I just can't believe how many fuel injector failure post I've read and even experienced it once myself. Something just doesn't seem right about this and it subtracts from the diesel reliability standards I expect. I'd just like to perform a little non-scientific study to see if fueling boxes may have any connection to this issue that is too common.


Here's my experience: At 44,000 miles one injector went bad filling the crankcase with fuel. Dealer replaced injector, core return, oil & filter under warranty. I had a Xzillaraider (race) in use for about 7,000 miles at the time of the failure (mostly used the 60 & 100 HP settings). The day before the failure I was testing the fueling box for best fuel mileage on the highway. I almost never use the highest HP setting, but did on the highway for about 80 miles (roughly) just to see if I'd get better MPG. Most likely not the intended (or proper) use of the highest HP setting. Anyway, the timing of the events sure made me wonder.

I really like the fueling box enhancements - improved MPG, power, drivability & so on. Sure hope the increased fuel rail pressure of the 60 & 100 HP settings do not aid in the death of our injectors.

Average Driving conditions: unloaded & 80% highway use. Pretty easy on the pedal 95% of the time. Edge EZ was used before Xzillaraider.

 

Injector's were cool however my injector pump went bad while on the Quadzilla 100hp setting. Replaced by dealer under warranty and im now in search of another box, i will be using FASS fuel pump this time also. Im thinking TST

 

I think this is a great poll. I was thinking the same thing, the Cummins may not be as reliable in the 325 600 form as it was at 175 hp.

It does not make much difference to me what component fails and leaves me needing to spend money and time to to make it go again.

My old IH 6.9 has ran 289k on the origional injectors, needed 1 lift pump, 1 injector pump, 1 water pump and 3 sets of glow plugs. I was hoping that the Cummins would be much more reliable given it's reputation.

Regards,
Jim B

 

Guys, Any box or downloader that raises pressure will be hard on the Injectors and fuel injection system at WOT only. This is when the injectors will be operating over their pressure spec. and the CP3 will be stressed by operating at high pressure at a higher duty cycle and will probably be short fueled by the lift pump. Injector failure with all 65+hp pressure boxes is higher than normal for sure.
With a duration box like VA 3.2 and TST you will need a higher volume and pressure lift pump to ensure the CP3 is always oversupplied with fuel to keep the lubrication at max and the supply volume high. I think injector failures with duration boxes are very low if not negligible.
CP3 and Lift pump failures are happening at stock because of undersupply of fuel by the stock lift pump. The intank "pushing" lift pump is probably a little better than the "pulling" stock lift pump. The big thing is to use a diesel additive regularily especially in cold climates and to change the fuel filter often especially in colder climates. The 03 and 04 in tank pick up is I think the weak link in the stock fuel supply...It is a flat plastic mesh filter which can crud up in the tank and there is no way ot replace it other than to drop the tank and clean or cut it out. ks

 

Not all 2004.5+ injectors are the same.

There was a change up in mid 2005. The newer engines also got a different injector harness. You can tell by the connectors on the outside of the valve cover.

The injectors themselves look identical. The nozzle assemblies are different.

 

Superduty, in mid 2005 they would be producing 2005's and 2006's wouldn't they?. When they went to the 610 from the 600 they went from 8 holes to 5 holes....DonM? I'm sure they used up the injectors not reserved for warranty. I think the ECM flash is specific to the injectors in the truck for sure. Maybe that is why some people have problems with downloaders? ks

 

I have seen it pointed out on here before that the 3rd gen trucks that are worked hard do not suffer injector problems like the trucks that are babied (no towing). Might be an interesting topic for another poll.

 

Nice poll!

In additon to the Poll's "box versus no box" votes, some additional comments/info might help determine a trend in the failures as well as the no failures. IMO, it would be very insightful, for the trucks that have expereinced injector failures, if those voters could post additional comments/factors such as:

1) What mileage the failure occured at and how many injectors failed?

2) Whether a lubricity additive was [Brand], or was not used?

3) If box was run, what brand box or stack combination was being run and for how many miles

4) Typical driving/usage - towing, non-towing, high-performance street play, run at track, etc?

