I was wondering what the general concensous is of the failures of a Common rail injector and if and what the aftermarket fix is for the failure. Seems to be alot of stock injectors on stock trucks having a failure.

Why would or does DonM's injectors help this issue? Does he use a better nozzle that is less prone to cracking?

Reason I post this in the upgrades section is because I am wanting to know more about DonM's injectors.

Thanks for the input on this issue.

 

Don M builds his injectors to withstand alot more pressure and abuse than a stock injector. He's got a heck of alot of knowledge when it comes to these things.

 

The main cause of injector failure is dirt larget than 5 micron......

 

Dirt and the addition of pressure boxes.Don's injectors are tested to 39,000 psi without cracking

 

I'm interested in this too, as my dad has at least one injector on his 04.5 with 110k miles on it thats gone bad. Truck runs great when warm, but when cold, it stumbles and spits black smoke (truck is all stock, with the exception of a built trans.) I am thinking about becoming proactive with my truck and investing in a set of Don M's injectors soon, just to be on the safe side.
Scott

 

is that enough to run pretty much any pressure box and be ok?

 

That my deal too. The truck is bone stock cept the rims and I wouldnt mind sticking a set of 50hp tip on it if it means there gonna last ALOT longer than the stock nozzles seem to. Ive seen guys take great care of there engine service wise and still have problems. The problem I have seen I guess is splitting tips, or cracking tips. Just wondering why Dons Tips are that much better, I know they are just wondering why--its my nature to wanna know why.

 

I had an injector crack at 39k miles. At that time, I bought a set of the DDP 50hp injectors. The dealer put them in and I never saw them. I think they just put new nozzles and chips in the factory injectors. Does this make them any stronger than factory?
Are Don's injectors the whole thing or just nozzles?

 

I am going with the filtering issue. I change my fuel filter on every oil change and I still had injector problems the last 2 months. Finally, after trying all kinds of snake oil and hard pulling I decided to take her in to the dealer. On the flow test there were 4 out of 6 that failed due to too much flow back (return).

I have been using Napa Gold filters all along, before the dealer was done I had them just throw in a Fleetguard to make sure since they had them in stock. Going to use these from now on to see if there is a difference. I think the final solution though is going to be giving GDP a call for a 2 micron system?

For what it is worth, over the course of time my truck was starting hard (long crank cycles) and was smoking at take off. Also, when I had the TST on anything higher than 3/2 it would act like I was draining the rail (loss of boost, high spikes in egt's and then a surge of power up and down), I used to be able to run it much higher consistently. I haven't been home yet to test it out yet but I am assuming this was all due to the poor stock injectors.

 

Ive injector failure 3 times within the past year first time blew stock ones, second time cracked 3 bodies on 100hp dynomite diesels, third time had injector problem somewhere no visible cracks on nozzles or bodies so sent off to brett at industrial injection to pop test hopefully just a hung solenoid and am putting stock nozzles back on them and selling truck. My new 07 will get Don Ms more then likely within the next few months heard nothing but good things about them, or some industrial injection 8 hole injectors when the come out on the market. I believe that don requires you to send in your injectors to be built and he does the whole thing reworks and tweaks bodies which hardly nobody does and does the nozzles no core charges. Industrial and Dynomite have core charges and do nozzles only i believe.

 

Is there a 2 micron filter that fits in the stock filter housing?

 

No... you have to mount seperate filter heads for 2 mic setups. I run dual 2 mic filters because I believe you can't have clean enough fuel with these common rails.

 

You also have to have a different lift pump in order to push the fuel through the 2 micron setup (Walbro, FASS, MITUSA, etc.).

 

Yes, the issue is dirt. The stock filter is only good down to 5 microns. The interior design of the actual common rail itself is meant to swirl the fuel and break up any particals that got through the filter down to at least 2 microns. Well, if you get some dirty fuel, this doesn't always happen. So what happens is a piece of dirt clogs the tip and then pressure builds up and cracks the body. Part of the reason that aftermarket tips helps is because they have a larger opening and can pass a larger dirt partical without it getting stuck and causing a restriction. But the real fix is to keep the fuel filtered down to 2 microns.