Lucas 300 HP Injectors installed

[DJP]

I just installed the Lucas (AKA 'Ol Blue Specials) today. Although there was a slight performance increase, it wasn't anything near what I was expecting.
Ever since I installed the Banks intercooler, I lost a good 5 lbs. of boost pressure. My boost pressure dropped from 20 psi to 15 psi max at W. O. T. after installing the intercooler. I also noticed a loss of power after the installation. I checked all of my connection joints, and everything is tight, maybe the intercooler itself is leaking? Anyway, after installing the Lucas injectors, I gained 2 lbs of boost and now have 17lbs max. boost pressure, and 1050F on the pyrometer at W. O. T. . I know something must be wrong, the 2 lbs of max boost pressure has made a noticeable difference in performance, but I was expecting a LOT MORE.
I think I'm going to fabricate a blanking plate to go under the grid heater, and a cap with an airhose nipple so I can pressurize and leak ckeck this intercooler system (with a regulated air source of course) or maybe I just need to crank the fuel? I don't get a whole lot of smoke now, and I don't get enough torque or horsepower to get the 4th gear Getrag growl that everyone else is talking about. Anyone got any suggestions?

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89 D-250 LE 5 speed 3. 55 Limited slip, Banks Intercooler, K&N, Full Boar Muffler, 3" exhaust, Diesel Dynamics Stage 1 kit, Boost/Pyro. & 16cm2 215K miles.

 

[mark93]

Hi DJP.

Fuel sounds like what you need since your smoke and boost are low and EGT is moderate.

As for lost boost and power after the intercooler install, that's strange. Did you notice an increase in smoke after it was in? If so, that would indicate a blockage or leakage. There should be no smoke increase at all. If not then the cooling action of the intercooler may be responsible somehow.

I remember that Banks recommends turning the full load screw 1/3 turn in to get the most out of the intercooler-perhaps they know about the power drop. There is no way you will get their claimed power increase without turning the screw.

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'93 W350 Club Cab, Bright White, 5 sp. , 136K, Factory Options: LE package, 4. 10 Limited Slip, 7600 lb. rear springs, tachometer, front stabilizer bar. Mods: Banks stinger plus, Linex bedliner, 25,000 lb gooseneck ball, 10,000 lb receiver, Tekonsha brake controller, POWER WAGON injectors-WAY faster than stock!.

 

[SRT-6]

Are you sure you got the rite injectors? I had to tighten the starwheel 2 full turns to control smoke. It still will pour a cloud if I stand on it before boost builds(found that it works well for lowriders at stoplights). I can bury my 35 psi gauge on flat ground also.

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88 GMC CREW CAB 4X4 89 6BT,NO INTERCOOLER YET,AUTO METER LIQUID FILLED GAUGES,NV4500,NP205,4. 10's,35 BFGA/TKO,6" LIFT,DETROIT LOCKER,16CM,K&N,3. 5 EXHAUST,BD "PRINCE OF DARKNESS"INJECTORS 96 215 hp on the way. J. Mason

 

[DJP]

These new injectors smoke less than my factory originals which had 216,000 miles on them. I didn't notice any increase in smoke after installing the intercooler, however. I did notice an increase in turbo lag and a decrease in boost and EGT. I notice my idle speed has decreased slightly after the injector installation. I don't have a tachometer, but I immediately noticed the engine seemed to idle smoother, quieter, and at a lower RPM. I understand it's normal to lose a few pounds of boost with the intercooler installation, but I used to see up to 22 lbs. of boost on a cold day. After the intercooler installation, 15 lbs was the best I've seen. After installing the new injectors I regained 2 lbs of boost which puts me now at a whopping 17 lbs. This extra two pounds of boost has cut my turbo lag time and has increased performance to a level that I will call slightly better than what I had prior to the intercooler installation. Maybe I will just crank the fuel and call it a day. I have not messed with the pump yet other than the Diesel Dynamics stage I kit which basically sets the AFC star wheel one turn out from the bottom, installs a shorter spring under the diaphram, and installs a new plunger with a fatter cam. This stage I kit was done prior to any of the other mods, and did give me quicker response off the line.

 

[R.E. Miller]

DJP,
Something is fishy, if you still have your old injectors you might be able to try this redneck trick.

Get a magnifiying glass and look at the orifices of both injectors. This sounds stupid, but I got to see a set of DDIII's and FWIW, you can see the orifices with your naked eye. With stock injectors this is impossiable. Just compare the two that you have, there should be a visable difference (correct me if I'm wrong here #ad
) with the 300hp's bigger then the stock ones.
Hope this helps.

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1992 W-350 Club Cab Dually 3. 5" straight pipe(thanks jardine!)
W-350 8' contractors dump with 3. 5"BD exhaust, 16cm^2 housing, DI pyro&boost
Russell

 

[Big Don]

Don,

you defintiely may have a problem with your hoses on the intercooler. I do not understand why you're so down on power. The injectors you have are identical to the ones in my truck. I love them. You guys have read my post and those by the guy with the GMC who has a set like them. These are THE injector for the first gen trucks. Contact me if I can help. I cannot say enough about these injectors, they are great. Sounds like you need to check the boost tubes and possibly check the pump for weakness. If you turn the pump up much at all with these injectors you will BLACK the sky, they do flow the fuel. Have you tried the fuel filter?? think maybe it or the air filter are clogged up?? I can understand the idle speed change. Almost everytime I change injectors I have to reset the idle speed.

