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155/30 DIY injectors and a PMAX

18K views 29 replies 13 participants last post by  Merc82 
#1 ·
Is it worth it? Been thinking of my goals for this truck and originally settled on 175/stock nozzles. Well I would like to keep the option for heavy towing open and see that a lot of you guys that tow heavy are running 155/30 warrens and a Stage 1 or Pmax. After tinkering with a spare set of injectors for a while and reading the "project outcast" Diesel Power article about the 155/40 Elite Diesel kit and Two Iceberg's injector mod post I am fairly confident on doing this. All it takes is to plug the spill port on an injector to make it a 155 CC right? Is this how Warren does it? I think that in a weekend, some material to plug the ports and some reseal kits I may be able to accomplish this.... Or am I too far fetched and just send them out? For my current non-studded situation, this should be an easy mod that will help my Pmax spool better, am I right? When I stud it maybe I can drop some coin on the nozzles because they seem pricey. What do you guys think and for those who are running this combo, how do you like it?
 
#2 ·
155/30's and a Pmax with a MTW billet wheel would be a good safe tow setup. Of course the MTW stage 1 with those injectors has proven to be a really good tow setup as well and comes with the billet wheel for less $$$.

Maybe read Coalfired's post with his thoughts on both turbos.
 
#3 ·
Thanks PGreen. I already have a Pmax with a MTW billet wheel. I like it, but didn't at first though it was way too laggy. But after I added the wheel, a custom tune and FICM tuning I like it and feel that these little tweaks here and there are making it better. And if a weekend warrior like me can do such things then why not try new things? I don't see many people trying to mod there own injectors and don't understand why.
 
#4 ·
I don't see many people trying to mod there own injectors and don't understand why.
Most don't have access to a lathe to cut the plunger and piston, or they feel intimidated with plugging the spill ports.

I'm gonna wait till I need to replace injectors, before I DIY my own. Even then, I'll buy all remans and start with fresh.




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#5 ·
I have a terrible memory and for this I appologize but I'm pretty sure I asked Patrick at Warren your exact question about 155 DIY kits and he informed me they not true 155 and that warren drills the main chamber or whatever. You could call and ask for clarification, if so do post. I do recal being capable of the DIY mod but after talking to warren comparing their 155s to Elites DIY kit was not apples to apples - dang I wish I had a better memory though - sorry!
 
#6 ·
I will admit that it seems kinda sketchy that you can just plug spill ports and instantly the injector is a "155cc" injector. However, I have did my own research and bought two brand new Alliant Power injectors. I tore them down and measured the internal capacity of each injector. One was 154.6mm^3 and one was 153.2mm^3 AND if you multiply those numbers by 1000 pulses (the number used to determine an injector's CC rating), then you get ~155cc injector. SO then taking into account that about 20cc leak out the spill ports, you get the ever acclaimed "130-135cc" stock injector. So the Elite DIY kit is (IMO) indeed one way of getting a set of ~155cc injectors. Hope this helps.
 
#7 ·
Jet jock and Lilpooh thanks. And you are right Pooh, a lot of people don't have access to a machinist they could trust or afford the downtime. I guess that is why have companies we can trust to mod and fall back on if something goes wrong. I do think I will mod my existing injectors and when the time comes and they start to fail I will just by a whole batch like you mentioned. Jetjock that is a good enough answer for me. One of the reasons I brought this up is because of the ideas of plugging spill ports, it seems to accomplish adding more CC to an injector, bit from all the reading I have done on here is that it seems to affect idle characteristics. I want my truck to run as it would normally. I was unsure on the 155s and I really haven't read much of folks using Elite's kit. JetJock, if you don't mind me asking did Warren mod your existing injectors? And how much did I run? Thanks for answering my questions guys. I am on my way to work and I just get these stupid ideas in my head and I think, "hell, that guy can do it, I sure as hell can too!!". To much coffee and Red bull..... simmer down now....
 
#10 ·
I,m not beyond asking a really stupid question - what is ^3 stand for ?
MERC 82 I,m considering the same set up and I hope you keep this alive .
I personally don't care for plugged spill ports as I believe it could bring on grief later.
Twoiceberg's write up on 175's is excellent and I would imagine you could accomplish
155's without plugs .
If you were to do this what nozzle size would be best 30% or 50% ???
 
#12 ·
There is a lot of self-to-self question and answering going on here!

