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Home >> Dodge or Ram Truck >> 2010 >> RAM 5500 Chassis Cab Truck 4WD L6-6.7L DSL Turbo >> Repair and Diagnosis >> Powertrain Management >> Computers and Control Systems >> Testing and Inspection >> Component Tests and General Diagnostics >> Checking the Fuel Delivery System >> Part 1

Part 1






CHECKING THE FUEL DELIVERY SYSTEM

For a complete wiring diagram, Refer to the Wiring Information






WARNING: Follow these safety precautions to reduce the risk of fire and possible serious or fatal injury when performing this test procedure.
- Fuel or fuel vapors are highly flammable. A fire could occur if an ignition source is present. Do not expose the fuel or the test equipment used in this procedure to open flames or sparks.
- Inhalation of fuel vapors could lead to disorientation and personal injury. Keep the service area well ventilated, or perform this test procedure in an area where there is a building exhaust removal system.
- Relieve fuel system pressure before servicing fuel system components.
- Use extreme caution when connecting and disconnecting fuel lines.
- Considerable fuel leakage may occur when servicing the fuel system. Wear protective eyewear and clothing to protect from fuel splash, and take suitable fuel containment measures.
- Wrap a shop towel around the fuel pressure gauge connection to absorb fuel leakage that occurs when connecting the test equipment. Place the towel in an approved container when complete.
- Never store fuel in an open container due to the possibility of fire or explosion. Have a dry chemical (Class B) fire extinguisher nearby.
- High-pressure fuel lines deliver diesel fuel under extreme pressure from the injection pump to the fuel injectors. This may be as high as 26,107 psi (1800 bar). Use extreme caution when inspecting for high-pressure fuel leaks. Fuel under this amount of pressure can penetrate skin causing possible serious or fatal injury.

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.

1. Turn the ignition off.
2. Visually inspect the Fuel Delivery System for external leaks and damage.
3. 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 or replace as necessary.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

No

- Go To 2

2. CHECKING FUEL QUALITY/CONTAMINATION
1. Check the quality of the fuel using the DIESEL FUEL CONTAMINATION TEST PROCEDURE. Fuel Contamination

Was any contamination detected?

Yes

- Perform the appropriate repair according to the testing and cleaning procedure.
- Go To 3

No, and vehicle starts and runs:

- Go To 3

No, and vehicle is a no start condition:

- Go To 5

3. CHECKING CYLINDER CONTRIBUTION
1. Using the scan tool, 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. This test routine should also be used to validate that the system is operating properly after the repairs are completed.

Do the results indicate that a cylinder is out of speck?

Yes

- Perform the CHECKING ENGINE MISFIRE / RUNS ROUGH / PERFORMANCE TEST procedure and continue troubleshooting the faulty cylinder condition starting at test step 9. Checking Engine Misfire / Runs Rough / Performance Test

No

- Go To 4

4. PERFORM THE HIGH PRESSURE FUEL SYSTEM TEST
1. Using the scan tool, navigate to System Tests and perform the High Pressure Fuel System test procedure.

NOTE: The High Pressure Fuel System test is a comprehensive fuel system test that operates the engine and fuel system under several diagnostic operating conditions. When the test is complete, the engine will stall. In MOST cases, this test can determine IF there are any fuel system issues, and if so, whether diagnostics should begin at the LOW pressure side or the HIGH pressure side of the system. Based on the results of the test routine, you will be directed to either start testing at the low pressure side (step 5) of the system or go directly into the high pressure side of the system in order to shortcut the diagnostic time. However, if the test routine fails and you are directed to the high pressure side of the system and do not find an issue at the completion of the test, it is recommended that you go back to test step 5 and continue with the rest of the fuel system testing. This test routine should also be used to validate that the system is operating properly after the fuel system has been diagnosed and repairs are completed.

NOTE: If you get ANY other combination of failures besides the three indicated below, start with the lowest numbered failed test in the list.

Follow the appropriate diagnostic path:

The Fuel System High Pressure test passed all tests:

- The test routine did not detect any fuel system issues. If you suspect the fuel system still may be at fault, then continue on to step 5.

