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We have changed all the injectors in a 3406E engine, replaces…

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We have changed all the...
We have changed all the injectors in a 3406E engine, replaces the ECM and had it flashed, and it runs great going down the road. You idle it down coming into the shop yard and it misses, smokes mostly white smoke and smells like diesel. We have taken it to a dealership and all of my mechanics have looked at it and are stumped. I find it hard to believe several new injectors are bad out of the box.
Submitted: 10 years ago.Category: Construction and Road Equipment
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Answered in 4 minutes by:
2/15/2012
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
Cat Man
Cat Man, Cat Engine Expert
Category: Construction and Road Equipment
Satisfied Customers: 10,344
Experience: I am ASE Master Certified.
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Hi. Thanks for using JA! I will try and help you out.

I assume the check engine light does not come on, correct? Let me know if it did.

If the check engine light did not come on, I would first suspect the engine may have a fuel pressure problem. Your engine should maintain a fuel pressure between 75 and 90 psi at all times. If it does not, it can cause your problem. I would change the filters first. If that does not help I would suspect you have a failed fuel pressure regulator or weak fuel transfer pump.

Please let me know if you need more help or have more questions.
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Customer reply replied 10 years ago
There is no codes or lights, I believe the dealership said it was at a constant 90 psi fuel pressure.
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
Thanks for the information.

If the pressure is a constant 90 psi. That is too high for idle speed. It should be around 75 psi at idle. If it is 90 psi, it sounds like there is a return line restriction in the system. I have seen this before. If there is, it can cause your engine to run like this at low RPM's and low load. At high RPM's and high load the engine will run good.

I would look for restriction at the fitting on the back of the head and all of the lines after it.
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Customer reply replied 10 years ago
I guess the dealership found 70 psi at idle and 85 above idle. we replaced timing sensor, checked timing, checked compression, etc.
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
I see. That pressure sounds OK.

Were they not able to use Cat ET and cut out the cylinders and try to isolate the problem?
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Customer reply replied 10 years ago
When we put the new injectors in and removed the exhaust manifold, 3&4 cyl. smoked all the time and 2 & 5 smoked every other cycle, 1 & 6 seamed to be OK. Have you ever seen 4 out of 6 new injectors bad?
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
When the inectorsn are Cat Reman I have unfortunately.

May I ask how the engine was running before replacing the injectors?

Or why the injectors were replaced?
Cat Man
Cat Man, Cat Engine Expert
Category: Construction and Road Equipment
Satisfied Customers: 10,344
Experience: I am ASE Master Certified.
Verified
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Customer reply replied 10 years ago
runningthe same way when we replaced injectors 3 and 4 it ran great for one maybe 2 days then it started the same thing so we replaced the remaining 4.
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
I see. It sounds like there may be an injector issue. Were they Cat Reman?
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Customer reply replied 10 years ago
no they were new cat injectors.
Mechanic: Cat Man, Cat Engine Expert replied 10 years ago
I see. Thanks for the information. It sounds like Cat has an issue with their injectors.
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