Attention: TDR Forum Junkies 
Sorry for the long post, some history, followed by injector part # questions:
On and off for the past 6 months or so, I've had some serious troubles with smoke, power, injectors, lift pumps, the whole works (some major help from folks in previous posts, thanks!), failing idle, truck not turning off, constant air out of high pressure line at one or two of the injectors, etc...
I finally turned the whole thing back to stock, except for the turbo housing. Old injectors, old pump settings, cleaned the fuel tank, blew out the lines, R&R all lines between lift pump and injection pump (found a loose fitting, one of my problems), new filter, new lift pump, R&R selenoids on pump, etc. If I'm not smelling like diesel, then the manure is just overpowering it.
Finally got it reliable, as you can probably tell by my quietness the last month, 1000 trouble free miles. So, I re-install the new injectors (PW injectors from the group purchase). Immediately all hell breaks loose. I get it narrowed down to 2 of the 6. Replace them, and things are fine. I had them pop-tested on a bench at the dealer today, both were bad, and have < 2000 miles on them! They just dribbled and spewed and were hurt bad. Tim at City Diesel (standing behind them completely!) speculates some crud got in there, past the filter, and is preventing them from reseating after firing. This causes the constant foam and prevents them from ever bleeding since compression air is coming back through them.
Coupled with my on again off again issue with the truck not turning off, I am wondering if pieces of my injection pump are flowing through the lines. This also coincides with total removal/clean/replace of fuel tank, filter, and lines, so I could have jarred stuff loose. Anyhow, I'm getting these fixed/replace, so I can be fully PW'd.
Disclaimer - I use "PW" only to describe the parts I am using. Nothing on Power Wagon here, his contributions here are awesome. I am dealing with a mfg defect or injection pump defect that are my problem and no one elses!
Question is this: Even when all PW injectors worked properly, I did not notice a major power gain. I noticed smoothness immediately, less smoke, but don't think I gained a thing (pump settings stayed the same). The idle never changed either. The nozzle number on the PW's is #9745, whereas the stock number was #9093. Both had 5 spray holes in them. The stock ones, when first replaced, came out pretty hard (crowbar on a nut screwed on to the top of the injector), so they'd been there a while at least.
Are these the right part numbers? Am I suffering from the fact that I have not calibrated my pump to the new injectors? PW's awesome explanation of the injection/burn process makes me think that timing would change when adding fuel differently.
Thanks for any insight, speculation, etc.
Jon
On and off for the past 6 months or so, I've had some serious troubles with smoke, power, injectors, lift pumps, the whole works (some major help from folks in previous posts, thanks!), failing idle, truck not turning off, constant air out of high pressure line at one or two of the injectors, etc...
I finally turned the whole thing back to stock, except for the turbo housing. Old injectors, old pump settings, cleaned the fuel tank, blew out the lines, R&R all lines between lift pump and injection pump (found a loose fitting, one of my problems), new filter, new lift pump, R&R selenoids on pump, etc. If I'm not smelling like diesel, then the manure is just overpowering it.
Finally got it reliable, as you can probably tell by my quietness the last month, 1000 trouble free miles. So, I re-install the new injectors (PW injectors from the group purchase). Immediately all hell breaks loose. I get it narrowed down to 2 of the 6. Replace them, and things are fine. I had them pop-tested on a bench at the dealer today, both were bad, and have < 2000 miles on them! They just dribbled and spewed and were hurt bad. Tim at City Diesel (standing behind them completely!) speculates some crud got in there, past the filter, and is preventing them from reseating after firing. This causes the constant foam and prevents them from ever bleeding since compression air is coming back through them.
Coupled with my on again off again issue with the truck not turning off, I am wondering if pieces of my injection pump are flowing through the lines. This also coincides with total removal/clean/replace of fuel tank, filter, and lines, so I could have jarred stuff loose. Anyhow, I'm getting these fixed/replace, so I can be fully PW'd.
Disclaimer - I use "PW" only to describe the parts I am using. Nothing on Power Wagon here, his contributions here are awesome. I am dealing with a mfg defect or injection pump defect that are my problem and no one elses!
Question is this: Even when all PW injectors worked properly, I did not notice a major power gain. I noticed smoothness immediately, less smoke, but don't think I gained a thing (pump settings stayed the same). The idle never changed either. The nozzle number on the PW's is #9745, whereas the stock number was #9093. Both had 5 spray holes in them. The stock ones, when first replaced, came out pretty hard (crowbar on a nut screwed on to the top of the injector), so they'd been there a while at least.
Are these the right part numbers? Am I suffering from the fact that I have not calibrated my pump to the new injectors? PW's awesome explanation of the injection/burn process makes me think that timing would change when adding fuel differently.
Thanks for any insight, speculation, etc.
Jon
