General Tech What did you work on Today?

[zmotorsports]

More testing but at least we’ve discovered the problem.

We again tested total fuel return back at the tank and although it was within the allowable specifications and less than the test we performed prior to the high pressure pump replacement, we decided to dig deeper.

We began to test the CP3 return rate as well as each bank independently. Here are the left and right banks with return lines connected.

Both banks were within the allowable limit but the right (passenger’s) bank was right at 16ml and left (driver’s) at 11ml. Some shops, maybe most, would say that they’re within spec so nothing more to do but we wanted to dig deeper. I explained to my son that we could still have one or two injectors per bank that are returning more than the 4ml limit and fall under the max limit per bank. Also worth noting was that the new CP3 was returning about 27ml so that is fine now.

We tore the upper and lower rocker boxes off and got down to the individual injectors for testing.

My test kit that I use for testing. I believe this is the same as the GM dealerships use.

Driver’s bank setup for testing.

After testing the driver’s side bank (even cylinders) we moved over to test the passenger’s bank (odd cylinders).

Conclusion: cylinders 1, 4 and 5 are all returning at least 5ml of fuel and #6 is returning a fat 3ml. All others are returning 2ml which are perfect. Personally I think we’re going to replace #6 as well.

I’m a little pissed off because we just installed these injectors in April of last year and they only have 15,335 miles on them and half have failed.

Closing up for the night.

More pics as parts get cleaned and the engine starts going back together.


Thanks for looking.

Mike

 

[Mouse]

What is the vintage of those injectors - rebuilt or new? If they are rebuilt, I am interested to hear who did the work for future reference for my diesel.

 

[zmotorsports]

What is the vintage of those injectors - rebuilt or new? If they are rebuilt, I am interested to hear who did the work for future reference for my diesel.

The Bosch injectors that are in there now are the new version and they were purchased new back in March 2019 and installed in April 2019. Only 15,335 miles on this set and the vendor is denying a warranty because of time. Complete BS with new injectors and I'm a bit pissed off especially when I've used them almost exclusively for the past decade or so. I'm now trying a new vendor that I have heard good things about with remanned Bosch injectors.

Mike

 

[ID Bronco]

More testing but at least we’ve discovered the problem.

We again tested total fuel return back at the tank and although it was within the allowable specifications and less than the test we performed prior to the high pressure pump replacement, we decided to dig deeper.

We began to test the CP3 return rate as well as each bank independently. Here are the left and right banks with return lines connected.

Both banks were within the allowable limit but the right (passenger’s) bank was right at 16ml and left (driver’s) at 11ml. Some shops, maybe most, would say that they’re within spec so nothing more to do but we wanted to dig deeper. I explained to my son that we could still have one or two injectors per bank that are returning more than the 4ml limit and fall under the max limit per bank. Also worth noting was that the new CP3 was returning about 27ml so that is fine now.

We tore the upper and lower rocker boxes off and got down to the individual injectors for testing.

My test kit that I use for testing. I believe this is the same as the GM dealerships use.

Driver’s bank setup for testing.

After testing the driver’s side bank (even cylinders) we moved over to test the passenger’s bank (odd cylinders).

Conclusion: cylinders 1, 4 and 5 are all returning at least 5ml of fuel and #6 is returning a fat 3ml. All others are returning 2ml which are perfect. Personally I think we’re going to replace #6 as well.

I’m a little pissed off because we just installed these injectors in April of last year and they only have 15,335 miles on them and half have failed.

Closing up for the night.

More pics as parts get cleaned and the engine starts going back together.


Thanks for looking.

Mike

I need a new Dad, are you adopting? Great work, I'm sure my Dmax needs this kind of attention.

 

[Bart]

Amazing work and attention to detail, like always.

 

[zmotorsports]

Amazing work and attention to detail, like always.

Thank you.

 

[zmotorsports]

Removed the injectors las night and cleaned the injector cups to accept the new injectors when they arrive.

Mike

 

[mbryson]

Where do you get those cool oil soakup towels? I need some of those

 

[zmotorsports]

If memory serves I purchased those from my local NAPA when they were on sale. They're not cheap but they sure are convenient.

Mike

 

[glockman]

Pig Matt. U-line sells them.

 

[UNSTUCK]

Napa DC on 1300 s 700w sell the pig Matt brand.

 

[Tebbsjeep]

We get our pig mat at work from grainger. I'm sure that's the most expensive place to get it though.

 

[N-Smooth]

We get our pig mat at work from grainger. I'm sure that's the most expensive place to get it though.

I disagree. I got some from Primary Children's hospital and that's surely the most expensive place

Ok so it's not the exact same stuff but it's close enough that when we left the hospital I took it. A nurse once told me that you pay for everything in the room so you should take it

I would just buy it on Amazon if I was looking. Like everything else...

 

[anderson750]

I was inspired by @zmotorsports hood latch upgrade.

 

[YROC FAB.]

We made juan of those tire bead breaking apparatuses.👌👨‍🏭🌽

 

[MikeGyver]

Needs a cheater bar... or a heavier operator!

 

[YROC FAB.]

Needs a cheater bar... or a heavier operator!

He put a cheater in there and bent the pipe a little. This krawler had 4 wraps of duck tape on the inner bead he was breaking

 

[moab_cj5]

Made some progress last night getting the pump and gear out.


I couldn't get the union off the gear without resorting to an air hammer. Rust sucks!


Then I put some pressure on the pitman arm with some penetrating oil and let it sit overnight.


Then I went to work swapping the gear off my old pump onto my new pump.


I then pulled out all the hoses to replace all 3.


New pump installed with a new pressure line.


This is where I quit for the night with the plan to grab new hoses this morning.

 

[moab_cj5]

After way too many trips to Home Depot and parts stores, I finally got my steering gear torn down and rebuilt.

It took some heat and a few strikes of a mini sledge, but the pitman arm popped off.


Picked up some new hoses for the power steering. They were a real PITA to get onto the hard lines.


Then I got started tearing the gear apart. This is the old sector shaft.


My beautiful new 105 sector shaft.


The power piston that holds 44 little balls that weren't as bad as I feared to deal with.


Fun parts.


The housing. It was freaking filthy.


Putting it back together wasn't too bad, other than I tore my new Teflon ring on the power piston, so I had to reuse the old one. Not cool, but it went back together after that ok.


Then I got it installed with a little help from my neighbor to hold the gear while I lined up the splines on the steering shaft, and then bolted it to the frame, hooked up the lines, and added fluid.


Then I bled the system. It took a while since I replaced the pump, replaced the hoses, rebuilt the gear, and blew out the hard lines that were still on the truck. After about 45 minutes it was bled and there was no more frothing in the reservoir.


It took entirely too much time to get to this point. But, I still needed to check the bushing alignment in my radius arms. I pulled the radius arms back out and pressed 5 of the 6 bushings out then back in in the correct orientation.

At 11pm, I called it a day.

 

[BCGPER]

The most tedious job in the world, checking bearing clearances using Plasti-gauge.