Duramax Rebuild

[Bigdawg90]

Started on the truck this last Friday. Started getting everything buttoned up last night. Waiting on some small special bolts and grommets that got stripped when I was dissembling. The last shop who did the injector job did a horrible job. Put the Allen head bolts on with an impact wrench. All of my fuel return lines needed to be replaced.

Honestly it’s been super easy so far. The head gaskets weren’t blown. Three of my injectors 3,7, and 8 were completely rusted through and two of my injectors cups had failed gaskets so I was getting blow by and coolant in my oil.

All in the diesel shop wanted 13-15k to do this job. I’ll be at 6k with all needed parts and tools. Bought some tools for convenience like a topside creeper. That’s with OEM+ parts and some new boost tubes. Installing a lift pump and making sure this doesn’t happen again for a long time.

Don’t know why I was ever intimidated by diesels. Slightly different fuel system, but once depressurized it’s just an ICE. Probably won’t be going to the mechanic anymore. Everyone is charging $175-$200 a labor hour. It’s just not worth it.

 

[Cowcatcher]

Pretty common for those aluminum pipes to get a hole worn in them. Aluminum loses the battle rubbing against anything has been my experience. I’ve welded or patched and welded a couple of them.

 

[Mr.Glock]

Sounds like you about whipped its ass! Great work.

 

[PanhandleGlocker]

Got more guts than me. I’d be scared to take on a job like that.

 

[Lee Beaittie]

Started on the truck this last Friday. Started getting everything buttoned up last night. Waiting on some small special bolts and grommets that got stripped when I was dissembling. The last shop who did the injector job did a horrible job. Put the Allen head bolts on with an impact wrench. All of my fuel return lines needed to be replaced.

Honestly it’s been super easy so far. The head gaskets weren’t blown. Three of my injectors 3,7, and 8 were completely rusted through and two of my injectors cups had failed gaskets so I was getting blow by and coolant in my oil.

All in the diesel shop wanted 13-15k to do this job. I’ll be at 6k with all needed parts and tools. Bought some tools for convenience like a topside creeper. That’s with OEM+ parts and some new boost tubes. Installing a lift pump and making sure this doesn’t happen again for a long time.

Don’t know why I was ever intimidated by diesels. Slightly different fuel system, but once depressurized it’s just an ICE. Probably won’t be going to the mechanic anymore. Everyone is charging $175-$200 a labor hour. It’s just not worth it.

They really aren't a big deal, and had I known Id have sold you a 4 month old lift pump setup off my 08 my grandson totaled the sat after Thanksgiving.

 

[Bigdawg90]

Finished buttoning it up today new boost tubes came in and I found a leak in the steering gear so fixed that as well. Put the new lift pump in and let me tell you that is a sucky one man job.

My wife won’t let me do anymore. It’s our date night so she wants me cleaned up. We’ll see how it runs tomorrow

 

[Ready_fire_aim]

Dang man, well done!

 

[_CY_]

well done! I'm a 12v bigot ...
but this might be worth looking at ..

Write Up: Bullet-Proofing the 6.0L PSD.​

https://www.powerstroke.org/threads/write-up-bullet-proofing-the-6-0l-psd.204386/

 

[Bigdawg90]

So I started up the truck, took it for a test drive and the turbo blew! Lol. I think the shaft got rusted and the oil seals blew. I had oil coming down the down pipe.

So I put a new stock turbo in, reset the PCM, changed the glow plugs and glow plug relay. Took it for a test drive today and it drives beautifully. Sounds great, but I get blue smoke.

I think I have a faulty/hung injector. No back into the engine once I figure out which injector is hung. Anyone near Sand Springs have a nice scan tool that give balance rates? That would let me see which one is off. I think it’s cylinder 8 as the glow plug smells like fuel.

 

[Mr.Glock]

You’re making headway!