3rd Gen High Performance and Accessories (5.9L Only) Talk about Dodge/Cummins aftermarket products for third generation trucks here. Can include high-performance mods, or general accessories. THIS IS FOR THE 5.9L ONLY!

Flux Injector Problems

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Old May 21, 2008 | 08:35 PM
  #31  
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From: Sturgis SD
No I wasnt able to find any washer anywhere. But I cleaned up after the install so thats probably where it is. Thanks again Don.
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Old May 21, 2008 | 09:09 PM
  #32  
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Originally Posted by SlowSixSpeed
So where did the washer go?

I dont see how you installed the flux's and forgot to install 1 washer but when you removed them to didnt notice you were missing a washer but all the washers were present when you put the stockers back in and running good.

Ive been seeing more and more Flux problems especially 03-04 and I dont want to go through the same nightmare. My Mach 5's installed easy and was an awsome injector with zero problems on my 99 but there always seems to be something or another going wrong after an injector swap on these CR's.

So has anyone installed a set of Flux 1.8-2.0 in a 03-04 and had zero problem's with nothing but goodtimes and 100 more hp.

I can just see my truck sitting at a shop for 1 month for an injector install.
What im sure happened was when I pulled the Fluxs out of the bags, one of the washers fell off and I didnt notice it. So when I installed them I thought all was well. I checked the stockers to make sure that they still had washers, but I never thought to check the fluxs when I reinstalled them. (I had way to many things running in my head). If I would have I would have found he problem right away. If I would have made sure that all the washers were on before the install would have gone smoothly. They were in the mail today so I hope to put them in tomorrow and I will report back.
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Old May 21, 2008 | 11:21 PM
  #33  
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From: an Alaskan living in Des Moines Iowa....
my flux's went in great, except for when tightening the injector hold down bolts, I accidently sheared one off. luckily I was able to get it replaced.

truck still runs like a top, idles great, awesome power, and I dont regret the purchase at all!
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Old May 31, 2008 | 05:55 PM
  #34  
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From: Sturgis SD
Results!

I found the washer it came out with one of the stock injectors. So it must have been on the injector when I first installed it.

I finally got everything back together and everything runs great now. Lots more power.

Two things I noticed. When starting sometimes, initally the starter sounds normal but after a crank or two it spins faster then back to normal and then starts. And when it sits for a while i get some white smoke on start up. But if it runs a for a few seconds and I shut it down and start again there is no smoke. Is this just because they are bigger injectors?
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Old May 31, 2008 | 09:34 PM
  #35  
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I spoke too soon. I have about 200 miles on them and all has been great. But just after I wrote that last post i went to get fuel and this is what happened.

Rail pressure stays good when under 25 psi. But you can see what happens after. RP goes to 540 and it has no power then slowly builds back up.

Here is a link to a video I posted on youtube

http://www.youtube.com/user/oldsmokey12

This is a video of what it sounds like when I start it. Notice how the starter spins faster

\http://www.youtube.com/watch?v=gE_xsxWYwKs

Any ideas?
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Old May 31, 2008 | 09:47 PM
  #36  
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From: In the Shop
I think FCA. Sure does run smooooth at idle.

I cant hear anything wrong at start up.

Cool dog, btw.
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Old May 31, 2008 | 09:52 PM
  #37  
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From: Sturgis SD
I also have codes P0202 Injector #2 Control Circuit, P2146 Bank 1 (Cylinders 1-3) Shorted High Or Low, P2509 Ecm/pcm Power Input Signal Intermittent.

Could that be a loose connection on an injector?
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Old Jun 1, 2008 | 02:59 AM
  #38  
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check your injector harness plugs. Sometimes the pins inside get loose or bent. That could be the 0202 code.
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Old Jun 1, 2008 | 08:51 AM
  #39  
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From: Houston Mo
Don M, please contact me I have several questions I need to ask, Pm me.
Sorry OldSmokey, that i jumped in on your thread
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Old Jun 1, 2008 | 10:05 AM
  #40  
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From: Sturgis SD
One of the connections was loose. So Im betting that was the problem. What about the white smoke on when I first start it?
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Old Jun 1, 2008 | 10:30 AM
  #41  
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There really should not be any white smoke on start up.

I had a thought. When the stock injectors went back in with the double stacked copper washers I wondered if the connector tube could have been tweaked enough to cause a high pressure leak?
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Old Jun 1, 2008 | 10:39 AM
  #42  
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My wifes truck ( a 07 QC ) is complete stock and smokes white when first started in the morning. That's even when using the heater grid. Guess it may depend on where you live and how cool is gets overnight.
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Old Jun 1, 2008 | 11:16 AM
  #43  
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Yep, the 04.5 and up trucks can smoke on start up, even stock. There have been ECM updates from Chrysler to remedy this.

The 03-04 235, 250, and 305 engines are rare to smoke at start up when stock. Even with 1.8's.
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Old Jun 1, 2008 | 11:19 AM
  #44  
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oh... my bad, I always forget to look at what year the truck is
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Old Jun 1, 2008 | 11:46 AM
  #45  
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From: Sturgis SD
How would I check the connector tubes, just pull them and put in new ones? I still hold 26k at wot with the injectors, tnt on 7 and a little pressure from the x2 and stock pump. Its been 40-60 degrees out so not cold, and its only smoke white for a few seconds when I first start it when it has set for a few hours.
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