I don't want to beat the subject of no start on the 2003 models. I currently have one myself that I have determined the injectors need replaced. Without going into tangents about the no start, can we please start a thread on what injectors y'all have experience with? I am considering DDP injectors with 50 hp nozzles. Anyone have them? Likes, dislikes? I am not looking to build tons of horsepower on this truck (I have a 12 valve for that). I would like a bit more power with fuel economy in mind. What else do you reccomend? Thanks!

 

1st you have to realize that all aftermarket companies use stock Bosch injector bodies. Only the difference in tips/nozzles is what seperates them. General rule of thumb says up to +100hp you are safe and maybe better off just honing out stock tips via extrude honing. Bigger, and you need to pony up the $$$ for EDM tips. Go really big and extrude honed EDM tips will be needed or something like that. LOL!!!

I personally like my DDP honed tips. Having a matched flow set of injectors really seemed to smooth out and quiet the idle and engine noise. Fact is, some 600 series owners have comented how much quiter mine is than theirs. Good luck, just pick a reputable company. Can't really go wrong with any of them.

 

Thank you for the input, anyone else?

I also read about the F1 injectors in another post on here. Sounds like they will repair your existing injectors for a minimal price if you buy their nozzles. Is this correct? Anyone have experience? I read on their website that their nozzles are EDM'd. I have heard this is not as good as honing like DDP does. Is this true? Sure would be a cheaper option than six new injectors!

 

Can someone confirm that we only need nozzles, not the entire injector to fix the no start problem.

thanks,
Mike

 

Hey Mike,
I started a post it was titled (Long Crank). It may help you some. Have you tried cleaning c.o.v.? Some guys have had good luck with that. I plugged my relief valve and cleaning the c.o.v. helped as well. It didn't fix my 03 however. I just got my injectors back from Don M. It wasn't as easy as just changing the tips on my injectors, I had 3 bad injectors according to Don. I wish I could call Don directly to ask him about what was wrong with my injectors but I understand Don doesn't like to take phone calls. Well I can't give you a complete assesment of how the injectors are working. After we got the injectors in we found a bad injector line so off came all the lines and were now waiting for the new lines to be overnighted from Cummins. I can tell ya even with a leaking line the truck starts better then it has in a very long time. So there ya have it. I'll be happy to tell how things are going after I get the truck going, should be tommorow.
Good luck,
Topper

 

Don M checks out the injectors completely and installs his new tips. I have the 40hp F-1 injectors and it was one of the best upgrades on my 03. It really woke up the bottom end. As to the no start problem I never had it with 30k and has not come up with another 30k on the new injectors. Hope this helps. You can not go wrong with F-1 injectors.

 

Well last weekend I removed and cleaned the C.O.V. and rail relief valve. I also removed all six injection lines and retorqued the transfer tubes (which were all a bit loose actually). I also adjusted all valve clearances. I think it helped the problem but it is definitely still there. It will start occasionally but I do not feel my truck will reliably start anymore and it never starts quickly. This weekend I am installing a Walbro 392 with 3/8" fuel lines, a two micron filter, and fuel pressure gauge (will also do fuel tank vent relocation). I figure this is good insurance if nothing else. I took it to Dodge yesterday and they said it already has the "long crank" update in the ECM (charged me $40 to do nothing). I will keep you posted on the new lift pump but at this point I believe I am looking at a major investment in injectors

 

Just to touch on the injector nozzle issue, the nozzles are not the only mode of failure with these CR systems. The injectors can malfunction by allowing too much fuel to return to the system, thus, making it hard to reach or maintain the necessary rail pressure required for starting. This is a "body" issue and not a nozzle issue. I still have a hard start. I have not replaced injectors yet due to $$$$$$$ I have to use ether for every start. It sux. - curtis

 

Hey guys,
Just wanted to update ya. I got my truck back on the road after the new injectors and all is good!!! Like I said earlier I sent them to Don M and he found 3 bad injectors so they were rebuilt and he put on 100hp tips. Well we got the truck back together and she runs fantastic! Better then that it starts fast. I don't think it makes 2 revs. before it starts. It's been cold up here, 6-8deg f in the mornings and she fires right up. (Not plugged in) By the way when my injectors were bad they didn't leak out the tips. Meaning I didn't have any extra fuel adding to my oil. I guess it was returning to the fuel tank via the return line that comes from the back of the head.
Good luck,
Topper

 

Thanks to all. I figured an oil sample would come back w/ fuel in it if I was leaking from the nozzle. Ive had this problem for thousands of miles now, oil still looks, smells, and is at reg, level for the oil, even though injectors have drained down prob. over 40-60 times on this oil. Dynamite Diesel was pretty sure it was just nozzles, but given this assessment, I couldnt understand how the nozzles could be that bad that the leak without injector firing, yet they made the truck get 20+ mpg and run 100% perfect.
I guess I need the whole injectors. Do they do second mortgages on trucks?

Thanks to all for advise.

Mike

 

Thanks Topper, I've read all 10 pages and theres thousands of dollars worth of savings just by reading the diagnostics of yourself and others.

checked cascade, not the problem. not sure about the rail relief valve... guess i'll have to find it and check it out.

 

not to sound too ignorant, but what is cascade?

 

its a pressure relief on the high pressure pump, type cof in the search and it will show you the simple disgnostics on fixing it.