Engine/Transmission (1998.5 - 2002) Pop Test DD 2 Injectors and found.....

[boydo]

I was noticiing a little bit of miss/stumble for about the last 5000 km or so, today I had some spare time and decided to pull my injectors and have them bench tested. The injectors looked great nice and clean no build up they have about 50000 km on them and always used redline conditioner. Injectors #1-3 didn't pop well and had sepage opening pressure 26 MPa. #4 bad pop uneven streams, and opened @ 29-30 MPa. # 5 had "4" plugged holes. # 6 was Ideal. I though that maybe 1 injector had a bad spray pattern but I never though 5 injectors would be NFG. I alway see lots threads about rough running, stumbles, missing, today I found my problem and all it took was 40 minutes to pull injectors and $ 15 to test them. Ordered Jammer # 3 for Piers this should solve problem.



Interesting results I thought a few people would be interested in them.

 

[fox]

I'm curious if the truck gets warm every time it goes or if it makes short trips. Also how long since it was dragging a trailer for a few hours.

 

[boydo]

The truck rarely makes a short trip, the average day; 10 minute warm up then a 100 - 200 km trip with a 5 minute cool down, then the same coming home at the end of the day. I tow 10000 lbs on average 3-4 times a month normally traveling 1000 km. I finished pulling a trailer for 100 km a couple hours before I pulled injectors.

 

[RustyJC]

boydo,



Your results are surprising since one of the benefits that I saw touted for DD injectors was much closer "spread" in pop pressure and flow than even the Bosch stock or 275 injectors. Since installing my DD2's, I notice that the idle is indeed a little "rattier" than stock, but I was attributing that to the fact that the DD2 is just a bigger injector and didn't atomize as well at extremely low flows. It looks like there may be more at work here than I suspected.



Now, how do I justify those new EDM injectors to the war department? :{ :{



Rusty

 

[boydo]

Some of the injectors ( about 4 of them ) took agressive poping to get them to chatter, the spray was streams of diesel not atomized at all. At this point I began to wonder if this was normal and the tech wasn't sure of how they should perform, then we got to the last injector it was perfect excellent pattern and chattered even with a minimal pop - it produced the finest mist of diesel and this proved the other injectors are NFG. I was very surprised of how different one was from the next, opening pressures anywhere from 24 MPa to 30 MPa, terrible atomization, plugged nozzles, and one perfect one, Go figure.

 

[Gary - K7GLD]

The REAL question is, were those injectors that way outta the box - OR perhaps got cruddy over a period of time from outside factors - poor fuel, etc...



After all, it WAS stated the poor operation was noticed only in the LAST 5000 Km or so!



Wouldn't be too eager to trash DD for circumstances they might not be responsible for...

 

[Hohn]

From what I understand, this is indicative of some of the QC problems that DD has experienced. Some vendors have even dropped the DD line entirely because of injector mismatching and general poor quality.



For a long time it was held that DD's honed injectors were the best of the honed fleet, better than Bully Dog and other vendors.



Assuming this was once true, a number of people have found pop pressures and flow rates to be all over the place in some cases-- even 10% variance or worse.



I can't say I've been unhappy with my injectors, but I can say that I feel very strongly that Don M's are much better by every measure.



I'll retell my EDM story here. I installed a set of the mild Mach 1 (65hp) injectors for a guy here in town. We then took out his truck for a spin.



The first thing to notice is how smooth the idle is! Engine runs great. Second, the smoke, or rather, the fact that there almost NONE even over 6000ft with the EZ set on MOST aggressive. My DD2s will smoke like a chimney in this altitude if I bury the pedal with the EZ set on most aggressive.



The most amazing part was that in terms of HP, they felt EVERY BIT AS STRONG is my DD2s. In terms of power, the trucks felt almost identical. Only his truck (also an ETH like mine) had about 80% less smoke! So the mach1 (65hp) seem to have the power of a DD2 (75hp) with MUCH less smoke.



Here's a quote from an email he sent me:

Just got back from a trip to s. Dakota, thought I would give you an

update. I got 23. 2, 22. 5, 21. 8, and 21. 5 MPG on the fillups, not

bad! Admittedly I was driving pretty conservitive keeping the cruise

about 65 MPH but still good for the performance. The trip computer

looks like about 2 - 3 mpg optimistic giving me 25 mpg.

Keep in mind this is 65mph in the windy conditions of S Dakota and Wyoming.



My next injectors WILL be F1 diesel Mach series injectors.



Justin

 

[boydo]

Gary, I'm not trashing Diesel Dynamics( I apologize if I came accross that way), I am buying another set of DD JAMMER # 3( edm). When it comes to performance parts 50000 km is an acceptable life span for injectors, hard run turbo's, etc.



I alway run shell or petro can diesel( never any rig fuel) alway add premium fuel conditioner, now the problem started a while ago approx 5000 km or longer, but this is when it became more noticable( rough running, sometimes missed), this is why I tested them.



I just though my findings were interesting, and like I said before there are alot of posts about rough running trucks, maybe some of these guys would find simular problems if they tested there injectors.

 

[SKneeland]

From what I understand, this is indicative of some of the QC problems that DD has experienced. Some vendors have even dropped the DD line entirely because of injector mismatching and general poor quality.



this being said, DDjammers or Don m for my next upgrade?

from what i can tell the jammers are a a few hundred cheaper for the set, so this has to factor into the decision also

 

[KLockliear]

Hey Boydo, stuff happens. I'm not going to stand here and say that after time they couldn't be off somewhat, but we always stand behind the product. The original owner can send them in to be tested FOC. So, if you are the original owner, send them in and we will test/check/fix/replace them for you.

 

[Big_Daddy_T]

One of my mentals was sticky. But I really liked the lope. LOL. So I left it alone.

 

[boydo]

Hi Kieth I am the original owner, and sure I will send them to you if you'd like to have a look at them. I just finished installing DD JAMMER # 3 that Piers rushed out to me ( thanks Piers) I going for the test drive right now, can't wait. I will send the DD # 2 to you for testing and repair, Thank Kieth, for your help.



Thanks, Bret

 

[The Adjuster]

Well here I am scratching and saving for injectors ... but if you guys want to start tossing your DD's out, let me know ... . hey a set of slightly off DD's is still gotta be better than 150K stockers



Kevin

 

[ProMac1K]

Thanks for bring this to our attention Bret! I agree that the problem should be addressed with Keith or DD. I understand that you are not knocking down Keith here, but something like that always seems to happen on TDR. Injectors are very touchy, the slightest bit of foreign material or anything internal can mess everything up. That's what warranties are for. Trust me, i've been through a good share and hope to continue going through them. Keith has offered to stand behind the product. That's great! Shows he has a good business going! Just throwing Keith a rope here before everything goes to he**. I want to keep vendors on the site, not drive them away.



Note: No affiliation with DD, just looking out for the future of TDR.