Ok, so my grandson's truck finally bit the dust. No start hot at first, then not start at all.
Passenger side injector top o rings were all worn but # 1 was the worst, completely through.
It lasted a year on HHC oil rail o rings, Chinese nipples, Alliant injector seals.

This time, I got HHC "leakproof" nipples, HHC oil rail seals, Alliant injector seals, o rings and crush washers. Stand pipes and dummy plugs were good so I reinstalled those.

We also replaced the fuel tank foot and sending unit. When we got it apart, the foot had disintegrated and the sending unit would not read, tank always stayed on zero. The new unit works fine so that's solved, I think.

Replace fuel filters (both) and after buttoning things up and attempting a start, HPO was great, had good LPO, truck started but it sounded like it was hydro locking on fuel. There was a lot of blue smoke. So we shut it down.

I took glow plugs out, spun it over, had two observers and it looked like a lot of fuel out of #1 and #2.

So today, just to continue, I took both oil rails off and did the spin the engine thing again. Results were not good. So upon spinning it over, #5 and 7, and #6 and 8 all four had a lot of diesel spray out of the glow plug holes. #1 and #2 had nothing spray out. The fuel pump was not on and I took off the engine front filter just to be sure the bowl was empty.

Cr*p. I'm thinking of just doing all 8 cylinders with new injectors. I'm tired of fighting it. When we started it, HPO was great. It didn't take long to pump up and running slow had about 1500psi so I think that part's ok.

If ya'll think of anything let me know.

 

Just a thought - have you verified that the ICP value is actual and not inferred (ie looked at the ICP sensor voltage output)? It is probably fine, but might be worth verifying.

 

I'll have to do that when I have it back together, until then I have the oil rails off, injector #2 out and the glow plugs out. I'm at a complete loss.

Going to watch some diesel tec Ron videos to see it I can gain something there. Wish me luck.Thanks,

 

I see "crush washers," so you took the injectors out already once? So, I assume they all looked good, no broken tips, clogged holes, etc., and that you torqued them all properly. But still you're getting fuel into the cylinders. I wonder if the last person to mess with the injectors over torqued and stretched the threads. Now, you're torqueing to spec, but it's not enough to seal the new washers?

Seems like since it started, you're sealed up everywhere else. You got a leak somewhere in the injector, washer, o-rings or (dang, forgetting my lingo) the injector tubes?