Excellent work, fiend...was it as bad as it sounds(shimming)?

 

I got all the shimming done today.
shimmed 6 out of 8 injectors. found the other 0 thou on the driver side that was causing the other low buzz injector test.

i did the hard side passenger side first. i flew through the driver side today.
#2 added 1 thou,
#4 added 2 thou
#6 added 2 thou
#8 was good.

All new glow plugs installed. i double and triple checked the injector plugs and glow plug plugs to make sure they are in place.
And put Valve covers back on.

I got the turbo off and apart today. I will rebuild it and install the bushings and new wheel tomorrow.
i decided i am going to take the plenums off tomorrow. i have been chasing a small vacuum or boost leak for the last two years.
it only dose it after 1st start of the day when i get to 10 bls boost for about 3 or 4 minutes then it go's away until the next cold start.

i installed the inner plenums boot sleeves and boots a couple of years ago trying to fix this leak and
over time i have spent a few hours with my home made air adapter and soapy water trying to fix this small leak,
I did find a few leaks and fixed them but i have yet to find this allusive morning leak,

before i put everything back on I am going to clean the cooler tubes and check for a possible small hole somewhere.

 

No, not really if you can be patient. very patient... LOL
i think my biggest fear was from over thinking it.

 

Did you have any scares from a shim falling?

Maybe you posted it already, but where did you get your kit from?

 

actually got it on e-bay. the kit has everything you need including the specialty tools.
link on the bottom of page


i took some old shirts and wrapped them around the injectors so if anything fell it would land on the rags and not in the head.
you do the shimming on a table or some kind of work area. if you do it per instructions, it is pretty hard to drop anything.

when you shim the armature screw, you put a dab of locktite on the bottom of the armature where the screw sticks threw.
the locktite will help hold the shim from falling

when you shim the solenoids. the shims go between the bottom of the solenoid and the spacer plate.
unless you drop the spacer when installing it. it is almost impossible to drop those shims.

the hard part is the lack of room to work..

https://www.ebay.com/itm/INTERNATION...!-1:rk:25:pf:0

 

Got the pedestal and plenums off .went to ford to get the sealant.
started caulking the first one and Oh crap, this is not grey. it says right on the tube, T30 ford motor sealant. EXCEPT 7.3 Diesel motors.
the guy gave me the wrong one. I needed T31.

Got back to ford and showed the guy and he says sorry. i ask for an exchange and he said it has been opened and cant be returned.
I said yes, that is how i found it the wrong sealant. and you know just as well as i do the your service guys will be in here anytime for a new tube of sealant for some other job in the shop.

he starts to say something and i stop him. i said look i know how this works. i worked at Harbor Chrysler years ago. and i know your service department guy get their parts from you.
He then exchanged the tube. i paid $35 for this and i was not going to eat his mistake.

So today i got the plenums and pedestal put back on and connected all the connectors to everything.
I found i have a fuel line leak at the back of the passenger side head. luckily i have a few extra o-ring sleeves i had from the last time i changed the fuel bowl.

Got the turbo apart and rebuilt it. was way easier than i though. only bad thing i did was over tighten the wheel.
I grabbed the wrong torque wrench and got to about 20 lbs and said this is not right. it was foot pounds. i backed it off and got it back to 60 Inch pounds.
everything feels good, smooth and snug. meaning no play.

I should be able to get it all done tomorrow.

 

Nice! Looking forward to a cold start on the newly shimmed injectors.

 

Ya Fiend..killer work man! Ill have a beer for ya

 

Nice, I also look forward to hearing how it starts for you with the shimmed injectors.

 

Ok here it is.
Got everything done.

shimmed injectors.
installed new glow plugs
re-sealed plenums.
rebuilt turbo. new bushings.
installed a anti surge wheel
fixed a fuel line leak.
installed new vacuum lines.
drilled armature spacers to drain oil.

Initially the truck ran ok when it was warm.
The last year or so it has been very hard to start. when it did it was only running on 6 cylinders until it warmed up and ran fine on all 8.
i did notice that lately it was blowing a lot more black smoke on my 80 hp tune than normal.

I had most of the parts to do this for some time now and finally had a chance to get to it.
It took me about 4 days to do and fix small stuff but i was not in a rush.
only 2 full days and a few hours on the other days

This was the first time i have gotten in to the truck like this without my brother in law diesel mechanic there to help.
being nervous at first, i just took my time and double checked everything i did.

I got it wrapped up today and turned on the key to let the fuel system re charge.
being nervous and wondering if i missed something i turned the key.
It started right up after about 4 seconds and on all 8

I let it warm up and took it for a drive.
It runs so much smoother. feels like it has a little more mid rpm and top end.
My tunes are not built for speed. i do tow a 15000 trailer a lot.

I did notice that there is was less black smoke blowing out under full throttle.
i also noticed a new whine. im sure it's the new wheel.
I did get 22 out of the boost which has not happened in a long time for a mostly stock truck.

Over all, everything did make a difference. it did not make my truck a race truck and i didn't expect that kind of outcome.
But is is running so much better.

I will get up early in the morning and see how it starts up.
it's only going to get to 42 in the morning.

I will post up.

 

Nice Fiend, you will fall in love with your truck once again.

 

Since 42 is the Answer, I'd say that is good.

Also bookmarking this thread, lots of good info. Reps!

 

Ok, i just went out to give it a spin.
it is 43 outside.
Truck NOT Plugged in

i was a little excited to see. i turned on the key and waited for the glow plug light to go out.
turned the key once for about 4 or 5 seconds.. nothing..

Then i looked and i didn't turn the tuner on. Dumb ***..
turned it again and she fired right up as soon as i turned the key, and on all 8.

as of right now, i would say that the cold start mod works.
can't wait to see when we go camping again in 35 ish deg weather.

usually in the mornings i would had to cycle the key several times and make about 6 long attempts
to start the truck. when it did fire i had to wait for it to warm up to run on all 8
or it would not go.

Not this morning..
I know 43 is not the coldest and other members live in areas that are down to almost 0 in the winter
i hope this could work for them.

 

Nice work dude!! I love a good success story...and one that doesn't take years LOL.

 

With your guidance and inspiration, I think that when my injectors start causing me problems I will probably just shim them. Who knows, I might get 500,000 miles or more out of them which is a huge cost savings.

Great job and thanks for taking lots of pictures and explaining everything you were doing.