Well heres the story, I got back from a deployment and got myself a nice 2004 Dodge Ram Cummins 2500 that has a 3" lift on 35's with an efi tune and a rhino lined paintjob and some nice goodies, i put some more money into it and traded my stock exhaust manifold and single turbo for a full twins setup and some $$ get everything put together and made a few 200-300 mile road trips around Wisconsin to gather the rest of the parts for my beast.. tubing, stack setup, toolbox, banks intercooler..... well apparently she was leaking more oil than i had noticed because upon return my my 3rd or 4th roadtrip i noticed that there was a nasty knock that would increase in speed as i hit the gas. Then she was having issues with starting, i tried running a bottle of stop knock through hoping maybe that would fix it... no such luck. Still having trouble with starting i replace the fuel filter and that helps she starts up a couple times... now she wont start at all and i still have the issue of the knock to deal with... so it looks like its time for an overhaul and some new nozzles and head studs

The ONLY local diesel shop wanted $7500 and i dont have the funds for that

so my questions are...

What are major issues i should be looking for... im guessing bad piston, rod, or bearing

What are some big hang ups guys have come across while pulling the motor(will be doing it in my garage)

i plan on using this overhaul kit
http://www.puredieselpower.com/catal...t-p-32212.html

im going to install these nozzles
http://www.ebay.com/itm/180HP-Bosch-...16dac5&vxp=mtr

and im going to go with a set of ARP Head studs

is there anything that i CANT or SHOULDNT do in my garage that could be detrimental to the functionality of my engine?

any info or tips and hints would be greatly appreciated. this will be my first cummins overhaul and im hoping to get it knocked out in about 9 days because thats all the leave time the military will give me

thanks again

 

Make darn sure that it wasn't injector knock before you start tearing down the engine. That knock will increase with speed too. On top of that you state that the engine won't start now.....won't turn over or just simply won't fire?

 

i turn the key and nothing happens.... an injector issue would make sense considering i was having issues with fuel delivery, i was unaware that an injector knock would be so loud and sound similiar to a rod knock... how would i test that... could i pull my injectors and take them to my local diesel shop?

 

the local shop may not be able to flow test them but they will for sure be able to send them to or point you in the direction of someone who can/will. and i agree deff check those puppies first before a full teardown and also be careful of ebay injectors i don't trust something like that to come from ebay regardless of who it says the seller is . i would check out exergey or flux for injectors but thats just me.

 

yea i assumed i would be alright with the BOSCH injector nozzles since they are a pretty big name, i was searching for information on them but i couldnt find out much.

i am going to contact my diesel shop and see if they can bench test them for me and if they cant who can... if it is an injector hopefully thats all it is and i can put my new nozzles in with a new injector and have her running smooth again *fingers crossed*

 

What is your rail pressure on cranking. If you have an injector that is bypassing fuel or stuck open you may not be building enough rail pressure for the ECM to fire the injectors. I think its 3000 psi to fire. I looked through my service manual but I cant find it.

 

I didn't realize EFI was available for 04 ?

 

^ Its not

 

Just got back to my truck. she turns over but doesnt fire. im going to check the fuel rail pressure

 

It is throwing codes

PO107-Manifold Absolute Pressure/ Barometric Pressure Circuit low
PO073-Ambient Air Temperature Sensor Circuit High
PO336- Crankshaft Position Sensor A Circuit Range/ Performance

 

Pulled my injectors out... three of the 6 nozzles are almost completely black. i am taking them to my local diesel shop on friday to have them bench tested and replace the ones that are bad...fingers crossed this will solve my problem

 

The nozzles will be black....it's carbon buildup and 100% common for an injector tip. There's still a good chance you have one or more injectors that are bad, be it a solenoid or something of that nature.

Keep us posted.

 

had all 6 nozzles bench tested and 6 out of 6 had flow issues

brand new DTech Nozzles with 180hp nozzles are on order and should be here and tested by Monday

 

injectors are installed and everything is tucked back in, bolted down and torqued to spec.. getting my banks intercooler installed and then fingers crossed she will be good to go

 

so it did not need a tear down?