They where edmed out to 5 hole .14" then extrude honed the guy at extrude hone said that they are extremely big and he never done any that big before.

 

Do you think that might be part of the problem,holes to big and the nozzels are weaker allong with the high rail pressure.

Just a thought

 

I honestly dont think that will work, try put in some marine bodys on your nozzles right, from what I have read they'll handle more pressure.

 

The nozzles are not cracking its the bodies itself

 

Does any one have a part # for the marine bodies

 

does anyone have a qsb serial number or a marine app commonrail motor serial number and i will give you the part #'s

 

Let me ask you, how are these injectors being installed? I have seen where the injectors are installed and the holding nut that holds the the fuel connector tube is over torqued or not torqued enough and that helps aid the injector body to crack. Most of the cracks that occur on the injector body happens where the fuel connector tube mates to the injector body. On the CR trucks...I ALWAYS torque every fuel component down, injectors, fuel connector tubes and the hold down nuts for the tubes and the injectors.

You also run dual cp3's, are you running the quad pressure box? I know you removed the BDDL but how about the quad? Your rail prassue is a bit high as others have mentioned at the speeds you reported as compared to most trucks which leads me to believe that something is adding pressure. I do not think that the injector tips have anything to do with your issue other than the 2 rerasons I mentioned above.

Richard

 

The connector tubes i torqued to 37ftlbs and the injectors to 89 inlbs.

The bd and quad are both off the truck 100%

When I buy new injectors do you think I shold buy new connector tubes agen?

 

I change fuel connector tubes about 95% of the time. They are inexpensive and if there is even a little nick on them where the tube face meets the injector body there will be trouble! A set of tubes is less than 250 dollars from cummins and I know they just dropped in price a bit.

Do you have a friend or buddy with a smarty or at a dealer. The reason I ask is that the BDDL have a tendency to never restore the ECM back to stock all the way. I am not bashing there product cause I have used it in the past but I have also had a few issues. I would have the ECM reflashed with the stock software to give you sort of a "fresh start". With a smarty BOB can send you a recovery program for your truck. Just trowing out some ideas.

Last but not least, I think you mentioned you had a problem with your pump controller. Check your FCA's too as they control RP on the truck. I am no longer a big fan of RP increases except for the dyno or racing due to the stress they put on the injectors and the bodies for everyday driving(increased pressure kills injectors...anyone that R&R's them will tell you that RP kills injectors quick). I have gone through 3 sets of injectors with similar problems till finally I got tired and put 6 new ones and new EDMed tips. No problems since but expensive not to say the least.

Richard

 

I have had 3 coustomers with 04 common rail 5.9 with the edge easy on 3 crack there injector bodys, a real common problem here.

 

i put new fca's on when i got the new controller. I think once i get all new injectors i will be fine. The diesel shop that I work at has a smarty on the shelf and I have been kickin' the idea around of tring it. I know that bosch has updated injectors out with a different style ball in them. Maybe thats all I need