I have an 04.5 325hp CTD 3500. I did a hand calculated full to empty tank, 75%city/25% highway use. My lie o meter was actually very accurate. It said 12.9, my hand calc said 12.5mpg. (i was hoing for higher, and dissapointed it was so accurate. I get a white puff out the rear view mirrior when I gun it to pass, but otherwise no running/idling or apparent issues. I met another 04.5 owner and he said the exact same thing about his. He did say he had a friend with a newer model that was in the 18mpg range, but I have no idea on the driving habits.
DD

 

Have you thought about installing aftermarket 50hp "econo" injectors? I don't think it will help, but I can't really think of anything else. Did the dealer check for leaks in the rail? Bully Dog products usually increase rail pressure in the higher modes and that can cause leaks.

 

here is a tsb for diagnosis of white smoke from dodge that i got online from a website i have access to through my work it may help if you know anyone who may have access to a scan tool if you were near las vegas i would be more than happy to help you look at it with my tool

NUMBER:

14-003-05

GROUP:

Vehicle Performance

DATE: July 8, 2005

DIAGNOSIS:

PRE-DIAGNOSTIC TROUBLESHOOTING PROCEDURE

For the engine circuit diagram, refer to the detailed service information available in

TechCONNECT, under: Service Info, 9 - Engine, Schematics and Diagrams. For a

complete wiring diagram, refer to the detailed wiring diagrams available in TechCONNECT

under: Wiring, 14 - Fuel System, Fuel Injection, (component)

Perform the existing “Pre-diagnostic Troubleshooting Procedures� available in

TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing.

WHITE SMOKE AND/OR MISFIRE AFTER COLD START

Possible Causes

Air in fuel supply

Coolant leaking into combustion chamber

Active DTC's

In very cold ambient temperatures, engine block heater is malfunctioning (if equipped)

Engine Coolant Temperature sensor malfunctioning

Engine Control Module (ECM) incorrect calibration

Fuel filter restricted

Fuel grade not correct or fuel quality is poor

Fuel heater element or fuel heater temperature sensor malfunctioning

Fuel Injector malfunctioning

Fuel injector hold-downs loose

Fuel injector protrusion not correct

Fuel injection pump malfunctioning

Intake/Exhaust valve adjustment not correct (too tight)

Intake manifold air temperature sensor malfunctioning

Intake manifold heater circuit not functioning correctly in cold weather

Internal engine damage

Restricted fuel supply side of fuel system

Preliminary checks:

·

·

more noticeable when cold.

·

normal white smoke; idle time, engine temperature, fuel source, cold ambient

temperature, high altitude.

NOTE: Steps 1 through 4 should be performed BEFORE the engine is started.

1.

soak, verify that the Intake Air Temperature (IAT), Engine Coolant Temperature (ECT),

Inlet Air Temperature, and the Battery Temperature sensors are showing similar and

appropriate temperatures. -

temperatures?

a. Yes >> Go to

b. No >> Repair the appropriate sensor or circuit. Refer to the diagnostic procedures

available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing. -

Go to

14-003-05 -2-

2.

verify that the Intake Manifold Pressure and Inlet Air Pressure sensors are showing

similar and appropriate pressure. -

appropriate pressures?

a. Yes >> Go to

b. No >> Repair the appropriate sensor or circuit. Refer to the diagnostic procedures

available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing. -

Go to

3.

overnight soak, verify that the fuel rail pressure reads 0 (+/- 500 PSI). -

rail pressure read 0 (+/- 500 PSI)?

a. Yes >> Go to

b. No >> Repair the fuel rail pressure sensor or circuit. Refer to the diagnostic

procedures available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis

& Testing. - Go to

4.

detailed service information available in TechCONNECT, under: Service Info, 14 - Fuel

System, Fuel Injection, Intake Air Heater, Operation. -

operating properly?

a. Yes >> Go to

b. No >> Repair the intake air heater or intake air heater circuit. Refer to the diagnostic

procedures available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis

& Testing. - Go to

5.

run at idle. Determine when the white smoke disappears. If the white smoke

disappears within one minute, it is normal. If the engine is operated in cold ambient

conditions and/or at altitude, white smoke at start-up is expected.

6.

each cylinder one-at-a-time. Note any change in smoke and/or misfire.

cylinder show a difference in smoke or misfire?

a. Yes >> Go to

b. No >> Go to

7.

a. Remove the valve cover.

b. Inspect the valve lash.

c. Remove the injector.

d. Inspect the injector seal washer and High Pressure Connector (HPC). Replace the

HPC if it is damaged.

e. Install the injector. Refer to the detailed service information available in

TechCONNECT, under: Service Info, 14 - Fuel System, Fuel Injection, Fuel Injector,

Installation.

f. Repeat test for injector misfire. Go to

NOTE: If the same single cylinder is still the cause of the miss or white smoke,

replace that single injector and HPC.

