BBI .5 injector failure at 30k

[Axekicker]

As my previous posts over the past several years indicate, I had a local shop rebuild my 5.9 from the ground up Sept. 2018 and 30k ago (see parts list below). The engine was rebuilt at 225k and now has 255k. It smokes on take-off but thins when once I get going. Just had it smogged last week and it passed no-problem. I run an MM3 with 5 tunes. On the two most aggressive tunes it smokes like my old 90 Dodge dually did, but the other 3 tunes are manageable if I ease into it. PROBLEM: I pulled in to an appointment a couple of days ago and when I came back out and started my truck, it started to shudder at idle and smoked badly and had no power...only 6psi-max boost. I drove (micro-slow) straight to my current diesel-repair shop (the shop that did the rebuild went DOA earlier this year...so I'm now at another shop) and dropped it off for a diagnosis. When they called, they said the injector wiring was 'shorted-out' in a couple of places and the #3 injector was stuck 'open'. They said I was only running on 3 cylinders when I came in. So.....they asked to see the invoice for the rebuild so they could order a matching injector. Since the rebuild, I've moved my office and the invoice is packed somewhere in a file-box and I can't find it. QUESTION: Shouldn't they be able to get a number off one of the other injectors and use that as a basis to order a replacement? My bigger concern at his point is...if one injector has failed, could others be far behind? Maybe I'm better off replacing all 6 at this point. Maybe go with BBI 1's or S&S Torquemaster's this time around? While you guys mull this one over, I've got to rub my Aspercream on my wallet. It's taking a beating this year. Your thoughts?
5.9 Stats: 2003-4 Mahle pistons, ARP mains, rods & head bolts, Colt Stage 3 cam, BD 2-piece exhaust manifold, all new 6.7 injector & cross-over tubes, Gen 4 rocker arms, upgraded valves & springs, 6.7 damper, FASS 'Platinum' pump and a 2018 BD 'built' trans.

 

[Darkbloodmon]

Was anything changed prior to the excessive smoke?

Would a shop Itemize each injector ID number on an invoice? When I ordered my BBI stage .1s it came with a flow balance sheet with ID numbers corresponding to each injector. I made a copy and notated which cylinder had which number along side of the injector tubes when I installed mine.

My bigger concern at his point is...if one injector has failed, could others be far behind?

My first and foremost question for the shop that did the diagnosis is what caused it to fail prematurely and how can it be prevented again? I wouldn't put money on a new or partial injector set before confirming what happened and that the problem is corrected first. Less you have this issue again down the road. "I don't know" isn't a answer I would sleep easy at night with after spending that chunk of change.

When they called, they said the injector wiring was 'shorted-out' in a couple of places and the #3 injector was stuck 'open'. They said I was only running on 3 cylinders when I came in.

How did it get shorted out? Is it coming in contact with something in the valve train?

all new 6.7 injector & cross-over tubes

Do you mean 6.7 feed tubes, The wording is a bit confusing.

 

[Axekicker]

Was anything changed prior to the excessive smoke? / NO, it's smoked since the rebuild.

Would a shop Itemize each injector ID number on an invoice? When I ordered my BBI stage .1s it came with a flow balance sheet with ID numbers corresponding to each injector. I made a copy and notated which cylinder had which number along side of the injector tubes when I installed mine / The diesel shop did not provide me with that build-sheet...but Martin @ BBI just emailed me back and said to get the injector set# and mail (DHL) the injector back to them and they'd build a single-replacement for it.



My first and foremost question for the shop that did the diagnosis is what caused it to fail prematurely and how can it be prevented again? I wouldn't put money on a new or partial injector set before confirming what happened and that the problem is corrected first. Less you have this issue again down the road. "I don't know" isn't a answer I would sleep easy at night with after spending that chunk of change. (AGREED)

How did it get shorted out? Is it coming in contact with something in the valve train? (I'LL FIND OUT TOMORROW)

Do you mean 6.7 feed tubes, The wording is a bit confusing.

Yes...the shop installed new 6.7 feed tubes, which flow better than the old 5.9's.

Great thoughts all. I appreciate your feedback and after a trip to the shop tomorrow I'll get back with an update.

 

[Tuesdak]

I would sample the fuel looking for water, gasoline smell, stuff growing in it. Aka drain the filter into a glass jar and look for water. Hopefully the shop has that covered.

It's a BBi stage 0.5 injector set, correct? You ordered the 2003 spray pattern to match the pistons used I would assume. So one could order a 0.5 2003 pattern BBi injector without needing the invoice, part number, etc. Did BBi maybe email you the order info etc you can pull up easy?

Have the injectors tested assuming the system isn't full of metal, water, or gasoline. Maybe you just had one fail and the shop tracked down other problems like the shorts.

I would ask them to borescope the cylinders in case the stuck open injector melted a piston. A compression test just to be sure. You are already there with the injectors out...

 

[Mhennessy]

Yes...the shop installed new 6.7 feed tubes, which flow better than the old 5.9's.

Great thoughts all. I appreciate your feedback and after a trip to the shop tomorrow I'll get back with an update.

Any updates on this?
I am hoping you got her back on the road.

 

[Axekicker]

I UPS'd the injector to BBI and they received it today. It's got a bad coil. They'll repair it and send it back next year

 

[BigPapa]

Just an FYI, 5.9 CR’s and 6.7’s use the same 2872288 Injector Fuel Supply Connectors.

 

[Axekicker]

UPDATE: Received the injector back from Martin @ BBI and the truck runs like a champ now. He replaced the solenoid and remapped the injector to match the other 5 BBI's in my truck. Many thanks to Martin and the crew @ BBI for great work and a quick turn-around.

 

[BigPapa]

Thanks for coming back and letting us know the resolution. SO many times we never know how a situation turned out.

 

[Mhennessy]

I like hearing about good customer service. I hope she gives you many more miles of smiles.
Thanks for the update.