Agreed . I have a bit to learn about the diesel's but I am a quick a pretty quick study. On that note I took the plugs out if the back of the head to intstall the crossover. Passenger side was easy pull threads where clean no dirt. Drivers side I thought I was going to snap it off when it finally came out full off dirt and crap. What is the best way to clean that with out getting a bunch of dirt into the cylinders? It was getting dark and assuming it doesn't rain I will open it back up tonight and mirror the passage to see the extent of damage. Drivers side is also the home for injectors 2 and 6 and those where the codes I was getting. Problem connected or no? Still havnt pulled passenger side injectors yet but hopefully tonight, time allowing or tomorrow if not.

 

I doubt it's an issue. Those plugs are usually super tight in the heads. Once you snapped it loose, did it thread out easy or could you hear it grinding etc? I can't imagine anything is actually IN the threaded area. Not really a good way to clean that out unless you had the head off the truck.

Are you putting a regulated return in, or just that x-over line?

 

Cross over line for now and later I will split that and run a return. I pulled all the injectors all seem good unless they have an internal issue. Pulled the exhaust manifolds to start the process of cleaning up the ports polishing and wrapping them the bolts on cylinder 2 where good and tight but the bolts on 6 where almost finger loose couple on the passenger side could have stood a torque wrench as well.
Put the gaskets up to the drivers side ports on the motor to check if they would be a good template and they are and noticed cylinder 4, 6, and 8 looked good but cylinder 2 was wet very very wet... now the truck hasn't had batteries in it for weeks and hasn't been moved or turned over etc etc. What would cause the exhaust cylinder to have oil/diesel all around it? not just at the bottom but all the way around it? I will take pictures tomorrow and figure out if its oil or diesel.
The shop I had it to had the heads sent out to a good machine shop and checked for cracks and bad valves and guides, there where no issues and I said to put seals in it why we where there. All keepers are in place and there don't seem to be any issues with a bent pushrod though I am thinking of checking the seals and will physically check the pushrods then. Also remember that, cylinder 2, was one of the injector codes that was being thrown out that and cylinder 6. Unless I have forgotten everything drivers side front cylinder nearest the headlights is cylinder 2 right?

Maybe injector cup?

 

Yes, that is cylinder 2. I really never read/hear about injector cups on these trucks. Sure it wasn't just an exhaust leak?

 

Yeah was doing a lot of research here and everywhere and that doesn't seem to be a common issue. That exhaust port being saturated is most Likely from a sticking injector that's wide open. Warren is going to test these add new 30% nozzles and the truck should be good to go. I will let you know what he finds out. Gotta get some new exhaust gaskets. Lol

 

Deffinatly diesel fuel in the exhaust port!

 

Probably just that injector then I'm guessing.

These injectors can't really stick "wide open" like a common rail, but the nozzles can crack and allow fuel to dump in like that. Or it might have just been sticking really bad and dumping fuel at the wrong time causing poor burn situations.

Might not hurt to get an oil analysis sample done to see if your oil has been diluted with fuel at all too.

 

Finally able to get on the site... Anyway I changed the oil about fifteen miles before I tore it down. would it still be worthwhile to drain some and send it off? If so to whom do I send it? If the nozzle had cracked would I be able to see it? I didn't see anything like that. They are in a box and getting overnighted tomorrow morning. They will test em and put 50% over nozzle this time. We will see what he says...

 

Seriously!? the packing tape was actually left on during assembly?

 

I'm sure Jesse will take care of you on the injectors.