Injector replacement can of worms

[jonny d]

Truck had fault code that said #1 injector problem. Tested solenoid with meter and it was way out. Decided on a set of injectors since I have 375k on these.

Got Bosch remans from local diesel shop, 505's I believe.

Installed them last night. Truck started fine, idle sounded smooth, tried to drive it and it was fine till it warmed up. With truck warm it won't idle right anymore. Bounces between 600 and 1k rpms. Fuel injector pressure bounce between 5k and 9k. Has slight smoke at idle.

When driving once warmed up it has no power, lots of dark smoke, and if I push in the clutch the rpms will drop off and the engine will die.

I called the shop I bought the injectors from and they seem to think I should just start throwing parts at it. Mpop, rail pressure sensor, rail relief valve. But what are the chances of that stuff going bad with the truck sitting in my shop for a week? I don't want to chase my tail on this by just putting random parts on.

I read somewhere of another person having similar problems and they resolved them by removing and re installing the injectors. Anyone have any better ideas?

Fuel filter has 3k miles since last change. Just cleaned the air filter. Diesel from the same place I always get it.

 

[seafish]

While certainly you can spend some quality time removing and then CAREFULLY and PROPERLY installing the remanufactured injectors, it is also possible that your truck is suffering from one or more poorly remanufactured injectors. Even if they are official Bosch remans, they are prone to being out of tolerance despite all of the effort Bosch puts into them!!!

I guess that my first questions would be--

Did you install the injectors yourself ??

And how familiar are you with the proper injector installation process??

Did you double check your work before, during and after the install process??

NO offense intended by these questions!!!

My next question would be -- how reputable is the shop you bought them from ??

 

[jonny d]

I did install them myself. I could probably talk you through the process including torque specs without looking anything up, but I do still look things up, because that is the best way to be 100%

I double checked my double checks throughout the process. I even have calibrated torque wrenches. I'm not a mechanic by trade so I double check myself alot, since it isn't what I do regularly.

The shop has been around for a while, I have had them rebuild fuel pumps on semi trucks for me in the past. I have terrible luck with shops lately though. Got a head replaced on a truck and they didn't adjust the valves when the reassembled, bent pins on connectors, and generally just sucked, I had some suspension work done and I watched them do it, asked what the torque specs were on the u bolts. And got my favorite answer of "our impact wrenches are set to the right torque". And since this shops first answer was throw parts at it I am wondering a little now. In there defense the are not a repair facility for vehicle or engines, strictly fuel system components. So diagnosing problems on engine might not be in there scope .

 

[jonny d]

And I won't take offense to anything, sometimes it is the simplest things that are easiest to overlook.

 

[Prairie Dog]

From all the advice I've read from our forum experts, I just could not use remans so I spurged on new.
Needless to say, they were totally problem free.

Remans are a crapshoot.

 

[jonny d]

Yeah, I'm wondering if I am not going to be kicking myself for not going new. I'm thinking I'm just going to buy the access to quick serve again so I can get all cummins troubleshooting info and get this figured out.

 

[seafish]

First you need to figure out if they are "official" Bosch remans. Given the shop, they may or may NOT be, despite the claim that they are. Once you figure THAT out, you will know more of what you are dealing with.

Then you should call TDR member TC Diesel and troubleshoot with him over the phone.
He is a dealer for, and actually likes the official Bosch remans and feels, unlike others, that they are almost as good as new Bosch injectors..

He is also an EXCELLENT HPCR troubleshooter but will ONLY work over the phone.

His contact is Todd Westfall at (763) 221-7121. This is his business phone so don't worry about calling him, just tell him you are a TDR member and what is going on with your truck. I am sure that he can get you going in the right direction!!!

Just my .02

 

[jonny d]

I will have to do that tomorrow, cause I'm sure I will still be stumped!

 

[TCDiesel]

Thanks Selfish, I get in trouble when I try and help on the Forum , OP ( Jonny d) its a easy fix call Today, I'm busy until 1pm CST, No need to worry it happens all the time.

 

[Wayne M.]

TC and Johnny, please summarize the outcome here!

 

[TCDiesel]

OK............

 

[BigPapa]

Thanks Selfish

Hey, seafish got a new name......

Dang AUTOCORRECT.....

 

[sag2]

Don't start throwing parts at it. if all you did was change the injectors and now it doesn't run you either have an install problem or a bad injector or injectors.

 

[p-Bar]

Don't start throwing parts at it. if all you did was change the injectors and now it doesn't run you either have an install problem or a bad injector or injectors.

You just gotta love the new generation mechanics...

 

[Wayne M.]

Don't start throwing parts at it. if all you did was change the injectors and now it doesn't run you either have an install problem or a bad injector or injectors.

This is my absolute biggest fear of the whole truck. Getting a good set when I eventually need em.

 

[jonny d]

I'm not gonna throw parts at it. I know the chances of something else going out at the exact moment an injector solenoid went out are pretty slim.

I think I'm gonna go to cummins while I'm in Portland today and see if the have the adapter for doing the return flow test. I am also dropping of an oil sample to be tested for fuel in it. I figure it is either injector or crossover tube related since the are the only things that changed.

It sounds like Todd has an idea of what is going on. I will be sure to update what I find and what corrects the problem.

 

[TCDiesel]

Call Me don't waste your time going to Portland..

 

[jonny d]

Your phone goes straight to voicemail

 

[Wayne M.]

Do the sample after it’s fixed, and a oil drain. I think you’ll have skewered results if you test now. A lot of us here use Blackstone.

 

[jonny d]

I did the oil analysis for one reason, fuel in the oil. I want to be sure that is not happening. I changed the oil when I did the injectors so the oil I got the sample from only has about 20 miles on it. So I don't expect the metals analysis to be good but, but for 24$ I figured it was worth knowing if there was fuel in there. I went to a local lab in portland and dropped off the sample and they said I should have a report in a few days.