How to Change Nozzles on 5.9 Cummins Injectors Setting Pop Pressure and Testing Power Driven 7x .011
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- เผยแพร่เมื่อ 14 เม.ย. 2021
- In this video I go thru setting up some 5.9 First gen Cummins injectors using aftermarket higher flowing performance tips. The nozzles came from power driven diesel and are 7 hole .011" diameter budget builder tips. They all set up ok and chatter and spray like they should. The procedures shown would apply to any Bosch KDAL injector. Swapping tips is not terribly dificult the hardest part is getting the pop pressures all set the same as that can require several different assemblies of washers to get them correct. If you need shims to set pressure or just want professionals to do the work the good people at AREA diesel service can fix you up. Thanks for watching!
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"One thing off the check list of things to do" LOL and six more added before the end of the day! It never ends 🤣
Thank you for another awesome video. No one should trust me with diesel work, but I find it fascinating anyway.
playin with fire, boys will be boys :)
Beavis and Butthead would have liked that fire routine pattern with the injectors going off like that, "Fire, fire, fire, uhhhhhHHHHh ahem hem, yeah, fire, ...!"
I'd never seen that done before. Really neat way to check them.
I was not heretofore familier with the flame test, just the pop test. I will gladly add that to my QC routine. Thanks for the wisdom.
The flame test really just for show and bit to see how the plume distributes but not something I do on every injector.
It is a good idea because doing this will tell you your assembly job was successful and you got a clean injector with nothing inside the nozzle plugging a hole. The flame you would see in the chamber while running if that was possible is not going to be the same inside a cylinder as there is turbulance that is going to have a big affect on that flame. As you most assuridly know and understand, with the combustion chamber inside the piston, things are going to be a LOT different. The difference in a set of Marine pistons is prime example, those are mainly intended to run a set rpm compared to a vehicle engine which is obviously going to have to have a wide power band. To do that, the dish is made smaller because the flame is going to be adjusted by the injection timing. It's still rocket science in a sense. Rockets don't have to deal with variable driving conditions though. Light the fire and go for a ride and hope it doesn't do a space suttle thing. NASA stands for Need Another Seven Astonauts also. Making a vehicle whether it's a gas or a diesel is always going to be a compromise, electronic control just gets a better compromise result.
I feel like I am almost ready for my own diesel injun. Seriously Brain thanks for the video.
Years ago I made my pop tester using a Flexibox pneumatic to hydraulic pump and controlled it using a regulator, could creep up on the opening pressure, easier than pumping on the handle, did many injector's with it.
Having the luxury of a surface grinder will give you accurate results, good job.
No doubt about it Brian you are a smart Man and have a wide range of Experience.
John, Australia.
Brian, you certainly make it look easy.
Thanks for that even if I never do it myself!
that was cool watching the injector fire!
Always fun to watch You play with fire Brian. Good Job!
I like the flame through test. Very scientific. Well done Brian.
Thank you Brian. You never fail to amaze me with your knowledge.
Take Care and Stay Safe
Bob
I appreciate that!
Very nice Brian
Pretty cool. Engines are black magic to me.
Now the fire bugs are happy, nice pattern.
That flame test gave me a fantastic idea for the 4th ..... thanks
You’re welcome 😊
Great demonstration!
Glad you liked it. :-)
Great video, super cool flame test
Glad you liked it
Fantastic Video
Thank you very much!
very nice , great fire test there,, impressive,, thanks for the video.
Thanks for watching!
Brilliant film Brian. That opening scene like a fireside chat. Then great narrative, culminating in the slow-mo fire. But you know how much went into it. Just to let you know it's appreciated. Thing is - you are still the same person you always were, and not changing into a 'star'.
A look at my view counts compared to other channels proves I will never be a star. Just a guy making videos of what he is working on. :-) Thanks for the kind words!
@@bcbloc02 Don't worry about your number of subscribers and view counts. Those of us that do watch your videos both enjoy and appreciate them. Your videos and work are essentially niche in scope. Specific areas of interest that relatively few people get into. But to those of us that do, we're REALLY into it. And we like seeing how someone does these things you do and your approach and methods, how you use the equipment available to you to achieve a good and workable result.
