Engine Dies at 155-160 degrees Water Temp

[DSchwefel]

I'm listing this for a friend. If I'm not giving enough info, pls be patient. We have an 05 3500 with 160K miles. Had very little power... . stock injectors were changed buy a shad tree mechanic, fuel pump changed, and inj pump changed. It starts up fine, great power until it reaches 155-160 degrees, then dies and will restart when it has cooled, etc.



Thanks for any assistance.



Dave

 

[sag2]

It sounds like a high pressure fuel leak, most likely connector tubes. Is it doing the same thing as it was originally when you changed the injectors? Without some basic diagnostic tools it would be difficult to diagnose. You need to run the fuel return test cold, and then hot, especially as it gets to the temp where it dies.

 

[Diesel Power]

Yep sounds like too much return flow. if the injectors were not done according to book it will not work corectly. i would check the injectors installation first!!

 

[JimmyDiesel]

I just changed my injectors with the exact same results. Took it all back apart and found one connector tube that I forgot to do the second and final torque on. First is tubes @ 11ft/lbs then injectors @ about 7. 5ft/lbs alternating between the two hold down bolts at 90 degree intervals then tubes again @ 34ft/lbs. The cylinder head expands as it warms up making the distance to the injector longer, and at 20,000 psi that torque is critical.

 

[DSchwefel]

Thanks gents for the info. Now that I have taken the no. 1 connection tube off I see how it is put together and understand the importance of the proper procedure.



What kind of test equipment is needed to test the return line pressures? What should the values/pressures be?



What is happening if the connection tube and the injector do not have a good seat? Where does the fuel go or not go?



Thanks again for the assistance.



Dave

 

[sag2]

Thanks gents for the info. Now that I have taken the no. 1 connection tube off I see how it is put together and understand the importance of the proper procedure.



What kind of test equipment is needed to test the return line pressures? What should the values/pressures be?



What is happening if the connection tube and the injector do not have a good seat? Where does the fuel go or not go?



Thanks again for the assistance.



Dave

You need a Miller 9012 and you measure the fuel return off the head (injectors). If the connector tube is loose or you have a bad injector it leaks and returns the fuel back to the tank via the banjo in the back of the head. I'm sure I have posted photos before of the procedure, I'll have to look.

 

[DSchwefel]

Gents, We completely disassembled the fuel system. We checked the injectors, checked the shims, checked the o-rings on the injectors, checked the seating area for the connector tubes, checked the o-rings on the connector tubes, ensured proper cleanliness and proper order to re-assembly. The proper torque sequence was followed to a Tee. She isn't running. Cracked an injection tube..... there is fuel. Used starting fluid to get it cranked over... ... will not run without the ether.



The injectors are new, along with the fuel pump and injection pump.



Any suggestions? Thanks again for the assistance. Dave

 

[MMeier]

Gents, We completely disassembled the fuel system. checked the shims, checked the o-rings on the injectors, checked the seating area for the connector tubes, checked the o-rings on the connector tubes, ensured proper cleanliness and proper order to re-assembly. The proper torque sequence was followed to a Tee. She isn't running. Cracked an injection tube..... there is fuel. Used starting fluid to get it cranked over... ... will not run without the ether.



The injectors are new, along with the fuel pump and injection pump.



Any suggestions? Thanks again for the assistance. Dave

We checked the injectors, How did you do this ?

 

[blacksheepdiesel]

What are the rail pressure readings???

Godspeed,
Trent

 

[DSchwefel]

Gents, the injectors were visually checked for uniformity... . nothing out of the ordinary was found. No rail pressure readings are available at this time. I did do a search of posts for sag2 and did some research and got myself informed on a few things like the rail pressure that is needed in order to start. I did take the plug off the back if the injection pump (I understand that this is a pressure regulator) and tried to start... . with negative results. Guess I'll have to get the pressure reading on the rail in order to supply a little more info for analysis. Thanks.



Dave

 

[RDyson]

Also, it's better never to "crack" the injector lines on a common rail. The pressures could be very high and cause severe injury to your hands or other body parts.



Randy