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William
William, Service Manager
Category: Dodge
Satisfied Customers: 46
Experience:  OEM Cummins
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5.9 Cummins..I have white smoke and rough idle..clears

Customer Question

I have a 2005 24 valve 5.9 Cummins. I have white smoke and rough idle. The white smoke clears up after about 1000rpm and there seams to be no power loss. Every now and then it seams to stall for just a second at take off. I haven't been able to find any fuel leaks but as I understand it the most possible problem is air in the fuel system. Where is the most likely problem spot? Possible transfer pump or injection pump?
Submitted: 4 years ago.
Category: Dodge
Expert:  William replied 4 years ago.
Good morning, do you have your engine serial number? I can supply the OEM cummins trouble shooting info.

Thank you,

Bud
Customer: replied 4 years ago.
I believe the s/n 57246518 cummins p/n(NNN) NNN-NNNN model ISB325 and Family 4CEXHO359BAD
Expert:  William replied 4 years ago.
Easiest place to start is at the injectors.

I will cut and paste the cummins info for you
shortly for all white smoke.

Start with checking for a weak cyl. Or bad injector.
Engine at idle, loosen one inj. Line at a time, then tighten it.

What you are looking for is a change in the idle, or no change. Do this to all six cyl. One at a time.
Letme know what you find
William, Service Manager
Category: Dodge
Satisfied Customers: 46
Experience: OEM Cummins
William and 3 other Dodge Specialists are ready to help you
Customer: replied 4 years ago.
Every injector I loosened gave the same result. I loosened the lines at the fuel rail. The idle dipped slightly then it sounded smoother, and the engine made less of the "diesel rattle" I guess thats what you would call it. Also the white smoke would not change unless the injector lines were loosend considerabley then it would change to black.
Expert:  William replied 4 years ago.

Here is the OEM Cummins info. for White Smoke:

 

Guided Step 2D - Smoke, White - Excessive

Action

Interview the driver and verify the complaint.

 

Is the engine symptom Smoke, White - Excessive?

 

Is the engine symptom Smoke, White - Excessive?

 

YESNO
No RepairNo Repair

Go to Step 2D-1

Go to Step 2E




 

Guided Step 2D-1 - Smoke, White - Excessive

Action

Interview the driver and verify the complaint. Verify if, along with the white smoke complaint, coolant is being used.

Check the coolant level.

Is the engine using coolant?

 

Is the engine using coolant?

 

YESNO
No RepairNo Repair

See the Coolant Loss - Internal Troubleshooting Symptom (TS) Tree.

Go To Step 2D-2




 

Guided Step 2D-2 - Smoke, White - Excessive

Action

Interview the driver and verify the complaint.

Check if the white smoke excessive complaint is only occurring when the engine is cold and during cold ambient conditions?

Some white smoke after a cold start in cold ambient conditions is not uncommon. If white smoke persists once the engine has reached the minimum operating coolant temperature, troubleshoot the white smoke complaint.

Minimum Operating Coolant Temperature: 60°C [140°F].

Is the white smoke excessive complaint only occurring when the engine is cold and during cold ambient conditions?

 

Is the white smoke excessive complaint only occurring when the engine is cold and during cold ambient conditions?

 

YESNO

Perform the checks in Step 3A only.

Step 4 - Fuel System Checks

Step 6 - Electronics Checks

 

Perform the troubleshooting steps in the recommended order listed below:

Step 4 - Fuel System Checks

Step 7 - Electronics Checks

 

Perform the troubleshooting steps suggested in the repair procedure.

Go to




 

 

Guided Step 4 - Fuel system troubleshooting procedures.




 

Guided Step 4A - Check for air in the fuel supply line.

Conditions

  • Keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the gear pump inlet.

Action

Check for air in the fuel

Use the following procedure in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-003 in Section 6. Operate the engine at idle and check for air bubbles. If the engine will not start, check while cranking the engine.

Note: Do not overheat the starter.

SMALL | MEDIUM | LARGE

Is air present in the fuel supply?

 

Is air present in the fuel supply?

 

YESNO

Locate and correct the cause of air ingestion in the fuel supply system. Sources of air ingestion include loose fuel filters, loose fuel line fittings, loose or cracked fuel tank stand-pipes, or severe restrictions in the fuel supply lines and filters that cause cavitation at high fuel flow rates.

