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Pop goes another injector

BigDogYJ

BigDogYJ

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Location
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Well, about 11k miles later... It appears the #4 injector quit firing. Took the camper out on a camping trip with the church and had a great time. Then headed home this AM, got about 30 mins down the road and noticed a loud knock. Assuming it was injector knock, I wasn't happy and started arranging for a tow. Got interesting since the camper on the back weighs about 3k pounds and would have had to wait 2.5hrs for a tow 30 miles from home. So I decided to just drive it home and pray for the best since it wasn't smoking. Made it home. hooked up EFI live and started isolating injectors. When I turn off Inj4 it smoothed out the idle, still knocking.
My plan is to pull it out tomorrow and Give Exergy a call. I'm pretty sure they have a warranty, and I bought all 8 in October of last year. I'll be updating tomorrow.
 
Well Exergy doesnt bother with Bosch's injector warranty as its a huge hassle to deal with them. Apparently they are really difficult to work with and get an injector covered under warranty. So after talking with Harvey @ Exergy, he would like to look at the failed injector to see if its just something that jammed it up. Im not convinced that's the issue as I've got a FASS 150HD with both a water separator and fuel filter, as well as a CAT filter on the oem filter housing... but anythings possible I guess. Im debating on just buying a new one to replace this failed one, and send the failed one to them to look at and possible repair then just keep it as a spare for the next time. As it seems this truck is cursed.
 
BigDogYJ said:
...Im debating on just buying a new one to replace this failed one, and send the failed one to them to look at and possible repair then just keep it as a spare for the next time. As it seems this truck is cursed.
Click to expand...
You haven't exactly had an easy time of it... :nonod:
 
So heres the plan.... Harvey is sending me out a new one so I can get it in and get the truck back up and running. Im going to send the failed one back so he can take a look at it. From there, after he determines whats going on, I'll most likely end up buying it back after he repairs it or replaces it, and just keep the spare. I've been somewhat lucky both times in that I wasn't too far from home. But I would hate to be stuck 500 miles or more from home when this happens again.
Big thumbs up to Harvey @ Exergy, he was been a great help and willing to make things right. Thanks!
 
While waiting for new injector, heres the balance rates i have recorded since the new injectors and CP3 back in October. I have a tendancy to check them every so often.
Its seems interesting that even with one injector appearing to not be firing, that the balance rates are still within "GM's spec". Just interesting... thats all.

Injector #10/15/13
New CP3 & injectors		07/17/2013
Running Fine 		08/02/2013
After inj 4 failed
10.31.12.0
2-0.40.51.3
31.00.31.0
42.1-0.10.5
5-0.10.10.5
6-0.8-0.90.0
7-2.7-1.0-1.6
81.0-0.1-3.0
 
BigDogYJ said:
Well Exergy doesnt bother with Bosch's injector warranty as its a huge hassle to deal with them. Apparently they are really difficult to work with and get an injector covered under warranty. So after talking with Harvey @ Exergy, he would like to look at the failed injector to see if its just something that jammed it up. Im not convinced that's the issue as I've got a FASS 150HD with both a water separator and fuel filter, as well as a CAT filter on the oem filter housing... but anythings possible I guess. Im debating on just buying a new one to replace this failed one, and send the failed one to them to look at and possible repair then just keep it as a spare for the next time. As it seems this truck is cursed.
Click to expand...

Bosch's problems had better not be your problems. Nice of the vendor to share the misery, but, hopefully they make good on their warranty. Not clear if they are or are giving you a hassle?

I would check electrical in regards to doing the icepick trick. These engines knock like crazy when the ECM turns off the pilot injection in limp mode. Maybe you have a harness rub through or bad connector at the injector. Just thinking an electrical issues causing the injector to have quit.
 
WarWagon said:
Bosch's problems had better not be your problems. Nice of the vendor to share the misery, but, hopefully they make good on their warranty. Not clear if they are or are giving you a hassle?

I would check electrical in regards to doing the icepick trick. These engines knock like crazy when the ECM turns off the pilot injection in limp mode. Maybe you have a harness rub through or bad connector at the injector. Just thinking an electrical issues causing the injector to have quit.
Click to expand...

The icepick fix is for 04-05 LLY ONLY. 06+ are a different animal all together.
 
