go To 3 .
2. INJECTOR RETURN FLOW TEST @ 1200 RPM AND 1800 BAR RAIL PRESSURE Operate the engine until the coolant temperature is above 82.2°C (180°F). Turn the engine off. Remove the banjo connector from the fuel drain tube at the rear of the fuel filter housing. Install fuel system test fitting (special tool #9012, Fitting, Fuel System Test) in place of the banjo connector. NOTE: Do not use test fitting (special tool #9014, Fitting, Fuel System Test). This fitting will block return flow from the High Pressure Delivery Pump and damage the seal and could potentially damage the engine. Install a 5/16 diameter rubber fuel hose (Hose A) onto the test fitting and into a fuel container. NOTE: This hose is used to measure the High Pressure Pump return flow. Remove the vehicle fuel return line (Quick connect) from the engine fuel drain tube. Install a 5/16 diameter rubber fuel hose (Hose B) onto the engine fuel drain tube and into the fuel container. NOTE: This hose will be used to measure the Injector return flow for this procedure. Start engine and allow to idle for 30 seconds. This step allows the flows to stabilize. Using the scan tool, navigate to ECM view -> PCM Cummins -> More Options-> System Tests -> Fuel Pressure Override Test. Select Start, then press Next. NOTE: While the test is running, record the FCA duty cycle % and actual rail pressure. Press the Run button to start the Fuel Pressure Override Test. The engine speed will elevate rapidly to 1200 RPM and the rail pressure will increase to 26107 psi (1800 bar). At this point, move (Hose B) from the bucket and insert it into a graduated cylinder. Collect the fuel until the Fuel Pressure Override Test times out (30 seconds). Measure and record the amount of fuel collected in the graduated cylinder. Repeat this three times and take the average of the three results. NOTE: Flow should be less than 210 ml for 30 seconds. If the flow is less than 210 ml/30 seconds, the test has successfully passed. If the flow is greater than 210 ml/30 seconds, turn off the engine and remove all 6 high pressure fuel lines. Re-torque the high-pressure connector nut for each injector. Inspect for damage, repair/replace as necessary. Reinstall the high pressure fuel lines. Re-measure the injector return flow using steps 10 through 13 as a guide. Continue on to next step. If the amount of fuel is still greater than 210 ml/30 seconds after re-torquing the high-pressure connector nuts, turn the engine off and remove the #1 high pressure fuel line. Cap the #1 fuel port using tool (special tool #9864, Cap, Fuel Rail) for the 6.7L engine on the fuel rail and re-measure the injector return flow using steps 8 through 11 as a guide. Repeat this procedure for injectors 2-6. Continue on to next step. Replace the Fuel Injector and High pressure connector of the injector that shows the largest amount of change when capped off. Did the vehicle pass the Injector Return Flow test at step 12 without any repairs needed Yes Injector return flow is within specification, and no repair is needed. No Replace the failed Fuel Injector(s) and verify repair. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .
3. NO START INJECTOR RETURN FLOW TEST DURING ENGINE CRANKING @200 RPM NOTE: Battery charger may be utilized if cranking speed is below 170 RPMs. Install (special tool #9012, Fitting, Fuel System Test) fitting in standard location on back of fuel filter head to measure pump and injector return flows. Install hoses to the test fitting and the injector return line and route them to a bucket or other container. Make sure test lines are straight and slope downward their entire length. This is to avoid trapping air/fuel in the lines while testing. Unplug the injector harnesses at the valve cover, Unplug the connector to the FCA. Crank the engine for least 10 seconds until fuel starts to flow out of the pump and injector return hoses. Turn Key off when finished. Let all the fuel drain out of each line before continuing. Place the injector return hose into an appropriate measuring device. Crank the engine for 10 seconds. Go from Keyoff to Crank back to Keyoff. Do not leave the ignition on between tests. Let all of the fuel drain out of the injector hose. Record the amount of injector return for a 10 sec crank. Flow should be less than 40 ml for 10 seconds of cranking. If the flow is greater than 40 ml after step 10, remove the #1 fuel injector supply line. Re-torque the high-pressure connector nut. Cap the #1 fuel port using tool (special tool #9864, Cap, Fuel Rail) for the 6.7L engine and (special tool #9011, Adapter, Fuel Pressure Test) for 5.9L engine on the fuel rail. Crank the engine and perform steps 7 through 9. Measure the amount of fuel in the graduated cylinder. If the amount of fuel is less than 40 ml, remove the #1 high pressure connector and the #1 fuel injector. Inspect for damage, repair/replace as necessary. If the amount of fuel is not less than 40 ml, repeat steps 12-14 for cylinders 2-6. Install all high-pressure connectors, fuel injectors, and fuel injector supply lines. Repeat steps 1-12 to confirm repair. SPECIFICATION: Less than 40 ml total fuel return flow for 10 seconds. Did the vehicle pass the Injector Return Flow test at step 12 without any repairs needed Yes Injector return flow is within specification, and no repair is needed. No Replace the failed Fuel Injector(s) and verify repair. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .

1. CHARGE AIR COOLER PRESSURE TEST Loosen the Air Inlet Tube clamp at the Turbocharger. Remove the air filter housing and the inlet tube from the vehicle as an assembly. Install the (special tool #10137, Adapter, Charge Air) on the turbo, securing it in place with the supplied three-fingered band clamp, tighten tool clamp to 8 N.m (72 in lbs) then tighten the 3 wing nuts to the puck. CAUTION: Never attempt to start or run the vehicle at any time during this test, engine damage may occur. Before attaching shop air to the pressure regulator verify that the regulator is at its lowest pressure setting (0 psi). Attach an air supply to the regulator and slowly increase the pressure until the pressure gauge reads 20 psi. WARNING: Never apply more than 30 PSI. Using Mopar Air Leak Detector or Equivalent, spray the Turbocharger, Turbocharger wastegate, Charge Air Cooler (CAC) Heat Exchange and CAC Hoses while watching for leaks. Before any attempt to repair the CAC system is made, it's necessary to completely discharge the system. This can be accomplished by turning the regulator knob counter clockwise. Allow for adequate time to pass before removing the CAC Pressure tester from the turbocharger inlet. Position the Air Filter Housing over the three mounting studs located on the inside front fender well and press down firmly to lock housing into place. Install Air Inlet Tube over the Turbocharger inlet and torque the band clamp to 35 in.lbs. View Repair Repair Test complete. Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Refer to «POWERTRAIN VERIFICATION TEST - 6.7L»(ref-457925-S17706294302012030200000) .