The results indicated that tests 1,3,7 ALL failed in COMBINATION:

- Go To 5

The results indicated that tests 3,5,7,11,13,15 ALL failed in COMBINATION:

- Go To 10

The results indicated that tests 11,13,15 ALL failed in COMBINATION:

- Go To 10

The results indicated a SINGLE test failure of test 1:

- Go To 13

The results indicated a SINGLE test failure of test 3, 5, or 7:

- Go To 5

The results indicated a SINGLE test failure of test 9, 11, 13, 15, or 19:

- Go To 10

5. SETUP TO CHECK IN-TANK FUEL LIFT PUMP FLOW

Is the Gas and Diesel Fuel/Pressure Decay Tester 8978A available?

Yes

- Go To 6

No

- Go To 8

6. 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.

1. Disconnect the low pressure fuel supply line from the High Pressure Fuel Pump. Connect the 5/16 Quick Connect Fitting 8978-2 from the Gas and Diesel Fuel/Pressure Decay Tester 8978A to the low pressure fuel supply line.
2. Connect the Fuel Pressure Gauge Assembly Fuel Inlet Hose 8978-1 (1) to the 5/16 Quick Connect Fitting 8978-2.
3. Connect the Drain Extension Hose 535680 (2) to the Fuel Pressure Gauge Assembly Drain Hose (4).
4. Connect the Reservoir Assembly 534960 (3) to the Drain Extension Hose 535680 (2).






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.

5. 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.

6. 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.

7. 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 - if vehicle starts and runs:

- Go To 10

Yes - if vehicle is a no start:

- Go To 15

No

- Leave the special tools installed. Replace the Fuel Filter/Water Separator. During Fuel Filter replacement, be sure to check and clean the secondary filter screen in the filter head outlet.
- Go To 7

7. RECHECK IN-TANK FUEL LIFT PUMP FLOW




1. 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).

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).

3. 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. Verify repair by performing the High Pressure Fuel System test procedure again.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

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 OK, remove the fuel tank and replace the In-Tank Fuel Lift Pump Module.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

8. IN-TANK FUEL LIFT PUMP FLOW TEST WITHOUT 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.

1. Disconnect the low pressure fuel supply line from the High Pressure Fuel Pump. Install fuel system test fitting 9863 onto the end of the low pressure fuel supply line. Then, connect one end of a section of fuel hose to the test fitting and place the other end of the fuel hose into an empty fuel container.
2. Turn the ignition on.
3. With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
4. With the In-Tank Fuel Lift Pump Module running, place the fuel hose into a 1,000 ml graduated cylinder for 10 seconds and then return the hose to the fuel container.

CAUTION: Stop all actuations.

5. Turn the ignition off.
6. Measure the amount of fuel in the graduated cylinder. The fuel output specification is 590 ml in 10 seconds.

Does the amount of fuel in the graduated cylinder meet or exceed the specification?

Yes - Vehicle starts and runs:

- Go To 10

Yes - Vehicle is a no start:

- Go To 15

No

- Leave the tools installed. Replace the Fuel Filter/Water Separator. During Fuel Filter replacement, be sure to check and clean the secondary filter screen.
- Go To 9

9. RECHECK THE IN-TANK FUEL LIFT PUMP FLOW
1. Turn the ignition on.
2. With the scan tool, actuate the In-Tank Fuel Lift Pump Module.
3. With the lift pump running, place the fuel hose into a 1,000 ml graduated cylinder for 10 seconds and then return the hose to the fuel container.

CAUTION: Stop all actuations.

4. Turn the ignition off.
5. Measure the amount of fuel in the graduated cylinder. The fuel output specification is 590 ml in 10 seconds.

Does the amount of fuel in the graduated cylinder meet or exceed the specification?

Yes

- Repair complete. Verify repair by performing the High Pressure Fuel System test procedure with the scan tool again.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

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 ok, remove the fuel tank and replace the In-Tank Fuel Lift Pump Module.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

10. PRESSURE LIMITING VALVE





NOTE: In the illustration provided, the pressure-limiting valve location is indicated by the number (1).

1. Reconnect the fuel supply hose.
2. Remove the banjo bolt from the Pressure Limiting Valve on the fuel rail.
3. Install fuel system test fitting (9012) into the Pressure Limiting Valve.
4. 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.

5. Start the engine and operate the engine at idle. Watch for fuel flow into the fuel container.
6. 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: There should be no fuel flow into the container.

Is fuel flowing into the container?

Yes

- Replace the Pressure Limiting Valve. Verify repair by performing the High Pressure Fuel System test procedure with the scan tool again.
- Perform the POWERTRAIN VERIFICATION TEST - 6.7L. Powertrain Verification Test.

No

- Go To 11
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