Aftermarket injector longevity.

[CKESSEL]

On my 04.5 H/O, I decided to change my injectors out as a just because. Was not having any issues with them at 119360 on the odometer. Put in some new, stainless body 60hp extrude honed units from Industrial Injection. At 141k on the odometer, its running very rough. Sent them in to get checked out and was told the units were worn out due to fuel cleanliness. I paid up so they could send them back to me after they re-built them, but I spent the rest of the day pondering. From the time the truck was new till 125514 on the odometer, I have used the 7 micron Fleetguard filter in the oe housing. My change intervals have been at 10k since it was new. This is also when I change the oil, 5-30 Amsoil, both the standard and bypass filters, again Amsoil, and rotate the six wheels and tires. To me, fluid and filters are cheap insurance. At 125514, I put the Airdog 2 micron unit on and its been that way since with regular filter changes. Now, I'm not the sharpest knife in the drawer but I also didn't just fall off the turnip truck. If there is an issue on my end, I want to fix it so this doesn't happen again. However, I think that the replacement injectors should have lasted as long if not longer than the oe units. I'm not pointing any fingers but really want to know if its a part/qc issue or me. What are your thoughts my diesel brethren???

 

[CToney]

That is strange that they only lasted that long. My dad and I put 50 hp injectors in our trucks last fall with the same thinking as you, change them on your schedule as preventative maintenance. Since 2008 I've had FASS fuel systems with 3 micron filters. I've always used a fuel conditioner and fuel is filtered out of our bulk tank for the majority of fill ups. Hopefully I have better luck than that. I'm not sure what you could do different. Do you buy your diesel from the same place all the time?

 

[CKESSEL]

I'm fairly consistent on the fuel purchases. Here in town there is one known place that does not have a filter on their pumps so I stay away from them. Every couple of months I run some of the Amsoil cleaner through. If I am going on a long drive, I'll add it in then also. Whenever I changed the oe filter, there was no build up of crud on the old filter so I'm suspicious that its a filtration issue like they told me. Like in my earlier post, 119k on stockers with no issues and 22k on a/m units completely wiped out. Really??? If this happens again sooner than 100k, I'm going elsewhere for replacements.

 

[seafish]

It really all depends if the injectors you used were new Bosch, reman by Bosch, or reman by aftermarket.

The ONLY way to assure injector consistency and longevity with replacments is with NIB Bosch injectors purchased from a reputable Bosch dealer.

While rare, even the Bosch certified reman injecotrs can have issues, but any other brand remans WILL have issues, it is only a matter of time before they do.

Some people use NIB Bosch marine injecors with good results, and others are now using NIB BBi injectors by Smarty Power. Both of these options are expensive, but likely worth it, seeing as how you will not need to replace the set TWICE.

 

[ColemanR]

First set on my truck went 160K lost an injector which took out a cyl. Rebuilt the motor installed a Fass system next set went 300K I got nervous changed them out with a new set(not rebuilt) around 250K later I noticed a very loud ticking then a cyl went dead. Long story short lost another injector(I believe a soliniod) Now I'm 10K into a set of BB 1's and I could not be happier. I actually thought my truck was getting tired as it was down on power a bit and didnt have the smoothest idle.(sounded like a weak cyl) Well I'm happy to say its as strong as ever. I just came back from a 5500 mile trip and my mpg average is up .92mpg. I averaged 11.98 for 5500 miles. I went over the Siskiyous's in Oregon 3 times the Rocky's twice and the Grapevine in Cal once. These pass's are no joke. I ran around 60mph in Cal and 62 to 65 everywhere else. Mind you this is all towing a 30ft trailer with a weight of between 5K and 10K. I believe in extra filtration and buying fuel where you know they go thru alot of it.

 

[cerberusiam]

Sent them in to get checked out and was told the units were worn out due to fuel cleanliness. What are your thoughts my diesel brethren???

I think you were attached to an object by an inclined plane wrapped helically around an axis?

No way in 20k that happened to a GOOD set of injectors. Yopu would have a tank full of sand and water and it would QUIT running long before that if the fuel was that bad.

Remans are a crap shoot, any of them. Remans other than Bosch are akin to shooting yourself in the foot, painful and expensive.