Some of the other channels you may have in mind are often more entertainment centered, or deal with more "well known" or culturally hip things that people who really have no personal interest in machining or actually hands on doing are going to nevertheless watch regularly. Maybe do a few tool and product reviews from time to time, give your honest opinion on their worth. Like that air pump you did recently. Or this videos here on the injectors. Good stuff. There is always room for good tool reviews, since people like us are always buying tools and want to know about them.
Your numbers aren't that bad, anyway. I watch several electronics repair channels. Damn good videos. Smart people. Many of them under ten thousand subscribers and usually maybe a couple thousand views on each episode. Most people just aren't interested in such things. Your numbers are two or three times what they have got. Such is the way things are. I see on my news feed some, um, cough, "dude" TH-cam Star I'd mercifully never heard of before rolled his Rolls Royce out West earlier today with one of his boyfriends. Lol, maybe you can dye your hair red or purple or whatever, limpen your wrist and get light in your loafers, wear women's clothes, wave your hands around your face a lot and start a cosmetics line and start getting into cat fights with other celebrities. Then you get 12 million or so subscribers like it says he has. Ridiculous how things are. But oh well. We like your channel and want you to keep making videos. Thanks.
@@robbieburns1664 Oh don't worry I plan to keep making videos of my boring content. :-) lol I am well aware most people watch you tube for entertainment but that isn't what I make my videos for. I am greatful for all my viewers that do watch, it means a lot that at least some people actually enjoy this stuff.
@@bcbloc02 Intertainment? I got this, PDD''s 6 second blast in the 1/8 and KABOOM, well there goes another engine and truck body. I was very intertained when I saw that and heard that engine went to 8.2k when all hell BROKE loose. I watched their video where the same thing happened at a Dyno Show. I thought the object was to see how much power a person could make and keep a running dependable ride? As Jim Cary said in the Mask, I GUESS NOT ! Gotta be wonderfulto have so much money and almost enought time for stuff like this. Personally I'm not that ambitious to keep building engines just to blow them up but seeing results like those guys do getting all that power is impressive in its own way.
@@brettschacher8644 if you push the limits you will find the limits. There is an inverse relationship between power and durability. The more power you make the less time it will last. I doubt it would take one hand to count all the 5.9 trucks making over 1000hp that have done over 100k miles at that power level without being apart.
Good morning Kentucky!
Morning!
very good video brian..thanks for your time
Glad you enjoyed it
That's like my M1A1 star burst flash***** at night. Matt C.
Excellent, thanks.
Thanks for sharing Brian. I thought tis was an interesting video. I liked seeing the spray pattern of the injector You have all sorts of tools and testing equipment I didn't know you had. I'M sure Bailey gave his wag of approval. Give him a good belly rub and a treat for me.
You bet
Thanks for sharing.
Glad Baily was herding murder chickens with you in the prone and I was going to say you might add a 'Clean Room' in the future but you had a paper towel. 'Who could ask for anything more' as the old song goes. A new set of tips and a pop test would help a lot of the old ether-logged motors too. Thanks, Pal and GBWYall!
Good stuff. When they say "If you can't find 'em - grind 'em"... I don't think they meant injector shims though Brian. LOL!
Nice save.
I've read in a post to not use 7 hole nozzles in a early 12v with a VE pump. I'm working on getting a new pop tester soon, used one yrs ago. It wasn't a real good unit and had a lot of use on it back then so this will be nice to be able to do. I'm un decided on a 5x.014, .016 or a set of 6x???'s. The engine is a mid 91, sold as a still 91 ym but with the IC's, the turbo has the large inlet with primary and secondary comp fan blades but the MWE was never machined in until I did that myself when I swapped the hot side from 21 to 12. What a difference this made along with a pump rebuild and turn up, 366 spring, then a 4" exh. system. It wasn't very long till I was forced to put a new clutch in. Now I'm collecting parts to build a compound system using this modified WH1c with a T76 abd a PS IC'r and 3" air tubes, intake horn. This is why I'm needing bigger sticks, so it will fuel better. I need to go back to the post with the nozzle #'s and compare fuel flow area for these hole sizes. With bigger holes, the fuel spray penetrates the chamber air charge better but smoke is affected so that's a big issue. Smaller spray jets gives better ignition but there's a trade off either way. A tough call. Will consider recommendations ! 400~500 HP area, manual trans so compounds is also for holding boost better between gears,
The powerjet stage 2 injectors from PDD will make right about 425hp pretty easy and will smoke less than stock. They are 5 hole with 2 additional pilot holes which really seem to help with the fuel mixing and burning. They are night and day cleaner than any other style injector. They also made almost 100 More hp than the 7x.011 and with Way less smoke.
