Hello, I would like to apologize for the long post!

Okay so I'll start it off with what I have done to the truck so far. It is a 1998.5 2500 5-Speed 4x4 Cummins. A little under 900 maybe 1000 miles ago I have installed a new VP44, Airdog 100, OEM Cummins connector tubes, 7x.009 100hp injectors, and I also had to have my computer rebuilt because the throttle circuit was shorted out(I may also add that the truck used to prime for 3 seconds and it no longer does, I used to be able to access system function from a scanner and no longer can, The truck sounded ever so slightly different after I installed rebuilt ecm aswell). I have a few more things coming within the next 3 days including banjo washers for the bolt at the back of the head(I may also buy the Fuel Grommets at the return T soon aswell), BD Boost Fooler, and an Adjustable Turbo Elbow. There is also a programmer for sale that I may pick up aswell next week. But anyways now to my problem. I installed the new injection pump and airdog at the same time and then drove the truck for about 2 weeks and it sounded slightly different but ran fine.Then I decided to pull the trigger on some DFI 7x.009s . I installed them and the truck started up, smoke white for about 30-45 seconds and slowly went away and the "Air-Filled" idle started to go away too. The truck still had a rough idle after letting it sit for a while. So I got into contact with Chris and he sent another set out the next day. Boom the rough idle is gone. If I am in neutral and let the RPMs climb and then hold them at a certain spot the truck will shake quite a bit or whenever I accelerate hard the truck shakes quite a bit aswell. But the acceleration could be bad u-joint on front driveshaft maybe? If I give the truck more throttle there is an odd "miss" sound coming from the exhaust(not from the motor that I can hear anyways) The sound reminds me of an old non turbo 7.3. I ordered feeler guages and they will be here Monday and I will be adjusting my valves to see if that helps as they have never been adjust before. I know of two 2002 6-speed dodges that have 100hp and 150hp injectors and they do not sound like mine. Does anyone have an answer of how to fix it? I'm guessing maybe the tune in the computer is off and I just couldn't hear it with the smaller stock injectors or maybe the valves are opening slightly off and it is doing this or something? 

Here is the video. 

 

Time to re-do the install of your injectors you most likely have a high pressure leak inside the return rail or possibly push debris into the injectors which would require pull them apart one at a time and checking.

So I should take apart each injector or just reinstall how you stated

If the connector tube had a piece of debris on the end of the connector tube would it cause this problem?

Do not have time to read all of this yet but in my experience popping is generally from an air leak on the high pressure side (normally a loose line) or too much timing from an electronic power adder. 

On 3/18/2017 at 2:22 PM, Cronus577 said:

And did your replacement ECM get flashed with a 235hp tune or a 245hp tune? I've read some articles that a SO truck doesn't like the 245hp tune

 

If this had happened he would have a HUGE host of other issues besides the rough idle.

Okay so I'm in the process of Re-installing the injectors and I pull out connector tube number 6 to find that the oring is busted.Would this cause my issue?

So I know I atleast need a new o-ring now. I guess Il pull the injectors out and check them out to see if I can see any damage to them.

17 minutes ago, Waydin_Stewart said:

Okay so I'm in the process of Re-installing the injectors and I pull out connector tube number 6 to find that the oring is busted.Would this cause my issue?

So I know I atleast need a new o-ring now. I guess Il pull the injectors out and check them out to see if I can see any damage to them.

That could very well be the source of the problem since all of it happened after the injector install. A local Cummins dealer should have them in stock, or you can order them. Home Depot, Orileys, auto zone might also have the right size for a temp fix, but I heard the rubber is too soft. 

Chris at DFI will be sending me a new set of O-rings. When he sent the connector tubes they didnt come with new ones so I re-used old ones that were only maybe 1.5 months old if that as I just rebuilt the stock injectors recently and decided to go bigger. He asked me if they had O-rings and I told him I reused the old ones. He just texted and said he would send out a set of o-rings to see if that fixes the problem. Wish me luck!

Make sure you lubricate the o-rings before putting them back in. Don't use a petroleum base lube like Vaseline because it'll cause the o-ring to swell and it might make it harder to pull out the next time. And use a crows foot 19MM with a torque wrench to get it torqued down properly, you don't want to crack the flare on the end of the tube. Should be 30ft lbs.

1 hour ago, Cronus577 said:

Make sure you lubricate the o-rings before putting them back in. Don't use a petroleum base lube like Vaseline because it'll cause the o-ring to swell and it might make it harder to pull out the next time. And use a crows foot 19MM with a torque wrench to get it torqued down properly, you don't want to crack the flare on the end of the tube. Should be 30ft lbs.

I use the oil in the top of the head to lubricate them. The oil is new I changed it maybe 500 miles ago. It is just now starting to turn a very slight tint of black. I took all the injectors out to make sure there wasn't any damage to them and noticed on cylinders I believe it was 3 and 4 or maybe 4 and 5 that there was quite a bit of buildup on the tip. The others didn't have this much buildup. Is this normal?

Build up? Sounds like ash deposits but hard to tell. Shot some pictures.

Edited March 20, 20178 yr by Mopar1973Man

Build up as in like black on the tip. It was just a little thicker on 2 of the injectors.

Spray issues? Lack of boost? 

If its lack of boost I'll have that solved today after the turbo elbow and boost fooler. They are brand new injectors so i would think they would have spray issues haha. I guess i could soak the tips in camp fuel to clean the stuff off and make sure nothing is in the tip.

Carb dip is the best so far. Coleman fuel works good. Even carb spray (using the red straw) works good for blowing the nozzle out. 

Camp fuel was just the knockoff on the shelf next to Coleman fuel at Walmart. I'll use some carb spray and blow it onto the tips to clean them. Have you had a thread on here before with an issue like mine?

Kind of where this article got started from...

 

Yeah I read that write-up multiple times before starting to clean my injectors. It was very helpful. But after I got the truck running again I figured I've spent this much money and replaced everything else why not the injectors and tubes aswell.

Okay! So I got the connector tube o-rings in and it solved the hard start and exhaust pop...to an extent. At low RPMs it still pops just a tiny bit I'm adjusting the valves Monday or Tuesday maybe that will fix it. BUT! I just discovered only 1 of my batteries is working? All grounds seem fine and the batteries were purchased same day and installed same day. The passenger side will not spark if I just grace the battery post So I know it has to be a ground for that one but I have no clue where to begin troubleshooting form. I tightened all grounds coming from passenger battery down but still didn't spark on contact.

Clean the crap out of the grounds!! Even the slightest bit of dirt can cause issues. If that doesn't help then check for exposed wire places it shouldn't be.

 

Glad you got a good majority of your issues fixed, you're on the home stretch now!