Power Wagon Injectors Installed!

[Midnite]

In addition to my new power lock limited slip, I now have my power wagon injectors in!



With my stock injectors, I was seeing about 15-16 psi of boost at WOT on level ground. That's now up to about 20-21 psi--is that about what it should be? My sig doesn't show it, but I replaced my stock muffler last year with a 3" straight-thru type. The rest of the exhaust system is stock.



Mike

 

[paccool]

That sounds about right if every thing else is stock. I have around 25 PSI and the pump has been turned up some. I thought I would get around 30 PSI but guess I need to do a few more things to get there. Hate to turn the pump up too high - costs to much if it breaks!

 

[Midnite]

Thanks Paccool!



I'm sure my 21. 5 cm2 turbo housing is probably hurting my boost a bit. I've decided to go with a 14 cm2, but I'll probably wait a few months at least. My credit card is already screaming in pain, and I haven't even started my Christmas shopping yet.



Mike

 

[Power Wagon]

You can get a non-wastegated 12 and 14 for quite reasonable.



That will help a LOT over that 21 housing you have now. Not only will you have a little more boost, it'll come on NOW, when you hit the pedal, and your egt and smoke will drop. I don't really reccommend the 12, though. The 14 would be great, I think.

 

[Speedo]

Do you notice an improvement in the seat of the pants performance? Did you get a new banjo bolt in there?

 

[Grey Wolf]

I get a maximum of 25 PSI with the 180 injectors and the 16 housing. This is with the original injection pump and no adjustments.

 

[Midnite]

Originally posted by Speedo

Do you notice an improvement in the seat of the pants performance? Did you get a new banjo bolt in there?

There was a definite improvement, although it wasn't a huge one. I *really* like the way it improved general driveability. Before, it seemed to require too much pedal pressure to maintain 45mph in third, but now it just seems so much easier to drive.



I still don't have a new banjo bolt yet, but I'm planning on hitting Cummins later this morning.



Mike

 

[J DeMaio]

Hey guys:



I'm thinking of getting a set of industrial injectors from www.smokindiesel.com These are supposed to give 60 horse and should help out my bombing needs My question is: What is the banjo bolt you guys are discussing? How hard is it to put in new injectors?



Thanks,

John

 

[EOliver]

Yes, Banjo bolt information please. I have only heard of the second gen guys speak of these...

 

[Midnite]

Banjo Bolt

If you look at the injectors in your engine, there's a metal line called the fuel manifold, or fuel drain manifold, or something like that. It should look just like the high pressure fuel lines, but runs from injector to injector. Look closely and you'll see that there are small 10mm bolts that connect this manifold to each injector. Those 10mm bolts are the banjo bolts. They're drilled through the center, and also thru the side, and have a groove around the circumference where the side hole is.



To change injectors you have to remove the bolts, copper washers and the manifold. The bolts and copper washers also greatly enjoy slipping out of your fingers when you're trying to put them back in, and falling down into small tight spaces which you have no hope of getting to.



In my case, I was lucky enough to have an extremely skilled guy helping me (Speedo ) who actually MADE a bolt for me! In about 10 or 15 minutes, Speedo found a bolt that he had which was the right size and thread, cut it to the right length, drilled it thru the center and then the side, and then made a groove with the edge of a file. I had also lost one of the U shaped copper washers, and we dealt with that using a pair of electrical connectors. The aluminum was probably about as soft as the copper, and turned out that it all worked beautifully. I actually drove about 150 miles with that homemade setup until this afternoon when I got replacement bolts and washers from Cummins.



Mike

 

[drives mopars]

BOLTS

BUY AT DEALER IF YOU DROP

THE OLD ONES YOUR NOT DRIVING IT



GET BOLTS AND THE BANJO CLIPS

MAKE A SLIDE HAMMER SCREW A BIG BOLT

USING NET ONTO INJECTOR END AND PUT A SMALL

PIPE ON THE BOLT TO IMPACT SLIDE IT



COST 5. 00 PULLS INJS EASY

 

[Midnite]

Drives Mopars,



I'm not quite sure what you mean. I agree that if Speedo wasn't there helping me, and I dropped a banjo bolt or washer that I definitely wouldn't be going anywhere. However, as I mentioned before, Speedo's ingenuity in drilling out a regular bolt got me on the road, and in fact I drove in excess of 150 miles using his homemade bolt. In hindsight, it would have been better if I'd gone to Cummins first and got 2 or 3 bolts and copper washer clips (hint to anyone considering an injector swap).



I'm a little confused about your description of a slide-hammer removal method for the injectors. Can you elaborate on that a little bit? I just used the instructions I printed out from Dave Fritz's dodgeram.org web site, and had no problems other than my own ham-handedness that I mentioned earlier.



Mike

 

[AlK]

Mike,

Regarding the slide hammer for removing injectors take a look at the following thread. Hope this helps?

https://www.turbodieselregister.com...p?s=&threadid=20590&highlight=Injector+puller



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Al