How does the sensor integrate/seal with that kit?

 

Here is the kit laid out.



Laid out with all the parts that come with it. I already have the rubber/metal washer installed where it connects to the HPOP housing. That that other washer is a spare from what I can tell.

Close up on the HPOP side.

Close up on the ICP side.

I plan on using Teflon tape on the non-AN connections here near the HPOP.

And on the non-AN connection on the ICP side.

 

I am re-wrapping my main harness and, while I am at it, I'm deleting the pigtails to the dummy connectors on the old intake elbow, locating the 'blue wire's ground wire close to the main wire harness connector and making my connection there and rerouting the ICP connection, away from the HPOP cover to where it will mate with the ICP reroute kit.



These are the pigtails to the two dummy connections on the old early PSD intake elbow as I found them.

If this wasn't a pigtail to a dummy connector I think I would have had some trouble.

And this one. I will make an update about this when I finish it.



The Blue Wire ground is one of these two. More on that in another post.

So, in preparation of the ICP reroute, I pulled the ICP wires back from where they were originally routed.

You can see more detail here.

I had test fitted where the ICP pigtail should go now and wrapped it with high heat wire loom tape.

For good measure I then wrapped it in loom sheathing.

 

I like the idea if protecting the new crossover felines, thank you. I'm going to go about it just a bit different as I have plenty of wire loom tape.

I plan to just use that and antichafing tape.



Here I am wrapping Maxwell antichafing loom tape over the Tesa loom tape wrap I have on the TamerX crossover fuel line.

As installed.

 

I bought a later model elbow and did that too with my harness to make it cleaner.

Thanks for showing the details of the relo kit. I had suggested that kit to people in the past and I know two who have had leaks and yanked them. And man do I feel bad that I ever suggested them so be forewarned. I'm going to do a relocation but a different path with a hard line. So take into consideration of what I'm about to say (aka, bad attitude).

They are using a retaining ring with an o-ring at the HPOP cover. I'm really not sure how well that is going to work. The retaining ring setup SAE and DIN is supposed to be a flat surface, but we have a port. There are some AN adaptors for our style of port, so I don't know why they don't use them. So that's one potential.

The second is the sensor. The retaining ring method is good for about 5,000psi to 6,500psi in the 10mm-12mm ranges, which should cover our normal operating range, but that's at 72ºF. The bonded metal washers to about 5,000psi. And initially, I thought that was acceptable, but some text messages with another member here warned me about them being OK. I think they can be if the opposing surface is machined flat and the right o-ring material is chosen. What you are showing is going from the factory sensor style port o-ring seal on a standard fitting with a slight chamfer. That could be problematic unless the instructions are to use the bonded washer you show in another picture in its place.

BTW, good pictures. What camera are you using?

 

Luvin it -- plus you're in Packer Country (fan here since (maybe before) birth)...........good techs across the great state of WI, have many friends there like the good folks at Calhouns (Bob, Gene) in Tomahawk and the great crew over in Oconomowoc at Precision.

Nice touch on the crossover and harness work !

 

I ran into a bit of a snag with my planned install today. I opened my new flexplate and didn't see any new bolts so I figured I could re-use the old one. After looking into that further I see it's not recommended so I'll go tot he dealership tomorrow and get some new bolts and plan to install on Wednesday.

That gives me a bit more time to install and test the high pressure oil system. I still need to install the injectors, oil rail, stand pipe and oil tube today so I'll just take my time.

 

What would you do differently with this kit? Headaches are something I would like to avoid

Samsung S9

 

Thanks! And I love it here in WI. I've lived in 9 states: TX, OK, IL, SC, MD, NC, OR, CA, WI. Been here 10 years from SoCal and though I miss OR I know I could never live there again due to current political/ freedom considerations.

I was a Cowboys fan and in 2011, bought a share to be a Packers owner. The thought was, as an owner, they'd have to listen to me when suggested trading Rodgers for Romo...

Anyway, after a few years of resistance, I realized I'm a much better owner than Jerry Jones and became a Packers fan.