THEFERMANATOR said:
The icepick fix is for 04-05 LLY ONLY. 06+ are a different animal all together.
Click to expand...

btfarm said:
Likewise the harness rub through. LLY specific. Had it on my LLY
Click to expand...
Yeah I thought about that originally but also dismissed it to affecting the LLY.

Injector showed up today. Thanks Exergy!
I'll be tearing into it this evening when I get home from work.
 
Well i installed the new injector tonight checked the hard line and it was clean. Checked the plug and it was ok. Hooked it all up and still not firing on cylinder 4 and knocking. Hooked up efi live shutoff inj 4 and idle smooths out but still knocking. I checked the wiring back to the big bundle while it was idling and nothing changed. I'm assuming the injector harness goes to the ECM harness? Guess I should check the pins and make sure they're all tight. I'm at a loss. Any ideas?
 
Swap the injector with another cylinder and see if the problem follows the injector, or is at the cylinder.
 
I thought about swapping the injector with another, but the one I just put in last night is brand new and its behaving the same way. Would it still be worth while to swap it wither another working cylinder? Seems odd to have that many bad LBZ injectors especially when they arent known for too many problems.

So theres no smoke at idle. or if I hit the throttle.
Oil doesnt seem like theres any fuel. I tried the drip on white rag and look for fuel ring, nothing. Doesnt smell like diesel either. Not overfull.
I started it and took off oil filler cap, no blow by.
Even with those tests, would you still recommend a compression test? I dont have the tool, which is why I ask. I could go get one from HFT.

I also tried to trace the wiring on the injector but didnt notice anything weird. No DTC's. I tested by unplugging injector 4 and seems the same, no change, but it did log a DTC (P0204). I loaded my stock programming back into the ECM. I was running the tow tune pulled from the DSP5 tune. Still no change. I can manually increase rail pressure and it holds steady at 24k psi @ idle.

Im supposed to bring my gooseneck trailer down to southern california on the 19th. I may be bringing truck back to Left Coast Diesel to see what they can find, if I cant figure it out in the next few days.

Thanks for the help guys.

FYI, Here's a video of how its idling: [video=youtube;kA37jgvUwDA]https://www.youtube.com/watch?v=kA37jgvUwDA[/video]
at the end i pan out to so you can see what I was hauling when this started. I was actually going downhill when it happened.

Thanks.
 
Last edited:
Nice looking Lance truck camper! :thumbsup:

Wish you luck on figuring it all out.
 
Alright so I'm reading through about every injector thread I can find online. And i came across a couple threads about the injector numbering in efi live not matching up with the physical cylinders in the engine. I can turn off inj 4 using dvt control in efi live CSS tool and the knocking is still there but the rocking of the engine smoothes out.
Any ideas about the dvt control numbers not matching actual cylinders?
Thanks.
 
BigDogYJ said:
Alright so I'm reading through about every injector thread I can find online. And i came across a couple threads about the injector numbering in efi live not matching up with the physical cylinders in the engine. I can turn off inj 4 using dvt control in efi live CSS tool and the knocking is still there but the rocking of the engine smoothes out.
Any ideas about the dvt control numbers not matching actual cylinders?
Thanks.
Click to expand...
The mis numbered cylinder issue was limited to the 04-05 LLY. Just because the shaking stop doesn't mean you found the bad injector. unfortunately the best thing you can do is to take them all out and send them out for testing.
 
Just a thought, but if you have a regular code scanner, check for DTC's with that and see what you come up with. It's worth a try.
 
RESOLVED: Pop goes another injector

Well. Apparently Im still pretty green with EFI Live haha.
In the DVT Control tab, the injector numbers do not correlate with the cylinder numbers of the engine. They correlate to the firing order.
So...
EFI Live Injector #'s = 1 - 2 - 3 - 4 - 5 - 6 - 7 - 8
Engine Firing Order = 1 - 2 - 7 - 8 - 4 - 5 - 6 - 3

So I swapped out injector in cylinder 8 for the good injector i pulled from cylinder 4 and now its all happy. Everything is back to normal.
in the end, the injector in cylinder 8 was the one causing the bad knock and loping idle.

Thanks for all the help, glad that worked out.
 
Something else I noticed that was strange. My odometer showed 93040 the night I put all new 8 injectors in back in October.
Last week when this injector failed I was exactly 30 miles from home. I was looking at the odometer now and it shows 104070. Subtract that 30 miles that I drove home, and that leaves me with 104040. Exactly 11k miles from when I installed them. just interesting, thats all.
 
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