Could we have a sticky for common mods?
#32
Here's a post by Kwik after he installed his new injectors:
https://www.ford-trucks.com/forums/s...d.php?t=480980
https://www.ford-trucks.com/forums/s...d.php?t=480980
Originally Posted by Kwikkordead
This day has turned out to be a good one.
A few days ago my injectors arrived from Beans deisel performance.
I ordered stockers with new, not reconditioned, nozzles and plungers.
I had originally planned to come in this Saturday to install them, but the workload at the shop allowed me to bring the truck in and install them today.
I was planning to take soundbytes of before and after the install but I was way too excited to wait.
11:00 am
I brought the truck in and pulled the valve covers, removed the gaskets and the wiring harness's.
I pulled both rear injectors and let the oil and fuel run down into the cylinder. I thought that just putting a shop towel over the hole would deflect the oil that comes back up through the injector hole. I rolled under the truck and proceeded to turn over the engine by hand and immediatly noticed that the oil came out with enough force to blow the rag out of the way and soak the air conditioner. UGH. (Stuff a ton of rags on top of the air conditioner unit.)
Ok, that hurdle is over; pull the rest of the injectors. Routine job.
The tips of the old injectors didn't appear to be that worn out, but they were sure making a lot of noise during operation.
Remove the oil deflector tubes using a 5mm allen and the 3/8" impact gun.
Install them on the new injectors, leave them a touch loose for the final adjustment later.
Remove all the glow plugs.
Install all the new injectors.
Torque them to 120 inch pounds.
Roll under the truck again and turn over the engine for two complete cycles ( 4 crankshaft revolutions) NO LESS. More if you hear oil spurting out of the glow plug holes.
Position some cardboard over the cylinder heads to deflect any flying oil.
Crank the engine over (no load on the starter with the glow plugs out) to fill the HPOP rail. This requires a couple of minutes total crank times. Don't do it all at once or you'll bake the starter. 30 seconds, go clean up your tools for 5 minutes and then come back and crank for another 30 seconds. Repeat a couple of times.
Remove the cardboard.
Install the glow plugs. I had a full set of Bosch part number 80 033 ( OEM ) glow plugs that I purchaced a couple of weeks ago to install along with the injectors.
Reinstall the valve covers, boost tubes, reconnect whatever sensors, connectors that were removed to gain access.
4:00 PM
I cranked on the starter for about 15 seconds and it fired with a big cloud of smoke.
I am immediatly struck with how much healthier the idle sounds. A deeper tone, more even, not a bit quieter. So crisp, so clean. There is NO SUBSTITUTE for new injector nozzles. Sounds like a BRAND NEW engine.
Driving around it's smooth, quiet, powerful, all the hammering is gone.
And the amount of throttle required to maintain speed is cut in half. I am positive that my lost mileage is coming back.
Underway the engine is so much quieter that I strain to hear the diesel noise over my 5" cannon, all four windows down.
I am completly satisfied with the fruit of my labors, starting with the Hutch mod, and removing the quick connects, the oriface mod to completly remove the air from the fuel rails and now the final addition: putting in the fuel injectors.
Life is good.
A few days ago my injectors arrived from Beans deisel performance.
I ordered stockers with new, not reconditioned, nozzles and plungers.
I had originally planned to come in this Saturday to install them, but the workload at the shop allowed me to bring the truck in and install them today.
I was planning to take soundbytes of before and after the install but I was way too excited to wait.
11:00 am
I brought the truck in and pulled the valve covers, removed the gaskets and the wiring harness's.
I pulled both rear injectors and let the oil and fuel run down into the cylinder. I thought that just putting a shop towel over the hole would deflect the oil that comes back up through the injector hole. I rolled under the truck and proceeded to turn over the engine by hand and immediatly noticed that the oil came out with enough force to blow the rag out of the way and soak the air conditioner. UGH. (Stuff a ton of rags on top of the air conditioner unit.)
Ok, that hurdle is over; pull the rest of the injectors. Routine job.
The tips of the old injectors didn't appear to be that worn out, but they were sure making a lot of noise during operation.
Remove the oil deflector tubes using a 5mm allen and the 3/8" impact gun.
Install them on the new injectors, leave them a touch loose for the final adjustment later.
Remove all the glow plugs.
Install all the new injectors.
Torque them to 120 inch pounds.
Roll under the truck again and turn over the engine for two complete cycles ( 4 crankshaft revolutions) NO LESS. More if you hear oil spurting out of the glow plug holes.
Position some cardboard over the cylinder heads to deflect any flying oil.
Crank the engine over (no load on the starter with the glow plugs out) to fill the HPOP rail. This requires a couple of minutes total crank times. Don't do it all at once or you'll bake the starter. 30 seconds, go clean up your tools for 5 minutes and then come back and crank for another 30 seconds. Repeat a couple of times.
Remove the cardboard.
Install the glow plugs. I had a full set of Bosch part number 80 033 ( OEM ) glow plugs that I purchaced a couple of weeks ago to install along with the injectors.
Reinstall the valve covers, boost tubes, reconnect whatever sensors, connectors that were removed to gain access.
4:00 PM
I cranked on the starter for about 15 seconds and it fired with a big cloud of smoke.
