[Engineersaab54]

I bought a one-owner, 2016 RAM 1500 Eco diesel w/34,800 miles on it a couple of months ago. Was loving the truck, until 10/11/19, fortunately only 26 miles from home at the start of a 900 mile trip, got odd engine sound, slight vibrations, high-rev/limp mode, white smoke pouring out from under the hood and out the pipes, and "Service Electronic Throttle Control" warning light. We were almost at an exit, so we "limped" off the freeway. Did not have the presence of mind to check and record engine temps. Thought it was on fire. Have extinguisher in the back, but smoke cleared upon opening the hood. Exhaust pipes are coated w/white dust and tiny white pellets.
After a minute tried to start it to see if SETC light would reset, as per Owner's Manual instructions. Massive white smoke plumes again, so turned it off immediately.
When wrecker arrived (four hours later! - Chrysler roadside assistance was worthless; my own insurance company more responsive but picked the wrong towing company to respond), we were able to start the truck and drive it up onto the tow bed - no smoke. Got to the dealership late Friday afternoon on the 11th. Researched this issue over the weekend, and told the dealer that the fix might involve new injectors, new turbo and EGR cooler, new sensors here and there, etc. Dealer said they had NEVER had to replace injectors at 36,000 miles. $125 for initial tech time.
The following week they cleaned the injectors and replaced a sensor, along with the can it had welded itself into, and updated the software. Mostly covered by warranty, except for $250 for the sensor, or something (don't have the bill, yet). Still limp. Getting a turbo issue code. But "let's change out the fuel filter, first, before we replace the turbo." $175 fuel filter - old filter was at about 75% life used up, if that. Changed the filter - didn't help.
They are replaced the turbo, and the EGR cooler, under warranty, after waiting a week for one of the 1,300 EGR coolers on back order in the United States to arrive. On 11/1, Friday afternoon, they informed me that "all repairs have been completed … but the truck is still in limp mode." They now want to replace a few more sensors. Still under warranty.
Anybody else have this issue accompanied by the smoke under the hood and residue in the pipes?
Anybody have a 'real' fix? Online forums indicate FCA doesn't really have good answers for this, yet, short of replacing the engine. Anybody successfully gotten FCA to replace an engine? I hear the 3rd generation, 2020's are supposed to have all the bugs worked out.

 

[Engineersaab54]

I see that on October 28th FCA posted a recall on EGR Coolers for 2014-16 Ecodiesels due to fire hazards. Am hoping THAT was the reason for 1300 of them being on back order, and that the one they installed on November 1st is of the recall-replacement variety. What are the chances. http://m.carcomplaints.com/news/2019/ram-1500-ecodiesel-coolant-leak-recall-egr-coolers.shtml

 

[Engineersaab54]

Make that 2014-2019 models. And we are to keep an eye on our coolant levels. I will look forward to doing that if I ever get a working truck back.

 

[Engineersaab54]

The second day I had my used truck, I had a regen pop up so I stayed on the freeway. Temps went high, overheating, and white smoke was pouring out the back and coolant was being sucked down. Got it in the shop the next day and it was a temperature sensor I think they said. Whatever they did fixed it. No other issues (except disappearing coolant) for almost 2 years, then after the update, I threw a code and my EGR had to be replaced. No issues since.
Not sure if this helps at all but it's what happened to me. I didn't notice any residue. Does it look like crystals similar to DEF?

Thanks, and glad to hear that you've had no issues since. Are you still seeing coolant disappearing? That is a sign of microscopic cracks in the EGR cooler that they are issuing a recall on. It's a fire hazard.
They have replaced several sensors in the last three weeks, and I'm pretty sure at least one was a temperature sensor. They replaced a throttle control this morning, but that did not fix the problem either. I asked if they'd checked to see if the exhaust system was blocked, but they assured me that if it was, the truck would not start. Hmmm.

 

[Engineersaab54]

There is one event that gives big humongus smoke out the back ,
and that was described as normal . OP going in limp mode is not part of that I guess...
see this thread : https://www.ram1500diesel.com/forum...scussion/64402-why-so-smoky-2.html#post972618

I talked to them this morning again about pursuing the cause of all the smoke, and was told it was "normal". Out the pipes, I'd say maybe, but out the hood? Doesn't sound normal to me! I was having to do a regen about every 10 days. Eight to ten miles on the freeway always cleared it up. I figured it was because my office is only a mile a half from home, so it wasn't getting warmed up on the commute. Dealer says there may have been a fault in the throttle control that wasn't letting it heat properly, or something like that, so they changed it out this morning. Still not getting any boost. They are on the phone to FCA as we speak...

 

[Engineersaab54]

The second day I had my used truck, I had a regen pop up so I stayed on the freeway. Temps went high, overheating, and white smoke was pouring out the back and coolant was being sucked down. Got it in the shop the next day and it was a temperature sensor I think they said. Whatever they did fixed it. No other issues (except disappearing coolant) for almost 2 years, then after the update, I threw a code and my EGR had to be replaced. No issues since.
Not sure if this helps at all but it's what happened to me. I didn't notice any residue. Does it look like crystals similar to DEF?

See my response to Kazimoto on smoke and regens. I never noticed any smoke when I was having to do a regen. But yes, we think the crystals must be DEF. Someone on another forum suggested the SCR must have blown up, but dealer wasn't buying that. Said they didn't think so, from what they were able to see. I initiated a customer care claim at FCA website last night. We'll see where it goes...

 

[Engineersaab54]

I don't have any disappearing coolant since the EGR was replaced. I still check probably once a week to see how the level is.
Pretty wild stuff you're having happen. I hope they get it all cleared up.

Good to hear. Thanks. Me too!

 

[Engineersaab54]

Here’s an update on the billowing smoke 2016 ED that has been in the shop 40 days and 40 nights now.
Last week the dealer discovered that the intake had melted. This was 30 days after it was towed in and I told them I thought the engine was on fire when the event happened. FCA told the dealer they didn’t know when they could get a new intake to them. I called my FCA Case Manager and the dealer had the part in two days.
They had to lift the cab off to do the repair. Found out this was the second time in this repair process that it had to be done. They completed the repair this morning.
They called me this afternoon at 4:30 and said they’d had it out for a long test drive and everything appeared to be running fine.
I picked it up and went almost two miles before the check engine light came on again. Took it back to the dealer at 5:30. The code has something to do with particulates in the exhaust system. They will check into it in the morning. Day 41.
Meanwhile, this morning I asked my Case Manager for a bumper-to-bumper warranty so that any components that might suffer reduced life expectancy as a result of this high temperature event will be covered. Supposed to hear back on that by Friday.
Keep the faith.

 

[Engineersaab54]

UPDATE: Did not hear back from case manager Friday and she is out all this week. But I DID get my truck back again this afternoon. So far (15 miles), so good! Ha. It seems to be running a little better than when I first bought it, and I thought it was running really well then. But it should - with all those new parts on it!
Will cross my fingers and keep a close eye on the coolant level!