I have the wimpiest engine and at 200k its time for injectors. I am installing myself to save money and am new to 3rd gens. I have the old injs out, and they look good, should I worry about them being useless cores? They have 200 on them.

Also, I want to do injectors once and need to now cuz truck is nogo, but they are breaking the bank for awhile. Can I run 90 hp nozzles without any other mods right now and still be daily driven? Not looking for crazy hp, would just like it to run like a 325/610 after all is done.My thinking is 235+90=325, am I correct? I have the in tank stock lp. Will it support them now @90?

Who has the best 60-90 hp injectors with brand new bosch units. Or is there a good reman out there.I prefer new so I dont have to go back in. Also plan on better filtration as soon as $$$ will allow.

 

I have a 235 HP (CA model) motor like you do....A smarty will make life much more interesting, and costs a fraction of what new injectors cost.

 

I must do injectors, it doesnt run currently. Smarty would be next.

Wondering what it is that holds these motors to 235hp? The injectors are the same for all three pre 04.5 models.

 

Programming only is the difference between the SO and HO. Internally, there are some differences. Valves and vlave seats are not as good and the SO's don't have the gallery cooled pistons. Just means you have to be a little more careful with EGT's.

The SO injectors tend to run out of potential around 500 HP. Beyond that wll regquire injector, CP-3 and LP upgrades plus software.

The 90's are too much to run without other changes and do anything but play. If that is where you want to go then the 90's can used with discretion.

If your looking for a little more power and efficiency stick with a 40-60 HP tip. That will work with your stock pieces and you can add a piece at a time without running into problems. If you need more fuel later a tip upgrade will be a lot cheaper.

 

SO's can still make lots of power. Soulezoo is at 900hp with his and a good bit of mods.

 

Programming not only difference, additionally: exhaust, mainly cat (can you say beyond restrictive??). Next to a programmer, you'll get your single biggest improvement deleting it. If that is not feasible, replace w/ 4" after market. An affordable way (well under $ 400) to get much needed additional air to those 90hp injectors is to swap out your existing HE 341 turbo & elbow for a HE 351 turbo & elbow (found on 04.5+). EGT's (1400-1500 range WOT)should be quite manageable with just the 90's and the above mentioned air flow improvements. Add a programmer to the 90's..you will spend some $$$$$$$ to keep EGT's manageable.
Stock in tank lift pump should handle the 90's by themselves just fine.
"Best" injectors?? Find a "reputable" (did not say big name) builder, hopefully some one local for you, who has the capability to flow test as well.
My 03 was rated at, as you say "wimpy", 235hp. After a couple of weekends worth of work, minimal $$, not going to lay claim to being the fastest by far, but sure wasn't "wimpy". Paid for, little $$ into making it fun, great mpg's..you bet I miss my 03.

 

Mykaos,
I do not think all 04 models had CAT or in tank pumps.. I purchased my 2004.5 and had looked at 2004 models and in MA and RI the SO models did not have a CAT. The 2004.5 HO I ended up purchasing did come from factory with the CAT and fuel pump on the rear of fuel filter, not in the tank. Which was a good thing when time to add a larger Pump.
I would recomend the 40-60 hp injectors, good fuel pump/filters and a Smarty and think you will be very happy with the increased power.

Not sure of your trans but that will be something to make sure you do not hurt anythng with the added power. Driven sensibly the extra power won't hurt anything unless your right foot tells it to.
Best of luck with your truck..

 

JP-4.5, you are correct in not all 03-04.5 not having cats or in tank pumps. Most were either 295hp (??) SO or 325hp HO. There was also a 235hp rated also known as CA spec. According to OP, he has a 235 hp, which "IF" I recall correctly, those did all have cats. They also all came from factory w/ canister mounted fuel pump. The in tank was a so called update done when the canister failed, even though the canister mounted was (& is) still available aftermarket.
I agree completley w/ you on transmission.
Also surprised to see 235hp truck in the east. Generally used to seeing them mainly out west here.

 

Mykaos, I believe your correct. All of the 235's came with CAT's. At least mine did(bought it in CA). If i'm not mistaken they all came with 47re's, atleast the early models like mine did.

Can any one confirm this. Do they also consider the SO's the triple nickel motors? I have nothing but great things to say about my "wimpy" SO. I wouldn't trade it for a new engine any day.

 

All the 235's were CA models so yes they had a CAT. The standard SO was like 260 or 265.

The triple nickel motors are the early HO's 305/555.

If the truck was built for sale in CA on or after Jan 1 2003 it has a 48RE.

 

I see.

I've always wondered what the stock TQ output was for the 235 motors?

I have a build date of March and I have the 47re. I double checked and tripled checked because everyone swears it's the 48 but it's not. They must of wanted to get them out of the factory and slapped it on mine. Infact, my old mans 03 was the exact same truck as mine, same build date and all. It was also equipped w/ the 47re.

 

460 ft\lbs for TQ I believe.

March of what year? The 47RE was not produced in 2003, all the builds were switched to the 48RE after the Christmas shut down and switch over. AFAIK, the only way a 47 got into a Jan 03 build was it was already assembled except for the body.

How do you know you have a 47RE? Have you pulled the trans and taken it apart? Visually there is no way to absolutely to differnetiate the 2.

 

March of 03 was the build date. Yes, I had the trans out and apart in August when I snapped my input shaft. It sortive boggles me aswell, but its in there. lol

 

Thats one for the books that a March build got a 47RE. They must have done just as you suggest, used the 47RE in all the Cali models and stretched it until they ran out. Everything else got the newer 48RE.

 

To the OP,

Your 235 is a solid engine. It is mostly programming that is the difference for you in the HP dept. Some of the other differences are described above.

The piston oil cooling "J" jets didn't occur until after 04.5. All the early CR's use "saddle" type jets. On my rebuild, I used both. Lot's o' oil going on down there now for better or worse.

OK, so the injectors are tired and need replacing. If you are seriously only wanting to get to 325hp (ok so maybe 400 even) then just stay with the stock nozzles. Every increase in injector tip size is going to reduce your fuel mileage some. With 90hp stix, you can expect up to a 3 mpg loss. Also you are adding heat that the 235 is not all that well equipped to handle.

Just installing a smarty to your 235 engine will bring it up to a 305hp... just programming. Going to sw3 gets you past 325. In fact, with just a turbo upgrade and enough fuel to the cp3, you can get mid-high 400hp with the smarty alone, no bigger injectors needed. If you are dead set on the bigger injectors, may I suggest no larger than 50's for your purposes. Then get a smarty jr and the different programming will make the truck run much better (not just more power). You will absolutely need a bigger turbo. And if you really think that going to 90's and you are going to be ok with a HE351 (stock turbo for 04.5 and up 325hp engines), well, let's just say you won't be. You have an HE341 turbo stock and it does not put out much air. You may be good to a hot high 300's at best.

90hp injectors are large injectors for the average truck and if supported correctly can provide over 700hp. Do you want or need 700hp? If not, save yourself the trouble... smaller is better usually when it comes to injectors.