Thanks for the update and the info. It's pretty bad when i get excited that the CEL (SES) light came on for a second on my truck. As soon as my scan tool gets here I'll be able to see what is going on under the hood. FWIW it came on at about 1500 rpm and then went off when i gave it some fuel.

 

Bill,
I got only 4 of the injectors rebuilt today. Long tedious process.
I've run into a problem and I'm unsure how to fix it. I now have measurements A and B within tolerances but C is contacting enough that it is hard to get my .0015 gauge out when the solenoid is energized.
Jim's kit says nothing about how to correct it other than to contact him. I'm wondering if you know what I need to do to get this back into check. From everything I read it appears that if the armature contacts the solenoid it will eventually lead to failure.
I obviously don't want that. After getting A and B back in check with his shim pack C seems to be the same as before the rebuild. I know it is supposed to be over .002 but am I right with my thinking that it may cause problems later on if I don't correct the issue?
I'm running out of time before I have to move and I'm pressed to get this done as soon as possible with as little money out of pocket as possible.
I may have to throw in the towel and find another set of injectors to throw in for now to get the truck running.
Any thoughts are appreciated.

 

Any update? I'm having a similar problem and am watching your progress.

 

I have been out of town until last night. I was able to finish the other 8 injectors but now I have clearance issues between the solenoid and the armature I have to fix. I have to find a good machinist in the area that can take .002" off the bottom of the armature so it doesn't contact.
I was able to rebuild the last four injectors in just over 2 hours. It took me close to 6 hours to do the first 3 so learning curve played a big part in it.
I don't know when I'll be able to get them to or back from a machinist so I'll update as soon as I can.

 

Hope you get er fixed lostman.

Have you found work yet? There is work up here in the oil field if you are interested.
Glendive Job Service Workforce Center

 

I'll check on that! I'm open to just about any kind of work right now.
Thanks for the headsup on that one! I've always wanted to try MT for a while.

 

If you come up here you have to look me up. I'm in the book,

Paul Zumpf

 

Hello Lost, I feel your pain. I seem to have your problem described to the "T". Just curious to know if you have figured it out.

 

I'm still looking for a machinist to take .002" off the armature. Then I can put the injectors back in and give a good report. Hopefully I'll be able to have it done in a day or two. Just trying to find a good machinist!
I will let you know, stay tuned for more updates!

 

UPDATE!!!
I believe I finally have this problem licked!!
Today I was able to get the armatures precision ground ($35) and everything back into tolerance. Re-installed the injectors and put everything back together.
It took a little bit of cranking to get all the oil back to where it was supposed to be (20 seconds at a time followed by about 10 minutes of cool down to not burn up the starter)
Then it finally started cold!!! It ran like crap for about 2 minutes and smoked like you wouldn't believe. The nieghbors didn't like it much. Then it settled into running okay but still smoking. I called a friend of mine who told me that was normal and took it on a 23 mile run with about 15 of that being freeway.
All I can say is WOW!! The difference is huge!! The rear tires will break loose (granted I have fairly worn out tires) without hardly trying. Before it seemed like a dog and wouldn't get out of it's own way.
The power was very good all through the throttle range, and could pass anytime I wanted on the freeway. After a few miles of driving the oil finally got all the air out of the rails and the idle smoothed out and it ran even stronger.
I will know for sure in the morning but I believe I finally have a good running truck.
I already bought a used DP-tuner from another forum and should have it next week after having it reburned.
One of the big things I noticed is that the engine cranks over much faster. I realized (after a talk with my friend) that it is because the engine is actually helping while trying to start!
Over all this issue has been a huge PITA but I've learned so much and have my truck running like a scalded dog for way less because of the problem so I shouldn't complain.
I will be ordering new rear tires and gauges tomorrow.

If anyone has questions please post up or PM me.
I would highly recommend Rosewood diesels DIY stage 2 kit for anyone wanting to pick up some easy horsepower while correcting older injector issues.

I'll update again tomorrow if anything else has been noticed, or missed
Have a great night everyone!!

CrazyKen

 

CONGRATS CrazyKen!!!!! I am glad this has finally come together for you!!

 

Ken


You will need to watch your EGT's now.

Depending on the tunes you choose, you could be looking for
more oil. The tunes can deplete the oil.

Now your trans will hate you!

Bill

 

My trans was rebuild about 90K ago and seem like it is doing very well. I'm going to change the oil here pretty soon.
Gauges are on the way and I will install them as soon as they arrive, probably early next week. DP tuner should be here next week as well.
Thanks for the encouragement and kind words from everyone through out this fun trying month!!

It started up smoothly and quickly this morning with no issues!! That is the first time is has ever started up cold since I bought it. The PO just plugged it in all winter, masking the problem he didn't know he had (or at least that is what he still says).

CrazyKen

 

way to stick with it!! and congrats on fixin it

 

Great job! Your perseverance really paid off! Don't forget about the turbo surge issue you will probably get with the new tunes. Get a wicked wheel or new housing to cure that.