 

[AH64ID]

Which filters are on your AD, many of them have far worse filtration the stock... Even the "2um" ones...

 

[CToney]

Are the 3 mic Fass filters any good? I'm looking at injectors for my 05 in the new year, it has 160,000 miles with only the last 6000 with 2 mic GDP filter. I was thinking 50 hp DDP. I wish our CAN $ was higher.

 

[AH64ID]

Which FASS do you have?

 

[CToney]

150/95 with 1003 fuel filter.

 

[BLNRAY]

Are the 3 mic Fass filters any good? I'm looking at injectors for my 05 in the new year, it has 160,000 miles with only the last 6000 with 2 mic GDP filter. I was thinking 50 hp DDP. I wish our CAN $ was higher.

I have a fass 150 I use the hf6604 and fs1003,fass was one of the first upgrades on my truck about 10 years ago and is probably the main reason I have 401,000 mi on the original injectors.

 

[CKESSEL]

The units I purchased from Industrial Injection were new Bosch updated units, s/s bodies with 60hp increase. At least thats what I paid for. Reman'd units back and in as of an hour ago. Runs good now. Am going to watch for issues since I now know what to look for when they start crapping out. Was at SEMA this week, found out some interesting information from a competitor on what the root cause was. NOT filtration. I've been dealing with this for almost 10k miles trying to figure out what was happening. Of course the warranty expired. Next time?????

 

[jhenderson]

Root cause a big secret?

 

[CKESSEL]

Poor qc and materials. What I was told is the combination of that and not testing on the mega buck [250k] test unit that only a very few have created my problem. I've been having issues for quite awhile but until they really started leaking, I could not figure it out. For a long time I kept getting po299 codes set, low boost. It would show up on light load, 10lbs or less on boost. Changed out map and intake temp sensors a couple of times. Here and there it would run rough on start up after sitting overnight. Rough start was getting more prevelant as time went on and the last time I changed the map there was soot on it. Should not have soot in the intake! What I came to realizing after talking to a friend, who is a Cummins tech, is that the exhaust pressure was higher than the boost pressure causing a reversion issue like you would get in a gas motor running a big cam at low rpm's. We figured that there was an injector issue causing the turbo to not get spun up enough to create adequate boost. Once the injectors really started leaking down, he ohm'd out the solenoids, checked rail pressue, charge air leaks etc. One thing he could not check was the contribution test and the local Dodge dealer could not also as they elected not to have any software capability for the older trucks in their new test systems. We figured it has to be the injectors. I was trying not to throw a bunch of parts at it and not fix THE problem. $1900.00 later for the reman units all is well. Other than I paid almost 3 grand for the intial units that should have lasted as long as my stockers. Buyer Beware!

 

[AH64ID]

150/95 with 1003 fuel filter.

Thats a good filter,and meets the OE spec for f/w separation and is rated for 90gph.

 

[CKESSEL]

I'm seeing that some of you are running the Bosch Motorsports or the BBI injectors. How do you like them, how many miles have you been using them, where do you buy them, how do thet stack up against the better companies like DDP and BD?

 

[cerberusiam]

I cannot complain about the BMS 50's I have. Have gained mpg in all phases and conditions.

 

[CKESSEL]

After this go around, I'll be watching and researching for replacements for when the Industrials fail. Hopefully its a fluke, but not likely.

 

[CKESSEL]

Found out some more interesting information that ties in with the latest TDR. Even NIB/Reman Bosch units are not perfect. After talking to my freind at NTG Racing about the common rail injectors, he told me that they have had to start testing the solenoids on replacement units as they have been bad straight out of the box. They discovered this the hard way after installing replacements, so now they get ohm'd before install. The Bosch certified supplier/repair facility didn't believe them until they were shown the facts. Even Bosch is not immune to issues. What do you expect for 300 plus bucks each? Perfection?? Dream on! Hopefully this gets fixed post haste by Bosch and not denied/ignored etc.

 

[cerberusiam]

Remans are a crap shoot, period. Even Bosch will have failures in units, just not as bad as others. Every single reman unit needs to be tested and monitored pre and post install to catch issues. Sometimes the problems are not showing up for several thousand miles. I will say it again, BUY NEW, if you want some sense of confidence things are good.