 

No Repair

Repair complete

Go to Step 4B




 

Guided Step 4B - Measure fuel pressure at the inlet of the on engine fuel filter.

Conditions

  • Keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the inlet to the fuel filter, or if equipped, the fuel filter head diagnostic port (inlet).

Action

Check for air in the fuel

Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-015 in Section 6.

Measure the fuel pressure at low idle:

  • Fuel pressure range: 5 to 13 bar [73 to 189 psi].

If the engine will not start, measure the fuel pressure during engine cranking

  • Fuel pressure range: 3 to 11 bar [44 to 160 psi].

Record the fuel filter inlet pressure measured.

SMALL | MEDIUM | LARGE

Is the pressure measured within specification? Note: Record the measured fuel inlet pressure for use in the next step.

 

Is the pressure measured within specification?

 

YESNO
No RepairNo Repair

Go to Step 4C

Go to Step 4B-1




 

Guided Step 4B-1 - Measure the fuel inlet restriction.

Conditions

  • Keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the gear pump inlet.

Action

Measure the fuel inlet restriction.

Refer to Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Operate the engine at high idle:

Maximum inlet restriction - 50.8 kPa [15 in-Hg] (vacuum)

If the engine will not start, measure fuel restriction while the engine is cranking.

Note: Do not overheat the starter.

Note: If the issue is intermittent (no start or engine shuts off unexpectedly) and no issues can be found while the engine is being serviced, there can be debris in the fuel system causing an intermittent restriction. Install a fuel filter minder, FleetguardTM Part Number(NNN) NNN-NNNN at the connection between the OEM fuel supply lines and the engine. A fuel filter minder will capture the peak restriction in millimeters and inches of mercury. If the issue occurs again, the fuel filter minder can be checked to see if there is something on the OEM side causing an intermittent high restriction.

SMALL | MEDIUM | LARGE

Is the fuel inlet restriction greater than the specification?

 

Is the fuel inlet restriction greater than the specification?

 

YESNO

Find and correct cause of high inlet restriction. Look for plugged OEM fuel filters or screens, or a restricted ECM cooler, pinched OEM fuel lines, or restricted stand pipe in the OEM fuel tank.

 

Replace the high pressure fuel pump. Use the following procedure in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 005-016 in Section 5.

 

Repair Complete

Repair Complete




 

Guided Step 4C - Measure fuel pressure at the outlet of the on engine fuel filter.

Conditions

  • Keyswitch OFF.
  • Engine OFF.
  • Connect required service tools at the outlet of the fuel filter, or if equipped, the fuel filter head diagnostic port (outlet).

Action

Measure fuel pressure at the outlet of the fuel filter.

Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-015 in Section 6.

Calculate the pressure drop across the fuel filter by subtracting the pressure measured here from the pressure from Step 4B.

Measure the fuel pressure at high idle:

  • Maximum pressure drop across the fuel filter - 2 bar [29 psi].

If the engine will not start, measure the fuel pressure during engine cranking

Is the pressure drop across the filter greater than the specification?

 

Is the pressure drop across the filter greater than the specification?

 

YESNO

Replace the fuel filter. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-015 in Section 6.

 

No Repair

Repair Complete

Go to Step 4D




 

Guided Step 4D - Perform INSITETM electronic service tool single cylinder cutout test.

Conditions

  • Turn keyswitch ON.
  • Engine running at low idle.
  • Connect INSITETM electronic service tool.

Action

If the engine will not start or is difficult to start, move to the next step.

  • In the ECM Diagnostic Tests menu of INSITETM electronic service tool, click on the Cylinder Cutout Test, and follow the instructions on the screen.
  • Operate the engine under the conditions in which the complaint occurs.
  • Use INSITETM electronic service tool to perform the Cylinder Cutout Test to disable individual injectors.

Note: If this test is performed and there is not a significant change while cutting out one injector, there can be a problem with more than one injector. It may be necessary to cut out multiple cylinders at a time.

Can the miss or excessive smoke be attributed to a single cylinder?

 

Can the miss or excessive smoke be attributed to a single cylinder?

