I don't remember what year common rail you have but you should be getting between 25-30psi stock.
Will

 

Build date of 03 on the engine. So something doesn't seem right with that boost level when on the stock SW setting...

 

Mine rattles on and off under load since mile 1. It is more like spark knock in a gasser. I think it is the timing being adjusted my the computer to get the HP up, and the fact that it is more noticeable with the smarty on #9 kinda confirms that. I believe #9 has added timing.

 

There may be one common problem. No boost could be from not enough fuel or improper timing. Sounds very similar to mine when it is about 5* outside. Goes away once warmed up. Now you say yours doesn't show up until warm, correct? What is giving the ecm the temp reading? OEM sensor of your FOMOCO sensor? Same with intake air and ambient temp? Might be related. I know you were pretty thorough when you wired it up, just checking. My 03 does not sound anything like that, except when really cold. Thats why I'm leaning towards a timing issue or temp reading ( that would change the timing )

 

I'm not a diesel expert by any means, but with what little knowledge I have gained in the past 2 yrs owning one I'm inclined to say it is timing related.

 

All sensors feeding the ECM is the stock dodge stuff using the engine wiring harness. No changes there. Ford sensors only feed the dash gauges (oil pressure, water temp). The dodge battery temp sensor is the only one that I had to run wires to. Not sure exactly what it is used for.

With no smarty, the noise is still there just barely noticeable (doesn't sound like an "issue"). With the smarty on #9, the noise is very noticeable, loud enough that it sounds like an "issue". And it seems to get alittle louder as the engine comes up to temp.

I need to take a trip to my dealer and borrow a DRB scanner. Go for a drive and monitor engine temps, IAT's, and rail pressure. I think they can also do some sort of injector test?

Thanks

 

That is injector/timing noise. And I was lucky to see 20psi on my 2003 305/555 when it was 100% stock. The noise is NOT normal but the boost is imho. My truck will make the same rattling noise at low rpm with a pressure box and a heavy foot. It doesn't do it any higher than 1700 rpm or so.

Andy

 

I guess I've just been spoiled running around in my other truck

Man, stock power levels suck

So what actually is the noise coming from the injector?

Would swapping to an aftermarket injector change the noise any?

 

I could hit 32 with just a boost bolt and K & N air filter. I never bothered to measure it without the boost bolt, but I can't fathom it making a 10 - 12 psi difference. I couldn't "feel" a 10 - 12 psi difference at least. I'll still wager on a timing issue. It is poor when in stock mode, and just amplified when smarty is on.

 

Not sure if this matters, but without the smarty I'm basically stock with a SPS62 turbo. Could it be that the SPS62 is flowing the same amount of air at 18 psi as a stock turbo at 30 psi?

Just a thought...

Either way, I'll head to the dealer this saturday.

 

From what I hear of the tick, it only gets louder with RPMs not faster. At idle can you tell if it's an interior noise or under the hood? Do you have a fan/blower going on inside?

Running with Smarty you should be able to see more than 18#. Has that be confirmed with a seperate gauge? Also by the way that it sounds, it could be timing. You could try running Smarty on a non-timing setting with adjusting the timing sensor back to see if that helps. Just out of curriousity how's the EGTs?

 

One thing I would be concerned about is IF in fact it IS timing, are you hurting the engine? Heard several guys talk about melted pistons and the egt never went over 1300*. The replies they got were that the heat was still in the cylinder because of the excessive timing. Just be aware until you get it figured out. Also.......what sticks? There weer some guys complaining of a similar noise, or excessive injector knock, with some of the 100HP sticks. Couldn't remember if you had stock sticks or not!? I will say that injectors DID take care of their noise. I'll look back for the thread, and see if I can figure out who they were.

 

Using the stock injectors right now. With Smarty loaded, boost is not a problem. I've seen 30 atleast. I don't really want to push it hard until I get it figured out. EGT's are silly. No smarty, I'd guess 800 max, very low. With smarty loaded on #9, I think I hit 1000 maybe. Didn't pay much attention because it isn't hot and I haven't pushed it yet.

 

I went from 22psi to 32psi by adding the Edge boost elbow. Best mod ever!

 

My 03 is stock and only hits 22 psi so maybe the different turbo is the reason for the low boost #.
Joe