2003 with 50k on it. Took it in for long crank times this morning and the Service writer called back saying that initial diags point to low FP. He stated that there was evidence of a box being installed. Yes, I was running a xzillerader box for about a year and took it off about 6 months ago. He stated that there was evidence via the ECM.

Update: Good news, fuel volume is great to the injectors.
Bad News: - One or more injectors are failing and letting too much fuel back into the tank. On the order of 190ML vs the expected 50ML or so.

Now, Off to search about injectors and what I can do to get them installed.

What is a good solution for injectors?
Replace all 6? Aftermarket? Should I upgrade injectors and keep the box or go with stock injectors? Where can I get them for a decent price? I think I can install them with a buddy and I.

Any and all advice is greatly appreciated.


Thanks in advance,
Brett

 

make him show where the evidence is and what it is. They can easily say anything they want to dodge out of warranty work.

I agree that you play, you pay,
but I am tired of dealers using any excuse they can to outright void warranties or deny claims.
just like saying that contaminated fuel is causing the injectors to screw up.

 

Yep, make him prove it.
Especially over 6 months ago....

 

It would seem that I really can't argure with them, They didn't pull one and verify it was bad and to do that "and" if they still do not cover under warranty, then I'm out several hundred more dollars. I accept the fact that the pressure box I was using, may have caused the problem. I'd love for warranty to cover it, but is it really worth the fight and hassle? Don't get me wrong, I can't afford this at all and will probably have to drive it as it is but do I really have a chance in getting it covered?
Brett

 

Only reason I would is I want him to prove to me the box caused the issue.
And if he did then id cut my loses, probably go get a set of injectors from Piers or someone...
If not, then hell be fixing them.

If it was 6 months ago, im wondering how he knew, of searched back that far(if you can) to see if there was more pressure, higher boost, etc...

Are there gauges on the truck? air intake, exhaust, etc?
Even then, id want him to prove it, since im guessing you didnt have any issues for the past 6 months the box has been off the truck...

 

The truck has run fine and I've pulled a 9500lb 5th wheel every weekend for the last 2 months over steep mountain passes here in Colorado. Upon reaching my destination at 10,500 feet, the hard starting issue developed. I thought it may have been bad fuel so I refueled swapped filters 2 times. It is a little better but still very hard starting to almost unstartable in the morning UNLESS I PLUG IN THE BLOCK HEATER. what gives with that? When I do that, it fires and 3-5 seconds of cranking.

I do have gauges but nothing else.
Brett

 

Depending on how cold it is, thats how EVERY truck is...

Less than 40-45*~ and I need to plug it in for a quick start. And if it gets cooler than that over night I do that to avoid freezing as well, and helps me have heat when I first start the truck
Heck, if my old 12valve wasnt plugged in when it got cold, it was NOT starting till you plugged it in for 30min-an hour...

You are going to have cold starts when its cold out(maybe higher elevation too, not sure, never lived outside of texas)

 

Check to make sure your grid heater is working. If not, that could cause hard starts on cooler mornings.

 

Initial diag point to low fuel pressure, but the lift pump passed the minimum flow test? Doesn't make sense.

Do you have decreased fuel economy that you have noticed? I agree by the injector return flow test that you have one or more bad injectors.

Your dealer is lying to you.

I also think that the pressure boxes cause the injector bodies to crack in extreme cases, which will dump fuel to the crankcase, not increase the fuel to the return.

Anyway, if you want to take the cost that is up to you, but just for chits and giggles I'd make him prove to you that the ECM shows evidence.

I'd even threaten litigation, hell, you aren't going to use them anyway and he certainly is screwing with you. You might as well return a little. For the very least as an attempt to keep him from lying next time to his customer that gave him $40k.

 

Sorry, I was not very clear on this. The temps have not been cold enough to need to be plugged in based on past experience with this truck, They have been anywhere from 30-45 degrees in the morning and in the past, even when at 10 degerees the time I have forgotten to plug it in, a double cycle on the heater grid will let it fire up rather quickly.

For some reason it helps it fire even though the temps are nowhere near cold enough to cause me to have to use it.

Brett

 

Hmm You raise some good points.

He even mentioned cracking. I think I'll change the oil and look fuel contamination or can I just look at the dipstick?

I've not noticed a signifigant drop in milage but I really have not been watching either. The last months have seen heavy hauling and longer trips so I didn't pay much attention to fuel mileage.

The wierd thing is that this truck still pulls strong! At least it feels that way to me but I really have nothing to compare it with.

I'm going to dig a little deeper into this cause and effect thing with the dealer and see where it gets me, I know of a friend of a friend who used to be the service manager at this place so I'll call him as well for his take on the deal.
Thanks for all so far.
Brett

 

whats the chance of you going to another dealer. obviously thi guy has an attitude and maybe the next place you go to will be of more help.

brett

 

- First thing you should do is take a oil sample and send it into get it anaylized.
- Second thing you do if that comes back with high fuel concentrations is spend a Saturday and remove your injectors yourself. Then take them into a Cummins certified/ Bosch shop to have them tested and cleaned. Make sure that you keep al receipts of this and ensure that you get a written report from them.
Oil sample $40 for new oil,
$20 for sample
1 hr of labour from Cummins for the injector test. Around $100,

Then take this data back to the dealer.

If the oil sample indicates no fuel or low fuel in the oil then that is not the problem.

 

Back from the dealer. Now I'm starting to get ticked off. Of course the tech had gone home for the day so they "could not" show me the readout that proved they saw the higher pressure readings from the ECM. They found the switch mounted in the ashtray for the box so thats how they said they knew there was a box( and the ECM reading).
I questioned him again about the injectors. He said that he never said they were "cracked" but that they were blowing too much fuel back into the return system. So I guess getting an oil sample would not be of any help.

I know I could go down the path of "prove to me that there was a box running on the truck" and since they were being evasive with me I may do that but I need to think on it some. I'm a little ticked right now and I need to digest it before I do more.

I do have another dealer 30 miles away, should I remove the switch and go there and see if they get the same ECM readings?

Any more suggestions?
Thanks for all the help.
Brett

 

Unless the dang switch says FUELING BOX on it in big letters I would simply inform them that it was used to run some other auxiliary item you had installed long ago. Make them prove you wrong!!! The burden of proof is theirs per the law.......