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Diagnostic Test

WARNING: This page is about a different car, the 2012 RAM Pickup and 2012 RAM Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.
  1. RELATED TSBs 
    NOTE:

    If there are DTCs present in the PCM, TCM, or ABS Modules, repair the DTCs before proceeding.

    1. Check for any TSBs or, PCM or CCN software updates that may relate to customer's complaint.
    2. Follow the appropriate diagnostic procedure in the TSB.

      Is vehicle repaired?

      Yes 

      No 

      • Go To  2.
  2. VISUAL INSPECTION 
    1. 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 

      No 

      • Go To  3.
  3. CHECKING THE AIR FILTER 
    1. 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 
    1. Check the quality of the fuel using the DIESEL FUEL CONTAMINATION TEST PROCEDURE. Refer to DIESEL FUEL CONTAMINATION TESTING PROCEDURE .

      Was any contamination detected?

      Yes 

      No 

      • Go To  5.
  5. CHECKING CYLINDER CONTRIBUTION 
    1. 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 
    1. Refer to DIAGNOSIS AND TESTING, 6.7L  and perform the INJECTOR RETURN FLOW TEST diagnostic procedure.

      Did the INJECTOR RETURN FLOW TEST pass?

      Yes 

      • Go To  7.

      No 

  7. CHECKING FUEL INJECTOR AND VALVE COVER HARNESS TERMINALS 
    1. Turn the ignition off.
    2. Visually check the valve cover connectors and Fuel Injector terminals for loose connections or damaged threads.
    3. 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 

  8. CHECKING VALVE LASH 
    1. Check the valve lash adjustment on the suspect cylinder or cylinders.

      Is the valve lash within specification?

      Yes 

      • Go To  9.

      No 

  9. COMPRESSION CHECK 
    1. Perform a manual compression check of the cylinder.

      Is the compression within specification?

      Yes 

      • Go To  10.

      No 

  10. FUEL INJECTORS 
    1. Change the Fuel Injector with a Fuel Injector from another good cylinder.
    2. With the scan tool, perform the Cylinder Cut-Out test.

      Did the performance issue follow the Fuel Injector?

      Yes 

      No 

      • Go To  15.
  11. CHECK THE FUEL DELIVERY SYSTEM 
    1. Perform the CHECKING THE FUEL DELIVERY SYSTEM diagnostic procedure. Refer to DIAGNOSIS AND TESTING, 6.7L .

      Were any fuel system issues found?

      Yes 

      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.

    1. Turn the engine off, ignition on.
    2. 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 

  13. CHECKING MASS AIR FLOW SENSOR OPERATION 
    1. Turn the ignition on, engine not running.
    2. With the scan tool, read the MAF Sensor value:
      • The MAF Sensor should be reading close to 0.01lb/min.
    3. 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.

    4. With the scan tool in Data Display, verify that the EGR Valve is at 0%.
    5. 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 

  14. CHECK CRANKCASE FILTER 
    1. Verify proper Crankcase Filter operation.

      Were any problems found?

      Yes 

      No 

      • Go To  15.
  15. CHECKING THE INTAKE SYSTEM 
    1. Check for inlet restriction, inspect air filter for excessive dirt/debris. Verify air intake lines are not kinked or restricted.
    2. Refer to DIAGNOSIS AND TESTING, 6.7L  and perform the CHECKING THE INTAKE AIR SYSTEM PRESSURE diagnostic procedure.
    3. Inspect Turbocharger for wheel clearance and proper wastegate operation.

      Were any problems found?

      Yes 

      No 

      • Go To  16.
  16. CHECKING THE EGR SYSTEM 
    1. 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 
    1. Perform the AFTERTREATMENT INSPECTION GUIDELINE procedure. Refer to DIAGNOSIS AND TESTING, 6.7L .

      Were any problems found during the inspection?

      Yes 

      No 

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