Help! Replaced injectors - now no power

[JimmyDiesel]

hope someone can help with this - I had my #3 injector solenoid fail on my 05 ctd. I have 150k (truck is bone stock) on it now and decided to replace them all with DDP 50 horse units. Installed them with no problems, checked valve lash, and it started right up, actually much quicker then i expected. As the engine got closer to operating temp I noticed the rail pressure decreasing incrementally untill the truck had no power. It also stalls at that point too and is hard to restart. Sometimes i have to cycle the key off for a min. Also during the injector install I broke the intake air temp and press sensor on the intake - replaced it. And because it was original, i replaced the fca, but i put the old one back just to make sure it wasn't that. I reset the codes after injector install and there are no new codes even after multiple sessions of warmups and problems. One other thing I noticed out of the ordinary is all the idiot lights turned on for a second and the guages sweaped while i was backing out of the garage last night??? Sorry for the long winded-ness. Thanks in advance

 

[sag2]

Look at this post and follow the link to the injector install with photos. It sounds like you have a leak in the system and you will probably have to retrace your steps, making sure you follow the instructions and cautions in my original post. Did the new injectors come with copper washers or did you transfer them from the old ones? Did you follow the torque sequence for the injector and tube?



https://www.turbodieselregister.com...2003-2007/218501-ddp-injectors-need-help.html

 

[JJPage]

You have a leak that is causing your rail pressure to drop, which also causes hard starting. Go back and re-torque everything.



Below is a proceedure with pictures, that a member (sag2), produced.

https://www.turbodieselregister.com...148621-injector-install-procedure-photos.html



Jess

 

[JWadford]

one of the injectors may have failed on the return side also, this will dump rail pressure back to tank, i have had this happen on three sets of injectors, i hope it is a simple retorque for you

 

[JimmyDiesel]

thanks guys, I hope it is just a re torque also. Its snowing like crazy her and i gotta go out and plow, so it will have to wait till tomorrow...

 

[JimmyDiesel]

Took it back apart and found #5 connector tube only torqued to the first spec. I was in a rush to finish and screwed up - that will teach me. Well, probably not!

 

[Motorhead]

Took it back apart and found #5 connector tube only torqued to the first spec. I was in a rush to finish and screwed up - that will teach me. Well, probably not!

So... ... Does it run better now? Better than stock?

 

[JimmyDiesel]

Sorry for the delay in response... The truck now runs better, not right though. When you get on it - it has tons of power, way better than stock. But when cruising at a set speed on the highway or country road it seem to surge. Sometimes its not so bad - you might think it is an uneven road, but sometimes its real bad - loosing 100-200 rpm. I thought it might be the torque converter slipping, but the rpms are going down then up. Change the load on the engine and it goes away. Driving me crazy. I've been driving around with my cheap scanner plugged in watching rail pressure. When cruising its above 20k. When surging it varies 500-750 psi, i assume because the engine rpm. Also I replaced the FCA for good measure. Does the ECM need to be re-fashed to work properly with the new injectors? Also does it in cruise control just the same as no in cruise. I am at a loss. Anyone have any suggestions as were to look next. I was thinking crank position sensor?

 

[TCDiesel]

No the the ECM Needs NO re-flash, rail pressure at cruising is to High, What is your idle pressure?

 

[JimmyDiesel]

7600 or so @ 750 rpm and 8400 at high idle about 1000rpm. what would make it run high< i replaced the fca, still have the old one, maybe ill swap it back. I have no power adders o boxes. Truck is stock except for the injectors. I never had a gauge or scanner connected before the injector change out. What is it supposed to be?

 

[JimmyDiesel]

Just thought about this, is that high pressure going to damage my injectors? I guess i am going to drive the service truck home again!

 

[TCDiesel]

Idle Presuure 4700-5300 Psi. 1000 rpms NO load 8000psi

 

[JimmyDiesel]

what about cruising at 70mph or so? Could the rail press sensor be bad? What should i check next?

 

[cerberusiam]

Mine runs 6-7k psi at idle, 8k psi at 1100 rpms no load, 17k psi cruising. Everyhting sounds good except cruise pressures, thats a little high for no programmer.



Not sure whats throwing it high at cruise unless the ECU is over compensating for the bigger injectors. Mine will hit 21k psi when the engine unloads on a hill but on the flat or steady pull it sits at 17k steady. Its possible what the ECU is seeing from the rail sensor is causing it to go high.



Check all electrical connections agian maybe?

 

[JimmyDiesel]

I'll check in the morning, not sure what could be bad - connection wise, because the rail readings are very consistent. Maybe the rail sensor is failing by getting out of calibration?

 

[cerberusiam]

I'll check in the morning, not sure what could be bad - connection wise, because the rail readings are very consistent. Maybe the rail sensor is failing by getting out of calibration?

I had that thought and its th eonly thing that makes sense. The scanner should be reading what the ECU sees so why would there be a difference? Possibly sensor reading high and the ECU trying to pull it back is causing the surge?

 

[JimmyDiesel]

Maybe, I'm gonna check when the next stock order is coming in, the whole rail with the relief valve and sensor wasn't to pricey. In the mean time i am going to try and find a better scanner then the cheapo one I have, maybe it will shed some more light... .

 

[TCDiesel]

JimmyDiesel, we have a test sensor for both the Sensor and LV, You just need to pay shipping with the Promise to return Them. .

 

[cerberusiam]

JimmyDiesel, we have a test sensor for both the Sensor and LV, You just need to pay shipping with the Promise to return Them. .

Are you seeing problems with the sensors not reading correctly?

 

[TCDiesel]

No. . generally when they fail the engine will not start.