 

Sounds like you were military with all those stop overs.

Tony's local and can predict stuff (defensive strategies) a smidge faster than Aaron.

Best Wishes with this awesome (cab on) project

 

Be aware the majority of my career was to find problems and potential problems ...... even when there isn't some would say. Some people have had issues with these kits and others have not. And I haven't had the good and bad in my hands to see the difference.

I am of the belief that the connection to the HPOP cover should be the same as the designed intent, for the port and whats on the sensor. It's actually the same as an SAE and ISO configuration, the main difference in the threads.













The AN adapter that is in the kit follows the BSPP style, mounting to a flat surface, utilizing a retaining ring over the o-ring or a bonded ring. But I can't see either of those able to utilize the o-ring with that wide of a port. So it the adaptor is wide enough to bridge the cavity, then the stock o-ring in place of the supplied seal method should work. But you'd have to see how everything fits up. It has to fully capture the o-ring and you can see that trace in my picture of the HPOP cover.








At the sensor, it was designed for the port. The sensor even has the groove cut into the body to identify the type of port. The fitting is a standard mm straight flat-faced fitting, that should utilize a retaining ring or bonded o-ring. I don't see how there is any integrity to that connection unless in the instructions it said to remove the o-ring and use the bonded seal that you show elsewhere. The bonded seal as I mentioned elsewhere should be able to hold 5,000psi, which should be sufficient in normal operation. That was my original plan and I was still going to try that before using the port cutter I have to machine the port we see in the HPOP cover. As long as I don't remove the wax covering, I can return the port cutter, so I'll be watching whatever you do.

I just don't see how that o-ring crushed between the sensor and the fitting has any long term integrity as is. With a retaining ring or a bonded seal, yes.





The is another option I have in my back pocket, and that is to use a stainless hollow sealing ring that is also used in hydraulics, and that's good for up to 10,000psi. It's a one-time crush seal. Either the bonded seal or the stainless crush seal would allow the use of the inexpensive adaptor you show the supplier is using, and then the cutter goes back and anyone can just buy the parts to make up a kit.

 

I installed the HPOP, Discharge tube with new seals, new stand pipes, new braided lines, oil rail nipple cups and new injectors. Though I'll be relocating the ICP I installed it in its usual spot for the IPR pressure test, installed the IPR test tool, regulated the air supply to 100 lbs and turned the valve...

Hiiissssssss on both sides. Cant seem to pin point it. Its everywhere but no where specific.

So, I pulled the Oil rails, make sure the nipple cups were torqued to 100l ft bs. Pulled the stand pipes, made sure they were torqued to 33l ft bs. Pulled the only injector that didnt install 100% smooth. Oiled the hell out of all the connections, reinstalled the oil rails, torqued them to 8 ft lbs. Fired up the test tool... hissssssss.

I tried to rationalize, attempting to convince myself that the system was virtually bone dry of oil and that had to be it but deep down I knew I was just lying to myself and that I was in the first step of the grieving process.

So, I knew what to do... it was time to get that beer I had been thinking about all day in my hot and muggy garage and after awhile, watch some YouTube, because after all I am a YouTube Master Diesel Mechanic... then call it a night


Then it struck me. I could try to isolate the oil rail banks if I could affix a airtool quick connect to an old stand pipe!

And with some redneck engineering, teflon tape and a judicious application of cross threading I did it!





Each bank holds pressure perfectly.

Now, the problem is someplace I can't see but I have an idea it's under the HPOP cover.

For now, it's time to drink that beer, watch some non-psd related show and call it a night.

 

Edit - I now see that you posted you used the IPR test tool.

With that in mind, the next things to check are the HPOP J-tube o-ring, and the HPOP suction o-ring.

 

Yes sir. I don't have it installed at the moment using the IPR pressure testing adaptor. I suspect it's the discharge tube or the HPOP seals. I'll hopefully know for sure tonight.

 

LOL - I just noticed that and re-worded my post as you were posting your response!

My apologies for not thoroughly reading your thread.