kcredneck

Please, can anyone recommend a mechanic in the Kansas City area to work on a 2004 CTD. Guys I am begging for help on this truck I wish I never bought it and I want it gone. First I bought it and found out it had a couple spun bearings so we rebuilt the motor. Once the motor was reinstlled we could not get fuel. Finally got fuel just not to the injectors. Got fuel to the injectors would not start. Got it to start smokes like a freight train, knocks and has raw diesel dripping from exaust. I have a lot of time and money wrapped up and I have to get it running. If anyone could recommend where to take it other than the dealer please let me know It is showing a ton of codes, I think there is an issue mostly with the 5th and 6th injector. Any help would really be appreciated. Thank You

rustyshakelford

i hope you get it all figured out. sounds like some bad bad bad injectors. im sure someone up there will chime in to help ya out

brett

kcredneck

I appreciate that. The thing that confuses me is other than the knock it ran fine before we rebuilt the motor. We did nothing to the fuel system other than disconnect and reconnect.

rustyshakelford

they couldve been damaged somehow...where they ever pulled?

brett

kcredneck

Well yes/no we did take the last injector apart to remove the engine. Only that one and just unscrewed it from the base. There is a tiny round deal smaller than a BB and we made sure to put it in the way it came out.

kcredneck

I am going over there to run the codes now and will post them in a while.

kcredneck

Wow have you ever seen this many codes? 0483,0237, 0524, 0525 ( Showed twice) , 0107, 0206, 0205, 2149, 0193, 0113, 2509, 0073. Can't be good!

vzdude

Did you pull the connector tube before the injector? That could be where all the fuel is coming from! The little bb shouldn't come out I don't think!

vzdude

REMOVAL
CAUTION: Two different fuel injectors are used (early and late). Although they physically look the same, they are NOT interchangeable. Be sure to reference the injector part number when replacing a fuel injector. This part number is laser-burned onto the injector. Failure to replace with the proper injector will cause severe engine damage.

CAUTION: Refer to Cleaning Fuel System Parts.

Six individual, solenoid actuated high-pressure fuel injectors are used (FUEL INJECTOR - DIESEL). The injectors are vertically mounted into a bored hole in the top of the cylinder head. This bored hole is located between the intake/exhaust valves. High-pressure connectors (HIGH-PRESSURE CONNECTOR), mounted into the side of the cylinder head, connect each fuel injector to each high-pressure fuel line.

Disconnect both negative battery cables from both batteries. Cover and isolate ends of cables.
Remove breather assembly.
Remove valve cover. Refer to Engines for procedures.
Remove necessary high pressure fuel line connecting necessary fuel injector rail to high pressure connector. Refer to Fuel Line Removal for procedures.
A connector retainer (nut) (HIGH-PRESSURE CONNECTOR) is used on each connector tube. Remove this nut(s) by unthreading from cylinder head.
Using special high-pressure connector removal tool #9015 (CONNECTOR TUBE REMOVAL), or (TOOL #9015 AND CONNECTOR TUBE) remove necessary high-pressure connector(s) from cylinder head. Tool #9015 threads onto connector tube. Use tool to pry connector tube(s) from cylinder head.
Remove necessary exhaust rocker arm assembly(s).
Disconnect injector solenoid wire nuts at top of injectors (FUEL INJECTORS).
Remove 2 fuel injector hold-down clamp bolts at each injector being removed.
USING TOOL #9010:
Special Tool #9010 (FUEL INJECTOR REMOVER - #9010) is equipped with 2 clamshell clamps, a sliding retainer sleeve to retain the clamshell clamps, a 2–piece mounting stud, and a pivoting handle. Do not attempt to remove the fuel injector with any other device. Damage to injector will occur.
The rocker housing (FUEL INJECTORS) is bolted to the top of cylinder head. The mounting stud from tool #9010 was meant to temporarily replace a rocker housing mounting bolt. Remove the necessary rocker housing mounting bolt. These mounting bolts are located at the center of each of the 3 rocker housing support bridges.
Install and tighten 2–piece mounting stud to rocker housing. If removing the #6 fuel injector, separate the 2–piece mounting stud. Install lower half of mounting stud to center of rocker housing bridge. Install upper half of mounting stud to lower half.
Position tool handle to mounting stud and install handle nut. Leave handle nut loose to allow a pivoting action.
Position lower part of clamshell halves to sides of fuel injector (wider shoulder to bottom). The upper part of clamshell halves should also be positioned into machined shoulder on the handles pivoting head.
Slide the retainer sleeve over pivoting handle head to lock clamshell halves together.
Be sure handle pivot nut is loose.
Depress handle downward to remove fuel injector straight up from cylinder head bore.
Remove and discard injector sealing washer. This should be located on tip of injector (FUEL INJECTOR SEALING WASHER (SHIM) LOCATION) or (MEASURING INJECTOR SEALING WASHER (SHIM)).

vzdude

Here is the installation as well. Also, if the connector tube wasn't damaged there is a seal at the bottom of the injector that should be replaced when having one out too! At the bottom there is a picture of the connector tube and one of the seal on the bottom of the injector.


