Interesting fact in 2005 service manual

[DDahl]

I just got the CD service manual for my 2005 CTD. While looking about in it, I discovered that there is an early build 2005 CTD and a late build 2005 CTD. The early build has three electrical connectors for the injectors, while the late build has only two and incorporates the wiring in the sealing gasket. However, the most interesting fact is that the injectors are different to the point that using the wrong build injector (early to late or late to early) can cause severe engine damage. Does anyone know what the differences are and whether perhaps DC made the change to quietly address the injector issues that appear to plague the 4. 5 and up models more than the earlier common rail designs?

 

[KBertetto]

I didn't know there were injector problems. I've heard of a few trucks having some replaced, but no where near what the PSD's & D'max's have gone through in the past. What percentage of trucks do you figure needed replacements?

 

[DDahl]

There was a survey of TDR owners recently. I think over 10% reported injector problems. Moreover, there was a short discussion in the most recent issue of TDR magazing by John Holmes (?) of injector problems on 2005 trucks.

 

[J.Davy]

I had not heard about the injector differences but as for the change up in the harness, T. S. T. warned us that D. C. was going to do this at some point in the production year . This was done in a effort to save money,hopefully the did not put a cheaper style injector in as well.

 

[jwilliams3]

Injectors from 04. 5-present are the same.

The change in the harness came in model year 2006.

 

[Bob4x4]

The change also addressed the cover's oil seepage issue.



Bob

 

[DDahl]

However, the manual clearly states that the injectors ARE (or will eventually be?) different and using the wrong injector will cause severe engine damage. Does anyone know about this or what are the differences between the two injector designs?

 

[jwilliams3]

The injectors for the 2003-04 Model years are the same.

The 2004. 5-2006 injectors are the same.



I dont know what the manual is getting at. Probably though they dont want techs mixing up or installing older style injectors. They have a different spray pattern and one more hole in the tip.



The injector harness connections have nothing to do with the injectors themselves. The actual injectors are still connected electrically in the same fashion with 2 wires and 2-8mm nuts that secure the wires to each injector.



Hey but don't take my word for it! How would I know? :-laf



**PS I will check just to make sure what I am telling you is correct.

 

[XJSuperman]

I'd make a guess that if the wiring is different... that the connections are also. So it might not even be possible to put the wrong injectors in since they may not plug up right??

 

[jwilliams3]

XJ,

Your guess is incorrect.

You could install the wrong injectors in a newer engine and not know it.

They install the same way. Same high pressure connections, same size, shape, etc. Same electrical connection.



The connection at the head is merely a point at which the harness can connect to the valve cover gasket/wire distribution point which in turn connects the same way the older versions of the engines connected to the injectors.