911!! Wont fire after injector swap

[SRossi]

Just did an injector swap and I cant get the truck to fire. . I've been cranking on it for about 5 minutes and not even a sputter. . The codes I have are P0113, P0480 and P0113

 

[Reb.B]

After i get fuel up to the CP3, i bump start it about twenty times(this bleeds the inj. ), then full throttle it and crank it for 10 sec at a time

 

[SRossi]

I got fuel up to the CP3. . Im tempted to crack the feed line to the rail but afraid to be sliced open by the pressure. .

 

[Digger]

You should bump start it 5-10 times first. Then try cranking it a few times. Try what Reb said. I wouldn't crank it right away. First bump start to keep the pump running. Should run for 20 seconds or so.

 

[OHale]

What they said. DO NOT open a high pressure fuel line!!!

 

[Tomeygun]

What they said. DO NOT open a high pressure fuel line!!!

As a side note though, without the engine started - the outlet PSI from the dicharge (into the atmosphere) of the CP3 is 0psi per TSB 14-003-05 (while cranking)

 

[OHale]

As a side note though, without the engine started - the outlet PSI from the dicharge (into the atmosphere) of the CP3 is 0psi per TSB 14-003-05 (while cranking)

Yes, understood. Still, the risk is so great that I would be concerned about the engine lighting off while the system was open. There was a fatality at a DC plant doing the same thing.



There is no need to open the system to bleed air. As noted above, the standard (and safe) procedure is to 'bump' the starter and then let the LP do the rest.

 

[Cattletrkr]

Wow, I didn't realize I was so brave. Before I knew how to diagnose a dead LP on my '01 I had to crack the injectors a few times after changing the fuel filter. It's not a big deal. Just crack it enough so that the nut moves and that's it. You won't get hit by any high pressure fuel. Don't put your fingers down there, that's what the wrench is for. The fuel only "shoots" out an inch or two if that.



Disclaimer: I ain't no expert so don't take what I say as gospel. Cattletrkr is not responsible for any injuries that may result from blah blah blah blah...

 

[JCleary]

Wow, I didn't realize I was so brave. Before I knew how to diagnose a dead LP on my '01 I had to crack the injectors a few times after changing the fuel filter. It's not a big deal. Just crack it enough so that the nut moves and that's it. You won't get hit by any high pressure fuel. Don't put your fingers down there, that's what the wrench is for. The fuel only "shoots" out an inch or two if that.



Disclaimer: I ain't no expert so don't take what I say as gospel. Cattletrkr is not responsible for any injuries that may result from blah blah blah blah...

Pressure on the '01 is a fraction of the pressure on a common rail...

 

[TCluff]

Just did an injector swap and I cant get the truck to fire. . I've been cranking on it for about 5 minutes and not even a sputter. . The codes I have are P0113, P0480 and P0113

open the line on top of your pressure relief valve, bend the line so it is off of the top of the relief, if you have fuel coming out of the line ie backfeeding, then you most likely have a high pressure leak most likely in the cylinder head, can be caused by a bad check ball in an injector, or a connector tube o-ring or not seated right, these things can and will bleed off enough pressure that the injectors wont fuel, it would be a lot easier to diagnose if you had access to a drb-3 scanner, i too ran across this problem, took me two whole days to figure it out without a scanner, ended up being a bad remanned inj, returning all my fuel pressure to the return line on the back of the cylinder head... ...

 

[JStieger]

I've had a couple high pressure fuel leaks. At idle the cardboard test didn't work, as all the fuel was just dribbling out the connections. However, after a hard run and then coming to a stop and immediately popping the hood, it was like a shower mist under the hood with the fuel spraying under high pressure with the fan catching the mist! Then as the rail pressure bled down it just returned to a dribble. We had a guy at work using a 3,500 psi pressure washer and accidently hit his leg with the spray gun 1 foot away and it broke through his jeans and drew surface blood. 3,500 psi is lower pressure than the rail at idle FWIW.



The worst fuel leak I had was when I blew the rail pressure relief valve a month ago. The return line could not handle the relief flow and pressure in conjunction with the normal return plus CP3 cascade overflow return and backed up out of the rubber splices on this line near the fuel canister. The truck dropped a 1/4 tank of fuel in 3 miles. The diesel trail is still visible on the street right to my apartment parking spot and I don't need to consider undercoating for years.

 

[sag2]

You need to do the fuel tests in the new engine performance diagnosis TSB. That said, to do it you need a Miller 9012 and 9011 for sure, and to do it correctly you need a 9013 and 9014. Most likely you need to double check the connector tubes and the injector install procedure. Contrary to what most technicians do, you need to use a socket and TORQUE wrench on the connector tubes. Most techs use an end wrench because they don't have to pull stuff out of the way. That is how they end up with leaks.

 

[Devan Manis]

Pressure on the '01 is a fraction of the pressure on a common rail...

Not exactly true. Lets assume that in a vp44 truck at idle that the highest pressure in the injection lines reaches pop off pressure of 4,500psi, In a common rail truck the pressure of the rail at idle is ~5,000psi

I've had a couple high pressure fuel leaks. At idle the cardboard test didn't work, as all the fuel was just dribbling out the connections. However, after a hard run and then coming to a stop and immediately popping the hood, it was like a shower mist under the hood with the fuel spraying under high pressure with the fan catching the mist! Then as the rail pressure bled down it just returned to a dribble. We had a guy at work using a 3,500 psi pressure washer and accidently hit his leg with the spray gun 1 foot away and it broke through his jeans and drew surface blood. 3,500 psi is lower pressure than the rail at idle FWIW.

That also had alot more flow with the pressure washer. If you were careful and stood 5 or so feet away while you had an injector line cracked and wore safety glasses you *should* be "ok". right?

Just trying to get a comprehensible handle on these things, how far off are my theory's?

 

[JStieger]

That also had alot more flow with the pressure washer. If you were careful and stood 5 or so feet away while you had an injector line cracked and wore safety glasses you *should* be "ok". right?

Just trying to get a comprehensible handle on these things, how far off are my theory's?

You're right - 3. 5 gpm on the pressure washer versus a lot less on the CR... and if you stood 5 feet or so away from the CR for example with safety glasses you would be fine. Nevertheless, I still wouldn't stick my hand/finder/appendage from where the pressure is being directly released. The key is before you even put your hands near any suspected high pressure leaks, move a piece of cardboard around the area - better the cardboard get cut up first rather than your hand.



At idle, I ran my truck with the banjo bolt and fuel tube disconnected off the top of my bad pressure relief valve and the fuel was just bubbling out the top of the valve like water simmering in a stove pot. If I raised the idle speed, the bubbling would turn into a 1 inch tall geyser so imagine what it would look like under WOT when the valve first blew! When I was observing this I just stood on my front bumper (about 4' away) with glasses and gloves on.

 

[Subby]

Sorry if this is straying a bit off topic but I thought the CP3 pressurized the rail to a certain % of actual injection pressure and the injectors produced the up to 23K psi? Similar to the old Cummins system sans the push tube/rocker arm operators. It sounds like the CP3 actually does the pressure and the injector is a computer controlled timing/duration nozzle. Please set me straight.



Thanks!

 

[Devan Manis]

It sounds like the CP3 actually does the pressure and the injector is a computer controlled timing/duration nozzle. Please set me straight.

Exactly. .