@@bcbloc02 Sounds like something I need to investigate. I read a post about nozzles with different size discharge holes, seems like they had 10, 5 one size and another 5 of another sized, custom made nozzles from somewhere.
@@bcbloc02 So far I'm not finding any info from PDD on these and I tried sending an email to them but it came back as un deliverable due the address I get from their web site. Bummer, I guess I'm going to have to try giving them a call this week.
@@brettschacher8644 what kind of info are you looking for?
Very cool
Bailey is going to be on you for playing with fire when you are supposed to be working!
I have 300,000. Plus on my 2001 5.9, thanks for the education my day is coming!!
Probably would help them start when it is cold out. :-)
I'm due to do a head gasket and RV275 injectors on my buddy's 2001, it's got well over 300K miles on it now.. I heard they're a nice mild upgrade.. It'll be getting an HE351 turbo too at the same time
@@bcbloc02 yes I’m never gonna live that down! 😆
@@Rx7man good luck
@@dmadere1 thanks.. I've done a number of them already, never done 24V injectors but with the head out of the truck it shouldn't be too bad to work on, same for getting the exhaust bolts on the turbo off
Topman👍
Hi Brian ! From France !!! 👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍👍
Hello there!
You have way too much fun! Can see a home made flame thrower in the works?
Man Brian, for a second there I thought I was looking at Burt Reynolds! Of course minus the bear skin rug and the banana hammock.
I would drive a 70s trans am. :-)
Good morning happy Thursday ! Did Keith get my books ?
Good way to remove the unwanted hair from the back of your hand Great video
Still got all mine though.
Hiya Brian
I have a set of 7x12's to go in my P pump truck to replace the 5x16's in it now, I'm going to tame the truck down a little bit, then I gotta build a few more sets for friends.. I have 5x16's in me VE pump truck and they're real nice for that
I was afraid 5x.016 would be a little more egt than I could keep in check with a single turbo pulling the trailer. Going to those 7x.12 should cut you back 20% on fuel.
@@bcbloc02 Yeah, on a 215 pump that's a lot of fuel for a towing truck with no fuel plate, but they work great on a VE truck with some extra air
Some before and after test data of the Cummins would be interesting.
I will be able to report boost and egt but probably not much else difference. I don't have a wheel dyno to test on.
Brian with your love for horsepower here's hoping a dyno's in your future. Imagine the vjos then!!!
Like the little pyrotechnic display. Probably rough on the eyebrows. Guess that is kinda like what happens in the cylinder.
Brian
I checked the stroke control valve and it was free and yes the pro works it appears to me that the front pump my not be getting any hydraulic oil the tank by the radiator had very little oil in it and I added some and it appears to have went down to the sump where you check the oil level also took hose off the top of the oil cooler and could not see any hydraulic fluid inside it
You can put a gauge in the top of the reservoir tank and check it should make pressure when running after a few seconds as the transmission pump should fill and pressurize it. If you have no oil flow to the front pump it won't pump.
Brian, when Adam B. @ Abom 79 did a shop tour sometime back, I saw 2 Mercedes parked, are both 300sd or 300d's? I still at 68+, still do some select customer services, and still rebuilding the injector for the 300 & 240's. Been using Monark in lue of Bosch for several years now. You tried, are probable may use Monark already? About to hang it up on mercedes service and start finishing up some of our personnel unfinished projects. Loved the laying down on the job shot,,,I sometimes find that under a car on an old blanket, is much more comfortable than sleep by a cold harted Bride,,(@@)! Love the ole 12valve cum mins,but getting pricey dw here in TX,,and most are wore slap a_ s out. Thxs for share,,catch you on another,,Bear in TX.
I had 2 83 300d's but the one got totaled when somebody blew a stop sign running 60mph.
I will probably never do this to my '96 but it was nice to know how easy it is, and after Googling a pop tester, I found they are less than $150. I wonder if I could up the HP on my motorhome's Cat 3208?
