Lost 2 injectors. Q's about Time for fuel system upgrade.

[Tuesdak]

So one of the reasons I took my truck into the shop for the manifold was that 'missing feeling' cold. Turns out the #2 cylinder wasn't contributing aka dead miss. The injectors were sent out for a test and #2 came back with nozzle dripping under pressure - no good and a return rate of 29.4 mm3/H. The #3 injector has a return rate of 130.1 mm3/H. The truck has had intermittent long hot crank with a puff of black since I got it.
The injectors all passed testing ~20K miles ago. #@$%! I guess most have 140K on them. Engine will have a compression test just to be sure. No blowby or other signs of engine damage.

The fuel system is stock down to the canister mount lift pump. It looks to be the upgraded canister lift pump.

I likely will be taking advantage of the 10% off New BBi stage 0.5 injectors with new crossover tubes. The 1 year NO LABOR warranty from BBi vs. (I hate to say the bold faced lie of "New" in Bosch's context of something rebuilt or reused still being labeled "new") new Bosch 2-3 year warranties no questions asked shop labor covered is the only sticking point.

The main question I have is is the stock canister lift pump will push through a CAT 1R-0750 after the canister filter? Is the stock canister lift pump capable of handling what I am doing: ~425HP, Smarty tuner, bigger turbo, 2x extra filters? (Including a CAT water separator that will also be added.) What else should I look at for a lift pump and filter setup? The PacBrake compressor is engine mounted and limits room for what I can do under the hood.

 

[BLNRAY]

my 03 3500 has 439k on it i installed a fass 150 about 400k ago,took the stock canister completly off.i have put 1 set of inj in and that was at 416k,i know from what i read on here i was pretty lucky with the first set of inj,i think at least some of the long life of inj was due to fass filter system. i highly recomend fass.

 

[p-Bar]

I would go with the BBI's they are the hot ticket. The cannister mount fuel pump is weak and to push through a 2 micron filter will be tough. Although I am not fond of any of the "brushed" fuel pumps it would be better than the what you have. I recommend this http://www.glacierdieselpower.com/product.aspx?pf_id=FW1220-TFK fuel filtration system. It mounts to the frame . I am using it with an in tank stock pump. I would look at http://fuelab.com/products/diesel/velocity-lift-pumps/velocity-lift-pumps-dodge/ brushless motor no brushes to wearout. Good luck

 

[Bob4x4]

Go with the BBI’s .5’s.I just installed a set,they are very clean and add a nice punch while still passing a snap idle test.The lift pump situation will spark plenty of controversy.I prefer the Orem retrofit for any mild builds.

 

[Tuesdak]

Just looking for ideas and suggestions.

 

[Tuesdak]

my 03 3500 has 439k on it i installed a fass 150 about 400k ago,took the stock canister completly off.i have put 1 set of inj in and that was at 416k,i know from what i read on here i was pretty lucky with the first set of inj,i think at least some of the long life of inj was due to fass filter system. i highly recomend fass.

I am leaning tward a FASS system. What all do I need to do to the fuel tank? It it typical to bypass the OEM filter canister?

 

[p-Bar]

Since you don't have the intake pump your good to go. Just install new pump and filters and drive it.

 

[HHhuntitall]

It's been my experience, the factory pump on the canister is inadequate and unreliable. I've seen them quit with as little as 35k miles, and replacements aren't any better. I've been using FASS for many years, as well as other lift pumps, such as Holley, AC Delco, AirDog, and recently, the AFE Power fuel system. I do like the FASS product and the way it installs. It's pretty easy. I've only had one motor go bad in several hundred pumps I've sold, and they warrantied it at no cost to the customer. The AirDog has a reputation for mediocre performance, and I've seen several that have quit, but I personally have only had a few quit me in the last 19 years I've been using them. The FASS is engineered to a level above anything else on the market, however. Their advertised 150 pump actually flows 160gph, and they have recently relabled them as such. The electric motor is heavy. Twice the weight of just about anything else.

The Fuel Lab products have been good, but my experience with them is limited. I've only used them in gas or alcohol race cars, but had zero problems.

If you use the FASS pump, their kit allows you to use the factory draw straw in the tank on the '03-04 trucks that haven't had the in-tank pumps installed. That's a good option if you're not pushing 450hp+. And it comes with tie straps for the lines, cut to length lines, and all the fitting needed to install it quickly and easily. The factory fuel filter canister will have to be retained for the return fuel lines, unless you find or manufacture a manifold to remove it, combining the fuel return lines from the CP3, overflow valve on the rail, and the injectors.