later
Don



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Ol' Blue "First of the first gens: 1989 D 250 Ice blue met. 5 spd 3. 54, 155,000, Banks stage III powerpack, 3. 5" straight exhaust, pump adjustments, "'Ol Blue Special" injectors.
1999 3500 4x4 Chassis cab Emerald green ISB 5 spd 4. 10 K&N Filter straight exhaust 9 ft flatbed WARN fenderflares,Let, 275hp injectors installed, boost and pyro gages, VA plug'n power and Practical Solutions boost module. Jacobs E brake. Getting ready to install Banks Power Pack TLC!!
May buy another one in 2009!!
Check us out at:
http://donstractorrepair. homestead.com

 

[DJP]

My injector pump was overhauled a little over a year ago at 194,000 miles, so I have 22,000 miles on the injector pump. I'm thinking I've got a boost leak somewhere that is not allowing boost to build past 17 psi, or maybe a turbo going south? When I mash the go pedal to the floor, I've got a little bit of turbo lag off the line. In other words, engine RPM needs to be up before I start to see any movement on the boost guage. Once the boost guage needle starts to move, it climbs quickly but runs out of breath at 17 psi. When I installed the intercooler, I had to rotate the compressor outlet down the 7 O'clock position. When I removed the compressor housing, I noticed there is a rubber seal between the turbo compressor and housing cover. Does this need to be replaced when the cover is removed? It looked good when I had the cover off, so I re-used it. I think I need to fabricate a cap with an airhose nipple to go on the compressor inlet and a blanking plate to go under the grid heater to pressure check the intercooler system. The again, wouldn't a boost leak cause excessive smoke and higher EGT? Like I said earlier, I have less smoke now with these injectors than I did with my stock injectors.

 

[Matt S]

I have these injectors in my truck and they are better than the Power Wagon's I replaced. From what you are saying about the EGT's and reduction in smoke mean your getting less fuel. It is possible with the amount of miles on your old injectors that you were getting more fuel before. The more miles, the more the injectors get 'bored' out, and the more fuel they will flow.

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90 W250, 5-speed, isspro gauges, 16 cm2, K&N, Borgeson shaft, JRE 3" exhaust, Banks Intercooler, Lucas injectors

 

[Big Don]

AS for the low boost causing alot of smoke, in some cases that may be true, but one must realize that as boost comes up it allows the diaphragm to drop and give more fuel. I agree with you Don on checking for leaks, but it still sounds like something else is wrong. I checked all the injectors before shipping to ensure they are truly the right injector. I can tell you that your truck had the hottest "stock" injectors availabel in the older trucks. You should still see a noticable gain in power. I think because you are seeing low boost (17psi max) that you have other problems. Most guys will agree that a setup like yours should make 30 psi easily with proper tuning.

later
Don


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Ol' Blue "First of the first gens: 1989 D 250 Ice blue met. 5 spd 3. 54, 155,000, Banks stage III powerpack, 3. 5" straight exhaust, pump adjustments, "'Ol Blue Special" injectors.
1999 3500 4x4 Chassis cab Emerald green ISB 5 spd 4. 10 K&N Filter straight exhaust 9 ft flatbed WARN fenderflares,Let, 275hp injectors installed, boost and pyro gages, VA plug'n power and Practical Solutions boost module. Jacobs E brake. Getting ready to install Banks Power Pack TLC!!
May buy another one in 2009!!
Check us out at:
http://donstractorrepair. homestead.com

 

[R.E. Miller]

DJP,
If you were short on boost and had the fuel these injectors should provide, your rear view mirrors should be useless #ad
I still think that they sent you the wrong injectors, this does not make sense. My dump truck with just a 16cm^2 housing and 3. 5" exhaust will pull 15psi FWIW.
Good Luck

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1992 W-350 Club Cab Dually 3. 5" straight pipe(thanks jardine!)
W-350 8' contractors dump with 3. 5"BD exhaust, 16cm^2 housing, DI pyro&boost
Russell

 

[DJP]

Well, I overcame my fear of fueliphobia, that is defined as the fear of breaking the virginity of your injection pump by tearing off the factory seal on the fuel screw and cranking it clockwise. I found by cranking the fuel screw in one full turn, it caused a nice cloud of black smoke to exit the tail pipe when hitting the go pedal, and much improvement on acceleration. In fact, so much acceleration, it took me by surprise when shifting into third gear while making a left turn. Both rear tires broke loose on dry pavement, and the rear bumper tried to say hello to the front of the truck. That's the first time that has ever happened in this truck on dry pavement! Turbo lag is now virtually non existant, and the needle on the boost guage almost instantaniously jumps to 24 psi on acceleration! This truck is now more of a blast to drive than my 67 Camaro with the LT-1 Corvette engine!

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89 D-250 LE 5 speed 3. 55 Limited slip, Banks Intercooler, K&N, Full Boar Muffler, 3" exhaust, Diesel Dynamics Stage 1 kit, Boost/Pyro. & 16cm2 215K miles.

 

[R.E. Miller]

Way Cool, glad to hear that fuel is flowing, and smoke is blowing #ad
What are you egts with these things? Just curious #ad

 

[Big Don]

Don,

Glad to hear you got it straightened out. I love to see those first Gen's spinning the tires and blackin the sky.

later
Don

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Ol' Blue "First of the first gens: 1989 D 250 Ice blue met. 5 spd 3. 54, 155,000, Banks stage III powerpack, 3. 5" straight exhaust, pump adjustments, "'Ol Blue Special" injectors.
1999 3500 4x4 Chassis cab Emerald green ISB 5 spd 4. 10 K&N Filter straight exhaust 9 ft flatbed WARN fenderflares,Let, 275hp injectors installed, boost and pyro gages, VA plug'n power and Practical Solutions boost module. Jacobs E brake. Getting ready to install Banks Power Pack TLC!!
May buy another one in 2009!!
Check us out at:
http://donstractorrepair. homestead.com