hey don
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Joined: Jun 2002
Posts: 3,347
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From: In the Shop
Well, we are waiting on the next set of prototype nozzles with the revisions. This will be the third set of revised nozzles to get everything I want/need. By the time the testing is complete I bet 6-8 more months will pass.
Unfortunantly, the common rail nozzles are nowhere near what the older styles were and this makes life somewhat difficult, so to speak.
In the interim, we are precision honing the stock injectors and the results are very good. I started this process in May and the trucks that are running them now report great results. Its all done "in-house" No contract honing. I tried that in years past with mixed results. We also flow test each nozzle within 1/10 of 1% in flow rate. The result is a super smooth and accurate nozzle that will run smoother than anything out there.
One of my dealers has a few sets in local trucks he has worked on and the guys that have them, love them.
We have 60, 80,and 100 HP available.
Since the newer injectors are electronic and no parts are available for repair we DO NOT use cores to build from. Messing with cores in the Common Rail engines is playing with fire. Most if not all the cores in junk yards and from core suppliers are cores for a reason. They either did not run good from the factory to start or they were throw aways from dealers that did not return them back to Mopar. We only accept your injectors from your truck. This way we have no core charges. Your injectors are disassembled, ultrasonically cleaned, honed, and reassembled. All the nozzles are pop tested in a fixture before honing and before reassembly to guarantee they work properly.
In most cases the injectors are turned around in less than 24 hours. It could be faster but it honestly takes 6-8 hours per set of 6 injectors to complete. The larger injectors take even longer.
The way it works now is the owner sends in his injectors VIA over night delivery, we start them right away and try to resend back that same day for you to have the following morning. Prepare for 3 days of downtime. You could pull them in the early evening on a Thursday and have them back on Saturday in some cases to cut downtime. ( if UPS/FED-EX delivers to your area on Saturday and your budget can take the charges )
Hope this helps,
Don~
Unfortunantly, the common rail nozzles are nowhere near what the older styles were and this makes life somewhat difficult, so to speak.
In the interim, we are precision honing the stock injectors and the results are very good. I started this process in May and the trucks that are running them now report great results. Its all done "in-house" No contract honing. I tried that in years past with mixed results. We also flow test each nozzle within 1/10 of 1% in flow rate. The result is a super smooth and accurate nozzle that will run smoother than anything out there.
One of my dealers has a few sets in local trucks he has worked on and the guys that have them, love them.
We have 60, 80,and 100 HP available.
Since the newer injectors are electronic and no parts are available for repair we DO NOT use cores to build from. Messing with cores in the Common Rail engines is playing with fire. Most if not all the cores in junk yards and from core suppliers are cores for a reason. They either did not run good from the factory to start or they were throw aways from dealers that did not return them back to Mopar. We only accept your injectors from your truck. This way we have no core charges. Your injectors are disassembled, ultrasonically cleaned, honed, and reassembled. All the nozzles are pop tested in a fixture before honing and before reassembly to guarantee they work properly.
In most cases the injectors are turned around in less than 24 hours. It could be faster but it honestly takes 6-8 hours per set of 6 injectors to complete. The larger injectors take even longer.
The way it works now is the owner sends in his injectors VIA over night delivery, we start them right away and try to resend back that same day for you to have the following morning. Prepare for 3 days of downtime. You could pull them in the early evening on a Thursday and have them back on Saturday in some cases to cut downtime. ( if UPS/FED-EX delivers to your area on Saturday and your budget can take the charges )
Hope this helps,
Don~
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Joined: Jun 2002
Posts: 3,347
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From: In the Shop
As of last week....no parts are available for the common rail injectors at all. Not even nozzles. At least not in the normal or legal chain of Bosch parts distributors. Some nozzles may be making their way out the back door, so to speak. I have no contacts on that front though.
Core injectors can be used to mine or rob nozzles from that are still stock. The nozzles are not the failing parts in 99% of the cores. The nozzles in stock injectors can get roached if the injector has an internal leakage. This leakage begins to cut into the sealing surafce on the nozzle. Leakage is the least found trouble I have seen though. Its mostly a bad solenoid or an orifice that is either partially/totally clogged.
Once they are modified they are modified. This is part of the reason I temper the decision to go with larger injectors over the smaller ones. I almost always pick a set of 60's or 80's over a 100 for most guys. You can laways go bigger later, but we cant go backward
Don~
Core injectors can be used to mine or rob nozzles from that are still stock. The nozzles are not the failing parts in 99% of the cores. The nozzles in stock injectors can get roached if the injector has an internal leakage. This leakage begins to cut into the sealing surafce on the nozzle. Leakage is the least found trouble I have seen though. Its mostly a bad solenoid or an orifice that is either partially/totally clogged.
