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I just recently had to have my 5.9 rebuilt. My 12 year old analog EGT gauge failed on me on a family vacation, and I pulled some steep passes towing my travel trailer. EGT's got too hot, and I fried the rings in #5 and #6 pistons. Full engine rebuild with .020 pistons, new injectors, arp head studs, a new southbend clutch (old one was just about done anyway, so I figured now was a good time to replace it), and an Edge CTS 2 monitor (so this doesn't happen again) cost me $9000. Expensive lesson to learn, but lesson is learned. I hope you can enjoy building your truck!
 

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Discussion Starter #63
I appreciate you guys helping to bump this post if nothing else, but I'm still left hanging, is there anything electronics wise I need to do sense it's a 07 motor going into a 06?
(Eventually I'll put a quadzilla on it, and if it should ever see 1200 of EGT itll pull back and cool it down, I cant recommend it enough for engine protection and preformance)
 

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Are you saying the Common Rail engines have powered rods? Everything I have read said they are forged steel and fracture split. Is that not correct?
You might find some of the early SO's with forged rods in them but all the later ones are cracked cap iron power. They have more tensile strength but much more brittle than a forged rod. Forged rod will bend enough to cause an obvious vibration to investigate, an iron powder rod will just break with no warning and usually windows the block.

I appreciate you guys helping to bump this post if nothing else, but I'm still left hanging, is there anything electronics wise I need to do sense it's a 07 motor going into a 06?
(Eventually I'll put a quadzilla on it, and if it should ever see 1200 of EGT itll pull back and cool it down, I cant recommend it enough for engine protection and preformance)
Zero problems, it is the same engine in 5.9 version. A 6.7 will also fit with no issues but likely have to use the 5.9 injectors.
 

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Discussion Starter #65
Are you saying the Common Rail engines have powered rods? Everything I have read said they are forged steel and fracture split. Is that not correct?
You might find some of the early SO's with forged rods in them but all the later ones are cracked cap iron power. They have more tensile strength but much more brittle than a forged rod. Forged rod will bend enough to cause an obvious vibration to investigate, an iron powder rod will just break with no warning and usually windows the block.

I appreciate you guys helping to bump this post if nothing else, but I'm still left hanging, is there anything electronics wise I need to do sense it's a 07 motor going into a 06?
(Eventually I'll put a quadzilla on it, and if it should ever see 1200 of EGT itll pull back and cool it down, I cant recommend it enough for engine protection and preformance)
Zero problems, it is the same engine in 5.9 version. A 6.7 will also fit with no issues but likely have to use the 5.9 injectors.
Thanks man appreciate it, the 07 I got is a 5.9
 

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You might find some of the early SO's with forged rods in them but all the later ones are cracked cap iron power. They have more tensile strength but much more brittle than a forged rod. Forged rod will bend enough to cause an obvious vibration to investigate, an iron powder rod will just break with no warning and usually windows the block.



Zero problems, it is the same engine in 5.9 version. A 6.7 will also fit with no issues but likely have to use the 5.9 injectors.
I’m still confused. Is it not possible to have a forged steel rod with a cracked cap? It just seems odd that all the published documentation says the rods are forged steel, including a response from Cummins.

I have no doubt that they are more brittle and break rather than bend based on your experience. I did read something that a Yamaha released suggesting something about fractured caps with steel rods. Honestly though I wasn’t quite clear what they were saying.
 

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Its possible but not done. The types of forging and heat treating are what makes the rods. It is just a process to supposedly cut costs with less machining and supposedly better consistency in weights. In actual practice it is another throw away part as they cannot be resized and if they have been stressed they are done. The claim that weights are more consistent doesn't fly either, up to 100 grams or better difference in rod weights WILL cause vibrations. If you are lucky you get a set that are closer, if not you have built problems. The difference between the rod types and the ability to balance them is very noticeable.

A forged steel rod will bend and twist while not coming completely apart because it has better elasticity. The PM rods have more tensile strength before they deform but they will not bend, they break. Cummins gave up on the PM rods anyway, all th e newer engines have gone to a forged rod, probably for NVH reasons.
 

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Discussion Starter #68
P0148
That's the code I'm getting, it makes no boost, when plugged in with a scan tool it says it's making 12lbs at idle.
It's got a new fuel filter on it, the lift pump is good.
What all could it be?
I've read that it could be the
pressure relief valve.
What about the sensor on the rail to?
It's not thick black black smoke, but a haze the entire time my foots on it, and it has no power.
 