 

YESNO

Look for a cause of the complaint, including valve lash and excessive crankcase pressure that may indicate power cylinder damage or camshaft lobe wear. If no other damage is found, replace the fuel injector in the cylinder that was identified using the single cylinder cutout test. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-026 in Section 6

 

No Repair

Repair Complete

Go to Step 4E




 

Guided Step 4E - Perform a manual single cylinder cut-out test.

Conditions

  • Turn keyswitch OFF.
  • Install the injector leakage isolation tool.
  • Turn keyswitch ON.

Action

Perform a manual cut-out test.

  • With the engine not running, disconnect the fuel line running from the fuel rail to cylinder number 1. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-051 in Section 6.
  • Install the injector leakage isolation tool

For 3.9L and 5.9L engines, install the injector leakage isolation tool, Part Number(NNN) NNN-NNNN on the rail where the number 1 cylinder fuel line connects.

Torque Value: 30 N•m [22 ft-lb]

For 4.5L and 6.7L engines, install the leakage isolation tool, Part Number(NNN) NNN-NNNN on the rail where the number 1 cylinder fuel line connects.

Torque Value: 35 N•m [26 ft-lb]

Attempt to start the engine or operate the engine at idle.

Repeat the above test, as necessary, with each cylinder blocked off.

SMALL | MEDIUM | LARGE

Did the engine start after blocking off a cylinder(s) or can the miss or excessive smoke be attributed to a cylinder(s)?

 

Did the engine start after blocking off a cylinder(s) or can the miss or excessive smoke be attributed to a cylinder(s)?

 

YESNO

Look for a cause of the complaint, including valve lash and excessive crankcase pressure that can indicate power cylinder damage or camshaft lobe wear. If no other damage is found, replace the fuel injector in the cylinder that was identified using the manual single cylinder cut-out test. Use the following procedure in Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-026 in Section 6

 

No Repair

Repair Complete

Go to Step 4F




 

Guided Step 4F - Measure the injector return fuel drain flow from the cylinder head.

Conditions

  • Keyswitch OFF.
  • Connect appropriate service tools to measure injector fuel drain flow from the cylinder head.

Action

Measure the injector return fuel drain flow from the cylinder head.

Use the following procedure in the ISBe, ISB, and QSB Service Manual, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-026 in Section 6.

Flow Specification:

Idle Conditions

4 cylinder engines - 120 ml/minute [4 fl-oz per minute] maximum

6 cylinder engines - 180 ml/minute [4 fl-oz per minute] maximum

Cranking Conditions

NOTE: Make sure not to overheat the starter.

4 and 6 cylinder engines - 90 ml/minute [3 fl-oz per minute] maximum.

Is injector fuel drain flow from the cylinder head greater than specification?

 

Is injector fuel drain flow from the cylinder head greater than specification?

 

YESNO
No RepairNo Repair

Go to Step 4G-1

Go to Step 4H




 

Guided Step 4G - Determine which cylinder(s) is causing excessive injector fuel drain flow from the cylinder head.

Conditions

  • Keyswitch OFF.
  • Connect appropriate service tools to measure injector fuel drain flow from the cylinder head.
  • Install the injector leakage isolation tool.

Action

Measure the injector return fuel drain flow from the cylinder head and isolate a cylinder one at a time using the injector leakage isolation tool.

Use the following procedure in the ISBe, ISB, and QSB Service Manual, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-026 in Section 6.

The flow rate will decrease below the maximum specified flow when the cylinder with the leak is blocked.

Note: If this test is performed and there is not a significant change in fuel return flow while cutting out one injector, there can be a problem with more than one injector. Compare the fuel flow difference across all injectors. Is there more than one injector that caused a noticeable decrease in fuel flow? If so, these could be the injectors with the problems.

Another cause of this problem could be that the customer is operating on fuels lighter than specified. Fuels with low viscosity will result in higher injector leakage and greater drain flow rates.

Did blocking off a cylinder(s) decrease the flow rate below the maximum specified flow rate?

 

Did blocking off a cylinder(s) decrease the flow rate below the maximum specified flow rate?

 

YESNO

Remove the fuel connector and inspect for damage. Replace if necessary. Remove the injector and inspect the fuel connector contact surface for damage. Replace if necessary. Use the following procedures in the ISBe, ISB, and QSB Service Manual, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-052 in Section 6. Refer to Procedure 006-026 in Section 6.