INSTALLATION
CAUTION: Two different fuel injectors are used (early and late). Although they physically look the same, they are NOT interchangeable. Be sure to reference the injector part number when replacing a fuel injector. This part number is laser-burned onto the injector. Failure to replace with the proper injector will cause severe engine damage.



Inspect fuel injector:
Look for burrs on injector inlet.
Check nozzle holes for hole erosion or plugging.
Inspect end of nozzle for burrs or rough machine marks.
Look for cracks at nozzle end.
If any of these conditions occur, replace injector.
Thoroughly clean fuel injector cylinder head bore. Blow out bore hole with compressed air.
The bottom of fuel injector is sealed to cylinder head bore with a copper sealing washer (shim) of a certain thickness (FUEL INJECTOR SEALING WASHER (SHIM) LOCATION). A new shim with correct thickness must always be re-installed after removing injector. Measure thickness of injector shim (MEASURING INJECTOR SEALING WASHER (SHIM)). Shim Thickness: 1.5 mm (.060”)
Install new shim (washer) to bottom of injector. Apply light coating of clean engine oil to washer. This will keep washer in place during installation.
Install new o-ring to fuel injector. Apply small amount of clean engine oil to o-ring.
Install injector into cylinder head with male (high-pressure) connector port facing the intake manifold. Push down on fuel injector mounting flange to engage o-ring and seat injector.
Tightening Sequence:
Install fuel injector holdown clamp (mounting flange) bolts. Do a preliminary tightening of these bolts to 5 N·m (44 in. lbs.) torque. This preliminary tightening insures the fuel injector is seated and centered.
After tightening, relieve bolt torque, but leave both bolts threaded in place.
Install high-pressure connector and retaining nut. Do a preliminary tightening to 15 N·m (11 ft. lbs.) torque.
Alternately tighten injector holdown bolts to 10 N·m (89 in. lbs.) torque.
Do a final tightening of the high-pressure connector and retaining nut. Tighten to 50 N·m (37 ft. lbs.) torque.
Connect injector solenoid wires and nuts to top of injectors (FUEL INJECTORS). Tighten connector nuts to 1.25 N·m (11 in. lbs.) torque. Be very careful not to overtighten these nuts as damage to fuel injector will occur.
Install exhaust rocker arm assembly. Refer to the Diesel Engine section.
Set exhaust valve lash. Refer to the Diesel Engine section.
Install high pressure fuel line. Refer to Torque Specifications. Be sure to use a secondary back-up wrench on the connector nut (fitting) while torquing fuel line fitting. Refer to Fuel Line Installation for additional information.
Install valve cover. Refer to the Diesel Engine section.
Install breather assembly.
Connect negative battery cables to both batteries.

kcredneck

We only disconnected the wires from the top of the injector and from the wiring harness. Did not disconnect the fuel lines.

vzdude

Did you remove the actuall injector? If you did, you damaged the fuel connector tube. That'll be half the problem!

kcredneck

No, we only disconected the wires on top of the solenoid on all six and the 3 plugs on the harness. On the last injector we unscrewed the top half from the base. We did not remove it from the head. As far as the injection tubes that actually spray the fuel , we did not remove them.

vzdude

P0073-inlet Air Temp Sensor Voltage Too High
P0107-inlet Air Pressure Sensor Voltage Too Low
P0113-intake Air Temperature (iat) Sensor Voltage Too High
P0193-fuel Pressure Sensor Voltage Too High
P0205-injector #5 Control Circuit
P0206-injector #6 Control Circuit
P0237-map Sensor Voltage Too Low
P0483-fan Speed
P0524-oil Pressure Too Low
P2149-bank 2 (cylinders 4-6) Shorted High Or Low
P2509-powerdown Data Lost Error

vzdude

I don't think it is supposed to come apart like that! As for all the codes , it sounds like a wiring problem! Check the wiring under the valve cover - I think someone else chimed in on that too. It also sounds like you may have to have the computer reflashed. I think if they sit so long they forget the fueling maps! ( someone else may have mentioned that too! ) All the other codes could be from having sensors unhooked or something while the key was on?