Injector Install gone Bad---Help!

[Ross]

I installed a set of DD II's and a Pyrometer in a friend's 2001 2500 QC 4X4 Auto this afternoon. I've done several sets, and for the most part, I've got the procedure down to about 2 hours... . til tonight. I won't get into the details, but after everything was finally done (six hours later), I went for the test drive..... Truck runs very strong, although I'm very disappointed with that little mickey-mouse turbo they put on the new automatic trucks... . Anyway, on the test drive, after about 1/2 mile, the voltmeter goes to 8 (pegged on the low side), and the idiot "check guages" light lights up. I turned the truck around, and limped home. Opened the hood, looked for a loose wire, found nothing out of the ordinary, and started her up again. Voltage hovered around 12, so I went for another spin. Same road, same 1/2 mile, and then the same thing happened with the voltage, dummy light, etc. I again turned around, limped home, and checked everything out. Again found nothing.



I cannot imagine anything associated with the injector install causing this. The alternator, voltage regulator, and all large cables were untouched, except for the grid heater. Is there something else I could have accidentally tampered with?



What gives, all you Dodge gurus? I need some help to get him back on the road. Any ideas?

 

[SLightfoot]

Check the intake heater!!!!

If you pulled the intake manifold off (which houses the intake heater), make sure that you don't have any shorts within, or on the external wiring.



This is heavy guage wire run to this device, and has the potential to pull down the voltage.

Change the intake heater wires for signs of heat, particularly the rubber boot over the bolt holding the wires to the intake manifold- they usually have the tell tale signs.



My. 02



Shawn

 

[Ross]

intake heater

Thanks for the reply, Shawn. I just pulled off the intake snorkel, and looked over the grid heater. It looks fine, the gasket is in good shape, the ground cable is ok, and all the relays to it look ok.



I buttoned it back up, and went for another spin. Same exact thing. 1/2 mile down the road, and poof! Voltage drops to nothing. I stopped, turned off the lights, then the engine, fired it back up, and voila! Voltage back up again, although only to about 12, and not 14 like I think it should.



Simultaneous, but unlikely voltage regulator failure?



I'm stumped.

 

[Ross]

Fixed It!

Alternator fuse. I did a TDR search for "alternator" and found a couple of old threads which discussed the same problem.



The TDR is great!

 

[hammong]

Wow!



What a strange coincidence. Do a injector boost module install, and your alternator fuse blows.



Is it possible that you hit the back wiring lug on the alternator in the process of removing the valve cover? As I remember on my truck, the alternator output wiring is exposed. You might have just touched it long enough to blow the fuse -- that valve cover is pretty unruly.



Greg

 

[JTBMC]

The altenator fuse. Mine blew when tightening the 7/16 clamp conections after injector install the rachet touched the expossed hot wire on the altenator. I've sense repositioned the clamps and protected the hot lead with tape.

I now carry a spare fuse in my truck

 

[Ross]

I believe I may have hit the back of the alternator while trying to get the turbo off to drill & tap the exhaust manifold for the pyro probe. Oh well... . live and learn. It sure had me scratching my head, though.

 

[Okie-Go]

I'm just glad it worked out ok.

 

[dieselboy25]

Where is this fuse?

Ok guys, here is my story. I had my truck in to get my lift pump replaced (under warranty) and my dealer tripped this same fuse because when I picked my truck up, the voltmeter was falling fast. I stopped the truck and they towed it back to the dealer where they replaced it for free. My question is where is this fuse and where can I pick on up at? I have no idea because they did all of the work. Do auto part stores carry them or are they a dealer only item. I want to have a spare just in case.

Thanks,

Eric

 

[Brandon]

its like the 140 amp fuse in the pdc I believe

along the drivers front fender

 

[K_Arts]

Yep, Brandon is correct, right behind the Driver side battery there is a black box that is just a fuse distribution block. When you take off the cover, closest to the engine block, you will see 2 pretty large wires coming into the box. Right on top of those wires is that Alternator fuse, I believe it is a 140 amp (or at least it is in my truck).



I blew mine while installing the boost elbow that came with my EZ... at least I know what to look out for now.



kev

 

[merryman]

An interesting point(at least new to me) on those large fuses in the PDC. They can look good and still be blown. Blew one of mine and couldn't find the problem till a friendly tech. at the dealer suggested checking with ohm meter.



Vaughn

 

[KatDiesel]

Originally posted by K_Arts

I blew mine while installing the boost elbow that came with my EZ... at least I know what to look out for now.

ZzZzZzTtTt!



I remember that whole "ordeal", and the guys face when we asked Hey got any 140amp fuses? at the local AutoParts store Hehehe

 

[SLittle]

Those square 20, 30, 40, & 50 amp fuses aren't real easy to come by either, might want to source a few to keep on hand.



Scott

 

[TomGolden]

So just where would a person get some of these monster fuses? I have always liked to carry spare parts of various kinds in my tool box, just in case I conk out on the side of the road someplace...



Thanks,

Tom

 

[Ross]

Fuse "gettin' place"

I called the local parts stores to no avail. My last resort was the local "5-star" Dodge dealership. He said, "140 amp fuse that's held in with screws???? No such thing!"



I told him that there was such a thing, and I was holding it in my hand. I told him it goes in the relay box on the drivers front fenderwell, and that it is held in place by two 5/16" hex/phillips head screws.



"..... let me check again. " he said.



When he returned to the phone, he said, "that's one big #@@&ing fuse!"



It was $9. 68. Don't buy too many at once!

 

[K_Arts]

Originally posted by KatDiesel





ZzZzZzTtTt!



I remember that whole "ordeal", and the guys face when we asked Hey got any 140amp fuses? at the local AutoParts store Hehehe

Sooo you remember that too... . LMAO.



Boy was the expression on that guys face a moment to remember... !!!!



Kev