If this has been discussed before, please pardon me. I missed it.

I have read a number of comments here about Pilot Injection, and about those that have it seem to like it, and those that had it lost it (as a result of a reflash I presume) are not all that happy they lost it because of lower mileage, less power, more noise, etc. And some of us never had it, and don't know all that much about it.

Can someone describe what Pilot Injection is (or was)?

What were its advantages or disadvantages?

Did anyone not like Pilot Injection, and if so why? (I have not read any complaints about it here.)

Why would, or did Ford change the tuning on the 6.0 PSD to eliminate Pilot Injection if so many owners seemed to like it, or complain about its discontinuance?

Is Pilot Injection something that the aftermarket flashers (Edge, Predator, etc.) can reinstall? If so, why don't they? If not, why not?

So many questions.

 

It is also called split charge. Basically at idle and low rpms the pilot injector injects fuel. This is suppose to be a smaller amount. It is supose to help with gas mileage and also reduce emissions and engine noise. Those trucks before the October Flash have it Those after do not. If you do not have it the truck runs louder at idle and gets a little worse mileage. I think it is disabled on all 2004 engines. The Dealer after I revelaed I wasn't happy about buying a 2003 in 2004 (body and engine made in August 2003 but labeled a 2004) tried to tell me that I had the best of both worlds since the engine problems had been resolved by April/May of 2003 and that unless I wanted to install the latest flash would keep the pilot injection. So far no issues but this is my first Diesel so I really don't know what to complain about. I noticed a slight discoloration at the bell housing the other day while I was draining the water seperator, but it didn't look fresh. I'll monitor and check my oil weekly. So far at 1200 miles getting about 17 to 18 mixed highway and city driving, no issues unless it is cold but 5 minutes of driving seems to take care of that. It accelerates well and I haven't seen any smoke out the exhaust.

 

I'm very confused on this pilot injection. My new 04 Excursion has it. I asked my service manager when I went in for a oil change and was told I had it and it was working.even after being flashed. Build date 01/04

 

Is pilot injection a special fuel injector that is controled by the ECM or is it just a program? If it is a special injector, do all 6.0s have it or are they being phased out, hence the new injector being used to replace defective injectors?

 

From what I've read on this web, it is a feature of the injectors controlled by the FICM. It is turned off in newer flashes for some reason. I think both type sof injectors have it.

 

Clock,
Pull up next to an ideling duramax sometime and compare sound levels. You'll know quickly if you have it working or not. I understand the new Cummins "600's" are possibly even quieter than the dmax.

 

Hmmmmm. Where to start?
Pilot Injection(electronically controlled)/split shot injection(Mechanically Controlled). Basically what this is, in layman terms, is a small injection of fuel to initiate the combustion process, reducing the extreme cylinder pressure and heat build up, which normally occurs with a single shot injection, such as the old Cummins 5.9. This then followed by the remainder of the injection pulse. What this does, is slows the flame front and cylinder pressure rise, which in turn quiets the engine down(reduces the knocking associated with deisel combustion). This can also be partly accomplished by raising the Cetane rating of the fuel. The 7.3 liter PSD accomplished this Split Shot Injection through a mechanical arrangement in the injector. The 6.0 does the electronically, throught the FICM, which is why the C94 injectors had problems handling this. Seimens, apparently did not know Ford was going to do this with their injector.(excuses, Excuses) The International version, does not use Pilot Injection. Controlling this through the computer, supposedly helped emmissions, and of course fuel mileage.

The original flash(original build engines model year 2003), works extremely well. Mileage and power were unbelievable. Many who were savy enough to not get it flashed if they had no problems, still are running well, WITH pilot injection. Unfortuantely, Ford had a miriad of components that were installed on these original engines, that were simply not up to the task. Most notably, the C94 injectors, which were replaced , depending on who you believe, in early april or the end of May in production engines. Pilot injection played havoc with these C94 injectors, which had a fairly high failure rate(1 in 10). They also had problems with the EGR, the oil rail pressure regulator, the turbo solenoid actuator , Injector O rings among other things. Since these items are expensive, Ford opted to try to cure their troubles with Flashes(computer code). Unfortunately, these flashes, are cumulative. They keep all the junk code and just add to it. Liken this to our congressional representatives. They all want to add new laws, to be the new savior. Now there is so much junk out there.... Well you get my meaning. {:^)

My take on the whole thing, is that if Ford were to use the original code loaded in the early engines, and replace all the substandard parts that were originally installed, they would probably have a good running truck again. With pilot injection.

On top of this, the engines were being overfilled with oil, which created foaming,(No windage tray below the crank) causing further problems with the injectors, since they rely on high oil pressure to create the injection pulse.

Hope this explains some of what is being asked here. I am not a tech. Just my humble opinion, and what I have learned.

Lariat

 

very well explained , and I agree with your idea on the programing, it would be great if they went back and checked at least.

 

Whow....very, very good......"read, copy, paste" and re-read again.

Thank You..

 

I drove the new cummins 600. Standing out side the cummins is so quiet you almost wonder if it's diesel. Inside is another story! Not only is the diesel sound a little loud, but right under the floor it sounds like a freight train is trying come in. Tons of power, but that's about it.

 

Well, unfortunately, Ford's better idea, way of thinking, may not allow them to think in that direction.

Ford, if you are reading this, at least try it. Replace all the substandard parts, and see what happens. Before you loose all your loyal customers!!!!

Thanks Guys!

Lariat

 

Probably a stupid thought - but if PI does 2 injections per stroke would not eliminating PI double the life of the injectors?

 

Yes it would, if your engine NEVER went above idle.