Category: Fuel System

Fuel Injectors for 2003 and Newer Cummins HPCR Engines – Previous Magazine Discussions & Aftermarket Processes

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Hartridge Injector Tester

Fuel Injectors for 2003 and Newer HPCR Engines Previous Magazine Discussions & Aftermarket Processes Over the years, diesel fuel injectors have had to deal with increasing system fuel pressures to improve atomization of the fuel for decreased exhaust emissions. Corresponding to the increases in pressures and emissions regulations, the injectors have been built to ever tightening specifications, including tighter clearances (millionths of an inch). The older 12-valve engines and the early 24-valve engines (up to 2002 model year) used mechanical injectors. These units use a stiff spring to hold the…

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

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Six new DDP Stage 1 injectors

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

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72i16. Disassembled bottom half of HPCR injector.

[ 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 seat in the center, and the solenoid and its nut to…

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

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Bosch HPCR Fuel Injector

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

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Specialty tools for HPCR injector replacement.

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 into its well in the head. Next is a blue painted…

Well, What Do You Know? The TDR

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As a niche supplier of parts for only Dodge/Cummins Turbo Diesel trucks, you can imagine that day-in and day-out we get asked many of the same questions. Often owners will want a reference location for the information that we discuss with them. Our go-to source for the data: the Turbo Diesel Register (TDR). Some will balk at a TDR subscription. That’s okay, we know they just want an answer to the problem of the day. We all acknowledge that the TDR keeps Dodge/Cummins owners up to date on problems and…