Popping Under acceleration

[Rawze]

According to the program this is also a Volvo truck.

Does this truck have an after-market CAC unit on it?... if it has a non OEM branded CAC unit on it, that could be a big part of the issues, as most non-oem CAC units are very restrictive, have less air flow capacity, and sometimes create a vacuum at the intake, etc.

[Phoenix6189]

Yep, you caught me, 2012 Volvo 780 with Cummins 2250, and 13 speed Eaton Ultrashift Plus. 3.55 rears.

OK, CAC is stock with 3 or 3 1/2 inch piping. Considered low HP 455. CPL 3719.

Factory program installed for testing purposes and I believe its a little better.

So changed out cylinders 1,2 with 4,5. Popping stops when shutting off 4 and 5. The exhaust cleans up when I shut those off as well.

So I believe someone knocked the injectors off my table, and no one want to be responsible, so I had to figure it out the hard way. The Shop I'm working at has a few different people coming in and out working on different things.

I'm sure I'm having problems with 1,2,4,5 injectors. Just going to find a six pack to install. They were fine before the head gasket issue.

[Rawze]

(08-29-2026 )Phoenix6189 Wrote:  Yep, you caught me, 2012 Volvo 780 with Cummins 2250, and 13 speed Eaton Ultrashift Plus. 3.55 rears.

OK, CAC is stock with 3 or 3 1/2 inch piping. Considered low HP 455. CPL 3719.

Factory program installed for testing purposes and I believe its a little better.

So changed out cylinders 1,2 with 4,5. Popping stops when shutting off 4 and 5. The exhaust cleans up when I shut those off as well.

So I believe someone knocked the injectors off my table, and no one want to be responsible, so I had to figure it out the hard way. The Shop I'm working at has a few different people coming in and out working on different things.

I'm sure I'm having problems with 1,2,4,5 injectors. Just going to find a six pack to install. They were fine before the head gasket issue.

are all the parts OEM certified?.. or something else?... because I have never seen after-garbage or "non-OE repaired" injectors that were worth 3 cents, nonetheless good enough for a commercial engine.

[Phoenix6189]

They are all Cummins. I paid for new injectors and head, but that's not to say they didn't use reman. The in-frame happened in Dallas and I live in 325 miles away. I had them send me Pics of the Cummins parts and boxes they came in, he told me I was real pain. They must have screwed something up, it only lasted roughly 250,000. Everything I have pulled has Cummins QR codes. Don't see any part with RX or PX. I also never let my Pyrometer get over 800. Not really sure what the max is but I figured 800 wasn't pushing it to hard. Now I was using the OLD file I sent you after the in-frame. That may have something to do with the failure.
I'll try tomorrow to get the new program done.
Do I need to change the File Name or will CT just recognize it? Push it just like the other stock or OLD files?

[Rawze]

(08-29-2026 )Phoenix6189 Wrote:  They are all Cummins. I paid for new injectors and head, but that's not to say they didn't use reman. The in-frame happened in Dallas and I live in 325 miles away. I had them send me Pics of the Cummins parts and boxes they came in, he told me I was real pain. They must have screwed something up, it only lasted roughly 250,000. Everything I have pulled has Cummins QR codes. Don't see any part with RX or PX. I also never let my Pyrometer get over 800. Not really sure what the max is but I figured 800 wasn't pushing it to hard. Now I was using the OLD file I sent you after the in-frame. That may have something to do with the failure.
I'll try tomorrow to get the new program done.
Do I need to change the File Name or will CT just recognize it? Push it just like the other stock or OLD files?

A lot more happens when you put the factory software back int it. Its not just putting in an updated version of the same old thing. - It wipes out everything in memory, etc.. and allows the engine ecu to re-learn everything like cylinder balancing, etc.etc.etc.. and this is always helpful, especially after injector replacements, inframes, etc. It gives it a fresh start with all new collected data along with the data that its supposed to be running on.

The files you sent me are all a few years old, etc.. + the 0.39 files are out of date by several years with a lot of run time on them.

If your going to do this yourself using the blank factory file I sent you then ... here is what needs to happen summed up ...
========================
To get it right ...

== (Insite) Back up all vehicle settings (in insite by making a work order + ecm template + ecm image). This backup using Insite will have all the vehicle-specific settings that the ecm needs from the vehicle itself, like cruise control button addresses, engine brake, mileage, etc. that are otherwise hard to get back if lost. Insite and its 'Work Order" system is the software for this.

tip: When in Insite, under features and parameters, copy the engine ser# and Vin# for the engine and paste the info into a note-pad text window on your PC. They are going to get lost during the update, and its easier to copy-paste them than it is to type them in again from scratch.

== Flash this latest base factory stock file in via CT (or with Insite). If using Insite to flash, then use the "restore features" check-box to restore the vehicle settings along the way.
.. HOWEVER!!!...
If using ClTerm,.. MAKE SURE there are NO check-boxes turned on for backup-restore parameters in CT!. - IT HAS ISSUES with doing this properly. - What You want instsead, is for it to put file just like it is unaltered. - Matter of fact, you should NEVER use those features in CalTrm, as it does not work properly and tends to restore things you did not want to keep, or slightly corrupt the file, non of it is good for the engine.

== After factory file is back in ... (Insite) Restore the work order/template (vehicle-specific settings) that was made in Insite before the re-flash, so that the engine knows the addresses of all the buttons in the dash are, vehicle settings, etc..

== (Insite) Clear all faults 2x in a row, cycling the keyswitch, and ...

For CM2250 and eraly model CM2350's,.. you will need to put/type back in, the injector trim data codes for the injectors that are in the cylinder head. = Older common rail ecm's are not able to read this from injectors.. so it has to be manually entered, or at least verified to be correct.

... then Run engine for 10 minutes on new factory software to rebuild data. It does not matter if it has some emissions systems or other related faults that do not go away at this point. It needs to re-build all the memory and do learn processes stuffs in the background, which only actually takes about 8 minutes or so.


- Restore (put back in) the vin# and engine ser# into the features and parameters using Insite. They often get lost during software update.

-- After the engine is back 100% factory programming and up to date + 10 minutes run on engine ...

== (Calterm) copy the clean updated file back out via CT and e-mail it (and the old file backup if you have not already) to me to have any custom programming re-done properly.

[Phoenix6189]

The new injectors didn't get in until yesterday. And that fixed the Fuel Knock. Updated the Cal file. The truck is running like it should. Taking it for a longer test drive today. Will update, afterward!

[Phoenix6189]

New Tune installed, no codes after double reset. Drives great Bobtail. Will do some test loads tomorrow and setup for redoing the motor correctly. Thanks for all the input Rawze!!!