Fuel Injectors for 2003-newer Cummins HPCR Engines

Fuel Injectors for 2003-newer Cummins HPCR Engines

Originally appeared in TDR Issue 72 May/June/July 2011 by Joe Donnelly The editor called with the assignment for this issue, “I want an all-encompassing article on fuel injectors for the Dodge Cummins 2003-and-newer engines that use the High Pressure Common Rail (HPCR) fuel system. Can you do such?” I asked for a little guidance: where to start, what to say. His recommendation, “Think about country music. Haven’t you heard that David Allen Coe song where he sings about the ‘perfect country music song?’ I want you to do the perfect…

Fuel Injectors for 2003 and Newer HPCR Engines – Injector Upgrades and Preventing Failures

Fuel Injectors for 2003 and Newer HPCR Engines – Injector Upgrades and Preventing Failures

Originally appeared in TDR Issue 72 May/June/July 2011 by Joe Donnelly Fuel Injectors for 2003 and Newer HPCR Engines Injector Upgrades and Preventing Failures In Issue 56 (page 96), Scott Dalgleish discussed his results with Dynomite Diesel Performance (DDP) injectors on his Third Generation Turbo Diesel. In his quest for mileage first, and power second, Scott chose a set of Stage 1 fuel injectors. His article described the aforementioned extrude honing manufacturing processes and provided dyno results verifying the horsepower claims of DDP. He reported an increase in fuel mileage…

Fuel Injectors for 2003 and Newer HPCR Engines – Inside the Injector

Fuel Injectors for 2003 and Newer HPCR Engines – Inside the Injector

Originally appeared in TDR Issue 72 May/June/July 2011 by Joe Donnelly [ Reman HPCR fuel injectors are available at Geno’s Garage. ] Fuel Injectors For 2003 and Newer HPCR Engines Inside the Injector We have looked at the pintle and nozzle with the remarkably tight clearance between them. Here are the components of the HPCR injector, first the bottom half with the nozzle nut, nozzle, pintle, and the main body to the right. Next is a photo of the top half with the armature to the left, check ball and…

Fuel Injectors for 2003 and Newer HPCR Engines – Frequently Asked Questions

Fuel Injectors for 2003 and Newer HPCR Engines – Frequently Asked Questions

Fuel Injectors for 2003 and Newer HPCR Engines Frequently Asked Questions Rail Pressure versus Fuel Mileage Q: In Issue 63, page 82, writer Joe Donnelly did an article about the 2003 and newer ECMs and reprogramming them using a “Smarty” by MADS Electronics. In that article we are told that added rail pressure does not give mileage gains and is “problematic to injector and injection system durability.” Then on page 110 there was a “Product Showcase” article where we are led to believe that increasing fuel pressure will increase mpg…

Fuel Injectors for 2003 and Newer HPCR Engines – Injector Removal and Replacement

Fuel Injectors for 2003 and Newer HPCR Engines – Injector Removal and Replacement

Originally appeared in TDR Issue 72 May/June/July 2011 by Joe Donnelly Fuel Injectors for 2003 and Newer HPCR Engines Injector Removal and Replacement Tools: You will need a few specialty tools to make the injector replacement easier. The aluminum plate at the top keeps the exhaust rockers in order and assembled. Under it at the left is a 15/16” socket cut down to 1” total length, with a connector tube nut in it. To the right of the nut is an orange painted tube that facilitates pressing the new injector…