What I like best about the AirDog and FASS is the filtration. Two filters, with a water separator filter to begin with, as it should have been done from the factory in 1989, and like most every other Cummins produced in that era. And the canister filters are easy to change and fairly high quality, with aftermarket filters available from Wix, and most affordably from the manufacturers. One particular 2004 I installed a FASS on in 2005 had 305k on it when it lost an injector. The same customer has a 2009 with 367k on it, and running strong.

As for the BBi injectors, I have seen zero problems, but my experience is limited with them. I've had good results from the Bosch New injectors, and decent to good results from Industrial injection rebuilds. Stay away from anything that says Flight Fuel or reman'd by a "certified Bosch" shop.... you'll regret cutting corners in that area.

 

[Tuesdak]

Is the "window" in the 24v block cast over for the mechanical cam driven lift pump the older 12v engines used? I was looking at Glacier Diesel Power's "belt fed" diesel pump driven off the the front of the crank. I have had horrible luck with lift pumps so eliminating electric is appealing. In talking with GDP they weren't sure if the cam driven lift pump window had a block off plate or was cast shut. They thought after checking pressures to not blow the canister lid off that a cam driven lift pump would be a good solution. I have an aftermarket cam that has the pump lobe.

Decided on BBi Stage 1 injectors with new connector tubes.

 

[Killer223]

get the in tank lift pump, it's far more reliable than the fass/airdog, and is available in just about every parts house across the country. then install a filter setup either on the frame rail or like the GDP kit under the hood. http://dieselfuelfilterkits.com/03_12_cummins_fuel_filter_kit.html

that would be a great option being you live in PHX.

 

[promisedland]

My Ram had the in-tank Lp when I got it, nice and quiet & pushing through 2 filters.
I had the Fass on a 2nd gen Ram & it was too loud. I didn't want it on the quieter 3rd gen!

 

[HHhuntitall]

The hole goes through, but there's no lobe on the cam for it.... you'd have to source an Ag/ marine cam, or a custom grind..... but where are you going to dump your blow by oil back in?

And I'm not sure reliable and in-tank belong together. I just replaced the one in my 2001, as it wouldn't generate any pressure. 80k on this one, 105k on the one before it... no more reliable than anything else electric.

 

[ColemanR]

Well I'm sold on the FASS installed one on my 06 at 160K I get nervous about the 275K mark and I change my injectors....well I just rebuilt my engine at 773K and sent my injectors(BB1's) in to be checked out...they said they look great keep doing what I'm doing my injectors looking great.

 

[promisedland]

Good to know!^^^^^ Use any fuel additives as well?

 

[Tuesdak]

Wound up on the phone with Richard at Glacier Diesel Power. He indicated the pickup assembly in the 2003 w/o the in tank pump was one of the better ones and sell real quick if they hit the market. I got the impression they are better than a draw straw. Saves me from dropping the tank. Richard indicated that the 2003 canister pump setup with a intake horn final filter kit works ok. I spoke with him in depth about other products and in short just info without any sales pitches.

After coasting from the fast lane a few times over dead electric lift pumps on other rides - And one time over the bad Wix plastic Duramax fuel filter design sucking air... I want something bullet proof. My lift pump graveyard: Mallory gerotor fuel pump 140 GPH lost the shaft seal under warranty, then brushes wore out, then the relay lost a wire, Walbro FRB-5 one of the longer lasting ones for me trashed from the bugs in fuel problems, Carter like they sell aftermarket for the Dodge 2nd gen started to run slow, OEM plunger pumps for the 6.5 didn't last long enough to bother bolting on... I have been surprised the lift pump on the Dodge has lasted so long. :-laf It's outlived 2 engine rebuilds. Nothing against FASS, my 1st choice, it's that I am just tried of electric lift pump failures.

So I decided to get the "Belt Fed Diesel" Fuel Boss Mechanical lift pump system and use the intake horn mounted final filter kit. As the fuel lines are already out of the way for the injectors I also got a Air-Boss Intake Plenum. Of course a spare belt. Nice part about the system is it's two lift pumps keeping the factory canister pump for priming or kicks on via a pressure switch if the belt drive pump quits. Richard went as far as to measure the belt pump to see if it would clear the 6.7 Cummins damper I have on my engine while I was on the phone.

 

[ColemanR]

I rarely use fuel additives actually only in the winter time like below 30deg. I buy my fuel at truckstops or high volume dealers.