With a nozzle change you could. Just setting the pressures won’t change power of a noticeable amount.
Great video 👍 and I thought 5 hole bosio injector tips were exotic.
Not nearly as hard as some make it out to be ... Thanks for sharing!
Not at all
👍👍
When are we going to see the Hyster in action?
Probably be June. It is Kentucky and the rainy season. Right now it will sink to china if I go anywhere with it.
Brian why don't you tighten up that test rig you were using? It was swinging around like a prick in a bucket! lol
You either need 3 elbows and 8 foot arms or it would take 2 people to tighten it up.
Not much to it! Not if you've got years of know how. Good video.
Is that stroke control valve the same as the filter bypass valve. Thanks
No stroke control valve is in the front pump. It comes out the bottom of it. Also check that your pto is still working Because if it isn’t then the supply pump to the front pump won’t be working and you will have no hydraulics.
Where did you finds a nozzle tester Brian ??? Looks like something I saw at the Napa engine shop years ago. Nice work fella too.
It came with the injection pump test stand it is mounted too. It is for fuel system testing on Deere 2cyl tractors.
@@bcbloc02 Nice work on the injectors. I like the lighting of the atomized fuel for the effect. I did the same thing with a huge Buday engine that runs like a top. They just do not make great engines like that any more. Peace too.
Did you put a bigger turbo on it that will run more boost, is that why the head studs are going in?
More fuel will make more heat which will make more boost. The truck currently runs 30psi and I bet it will go over 40 with the bigger injectors. Anytime you get a 12v over 40psi the head gasket is in danger.
Are going to be turning up the pump and are you going with bigger turbo?
Pump has been maxed out for as long as I have had it. If anything I may wind up turning it down to keep egt's in check.
I'm about to start my bmw 524td (uses bosch ve with AFC boost thingy) with some monarks at 7:17 you said one of your new nozzles was dirty how did you go about cleaning it? brake clean? I'm afraid to take out the nozzle tip in my dirty garage.
It has to be taken apart to clean it properly.
I replaced two injectors on mine back when the plunger springs in the pump shattered and sent metal shavings into them, blocking them open and allowing the pump to fill with air. With over 480,000 on the truck, I really need to look into going through all of them (I can't recall which two were replaced now), so this will be helpful. Did the stock injectors have the same spray pattern as those?
I still have the engine out of my old rabbit, with the VE pump. Thinking on how I could use that to build a means for testing, since it's belt driven.
My stock injectors are 145deg these say 145 and 148 depending at what you look at regardless they are very close to the same.usually when the plunger springs go you get a high rpm missfire you can catch.
@@bcbloc02 on mine, it quit and would not restart. One of the two times I had no choice but to get a tow. The other time was when the fuel shutdown solenoid failed, and I didn't have the right tool to pull the plunger out of it.
Where in the hell did you find a place to lay down in your shop?
It is the old shop. LOL
@@bcbloc02 Next to Baily's couch!
@@lewiemcneely9143 Naw.... He had to hide from Bailey:)
@@10swatkins Maybe BEHIND Baily's couch but probably not. That's where Baily's treat stash is/was hid.
Ha... now that's funny Steve IDC who you are...
So, the weight set; is Bailey working out now? Wants to get buff like looney tunes Spike the bulldog?
He could use some more excercise!
Hey Brian I have a 2640 JD and I’m having hydraulic problems I’ve lost all hydraulics, steering and lift and loader. Changed filter and cleaned strainer in sump still nothing. It quit suddenly working fine and quit all at once. You have any suggestions? Thanks
First thing to check is that the shaft going into the front pump is turning. Sometimes the couplers strip. If it is turning and still nothing next would be to pull the stroke control valve out and make sure it isn't stuck or scored.
Ok thanks i check and the shaft is turning I’ll make sure the pump is turning also. Thanks a lot Brian
4:31 If you listen carefully, you can hear Bailey bark the proper torque click for the wrench......
Was that a commercial pop tester or something you put together yourself?
It is an old Bacharach tester from the 50’s
I didn’t have a fitting with right thread to screw into tank but held thumb over hole and no pressure. Do you think transmission pump
Could be. That is why I asked if PTO was working because it is driven off the pto disk in the pressure plate and sometimes they fail and quit running the pump but when that happens the pto won't run either. If its is trans pump you get to split it and that is a lot of fun.
