lmorris Posted November 27, 2014 Share Posted November 27, 2014 Low pressure system 7 psi, fuel had way to much conditioner in it for my liking so I flushed out the fuel system to be sure. High pressure system makes 7000 PSI with in 2 seconds of cranking and settles down to 4600 PSI if you keep in cranking. Has SYNC and RPM signal. No fuel is getting into the cylinders, no evidence of rust or contaminants in the fuel system. No codes. Customer said he was cruising on highway when it started to chug, belched a bunch of smoke, settled down to normal then 10 minutes later it shut down. Truck is tuned with exhaust delete. I tried returning to stock with no change, installing tune back in had no change either. I have had one truck before that needed 8 injectors to get it going, for no apparent reason. Oh, an BTW it also has low compression, 250 PSI across the board, low, but should still fire. Thoughts? Quote Link to comment Share on other sites More sharing options...
cbriggs Posted November 28, 2014 Share Posted November 28, 2014 Run the inverse fuel injector test but leave them connected to verify no spray? Any metal in the hp rails? Possibly the pump coming unzipped and spraying out metal? Just a thought but is the egr throttle body closed for some reason? Does it fire on an alternate fuel source? 250 is low, but it was rolling down the road when it died.... Quote Link to comment Share on other sites More sharing options...
Aaron Posted November 29, 2014 Share Posted November 29, 2014 Anything glittery in the fuel? Quote Link to comment Share on other sites More sharing options...
forddieseldoctor Posted November 30, 2014 Share Posted November 30, 2014 Run the inverse fuel injector test but leave them connected to verify no spray? Any metal in the hp rails? Possibly the pump coming unzipped and spraying out metal? Just a thought but is the egr throttle body closed for some reason? Does it fire on an alternate fuel source? 250 is low, but it was rolling down the road when it died....What's the inverse fuel injector test? We don't get many 6.4's at work. Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted November 30, 2014 Share Posted November 30, 2014 Remove the injs and reinstal fuel line and replug in the injectors upside down this way you can watch to see if any fuel is being injected. also helpful on finding leaking injector. If you remove valve covers going in to do inverse inj test pull fuel sample from rails first. To do this remove the fuel line to inj reinstall the line to the fuel rail and catch fuel coming out when you crank the engine. Catch the fuel into a black container to see the glittery debris the easiest. Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted November 30, 2014 Share Posted November 30, 2014 When taking samples from high pressure rails take from the front cyl. I use a spray paint can cap to catch the fuel. Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted November 30, 2014 Share Posted November 30, 2014 23. Inverse Fuel Injector Leak Test Purpose: WARNING: Contact with exposed fuel injector wiring, if energized, may result in electric shock. Use care when working on or around energized fuel injector wiring. Fuel injector wiring supplies high voltage to operate the fuel injectors. Failure to follow this instruction may result in serious personal injury. WARNING: Before working on or disconnecting any of the fuel tubes or fuel system components, relieve the fuel system pressure to prevent accidental spraying of fuel. Fuel in the fuel system remains under high pressure, even when the engine is not running. Failure to follow this instruction may result in serious personal injury. NOTICE: If the fuel system is not bled, a fuel injector may be incorrectly diagnosed. The purpose of this test is to check for leaks from the fuel injector at the nozzle or the return port. Inverse Fuel Injector Leak Test NOTE: Additional DTCs may result during this procedure. • Carry out the Inverse Fuel Injector Leak Test. Bank Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted November 30, 2014 Share Posted November 30, 2014 • Ignition in the OFF position. • Remove the right hand and left hand valve covers. Refer to the Workshop Manual Section 303-01, Engine, Valve Cover. • Release the fuel pressure. Refer to the Workshop Manual Section 310-00 Fuel System, for the Fuel System Pressure Release — Diesel Engine procedure. • Disconnect the 15-pin inline connector on the left hand valve cover harness. • Disconnect the 15-pin inline connector on the right hand valve cover harness. • Disconnect all the fuel injector connectors. Refer to the Workshop Manual Section 303-04, Fuel Charging and Controls. • Remove all the fuel injector supply tubes, fuel injector hold down clamp assemblies and the fuel injectors. Refer to the Workshop Manual Section 303-04, Fuel Charging and Controls. • Assemble all fuel injectors except the cylinder number 1 fuel injector to the fuel rail using the original fuel injector