Once they are modified they are modified. This is part of the reason I temper the decision to go with larger injectors over the smaller ones. I almost always pick a set of 60's or 80's over a 100 for most guys. You can laways go bigger later, but we cant go backward
Don~
Registered User
Joined: Aug 2004
Posts: 228
Likes: 0
From: sutter CA
Hey don, any new news to share with us on the Turbos and the EDM's? How about the Turbo/TST combo? One other quick question, How are these bigger turbos spooling on the CR motors to bring on the fueling? If these CR's are 99% based on boost for fueling wont that make a slightly laggy turbo a really laggy turbo on a 3rd gen? I know that the 24v's are a little worse than the 12v's but I understood that the CR's were pretty bad compared to the 24v's?
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Joined: Jun 2002
Posts: 3,347
Likes: 1
From: In the Shop
I have a small update. The testing today went pretty good with the newest EDM injectors. We ended up with a best of 577 out of 13 runs. 574-577 was the range. Dern Dynojets are sooo accurate its not even funny
The was using a TST box. No pressure has been added yet. I feel certain that with the other data we have collected with pressure boxes we will pick it up over 600 HP with ease.
This new EDM produces less smoke than a stocker, has super smooth idle, and driveability. Fuel economy should increase. The truck currently gets about 16 MPG. I honestly look for 2-3 MPG increase.
Total EGT was at 1100 degrees on the highest TST box settings. This was on the dyno. It is higher on the street Im sure, but I dont have the data yet. The truck did make 1300 degrees on the dyno with the old injectors. I am hoping this little injector will be part of the answer to some EGT relief and fuel economy for the 04.5 trucks. The first test truck was a 04.5. The other year models will follow.
Don~
The was using a TST box. No pressure has been added yet. I feel certain that with the other data we have collected with pressure boxes we will pick it up over 600 HP with ease.
This new EDM produces less smoke than a stocker, has super smooth idle, and driveability. Fuel economy should increase. The truck currently gets about 16 MPG. I honestly look for 2-3 MPG increase.
Total EGT was at 1100 degrees on the highest TST box settings. This was on the dyno. It is higher on the street Im sure, but I dont have the data yet. The truck did make 1300 degrees on the dyno with the old injectors. I am hoping this little injector will be part of the answer to some EGT relief and fuel economy for the 04.5 trucks. The first test truck was a 04.5. The other year models will follow.
Don~
Registered User
Joined: Aug 2004
Posts: 228
Likes: 0
From: sutter CA
Originally posted by Don M
The was using a TST box. No pressure has been added yet. I feel certain that with the other data we have collected with pressure boxes we will pick it up over 600 HP with ease.
Don~
The was using a TST box. No pressure has been added yet. I feel certain that with the other data we have collected with pressure boxes we will pick it up over 600 HP with ease.
Don~
Ive heard that the fuel rail in the new motor has been tested numerous times with MANY DIFFRENT MODS to only see about the upper 500's for power before the rail drops the pressure down to the lower thousand teens, thus needing a bigger fuel rail. Don it sounds like you may have proved this theory to be false, I hope so and excellent work, Keep it up!!!!
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Joined: Jun 2002
Posts: 3,347
Likes: 1
From: In the Shop
KO,
No testing the 235 engine yet.
MM,
The truck did 331 with injectors only. Using the TST box we gained 246 HP
Too cool!
The truck specs are as follows:
04.5 325/600
DTT Auto
Twin Turbos. ( conservative set ) Total boost limited to 46 PSI with the TST on Kill. No box, injectors only..it makes 31 PSI
TST PMCR
EDM injectors
Stock MLS head gasket ( contrary to the belief of just about everyone the stock head gasket will hold in high power applications )
The stock head bolts were replaced with ARP 2000 Studs
No Pressure box was used.
Yes, the Common Rail fuel delivery system on the high pressure side is limited when compared to other systems
That being said...dont believe the rumors that are constantly flying around the internet. We are not done for yet! There is some left and we are slowly figuring out how to manipulate it.
Don~
No testing the 235 engine yet.
MM,
The truck did 331 with injectors only. Using the TST box we gained 246 HP
Too cool!The truck specs are as follows:
04.5 325/600
DTT Auto
Twin Turbos. ( conservative set ) Total boost limited to 46 PSI with the TST on Kill. No box, injectors only..it makes 31 PSI
TST PMCR
EDM injectors
Stock MLS head gasket ( contrary to the belief of just about everyone the stock head gasket will hold in high power applications )
The stock head bolts were replaced with ARP 2000 Studs
No Pressure box was used.
Yes, the Common Rail fuel delivery system on the high pressure side is limited when compared to other systems
That being said...dont believe the rumors that are constantly flying around the internet. We are not done for yet! There is some left and we are slowly figuring out how to manipulate it.Don~