Fuel System - MIL ON/DTC P0251 Stored In Memory
NUMBER: 14-001-10GROUP: Fuel
DATE: February 2, 2010
THIS BULLETIN SUPERSEDES TECHNICAL SERVICE BULLETIN 14-004-05, DATED JULY 8, 2005, WHICH SHOULD BE REMOVED FROM YOUR FILES. ALL REVISIONS ARE HIGHLIGHTED WITH **ASTERISKS** AND INCLUDE ADDITIONAL MODEL YEARS AND ADDITIONAL DIAGNOSTIC INFORMATION.
SUBJECT:
Electronic Fuel Control Actuator (FCA) Available For Service / New Diagnostics Available For DTC P0251
OVERVIEW:
This bulletin involves replacing the Fuel Control Actuator (FCA), **(now serviced separately)**.
MODELS:
2003 - **2009** DR/DH Ram Truck
NOTE:
This bulletin applies to vehicles equipped with a 5.9L Cummins Turbo Diesel (sales code ETC or ETH).
SYMPTOM/CONDITION:
Engine surges at idle or **MIL illumination. Further investigation may identify DTC P0251 - CP3 PUMP REGULATOR CONTROL - DIESEL. If P0251 is present, follow the diagnostics in this SB. If other DTC's are present, repair as necessary before proceeding further with this bulletin**.
DIAGNOSIS:
ENGINE SURGES AT IDLE
Always perform the Pre-Diagnostic Troubleshooting procedure before proceeding.
1. DTC's - Check for any Diagnostic Trouble Codes (DTC's) present **other then P0251 ** - Are there any DTC's stored or active ** other then P0251**?
a. Yes >>> Repair as necessary before proceeding further with this bulletin.
b. No >>> Go to Step # 2.
2. Verify complaint - Verify proper fuel quality, grade, and level in the vehicle. Using the DRBIII(R), log the fuel pressure set point and fuel pressure. Operate the engine at idle speed. A good system will have actual fuel pressure that is +/- 500 PSI from the set point. (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). If fuel pressure variation is excessive, an audible surge will be present. If the variation is severe, a slight engine speed variation may also be noticed. - Does the fuel rail pressure fluctuate more than +/- 500 PSI?
a. Yes >>> Go to Step # 3.
b. No >>> Go to Step # 7.
NOTE:
A loud "knock" and black smoke that exists with a pressure drop may be an injector issue and should be identified using single cylinder cut-out test.
3. Verify proper low pressure fuel supply to the injection pump. Perform the "In Tank Fuel Lift Pump Flow Test - Diesel". In a good system fuel flow of **590 mL** in 10 seconds or better is expected. Be sure there is no air in the system. Is the low pressure fuel supply sufficient?
a. Yes >>> Go to Step # 4.
b. No >>> Repair the low pressure fuel supply system. Refer to the detailed diagnostic information available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing, Fuel Lift Pump - Diesel. - This bulletin does not apply.
4. Verify High Pressure Fuel Pump Performance. - Remove the fuel pump to rail high pressure fuel line. Inspect the fuel pump outlet port for rust, debris, or other sign of contamination. - Is contamination present?
a. Yes >>> Go to Step # 6.
b. No >>> Go to Step # 5.
5. Verify fuel injection pump flow. - Route the high pressure fuel line to a graduated container. Crank the engine until fuel exits the line (with the discharge line routed to atmosphere, fuel will discharge at 0 PSI). Crank the engine for three 10 second intervals, pausing to allow the starter to cool between each crank event. Fuel flow specification is based on engine cranking speed. 1. Minimum fuel pump flow at 150 RPM; 70 mL in 30 seconds. 2. Minimum fuel pump flow at 200 RPM; 90 mL in 30 seconds. Is the fuel flow sufficient?
a. Yes >>> Go to Step # 8.
b. No >>> Step # 6.
6. This bulletin does not apply. Replace the fuel injection pump. Check for source of water to prevent future complaints. Refer to the detailed service information available in TechCONNECT under: Service Info, 14 - Fuel System, Fuel Injection, Fuel Injection Pump.
7. Further diagnosis is necessary. This bulletin does not apply. Refer to SB 14-003-05.
8. Perform the Repair Procedure.
PARTS REQUIRED:
SPECIAL TOOLS/EQUIPMENT REQUIRED:
REPAIR PROCEDURE:
1. Replace the FCA as follows, if the high pressure fuel pump is discharging the correct amount of fuel.
a. Remove the cap screws (3).
b. Using a (Clockwise/Counterclockwise) twisting motion, remove the FCA.
c. Using a (Clockwise/Counterclockwise) twisting motion, install the FCA.
d. Install the cap screws (3). Torque the cap screws in two steps. Step 1 - Torque all cap screws to 3 N.m (27 in. lbs.). Step 2 - Torque all cap screws to 7 N.m (62 in. lbs.).
e. Start the engine to remove air from the fuel system. >> Go to Step # 2.
2. Repair Complete - For all years, perform powertrain verification test - 5.9L. Refer TechCONNECT > MY 2009 > DH - Ram 2500 Pick Up > 5.9L Cummins > 28 - DTC-Based Diagnostics > MODULE, Engine Control (ECM), 5.9L > Standard Procedure > POWERTRAIN VERIFICATION TEST - 5.9L.
POLICY:
Reimbursable within the provisions of the warranty.
TIME ALLOWANCE:
Use standard labor operation number available through Quick Labor Operations in DealerCONNECT.
Disclaimer:
This bulletin is supplied as technical information only and is not an authorization for repair.