Noisy injectors above 30% throttle - Diesel Forum - TheDieselStop.com
'99 & up 7.3L Power Stroke Engine and Drivetrain Discussion of the '99 & up 7.3L Power Stroke diesel engine and drivetrain in the 1999-Up Super Duty trucks and Excursions. No gas engine discussion allowed except on transmissions and drivetrain that pertain to all models. Please confine discussion of topics in this forum to those items that are specific to the 7.3L Power Stroke engine.

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post #1 of 12 (permalink) Old 01-29-2017, 08:06 AM Thread Starter
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Noisy injectors above 30% throttle

So I recently drove my 97 and 99 back to back. Wow does the 99 have louder injectors over 30% throttle. Below that you can hardly hear them firing. The 97 is actually quieter than the 99 above 30% throttle.

The 99 has a new fuel pump and rebuilt regulator with OEM parts. I do not have a fuel pressure gauge, but when checked at idle it is at 68 psi, and the truck runs great with good power.

I also have done sound deadening with foam in the dash, door seal mod, new steering shaft seal, and foam under the shifter boots.


I am thinking of doing the Hutch mod kit from drivendiesel for $199, HPO cross and the Fuel Rail Crossover™ (FRx) from riffraff for $180 to try to quite it down.

Any thoughts?

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #2 of 12 (permalink) Old 01-29-2017, 09:22 PM
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I think normally it's the other way around.
Is the 97 a cali model? (With split shot injectors)

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1994 F350 7.3 PSD 4X4 ZF5 DUALLY
PHP HYDRA, 6637, 3-4 DP TO STRAIGHT 4 BEHIND THE TIRE, 1.0 EXHAUST HOUSING, DIY D66 TURBO, FUGA E-FUEL, EBPV DELETE. Cooper discoverer AT/3'S.

2010 VW JETTA TDI DSG Kerma tune. Hankook ventus v2 concept 2.


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post #3 of 12 (permalink) Old 01-30-2017, 03:52 PM Thread Starter
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Originally Posted by 79jasper View Post
I think normally it's the other way around.
Is the 97 a cali model? (With split shot injectors)

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97 isn't cali model

Pulled the hydra chip. Injectors are nice and quiet now throughout the go pedal range.

Why the hydra makes them noisy above 30% throttle I have no idea.

The only thing I can think of is that the PCM/HEX code for my truck doesn't have any tuning and I had to use a difference PCM/HEX code to program the chip.

I am going to look to see if any other tuners offer downloadable programming for the hydra chip.

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #4 of 12 (permalink) Old 01-30-2017, 06:24 PM
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Ah, tuning could very well be it.
I do believe several others offer tunes for the hydra.

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1994 F350 7.3 PSD 4X4 ZF5 DUALLY
PHP HYDRA, 6637, 3-4 DP TO STRAIGHT 4 BEHIND THE TIRE, 1.0 EXHAUST HOUSING, DIY D66 TURBO, FUGA E-FUEL, EBPV DELETE. Cooper discoverer AT/3'S.

2010 VW JETTA TDI DSG Kerma tune. Hankook ventus v2 concept 2.


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post #5 of 12 (permalink) Old 01-31-2017, 03:57 PM Thread Starter
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After some research it appears I have an ZDR3 PCM and should probably switch it out for a DCA3 for better programming?

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #6 of 12 (permalink) Old 01-31-2017, 05:23 PM
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@[email protected] would know best.
I can't remember the code they usually recommend.

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1994 F350 7.3 PSD 4X4 ZF5 DUALLY
PHP HYDRA, 6637, 3-4 DP TO STRAIGHT 4 BEHIND THE TIRE, 1.0 EXHAUST HOUSING, DIY D66 TURBO, FUGA E-FUEL, EBPV DELETE. Cooper discoverer AT/3'S.

2010 VW JETTA TDI DSG Kerma tune. Hankook ventus v2 concept 2.


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post #7 of 12 (permalink) Old 02-01-2017, 01:06 PM Thread Starter
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I have researched that the base tuning in the E99 PCM is bunk, so I read it is a good idea to upgrade the PCM and then download the hydra tunes for the newer PCM to make the truck run right. There are no specific PHP tunes for the PCM that is currently in the truck.

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #8 of 12 (permalink) Old 02-01-2017, 01:36 PM
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interesting...

maybe try gearhead tune, or give a call to PHP maybe they can fix their tune

F350 2002 7.3

auto, 37/13.5/20 open country, Bushwaker cut-out flare, Bilstein 5100, Maxtow gauges (EGT, Trans temp, Boost), 4 inch diamond eye turbo back axel drop with BTM muffler, S&B intake, RR AIH plug, billet FPR with gold spring, CNCfab Sgt 1 HPOP, CNCfab HPOP line with cross over, CNCfab 4 line fuel kit, ARP heads stud, RDP plenum reinforcing insert, complete CAC intercooler boot kit, full engine seal and gasket kit, 360* turbo rebuilt, WWII, EGPV delete, dark blue CPS, Hydra chip with SDK tunes, Polished compressor manifold, HD coolant, 203* thermostat, Transgo HD kit, Energy suspension bushing kit, front and rear diff fully rebuilt with 4:88 gear ratio, Z36 powerstop heavy hauling brake kit, headlight relay mod, Fumoto drain valve AND STICKER

F350 2008 6.4 (sold)

TT 26' Springdale 2014
7x17 enclose trailer (shop) 2012
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post #9 of 12 (permalink) Old 02-15-2017, 10:45 AM Thread Starter
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I wonder if a CLB5 DAC-401 PCM would swap in so I can use the newer tuning files?

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #10 of 12 (permalink) Old 02-15-2017, 01:31 PM Thread Starter
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Looks like I'd actually need a DPC-421

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #11 of 12 (permalink) Old 02-19-2017, 05:46 PM Thread Starter
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found a DPC-421 out of an F-450, I'll assume it will work with any of the DPC-421 program files

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH
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post #12 of 12 (permalink) Old 02-25-2017, 08:08 PM Thread Starter
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The swap was as easy as it gets. Took a DPC-422 PCM out of a 2000 truck with automatic transmission. Prior to swapping I moved the hydra chip to the new PCM and programmed it on my workbench with DAC3, Hex code VOAA7P6 which is for 2000 zf6 truck.

I was concerned about the additional shunt wiring for the california emissions but it turns out that the wires go to unused pins on the new PCM (no SES light)

Noticeable differences:

1) truck idles much smoother at first start and coming off throttle

2) power is smooth throughout the rpm band

3) injector cutoff is higher for whatever reason. Coasting in gear with the newer PCM cuts off the injectors above 1200rpm, the old PCM cut the injectors off at anything above idle

4) exhaust note is "cleaner", hard to describe, probably has something to do with different timing strategies compared to cali emissions.

5) MUCH quieter injector noise regardless of throttle input

I should have done this a long time ago, E99 and cali emission programming is terrible!
79jasper and yan7gin like this.

Gunga galunga...gunga -- gunga galunga.

97 F-250 CC 4x4 7.3L PSD E4OD
99 F-250 CC 4x4 7.3L PSD ZF6 E99 CALI DELETE
ROTELLA 5W-40, MOBIL1 ATF, PENNZOIL SYNCHROMESH

Last edited by greenskeeper79; 02-25-2017 at 08:12 PM.
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