injector removal/replacement

[ASymington]

well santa brought me a set of 90 hp dpp injector nozzles, long story short after putting back together and taking apart 3 times now second guessing myself, truck will crank and crank but nothing. right now i am believing it to be the lift/transfer pump on the side of the fuel bowl has gone bad. i know they go bad and maybe it was a domino effect this time. anyone else have this happen or perhaps it is a common occurrence.

 

[jwilliams3]

1. Check lift pump pressure.

2. Find someone who knows what they are doing.

 

[Partyat33]

You need to bleed at least one or two injectors. If you don't you can crank a lifetime and it won't start.

 

[Partyat33]

Considerably loosen two injectors nuts. Have someone else crank it if possible. Watch for diesel leaking from the injectors. I highly recommend you wear safety glasees. You do not need to get close to the inector to see the fluid. It will be REAL obvious. As each injector bleeds, stop the cranking and close it up.



Should start and run a little rough. A little rpm increase tends to clear it up faster.

 

[ASymington]

2. Find someone who knows what they are doing.

what is that supposed to mean? i was just asking for help.



last night up until about 1 am we were bleeding all night long and still nothing, i had the battery charger set up too but maybe i need more juice to get it spinning faster. we had fuel coming out of the rail and lines but hardly any coming out of the lines going into the block.

 

[jwilliams3]

what is that supposed to mean? i was just asking for help.

Thats not a dig. I am just trying to give you good help, advice etc.

Common rails do not need to be bled like the previous years. They usually start right up.



Maybe you erred during the nozzle install?



Send me a PM I'll give you my cell number if you need help.

 

[Partyat33]

Sorry, I did not realize it was a common rail. I don't know jack about those.



Good luck

 

[RobertP]

tq the transfer tubes to 40lbs and she should crank right up.

 

[jwilliams3]

Really its more like 37 ft lbs...

 

[JLibert]

I assume you've double checked all of your electrical connections at the injectors and injector harnesses.

 

[jwilliams3]

Here are some directions from a post I wrote 3 years back:



Here are some directions:



1. Remove plastic vanity cover

2. Remove hoses from breather bottle on top of valve cover.

3. Remove Valve Cover, Remove intake arm and grid heater.

4. Remove wire harness connections from rail and combo sensors, also remove injector harness connections (3 on the side of rocker box)

5. Loosen and remove all injector wires from each injector.

6. Remove rocker box (mid piece between vc and head).

7. Completely loosen all injector lines at the head, next remove bleed off banjo from top of rail

8. Remove rail feed line from CP3 fuel pump.

9. Next remove securing bolts for common rail and securing bolts for fuel lines, this will allow you to remove the common rail with all fuel lines attached.

10. Remove all male connector securing nuts and pull male connectors out enough to allow injector removal.

11. Number each Exhaust rocker, remove each exhaust rocker (sometimes it maybe necessary to bar over or remove intake rocker to swap an injector), do not loosen adjustment nut.

12. Remove all injector securing bolts.

13. Next pull out injectors.



Torque specs:

Injector securing bolt: 8mm 10nm

Injector wire nut: 8mm 1. 25nm (thats extremely light) Be very careful here, if you break off the copper stud on the injector, you'll be having a very bad day!)

Rocker: 10mm 36 +/- 2nm

Male connector nut 24mm 50nm

Fuel lines: 19mm 29-31nm

Intake arm 10mm 24nm

Rocker box bolts 10mm 24nm

Valve cover and vanity cover bolts 10mm 24nm

Fuel line and rail securing bolts 10mm 24nm

Remember the Yellow and Brown wire nuts always will be closest to the intake side or rocker.



Be careful to isolate fuel system components to keep debris out of system.

 

[gsbrockman]

Sorry, I did not realize it was a common rail. I don't know jack about those.

Well... ... it is in the 3rd GEN 5. 9L Engine & Transmission Forums.

 

[ASymington]

well me and my brother went at it again tonight after work, tried a bunch of suggestion from guys at work and a guy at cummins themselves but nothing. everything is snug and hooked up properly, here is where we are at now... . we have more or less then no pressure coming out of the rail and i mean none. we even out the air gun in the tank to pressurize that and loosened the feed banjo bolt and the fuel sprayed pretty nicely while doing that and then air started coming thru. so pretty much there is no pressure coming out of the rail.

 

[JLibert]

Do you have pressure TO the rail? Maybe open the drain on your filter housing and bump the starter. Fuel should pour out of the hose (put a catch can under it). Let us know.

 

[B.G. Smith]

... we have more or less then no pressure coming out of the rail and i mean none. we even out the air gun in the tank to pressurize that and loosened the feed banjo bolt and the fuel sprayed pretty nicely while doing that and then air started coming thru. so pretty much there is no pressure coming out of the rail.

If air came out while you were pressuring the tank maybe there is a hole in the line inside the tank or you are out of fuel???? Just a thought. bg

 

[RMalone]

Take the feed to the cp3 off and bump start it. That should tell you in hurry if your lift pump is good. The bottom of the filter housing would tell the same (as mentioned) but I think the cp3 feed is easier to get at. Your missing something simple (I think), too coincidental that something major happened right when you did the injector job.

 

[TGroves]

same thing happen to me with my 04 i put some injectors from hasileys 90 hp

got them in stated stated and stated tried everything under the damm sun ,,, so i said what the hell put the old factory injectors in ,,three cranks later the damm thing fired off and ran ,,, so i changed the tips from the new injectors to the factory ones and she fired after the second crank and i put injectors in mine at 9000 miles and i has over 80,000 now with not one problem ,come to find out the solenoid in top of the injectors where bad (all 6 ) i don't know all i know is i changed the tips and called it aday or week and half later

 

[ASymington]

im thinking very coincedental also (sp) perhaps its electrical maybe a fuse or relay which feeds the pump, i took a look in the book but couldnt find anything that has to do with the cp3, if you guys know which fuse or relay and where it is maybe that is the problem.