 

No Repair

Repair Complete

Go to Step 4H




 

Guided Step 4H - Measure fuel drain line restriction.

Conditions

  • Keyswitch off
  • Connect appropriate service tools to measure fuel drain line restriction

Action

Measure the fuel inlet restriction.

Use the following procedure in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 006-012 in Section 6.

Operate the engine at high idle:

Maximum fuel drain line restriction: 0.19 bar (2.7 psi).

Is the drain line restriction less than specification?

 

Is the drain line restriction less than specification?

 

YESNO
No Repair

Check OEM fuel drain lines to tank for proper size, leaks, bends, clogs and fuel tank vents for plugging.

 

Perform next troubleshooting procedure as outlined in Step 2.

Repair Complete

 

 

 

Guided Step 7 - Perform base engine mechanical checks.




 

Guided Step 7A - Verify overhead adjustments are correct.

Conditions

  • Keyswitch ON.
  • Connect INSITETM electronic service tool.

Action

Measure the overhead settings.

Use the following procedure in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 003-004 in Section 3.

SMALL | MEDIUM | LARGE

Are the overhead settings within the lash check limits?

 

Are the overhead settings within the lash check limits?

 

YESNO
No Repair

Adjust the overhead settings again. Use the following procedure in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 003-004 in Section 3.

 

Go to 7B

Repair complete




 

Guided Step 7B - Check exhaust restriction.

Conditions

  • Turn keyswitch ON.
  • Engine running at rated speed and full load.

Action

Measure the exhaust system back pressure

Measure the exhaust system back pressure by installing a pressure gauge, Part Number ST-1273, into the exhaust system immediately downstream of the turbocharger exhaust outlet.

Maximum back pressure measured at the turbocharger outlet (exhaust manifold outlet for naturally aspirated engines) is:

  • 10 kPa (1.5 psi)
  • 15 kPa (2.2 psi).
SMALL | MEDIUM | LARGE

Is the exhaust back pressure greater than the specification?

 

Is the exhaust back pressure greater than the specification?

 

YESNO

Correct the cause of high back pressure; look for collapsed or plugged exhaust pipes.

 

No Repair

Repair Complete

Go to 7C




 

Guided Step 7C - Verify engine crankcase pressure (blowby) is within specification

Conditions

  • Turn keyswitch OFF.
  • Connect appropriate service tools to measure blowby.

Action

Measure engine crankcase pressure (blowby).

Use the following procedure in the Troubleshooting and Repair Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 014-010 in Section 14.

SMALL | MEDIUM | LARGE

Is the engine crankcase pressure (blowby) less than specification?

 

Is the engine crankcase pressure (blowby) less than specification?

 

YESNO
No Repair

See the Crankcase (Blowby) Excessive Troubleshooting Symptom (TS) tree.

 

Go to 7D

See the Crankcase Gases (Blowby) Excessive Troubleshooting Symptom (TS) tree.




 

Guided Step 7D - Check for internal engine damage.

Conditions

  • Keyswitch OFF.

Action

Remove the oil filter.

Use the following procedures in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System) Series Engines, Bulletin(NNN) NNN-NNNN Refer to Procedure 007-013 in Section 7.

Refer to Procedure 007-083 in Section 7.

Cut the oil filter open and inspect for debris and area of probable damage.

Did cutting the oil filter open reveal evidence of internal engine damage?

 

Did cutting the oil filter open reveal evidence of internal engine damage?

 

YESNO

Determine the area of probable damage and repair as necessary. Remove the lubricating oil pan and rocker lever cover, if necessary, to inspect for damage. Use the following procedures in the Service Manual, ISBe, ISB, and QSB (Common Rail Fuel System), Bulletin(NNN) NNN-NNNN Refer to Procedure 007-025 in Section 7. Refer to Procedure 003-011 in Section 3.

 

No Repair

Repair Complete

Perform the next troubleshooting procedure as outlined in Step 2.



 

Expert:  William replied 4 years ago.

If there is anything more you need, just return to this message and let me know.

 

Thank you,

 

 

 

Bud

 

 

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