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Could be a lot of things should go thru diagnostics :wink2:

Possible Causes
OTHERS DTC’S PRESENT
FUEL LEAKS
FUEL CONTROL ACTUATOR
FUEL PRESSURE SENSOR
CASCADE OVERFLOW VALVE
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
LIFT PUMP FLOW
AIR IN FUEL SYSTEM
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
HIGH PRESSURE FUEL PUMP
INTERMITTENT CONDITION

Diagnostic Test
1. OTHERS DTC’S PRESENT
With the scan tool, read DTCs.
Are any other DTC’s present?
Yes >> Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No >> Go To 2
2. FUEL LEAKS
Ensure that the fuel level is above 15% using the scan tool.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components.
Do you have any fuel leaks or damaged components?
Yes >> Repair the fuel leak.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 3
9 - 1116 ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL DR/DH
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)
3. FUEL CONTROL ACTUATOR
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.
NOTE: The fuel control actuator will only click when cycled off..
Do you hear a click from the actuator when you cycle the actuator off with the scan tool?
Yes >> Go To 4
No >> Replace the fuel Injector pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
4. FUEL PRESSURE SENSOR
Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
Yes >> Go To 5
No >> Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5. HIGH FUEL PRESSURE
Using the scan tool compare the fuel rail pressure set point with the actual fuel rail pressure.
Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Yes >> Go To 6
No >> Go To 9
6. CASCADE OVERFLOW VALVE
Perform the no trouble code test 9*fuel pump return flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the fuel injection pump pass the test?
Yes >> Go To 7
No >> Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
7. CHECK VALVE DAMAGED OR BLOCKED
Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?
Yes >> Repair the cause of the damaged or blocked check valve or replace the valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 8
DR/DH ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL 9 - 1117
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)
8. FUEL RETURN LINE OBSTRUCTION, DAMAGED OR DEBRIS
Check the fuel return lines for signs of obstruction, damage, or debris.
Are the fuel drain lines damaged or blocked?
Yes >> Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 9
9. LIFT PUMP FLOW
Perform the no trouble code 9Lift Pump flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the Lift pump pass the test?
Yes >> Go To 10
No >> Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
10. PRESSURE LIMITING VALVE
Perform the no trouble code test 9 Pressure Limiting Valve on the Fuel Rail for internal leaks9.
Did the pressure limiting valve pass the test procedure?
Yes >> Go To 11
No >> Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
11. LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
Perform the no trouble test 9*Injector return flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Are any Injectors leaking or high pressure connectors leaking?
Yes >> Replace or repair the leaking fuel injectors or high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 12
12. HIGH PRESSURE FUEL PUMP
Perform the no trouble code test 9
HIGH PRESSURE FUEL PUMP PERFORMANCE TEST9. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING)
Did the fuel pump pass the high pressure fuel pump performance test?
Yes >> Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No >> Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/
 

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Discussion Starter #70
Could be a lot of things should go thru diagnostics <img src="http://www.cumminsforum.com/forum/images/CumminsForum_2016/smilies/tango_face_wink.png" border="0" alt="" title="Wink" class="inlineimg" />

Possible Causes
OTHERS DTC’S PRESENT
FUEL LEAKS
FUEL CONTROL ACTUATOR
FUEL PRESSURE SENSOR
CASCADE OVERFLOW VALVE
CHECK VALVE DAMAGED OR BLOCKED
FUEL RETURN LINES OBSTRUCTION, DAMAGE, OR DEBRIS.
LIFT PUMP FLOW
AIR IN FUEL SYSTEM
LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
PRESSURE LIMITING VALVE
HIGH PRESSURE FUEL PUMP
INTERMITTENT CONDITION