NOTE: Perform the following test if a single cylinder was not identified by the

cylinder cutout test to be causing the white smoke.

-3- 14-003-05

8.

block the high pressure fuel line at the rail, one injector at a time.

the cause of the white smoke and/or miss?

a. Yes >> Replace that injector and HPC. - Go to

b. No >> Go to

9.

the detailed diagnostic information available in TechCONNECT under: Service Info, 9 -

Engine, Diagnosis & Testing.

Test�?

a. Yes >> Go to

b. No >> Go to

NOTE: Maximum leakage allowable for all injectors combined is 180 mL (6.1 fl. oz.)

(At idle pressure).

NOTE: It is critical that all HPC nuts are tightened to the correct torque. Refer to the

detailed tightening information available in TechCONNECT under: Service

Info, 14 - Fuel System, Fuel Injection, Fuel Injector, Installation. Retest when

all HPC nuts are properly torqued.

NOTE: Any injector contributing more than 40 mL (1.4 fl. oz.) is excessive (Example:

If total injector leakage is 200mL (6.7 fl. oz.) and blocking cylinder #1 reduces

the leakage to 160 mL (5.4 fl. oz.), cylinder #1 has excessive leakage).

NOTE: Test should be repeated to confirm measurements.

10. If any cylinders are deemed excessive

a. Check HPC tip for damage, replace HPC if damaged. Refer to the detailed service

information available in TechCONNECT under: Service Info, 14 - Fuel System, Fuel

Injection, Fuel Injector, Removal/Installation. - Go to

b. If HPC tip is undamaged, replace the injector and HPC. Refer to the detailed service

information available in TechCONNECT under: Service Info, 14 - Fuel System, Fuel

Injection, Fuel Injector, Removal/Installation. - Go to

c. If total injector return flow is high and individual cylinders cannot be identified as the

source, replace all injectors and HPC's. Refer to the detailed service information

available in TechCONNECT under: Service Info, 14 - Fuel System, Fuel Injection,

Fuel Injector, Removal/Installation.

Step #12

11. If the engine passes the previous tests and still exhibits white smoke that clears with a

warm engine, check the following:

a.

b.

operating temperature.

c.

d.

lubricity additive.

e.

f.

g.

14-003-05 -4-

h.

available in TechCONNECT under: Service Info, 9 - Engine, Diagnosis & Testing,

Smoke Diagnosis Charts, Excessive White Smoke. - Go to

12. Repair Complete. - Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).

Refer to 8 - ELECTRICAL/ELECTRONIC CONTROL MODULES/ENGINE CONTROL

MODULE - DIAGNOSIS AND TESTING.

 

NUMBER:

18-037-04

GROUP:

Vehicle Performance

DATE: September 27, 2004

SUBJECT:

Flash: Fuel Economy Improvement, White Smoke On Start Up, Accuracy Of Fuel Mileage

In Overhead Consloe Display

OVERVIEW:

This bulletin involves erasing and reprogramming the Cummins ECM with new software.

MODELS:

2004 - 2005 (DR) Ram Truck

NOTE: This bulletin applies to DR vehicles equipped with a 5.9L Cummins Turbo

Diesel engine (sales code ETH), with an engine serial number 57130285

through and including 57246361 ; and the engine date of manufacture

12/10/2003 through and including 8/17/2004.

 

I will run that TSB by him. He doesn't want aftermarket injectors because of his warranty.
Well today the truck is going in so in a couple of days I will let everyone know what is going on. In the mean time, I think I am going to research another programmer for him other than that bullydog.

 

Well, the dealership said they suspect him of using a chip because of the memory loss. So they called up dodge, and dodge told them they were not paying for anything or doing any work and the vehicle is basically black flagged now on their database and no warranty anymore. All he can do I guess is keep trying to reach someone and act as if he doesn't know what they are talking about. Other than that, the vehicle is all stock with 36,000 miles on it. Anyone have any idea what to do? Thanks guys.

 

Was That Greenway Dodge, I have to find a way to make them prove it and remind them they might want to sell me another truck some day

 

Appreciate the support, if they don't help him, he won't ever buy a dodge again. Yes, that is the dealership, but it was dodge that told them they were not going to touch it. If you care for his #, PM me.

 

You can't blame Dodge as a programer like a BD or what ever brand you use things can break or other problems. The problem your dad has is why you become your own waranty station any time you add any power box or programer to your truck as your warranty goes out the door.

 

We are working on the problem here also, I have a customer with an 05 2500, same deal 5 to 9 mpg is the best he gets, and his rear quarter panel is always black, local dealer shrugging their shoulders, and this one has never been chipped. I hope we find it keep on keepin on!