I am immediatly struck with how much healthier the idle sounds. A deeper tone, more even, not a bit quieter. So crisp, so clean. There is NO SUBSTITUTE for new injector nozzles. Sounds like a BRAND NEW engine.
Driving around it's smooth, quiet, powerful, all the hammering is gone.
And the amount of throttle required to maintain speed is cut in half. I am positive that my lost mileage is coming back.
Underway the engine is so much quieter that I strain to hear the diesel noise over my 5" cannon, all four windows down.
I am completly satisfied with the fruit of my labors, starting with the Hutch mod, and removing the quick connects, the oriface mod to completly remove the air from the fuel rails and now the final addition: putting in the fuel injectors.
Life is good.
#35
#36
Scott, there are two great articles over on TDS in their FAQ - I used them when doing those maintenance items on my truck for the first time. Think there'd be any way to skirt around the no-links-to-other-forums rule for this instance? If not... I suppose I could copy/paste it all here and give the author credit, but with no actual link. Just seems a bit silly when they're all posted already, pics and all. Let me know what you think.
PS - I think the fuel filter one does not have any pics, so it'd be easy to copy/paste the text and give the author credit... Oil change article though has pics, including four pics showing the four grease zerks to service in the front end components. I can link you to the articles in a PM, if you'd like.
PS - I think the fuel filter one does not have any pics, so it'd be easy to copy/paste the text and give the author credit... Oil change article though has pics, including four pics showing the four grease zerks to service in the front end components. I can link you to the articles in a PM, if you'd like.
#37
I didn't see any instructions for shimming the stock pressure regulator. I got to searching and I thought these were really good instructions:
http://community.webshots.com/album/38099902LAqFDW
http://community.webshots.com/album/38099902LAqFDW
#38
Removing the foil insulation wrap (installed by Ford to deaden the turbo whistle, shame shame ) from the hot side (driver side) intercooler pipe.
https://www.ford-trucks.com/forums/s...d.php?t=487115
https://www.ford-trucks.com/forums/s....php?p=3657312
https://www.ford-trucks.com/forums/s...d.php?t=488594
Ends up looking like this (pic of my truck's pipe freshened-up a bit ):
http://community.webshots.com/photo/...86590301OtHfpL
https://www.ford-trucks.com/forums/s...d.php?t=487115
https://www.ford-trucks.com/forums/s....php?p=3657312
https://www.ford-trucks.com/forums/s...d.php?t=488594
Ends up looking like this (pic of my truck's pipe freshened-up a bit ):
http://community.webshots.com/photo/...86590301OtHfpL
#40
Originally Posted by ryaneverk2
Removing the foil insulation wrap (installed by Ford to deaden the turbo whistle, shame shame ) from the hot side (driver side) intercooler pipe.
https://www.ford-trucks.com/forums/s...d.php?t=487115
https://www.ford-trucks.com/forums/s....php?p=3657312
https://www.ford-trucks.com/forums/s...d.php?t=488594
Ends up looking like this (pic of my truck's pipe freshened-up a bit ):
http://community.webshots.com/photo/...86590301OtHfpL
https://www.ford-trucks.com/forums/s...d.php?t=487115
https://www.ford-trucks.com/forums/s....php?p=3657312
https://www.ford-trucks.com/forums/s...d.php?t=488594
Ends up looking like this (pic of my truck's pipe freshened-up a bit ):
http://community.webshots.com/photo/...86590301OtHfpL
https://www.ford-trucks.com/forums/s....php?p=3672941
(wish I could just edit that post to add it in, but can't )
#41
This link is to JTHarvey's Pre and Post turbo pyrometer readings.
https://www.ford-trucks.com/forums/s...58#post3684558
.
https://www.ford-trucks.com/forums/s...58#post3684558
.
#42
Removing the E-clip on wastegate arm, for removing or replacing wastegate actuator:
https://www.ford-trucks.com/forums/s....php?p=3716297
Note the recommendation for the Napa clips as a replacement for the stock clip.
https://www.ford-trucks.com/forums/s....php?p=3716297
Note the recommendation for the Napa clips as a replacement for the stock clip.
#43
Here is a link to how to do a Lighted display for a flip chip
https://www.ford-trucks.com/forums/s...d.php?t=488652
https://www.ford-trucks.com/forums/s...d.php?t=488652
#44
IPR rebuild: http://cw-diesel.com/LuxSite/IPRInfo.htm
IPR o-ring kits: https://www.ford-trucks.com/forums/s...d.php?t=501097
Rebuilding HEUI injectors at home: http://www.thedwilsons.com/powerstro...-Assembly.html
SpringerPop's 6637 dust cover: https://www.ford-trucks.com/forums/s...d.php?t=476325
IPR o-ring kits: https://www.ford-trucks.com/forums/s...d.php?t=501097
Rebuilding HEUI injectors at home: http://www.thedwilsons.com/powerstro...-Assembly.html
SpringerPop's 6637 dust cover: https://www.ford-trucks.com/forums/s...d.php?t=476325
#45
Upgrading to/wiring up 2003+ TT mirrors with heat/clearance/turn signals:
https://www.ford-trucks.com/forums/s...d.php?t=123257
https://www.ford-trucks.com/forums/s...d.php?t=123257