2002 225 HO FICHT Ram, one melted piston

[jedimaster]

Hey, ok so I had one piston melt on a 2002 225 HO Ficht with about 300 hours on it. I pulled the head and the cylinder looks good. A hone job should be good enouch, I shut it down the instant I heard something rattle so damage was fine. I'm not too worried about the mechanical of the rebuild that I can do no problem. My question is what happened. The Plug was showing a lean condition so would you say this is a condition of that ficht pump gone bad? Is there a way I can Bench test it now that its off? Also has anyone used something like this to read the Codes and replace an injector if need be? http://www.ebay.ca/itm/PROFESSIONAL...t-EMM-diagnose-restoring-update-/190868940025
If you have any other ideas on what I can check and look for as a cause please I'm all ears. Right now I am just continuing to tear down the motor to prep it for a rebuild.

 

[jedimaster]

I should add that this happened at WOT at 5800 RPM's, Water pressure was at 25psi when this happened and have had no other issues seen.

 

[Faztbullet]

Without seeing piston you need to check the ring locating pins have not backed out as these have a history of migration issues. If it was a lean issue you need to have the injector rebuilt/replaced and the EMM tested.

 

[jedimaster]

It threw part of one of the ringsand it was in the cylinder all banged up. I won't be able to get a picture of the piston until I get it out. Maybe later today. I can take a picture of the top of the melted up piston if that helps diagnose it.

 

[Faztbullet]

If ring did break you will find the locating pin missing...this means the other 5 will need replacing as they will soon follow. If it is a bad injector and cannot be rebuilt good luck finding a new one.

 

[jedimaster]

Is there any way to bench test the injector or does it need to be sent away? I don't want to start ordering rebuild parts if the injector is bad. Will just strip it and part it out.

 

[Faztbullet]

Call or send injector and EMM to DFI and have tested...then you will know if to fix or scrap.

 

[jedimaster]

Just talked to DFI (Thanks btw) I think I am gonna send them the injector. Now that the injector side is sorta figured out as to what Im gonna do, Is there a way to test the oil injector on that cyl?

 

[Faztbullet]

Single injector feeds oil to all cylinders.....

 

[jedimaster]

Yah I went through the manual and confirmed what my eyes were seeing. Thought there may be some weird injector going on after the pump. Another question, I may have a line on a new oem 2000 powerhead for a 200-225. Would I be able to bolt everything from my 2002 225 HO onto it?

 

[Faztbullet]

Sorry but no as the 2000 is a 3 liter and your should be a 3.3.

 

[racerone]

I think you will find that a replacement injector has to be matched to the ECU / EMM.----This stuff is not " plug and play "

 

[daselbee]

I think you will find that a replacement injector has to be matched to the ECU / EMM.----This stuff is not " plug and play "

Easy enough...IF YOU FIND A REPLACEMENT INJECTOR WITH A SQUARE DATAMATRIX CODE on the sticker. The label must be undamaged and readable. That code can be read with any smartphone QR code reading app, and the parameters obtained that way.
And then, you must always consider that the replacement USED injector might have a problem too. There are filters internal to these injectors.

Now... the tricky part...getting the parameters into the EMM. You must use EvDiags software version 4.5. That is an old version. The newer versions do not let you simply type the parameters into the fields, and then load up to the EMM.
This was apparently a software change required by the EPA to prevent users from messing with the mixture of an engine simply by modifying the injector parameters.

DFI can possibly supply you with an injector .DAT file to use with the newer software versions to load the parameters into the EMM. Maybe...dunno.

A bit more info....Newer engines (ETec) use a different .DAT file, and have more than four parameters to program. The .DAT file can be downloaded off the internet, but you MUST HAVE the CS number (check sum number) that is on the plastic part number tag that is attached to the wiring harness of the injector.
There is NO DATA in these .DAT files that in man-readable. It is all encoded, to deter hacking and tampering.

 

[jedimaster]

I'll post some pictures in thenday or two. I will also be sending the injector off the dfi. I have the software and cable on order and it should be here soon. So here is my next question, the head is damaged from the ring getting mashed. Is it better/cheaper to have a shop clean it it up and fix it or just by a new/used cyl head. Also any issues with just buying an nos piston? Was having no other issues and the other pistons look good and compress was good. Thinking while it's apart I may just replace the rings on the other. They apart still have a partly good cross hatch. I don't really want to get into having the crank worked as it was running awesome. What's the minimum I should do? A full rebuild kit runs between 1100 apartllnd 1300. I can get a single nos piston and ring kit for around 100, then add gaskets. Trying to be economical amd not replace whay i dont need to but not mess things up.

 

[jedimaster]

And thank you btw. I really appreciate all the info.