Diagnostic Test
1. OTHERS DTC’S PRESENT
With the scan tool, read DTCs.
Are any other DTC’s present?
Yes >> Repair other DTC’s first.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL).
No >> Go To 2
2. FUEL LEAKS
Ensure that the fuel level is above 15% using the scan tool.
Visually inspect the low and high pressure side of the fuel system for fuel leaks or damaged components.
Do you have any fuel leaks or damaged components?
Yes >> Repair the fuel leak.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 3
9 - 1116 ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL DR/DH
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)
3. FUEL CONTROL ACTUATOR
Check for a mechanically stuck Fuel Control Actuator (FCA). Using the scan tool, actuate the fuel control actuator.
NOTE: The fuel control actuator will only click when cycled off..
Do you hear a click from the actuator when you cycle the actuator off with the scan tool?
Yes >> Go To 4
No >> Replace the fuel Injector pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
4. FUEL PRESSURE SENSOR
Using the scan tool, monitor the fuel pressure reading from the fuel rail pressure sensor at idle and at 2000 RPM
Is the fuel rail pressure reading higher at 2000 RPM than at idle?
Yes >> Go To 5
No >> Replace the fuel pressure sensor.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
5. HIGH FUEL PRESSURE
Using the scan tool compare the fuel rail pressure set point with the actual fuel rail pressure.
Is the actual fuel rail pressure higher than the fuel rail pressure set point?
Yes >> Go To 6
No >> Go To 9
6. CASCADE OVERFLOW VALVE
Perform the no trouble code test 9*fuel pump return flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the fuel injection pump pass the test?
Yes >> Go To 7
No >> Replace the Fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
7. CHECK VALVE DAMAGED OR BLOCKED
Check the fuel drain line check valve in the rear of the cylinder head for signs of damage, blockage, or debris.
Is the check valve damaged or blocked?
Yes >> Repair the cause of the damaged or blocked check valve or replace the valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 8
DR/DH ENGINE - ELECTRICAL DIAGNOSTICS - DIESEL 9 - 1117
P0148-HIGH PRESSURE COMMON RAIL (HPCR) CHECKSUM (CONTINUED)
8. FUEL RETURN LINE OBSTRUCTION, DAMAGED OR DEBRIS
Check the fuel return lines for signs of obstruction, damage, or debris.
Are the fuel drain lines damaged or blocked?
Yes >> Repair cause of high fuel drain line restriction.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 9
9. LIFT PUMP FLOW
Perform the no trouble code 9Lift Pump flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Did the Lift pump pass the test?
Yes >> Go To 10
No >> Replace the Lift Pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
10. PRESSURE LIMITING VALVE
Perform the no trouble code test 9 Pressure Limiting Valve on the Fuel Rail for internal leaks9.
Did the pressure limiting valve pass the test procedure?
Yes >> Go To 11
No >> Replace the Pressure Limiting Valve.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
11. LEAKING FUEL INJECTORS OR HIGH PRESSURE CONNECTORS
Perform the no trouble test 9*Injector return flow test9. (Refer to 9 - ENGINE - DIAGNOSIS AND TESTING)
Are any Injectors leaking or high pressure connectors leaking?
Yes >> Replace or repair the leaking fuel injectors or high pressure connectors.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/ELECTRONIC
CONTROL MODULES/ENGINE CONTROL MODULE - DIAGNOSIS AND TESTING)
No >> Go To 12
12. HIGH PRESSURE FUEL PUMP
Perform the no trouble code test 9
HIGH PRESSURE FUEL PUMP PERFORMANCE TEST9. (Refer to 9 - ENGINE
- DIAGNOSIS AND TESTING)
Did the fuel pump pass the high pressure fuel pump performance test?
Yes >> Refer to the INTERMITTENT CONDITION Symptom (Diagnostic Procedure). (Refer to 9 - ENGINE -
DIAGNOSIS AND TESTING)
No >> Replace the High pressure fuel pump.
Perform POWERTRAIN VERIFICATION TEST VER - 1 (DIESEL). (Refer to 8 - ELECTRICAL/
I've been going threw this list, where did you get this from? Is there a book or possibly a link to a free PDF were i could download the whole book / manual?
 

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Discussion Starter #72
2005 FSM, search here for your truck <img src="http://www.cumminsforum.com/forum/images/CumminsForum_2016/smilies/tango_face_wink.png" border="0" alt="" title="Wink" class="inlineimg" />
https://www.cumminsforum.com/forum/3rd-gen-powertrain/1909713-newbies-guide-your-new-you-truck.html?highlight=newbies+guide
Appreciate it, I checked it out and downloaded the 06
Thank you.
Haven't had hardly anytime to mess with it, its crashing ya know till 2020. I'll definitely take a look at er soon, been picking up a lot of doubles recently.
 

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Discussion Starter #73
Got a new set of injectors
Waiting on cross over tubes
I'm curious here, was told my ecm might need reflashed to work better with this different engine, and could be the reason for my codes.
I've gone threw everything but injectors.
 

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Discussion Starter #75
Parts should be here Tuesday or so.
Noticed the voltage gauge says 15 while idling/ driving. Is this normal?
I just put in 2 brand new CAT batteries.
 

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Like all the other gauges in truck it is an indicator ie software based, what Dodge engineers thought customer would like to see.
Best to take voltmeter and measure voltage at both batteries, running 14+ volts, dependent on temperature, how drained batteries are. Engine not running fully charged batteries should be 12.6+ volts
Voltage difference between 2 batteries should be 0.1-0.2 volts otherwise should check cables/batteries out.
 

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Discussion Starter #77
could i get the torque specs for for the over head please?
im looking threw the service manual but no luck so far. i have injectors and connector tubes.
could i get all the torque specs needed for this process please?
 

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Check your inbox for a PM
 

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Discussion Starter #80
Apologies guys, didnt realize I could click on titles and it would bring me to that section... spent hours scrolling threw individual pages.... LOL!
 
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