Attention: TDR Forum Junkies I accidentally overfilled my 2001 Dodge Ram 3500 Cummins after an interruption. Not clear if I ended up putting two 3 or 4 jugs of oil in, or the equivalent of 15-20 quarts, but oil traveled full circle through the intercooler and back into the intake.
I was initially unaware of how much extra oil was in there and could not restart the truck when I tried.
I then figured out what happened and drained the excess oil, but still no start even with excessive cranking.
I had had prior codes relating to the injection pump timing and also a limp accelerator pedal after cold starts for about a mile or two of driving. The accelerator pedal also "went to sleep" at highway speeds requiring a pause of 4-5 seconds before pushing the accelerator again to be able to increase speed, or pushing the pedal down until a downshift was forced and then only being able to accelerate again.
Therefore I decided to replace the injection pump and the throttle position sensor. I calibrated the TPS as well. Then I installed a new lift pump as well.
I bled the injectors by backing off the hex nuts at the head and making sure diesel was available there, but still had difficulty starting. I was able to start it again, but it was putting out massive amounts of black smoke out and ran very poorly for 15 minutes, until it progressively got to a normal smooth idle. When it first started and for 5-10 minutes after that there was a loud clanking in the front of the engine, almost like a rod knock sounds on a gasoline engine. Even at smooth idle the smoking was still there and it took 25-30 minutes for the smoke to turn a little more toward a gray-white.
I subsequently drained the intercooler as much as possible by disconnecting the lower hose on the driver's side (which feeds into the metal duct and then into air horn on the intake).
I also used a rag inside the intake when I had the air horn off of it to soak some of the oil out of there.
Again it took a while to get it started and the poor running, clanking and heavy smoking was repeated, though it gradually smoothed out.
Firs time I ran it there was no response to depressing the accelerator pedal, but the second time there was a minute response, though the idle did not raise much at all.
What should be my next order of things to try? What sensors or engine controls could have been affected?
Thanks to all that can offer some advice.
I was initially unaware of how much extra oil was in there and could not restart the truck when I tried.
I then figured out what happened and drained the excess oil, but still no start even with excessive cranking.
I had had prior codes relating to the injection pump timing and also a limp accelerator pedal after cold starts for about a mile or two of driving. The accelerator pedal also "went to sleep" at highway speeds requiring a pause of 4-5 seconds before pushing the accelerator again to be able to increase speed, or pushing the pedal down until a downshift was forced and then only being able to accelerate again.
Therefore I decided to replace the injection pump and the throttle position sensor. I calibrated the TPS as well. Then I installed a new lift pump as well.
I bled the injectors by backing off the hex nuts at the head and making sure diesel was available there, but still had difficulty starting. I was able to start it again, but it was putting out massive amounts of black smoke out and ran very poorly for 15 minutes, until it progressively got to a normal smooth idle. When it first started and for 5-10 minutes after that there was a loud clanking in the front of the engine, almost like a rod knock sounds on a gasoline engine. Even at smooth idle the smoking was still there and it took 25-30 minutes for the smoke to turn a little more toward a gray-white.
I subsequently drained the intercooler as much as possible by disconnecting the lower hose on the driver's side (which feeds into the metal duct and then into air horn on the intake).
I also used a rag inside the intake when I had the air horn off of it to soak some of the oil out of there.
Again it took a while to get it started and the poor running, clanking and heavy smoking was repeated, though it gradually smoothed out.
Firs time I ran it there was no response to depressing the accelerator pedal, but the second time there was a minute response, though the idle did not raise much at all.
What should be my next order of things to try? What sensors or engine controls could have been affected?
Thanks to all that can offer some advice.
no limit. Sounds like you are doing fine. The turbo is not hard to rebuild, I did use genuine Holset parts, it may not matter. Do you have the HY35W or HX35W? Is your engine stock?
