My injectors have been tired for a little while. They had a little over 320k on them and have been resealed twice.The cold weather made it worse. My truck was starting slow, had white smoke and idled rough on start up. Had that eye burning raw fuel smell and reduced fuel economy. As it warmed up, it ran better and the smoke reduced but would idle rough once in a while. I came out to Tennessee from California for work and decided it was time to put new injectors in for the trip back. Bought stage1.5’s from full force diesel. They are located fairly close to my cousin’s place so I was able to bring them the cores and get my TS chip flashed all in the same day.

Removed the old injectors, inspected the cups, cleaned and pressure tested them. No leaks. Replaced valve cover gaskets, harnesses, pigtails, oil/ filter, fuel filters and glow plugs. Put her all back together and got her to fire up. Blew some white smoke on start up and still smelled rich. Figured it had to clear everything out. Went for a drive to purge the air out of the system. It would run good then would feel like it’s dropping multiple cylinders. Didn’t feel right. I don’t remember it being this bad when I did the orings in the past. Talked to Fullforce diesel, and they felt like I had one or more injectors that were not seated properly. Never had that problem before but you know how things can go. Pulled it back apart gave all the injectors a whack with a rubber mallet, retorqued everything and put her back together. Same issues.

Bought an OBD Link Mx+ and downloaded FORScan lite and pulled some codes. The initial codes I erased on accident and could not get them to come back. Ran some tests and live data. IPC,IPR and MAP sensors all checked out. The codes showed up in the tests.

KOEO output state self test
P0113 P0603 P0237. P0238

KOEO on demand self test
P0475. P0605. (P0273. P0276. P1265. P1276 came up in buzz test also)

I have taken ohm readings from the valve cover pins, 42 pin connector and IDM. All values are 2.9 - 3.0. I have tested all the ground circuits and everything comes back good. The main harness has no visible damage. I am feeling kinda Stuck. I guess the next step is pulling that harness apart. What are the odds two new reman injectors ohm out and are bad? Is it the IDM? PCM? Improperly programmed chip? I could burn through a couple grand here throwing parts at it. Any help would be appreciated.

 

did you have any that moved after tapping with a mallet? Did any of the bolts move when you re-torqued them?

 

Two moved. #8 about a full turn and #2 about half a turn. The faults are on #5 and #6. I have thought about pulling all the injectors to inspect the and redo the crush washers. I could swap cylinders with the injectors to see if the problem follows.

 

Maybe try swapping solenoids around and see if the codes follow them. Double check for pinched wires under the valve covers first, though.

Edit: if you do pull solenoids, look for any signs of the armature plate contacting the underside of the solenoid.

 

What is involved with swapping the solenoids? Pretty easy?

 

Yeah, it's simple. The fasteners are actually Torx Plus, but a regular Torx will work as long as you're careful. Just unscrew the 4 screws from the solenoid and it lifts right off.

 

Everything is intact and there are no parts that can fall out other than the screws? And do you know the torque specs by chance? Sounds a lot easier than swapping injectors. I got a new harness on the way also. This sucks, I’ve owned this truck since 98 and all the issues I have ever had have been pretty easy to figure out but this one is a pita.

 

Everything is intact and there are no parts that can fall out other than the screws? And do you know the torque specs by chance? Sounds a lot easier than swapping injectors. I got a new harness on the way also. This sucks, I’ve owned this truck since 98 and all the issues I have ever had have been pretty easy to figure out but this one is a pita.

 

How many miles did drive it? It can take awhile for the air to purge out.

 

There are just the 4 screws and there's an aluminum spacer under the solenoid. The spacer is the same shape as the solenoid, and about 1/4" or so thick. Nothing really to worry about there. I don't remember the torque spec off the top of my head, but I've never actually torqued those screws. I just use a screwdriver type bit holder and go reasonably tight.

 

More than air. It’s dropping cylinders, #5 and #6 are failing a buzz test. Replaced the main harness today and still fails. Getting read to swap solenoids to see if it follows. Everything ohm’s out at 2.9-3.0. If it’s not the injectors I’m thinking IDM next.