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Symptoms · 5.9 Cummins (1994-2007)
5.9 Cummins (1994-2007): white smoke from the exhaust
2 documented failures on this engine list this among their signs. They are ordered from the most widespread down. Each one shows the signs in its record's own words, how to tell it from the others, the usual fix and any recall or bulletin.
Not sure which engine you have, or want the recalls for your exact truck? Check your VIN: it names the engine and lists the campaigns for that model year. Whether a recall is still open on your VIN: nhtsa.gov/recalls.
verified
How widespread: Common
How it shows up
- cold-start rattle and white smoke that clears warm; uneven idle; rising fuel consumption
Its other signs
- metal-on-metal tick from a failing injector; copper crush washer blow-by at the sleeve
How to tell it apart
- balance-rate test (bidirectional scan tool or dealer test) pinpoints the weak injector before replacing a set
- inspect connector tubes and copper washers for blow-by soot
Usual fix
replace the worn injector(s) with new/reman units; new copper washers and connector-tube seals every time
Root cause, parts and sources →
verified
How widespread: Occasional
How it shows up
- long crank and white smoke in cold weather; 'wait to start' behaviour that ignores temperature
Its other signs
- in severe cases: melted grid heater elements or welded relay contacts, battery drain
How to tell it apart
- verify relay operation and voltage drop across the high-current studs at key-on
- check for intake sooting and loose grid-heater plate bolts (air leak into the intake)
Usual fix
replace relays/repair the high-current circuit; reseal or replace the grid heater assembly
Root cause, parts and sources →
Other symptoms on the 5.9 Cummins (1994-2007)
Hard start, long crank or no-startLoss of power, limp mode or derateLosing coolantTicking, knocking, rattle or whineMisfire, rough idle, hesitation or surging
Everything on the 5.9 Cummins (1994-2007)Its recalls and bulletins