Might want to take the lines loose at the trans on the right side and make sure the check valve hasn't come apart and blocked the line.
@@bcbloc02 I was afraid I would have to split tractor I will check the check valve thanks
I pulled the check valve off it seems to be intact I had to tap the seat out with hammer and punch the first shim was holding seat so tight should it have been that tight put it back together and nothing changed
@@mikec.9177 The check valve is really just anti drainback it will work fine even with out it so if the ball wasn't stuck up in the line it should have worked fine. Sounds like you are ready for typical utility tractor life and split that thing between clutch housing and transmission.
You're advertising PDD parts here but I haven't been successful in gettin getting in touch with those guys. The video is discussing 7x.011 nozzles, what I'm asking is what are the nozzle hole sizes? I though I put that in my message. Next is how much are those stage 2's and where does a person get a set if PDD isn't responding to mail sent to them? I'm certain they are having some injector shop make these up for them and not making them themselves. I could be wrong though. So many posts dealing with P pump engiines or converted engines from VE to P or VP44 converted to P. I guess I'm just going to have to purchase a set of inexpensive sticks to use as cores and get my pop tester, a set of nozzles and shims etc. and go to work.
I am pretty sure PDD has dynamite make their tips then they assemble them themselves. Way more too it than just hole size. I made 360hp and like 930tq with the 7x.011. I went to the stage 2 powerjets and made 430hp and 1030tq. They are about a 5x.010 but make way more power with less fuel and smoke because they burn better.
@@bcbloc02 TKY for the # results. Are you referencing a VE pump engine or a P? I know the P is going to make more power with a particular nozzle simply because the Pop pressure is a bit higher. I know every engine is going to be a little different based on the complete package and advertised ratings are subjective. Dyno #;s tell the truth, need to get my new pop tester and go to work I guess, that and get a set of main bodies to work with so I can have everything assembled and ready to do without keeping the truck out of service extended times.
@@brettschacher8644 Those dyno numbers are for my stock intercooled ve setup with the s300g turbo.
@@bcbloc02 Interesting. I've been of the opinion for info found online the OE nozzles for a early IC'd engine were 5x.009. So stepping up to a set of 5x.014 is a pretty big increase. It is stated that a larger spray plume is going to penetrate into the combustion chambe harder but as it is easily understood that large jet of fuel is going to take longer to get lit off and going to make more smoke, so, common sense tries to tell a person that smaller jets are going to ignite easier and burn cleaner, so to get more fuel into the chamber to burn with the increased Oxy so find a suitable compromise of size & count.
@@brettschacher8644 5x.014 is personally more than I would advise to street drive if you want it clean. The factory truck intercooled nozzles are 6x.009
Is your pop test station one of your own shop built tool?
No it is a factory unit from the 50’s
@@bcbloc02 I’d like to have one ,thought if you built it you would show us how
Maybe should have warned people not to get too near the high pressure mist....I can see someone trying that with a cigarette lighter not knowing about the dangers of high pressure diesel injection through the skin...
Hold on I need a cup of coffee first..... Ok go ahead......
Hot Damn injectors n stuff ... love to hate 'em
Shim info was great, but I want to know if the metal snap button at the top of your shirt catches your beard like mine do. Dang that hurts
I have not had that happen but I do never button it so....
@@bcbloc02 may just be me, the older I get the more I have to look over and under my glasses, or either my goatee is too long🤣🤣, lovin your vids. All my fathers folks are in eastern Ky coal fields so when I first saw your vids I had to click. Been enjoying them since, except for when the cable snapped. I think my heart dropped as far as yours did but I knew you could over come that{ little}, set back.Keep putting them out and let our youth know there are good paying careers if you don’t mind getting off your arse. I’m a truck driver by the way and my teacher said I’d never make a living staring out the window.I Won🤔🤣😁👍
Have you given up fixing that car you tore apart a few videos ago?
Waiting on parts, most things are national back order. :-(
Looks like you are running out of room in workshop. Build another one?
Don’t have money to finish the one I have much less to build another! I had money to put the ceiling in then the prices more than doubled. Now I can put a 1/3 a ceiling in. 😭