Watch out for your Air Filter!!!

[03 Rammer]

ALL DIESEL OWNERS PLEASE READ!!!

After rolling over 100K I took my air inlet tube off and was shocked to find dust inside the tube and inside the turbo. I was sorta pissed. After doing some research for hours I found out the problem was my K&N drop in air filter.

Read for yourself what I read and found out. And you be the judge to run what air filter you want or not want to run. Including CAI, air intakes.

Links:
http://www.genosgarage.com/TechArtic...irCleaners.pdf
http://www.genosgarage.com/TechArtic...R59_AirBox.pdf

Cumminsforum users:
http://www.cumminsforum.com/forum/se...archid=7272630
* or search "trubo dusting"


TSB related to Air Filters:
There is also an old TSB about air filters like K&N, but I can not seem to find it.
NUMBER: 09-001-10

GROUP: Engine

DATE: July 2, 2010

SUBJECT:
Dust-Out Diagnosis For Cummins Diesel Engines

OVERVIEW:
This bulletin involves proper inspection procedures to determine engine failure due to dust-out condition. Engines damaged due to the infiltration of dirt and/or debris through the air intake system are NOT WARRANTABLE.

NOTE :Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected.

MODELS:

2003 - 2005 (DR) Ram Pick Up Truck (2500)

2006 - 2009 (DH) Ram Pick Up Truck (2500)

2010 - 2011 (DJ) Ram Pick Up Truck (2500)

2003 - 2005 (DR) Ram Pick Up Truck (3500)

2006 - 2009 (D1) Ram Pick Up Truck (3500)

2010 - 2011 (D2) Ram Pick Up Truck (3500)

2007 - 2010 (DC) Ram Truck Cab Chassis (3500)

2011 (DD) Ram Truck Cab Chassis (3500)

2008 - 2010 (DM) Ram Truck Cab Chassis (4500/5500)

2011 (DP) Ram Truck Cab Chassis (4500/5500)

NOTE :This bulletin applies to any Cummins diesel equipped vehicle still covered under the manufacturers warranty.

SYMPTOM/CONDITION:

Engines that exhibit particular symptoms that may have been caused by improper air filtration. Some of these symptoms are listed below (not limited to)

^ Knocking

^ Hard or no start

^ Low power / poor performance

^ Oil consumption

^ Lower end bearing failure

^ Smoking

^ Blow-by (rings not sealing)

^ Oil on turbo (dust damage to seal/bearing)

NOTE :See the "Cummins Diesel Dust-Out Inspection for Warranty" document located in eFiles Under: Service> STAR Center> Cummins - HEV documents for pictures regarding dust-outs.

NOTE :Canadian dealers can refer to Tech-Tip # 18 - CUMMINS DIESEL ENGINES FAILURES DO TO DIRTY AIR ENTERING THE INDUCTION SYSTEM - HOW TO INSPECT FOR SIGNS OF A "DUST OUT" ENGINE FAILURE sent 05/19/2010 for pictures regarding dust-outs.

DIAGNOSIS:

1. Perform a compression test. Low compression is generally due to ring/piston/valve issues. High compression may be due to oil infiltration causing a hydraulic effect.

2. Major mechanical damage can also be caused by fuel, fuel injectors or "Up-rate kits or "programmers". Inspect vehicle for any device that adds more power, (fuel) which may damage the engine mechanically. Check for any aftermarket power enhancer or "box" or "downloader".Repairs of failures caused by these devices do not qualify for warranty coverage.

3. Inspect all air handling ducts and components. (See eFiles document). If dirt is found in the air handling components, further diagnostics may not be necessary. Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage.

4. Inspect for aftermarket "cold air" performance air filter housing, duct work and filters. Again, Engines with dirt detected on the "clean side" of air filter will not qualify for warranty coverage.

5. Inspect cylinder bore(s) for cross-hatching and excessive piston ring ridge. The absence of cylinder bore cross-hatching MAY be one of the first signs of cylinder dust or dirt damage. Cylinder bore(s) for cross-hatching and excessive piston ring ridge may be inspected using a bore scope (if available), or cylinder head removal may be necessary. Contact your Business Center or Service and Parts Area Manager if dust out evidence is noticed or any type of tampering is suspected. Dirt carried in through the air handling system is typically funneled and concentrated to the end (1 & 6) cylinders*. Vertical scratches (broken rings) will follow. Generally, a properly maintained engine will have well defined hone marks visible beyond 100,000 miles.

NOTE :Be aware of stains or marks in cylinder wall(s). Marks may follow the ring gap but have no depth or damage to the cylinder bore wall. These marks have a look similar to a "scored" cylinder, yet have no physical damage to the surface and will not cause any harm. These marks be checked by physically inspecting (scratching) the surface to detect if cylinder wall is damaged (grooved).

6. When inspecting the cylinder bore(s), compare cylinders # 1 & # 6 to the others. Cylinder honing (cross-hatching) performed in the Cummins engine manufacturing process is very aggressive. Engines that have dirt introduced will "polish out" this hone witness mark first and then start cutting or wearing down the cylinder walls which will create a ring ridge in the cylinder bore at the top of the bore. The absence of the cross-hatching ALONG WITH dirt found anywhere in the "clean-side" of the air intake system, is evidence of a dust-out condition.