5) Any other modifications, or interesting factors, that might come into play - pump mods or replacement, typical Brand fuel type, fuel filter frequency change and brand, ever see Water in Fuel indicator, etc; etc.

Similiar comments from the NON FAILURES RUNNING BOXES with significant mileage accumulation [ >5K ] would also be an interesting comparison.

 

I just know there is a part number change and the injector harness is different.

Ideally the poll would ask about fuel filters too. And failed CP3s.

I helped troubleshoot a truck about a month ago that had 3 injector changes on it. We convinced the dealer to change the CP3. It now runs perfect. Some of the injector swaps you are seeing might be due to mis diagnoses.

 

I have seen injectors fail with or with out pressure boxes i have seen them fail on trucks any where from 03 to 05 both engines. I have seen them fail and destroy engines because the got stuck wide open and fluid cut the top of the piston away,ive also seen them split where the solenoid meets the injector body. Its a crap design chrysler knows about it but wont do anything but try to get out of paying for them. ive done more engine replacments due to injectors in the last 2 yrs. the only other ones ive had to replace are split 53 blocks. I personally in my 03 "knock on wood " run a edge pressure box,let the truck idle a good part of my work day and run the ***** out of it with no problems so far at 42000 miles

 

Here's my experience: At 44,000 miles one injector went bad filling the crankcase with fuel. Dealer replaced injector, core return, oil & filter under warranty. I had a Xzillaraider (race) in use for about 7,000 miles at the time of the failure (mostly used the 60 & 100 HP settings). The day before the failure I was testing the fueling box for best fuel mileage on the highway. I almost never use the highest HP setting, but did on the highway for about 80 miles (roughly) just to see if I'd get better MPG. Most likely not the intended (or proper) use of the highest HP setting. Anyway, the timing of the events sure made me wonder.

I really like the fueling box enhancements - improved MPG, power, drivability & so on. Sure hope the increased fuel rail pressure of the 60 & 100 HP settings do not aid in the death of our injectors.

Average Driving conditions: unloaded & 80% highway use. Pretty easy on the pedal 95% of the time. Edge EZ was used before Xzillaraider.

 

I was not sure how to answer this one but went with the pressure box option. I have a Ramifier (in cab adjustable) but 99% of the time I run with it at about 10% setting as I get just about a half a mile per gallon better that way (every little bit helps ).

Have just over 26K miles on the truck in about one and a half years with no issues, well torn door seals but I was aware of that one before I bought the truck thanks to this site.


I do run PS and a little Lucas with every tank if someone is keeping track of failures/no-failures vs. additive/no-additive

 

I don't know the exact mileages but I'll do my best.
With my dads 05 It got a Edge EZ the one with the 3 way toggle switch to adjust the levels, and also it got a Bully Dog Power Pup. Both boxes were added at the same time and mileage was probably only 5000. Bully dog was almost always on tow setting except maybe 10 times playing around it was on extreme. Mileage probably around 10-15,000 injector 5 cracked and flooded the crankcase causing oil to leak out onto the front diff and on the ground, this also caused the low oil press light to come on while idling. 2nd time was maybe at 3000 after the first one and the symptoms were rough (rattly) idle and injector 5 was changed again. then no later then 20,000 injector 6 cracked and flooded the crankcase again. And now at about 26,000 the injectors are pretty noisy/rattly but truck has no been in the shop yet to get dianosed.

Note: all mileage is in Kilometers, sorry.

 

Alright, I know this is just a poll loosely conducted, but I see (01/17/06) that the number of injector failures appears to be more often with a fuel box installed. Please correct me if I'm wrong, but is it now possible to suggest that our fueling boxes are compromising the injectors and aiding in a much too early death? I love my box but considering removing it to gain reliability that the diesel is known for. So, is it the extra fuel rail pressure that's reducing the lifes of fuel related items (fuel pump and injectors)? We all know that adding after market items to the motor add some element of risk, but this just may be too risky for me now.

 

It is a pretty dramatic difference, too.

Without a box, 2 in 25 have failures or 12.5%.

With a box, 11 in 23 or just about 50%.

People with a box have 4x the frequency of failure.