I want Merc82 to put a shaft out the back an make a convertible boat mod :D

The plugs can be as simple as 3mm brass rod cut to size or SS ball bearing just punched in to bite/hold. No real need to score the SS barrel to crimp it, but this has been done as well to hold the plug/BB in. It can be long enough to be held by the casing as well. Some have reported that when they took apart their injectors after a failure that the plug fell out. Whatever you do, please don't weld it, unless you are very aware of heat deformation issues; the tolerances are too tight to risk barrel warping if it gets too hot.
 
#15 ·
Good info Frank now I have to go back and reread your threads it's been on my list of things to do.
 
#13 ·
My memory is bad, already threw out that disclaimer but I believe I paid $1150-1200 with a 10% military discount. This is with 30% nozzles. I sent them my injectors and had them back in my hands 10 days later. My idle runs perfect, exact sane as before. I did get an on-off-on idle cut-out type of deal going on but it only happens when I'm slowing down foot off gas as the engine spools down to idle, at idle it's same as stock. This has no effect on how the truck runs, I've gotten used to it and have come to like it lol, sounds just like my old 7.3 did when that happens, kind of "lopping" like, it only does it when slowing down. So if I'm going 80 mph and I remove foot off pedal, my truck will go silent initially, that's the factory input of stopping fuel, but going thru 30mph or wherever the idle kicks back on, right then it will lope as I'm still slowing down until about 5mph to stoped where idle becomes completely normal.
 
#17 ·
MIne do exactly the same. I called Warren and they confirmed the same and that all is normal. I am so used to it. The only thing that still throws me off is coming to a stop it is at a higher idle for a few seconds.

I personally would leave injector mods up to the pros... but thats just me..
 
#14 ·
Another input for guys looking at warrens 155s, when I dropped in my 155/30s on the same tune I was running prior, I was filling the streets with black smoke, I mean turning day into night for traffic around me lol, so they made a much larger differance then I was expecting for what's that's worth. With stock injectors in the same tune, my truck never even hinted at smoking, I always run a mild tow tune. Once I had my tunes modified for 155s, then all was well.
 
#20 ·
Does anybody even offer non plugged 155's that you gentlemen know of ?
I may be barkin' up the wrong tree here , but I'm nervous about plugged spill ports.
Frank , can a person back calculate from your 175 cc write up to achieve 155's ?
( Your write up , with pictures , is excellent reading - Thank you for sharing your
knowledge with us ! )
 
#21 ·
Aren't spill ports usual plugged at the 190cc level and beyond, (haha sounds like buzz light year) except when modifying injectors for really cheap?
 
#22 ·
Well after thinking about this and looking at the price of everything, it might be more cost effective and logical to just send my injectors to warren to be gone through and bumped to 175. A Powermax with a billet wheel should be capable of cleaning those up right?
 
#25 ·
Kind of what I am looking for: a setup I can tow with, don't have to worry about an updated fuel system and can have fun with.
 
#24 ·
Does anybody even offer non plugged 155's that you gentlemen know of ?
I may be barkin' up the wrong tree here , but I'm nervous about plugged spill ports.
Frank , can a person back calculate from your 175 cc write up to achieve 155's ?
( Your write up , with pictures , is excellent reading - Thank you for sharing your
knowledge with us ! )
The point is, if you are already there, just go 175. 175s open port would be fine for any application since the tuning is what affects all of the parameters. The nozzles are the most critical for intended use. I can't see how 30% nozzles with proper tuning couldn't be used in any application, as long as you have a proper turbo. However, if 155 is all you want, then you could probably do it with just the intensifier piston cut. You might need a slight amount off the plunger, but probably not.
 
#27 ·
Nothing yet my friend. I was kind of waiting till I pull her down to stud her before I made that decision, probably going to stick with the 175/stock, they seem to be the best for my needs, I even entertained the the thought of 190/stock and having them detuned to tow, since they only seem to be $50 more from Warren, but then again there comes a charger upgrade as well. So many options Just been doing lots of reading to as much as I can, before I make this decision.
 
#28 ·
Thanks for the reply , I'd like to keep this going because like you I'm trying to make
the rite decision . Lots of reading is required to get the full picture .
I too DD mostly but don't want to cut myself short in case I want to hook onto
something .I'm leaning towards 175/stock which seems to be the "overall " nicest
set up without breaking the bank having to purchase the support stuff ie. turbo , fuel
etc.
 
#29 ·
Any words on this yet? been a few monhs.
 
#30 ·
No sir, decided to get rid of/or modify my Powermax and move up to a stage 2-2.5 turbo by this summer. The injectors aren't going to happen till winter.
 
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