supply tubes. Position the fuel injectors so the fuel nozzle and drain hole are visible and the nozzle is directed towards the valvetrain. • Connect the open end of the hose from the Air Purge Adapter 310-184 to the fuel injector supply tube, put the other end of the hose in a fuel container and crank the engine for 15 seconds. Attach the cylinder number 1 fuel injector to the fuel injector supply tube with the fuel injector positioned so the fuel nozzle and drain hole are visible. • Disconnect the cylinder number 2 fuel injector from the fuel injector supply tube and put the other open end of the tube in a fuel container and crank the engine for 15 seconds. Attach the cylinder number 2 fuel injector to the fuel injector supply tube with the fuel injector positioned so the fuel nozzle and drain hole are visible. This must be done or a leaking fuel injector may not be detected. • Install the Fuel Injector Cups 303-1261 or equivalent to the fuel injectors to contain any side spray from the fuel nozzles. • Ignition ON, engine OFF. • Crank the engine for 10 seconds. Check for fuel injectors that are leaking fuel from the fuel nozzles or drain holes. • Ignition in the OFF position. Diagnostic Subroutines 4-27 Hard Start/No Start Diagnostic Procedures 2009 Powertrain 1 Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted November 30, 2014 Share Posted November 30, 2014 • Install a new fuel injector for any identified fuel injectors that are leaking fuel from the fuel nozzles or drain holes. Refer to the Workshop Manual Section 303-04, Fuel Charging and Controls. • Remove the Fuel Injector Cups 303-1261 or equivalent from the ends of the fuel injectors. • Install all the fuel injectors. Install new fuel injector supply tubes, O-rings and combustion washers for all fuel injectors that were removed. Refer to the Workshop Manual Section 303-04, Fuel Charging and Controls. • Reassemble the engine. • Bleed the high pressure fuel system. Refer to the Workshop Manual Section 310-00 Fuel System for the Fuel System Bleeding — High Pressure, Diesel Engine procedure. • For a no start condition with no leaks present and the engine oil level is correct, carry out the Monitor FRP Sensor No Start Test in this section to continue diagnosis. • For a hard start condition with no leaks present and the engine oil level is correct, check for electrical harness chafes. GO to Pinpoint Test ME. • If entering this test from pinpoint test AB, no leaks are present and the engine oil level did not increase, there is no fuel system concern. Refer to Section 3, No Diagnostic Trouble Codes (DTCs) Present Symptom Chart Index and follow the diagnosis for Exhaust System Concerns. • If no leaks are present and the engine oil level increased when carrying out the High Pressure Fuel System Test and Fuel System Leak Test, install a new high pressure fuel injection pump. Clear the fuel injector adaptive tables using the scan tool. 1 Quote Link to comment Share on other sites More sharing options...
lmorris Posted December 1, 2014 Author Share Posted December 1, 2014 After having to fill 3 plastic cap fulls to get the "conditioned fuel" out of the rail, so I could actually see what was in there, I did find metallic flakes. Also checked compression on right bank, #1 puts out 170 PSI. Quoted a 6007 assembly to get this guy on the road. I am leery about the response. I might just be putting injectors in this thing for now. Quote Link to comment Share on other sites More sharing options...
tonybullitt Posted December 1, 2014 Share Posted December 1, 2014 I would warn him that the hpp is the cause of the debris in injectors and suggest a pump at same time or he will ruin new injectors. Then he has a new fuel system for the enhanced short block it will need later. Quote Link to comment Share on other sites More sharing options...
lmorris Posted December 1, 2014 Author Share Posted December 1, 2014 I quoted a complete drop-in engine. And for shits and giggles I made up 2 more quotes, One for injectors, the other for the HPP. We shall see what happens. Plus he wants his 1 year old dead and won't hold a charge Canuckian Tire batteries put back in. We advised him that no work will be done unless it has 2 good batteries in it, and if he wants us to take the ones I just put in it out, he needs to come get his old ones and take them back to Canuck tire for warranty. If not it gets pushed back outside. Quote Link to comment Share on other sites More sharing options...
lmorris Posted January 12, 2015 Author Share Posted January 12, 2015 This one went after warranty assistance. Not sure whats being covered, but I have an enhanced short block, 2 heads and a complete high pressure system waiting to go in it. Customer is supplying the turbos and dropped off a set of ARP studs. Quote Link to comment Share on other sites More sharing options...
Recommended Posts
Join the conversation
You can post now and register later. If you have an account, sign in now to post with your account.