03 Melt Down

Here we go this is the wreckage from my 2003 six speed. Oddly enough the burned out cylinder had a remanufactured injector the other five were the original ones with 190,000 miles on them how should I go about this repair and rebuild the cylinder is not scored at all. Just a couple new used pistons and an injector test and rebuild? Im pretty new to common rail diesels any help means alot! Thanks heres my number if you think you can help 270-427-6301

03 Melt Down

One other thing is this head reusable it did break a valve and is pretty beat up, the head only has around 20,000-30,000 miles and has never been milled. Also how much carbon should be around the upper cylinder sort of like a ring groove and should i renove what carbon is in the cylinder?

DragonSlayer

I'd mill the head and replace the damaged piston(s) and replace all the rings and bearings. Replace the one injector, or at least have it checked out, all of them for that matter. Then I'd run the crap out of it some more. JMO

03 Melt Down

Ok, so i talked to my engine builder I didnt notice it but i dropped a valve seat that caused the damage Im guessing I had an injector stick melt the piston and the heat caused the seat to drop. The cylinder was not egg shaped or scored so im gonna hone it out good and run it. My head rebuild was quoted at $607 with new exhausrt valves and seats, guides and valves lapped hows that sound?

DragonSlayer

I've not yet had the pleasure of rebuilding the head on these things. What else can you do?

03 Melt Down

The only other option than rebuilding the head would be to replace it with a new or used one. From what I hear if you have a 2003 or 2004 truck and keep it long enough you will eventually run into this problem.

soulezoo

^^^ that is true. Valve seats for that year was an issue.

The cost you quote is reasonable. The cost for a remaned head through Cummins is double that. The head may not have many miles, but let the machine shop determine whether or not the head/block needs milling.

you were lucky that the melted piston aluminum did not end up plastering the cylinder walls.

You should be ok With the minor rebuild replacing rings, affected pistons (new pistons aren't all that much as I recall)

Bearings should also be replaced IMHO.

seafish

Sorry to hear of your troubles....unfortunately NOT odd at all...unless it was purchased from Bosch or Exergy or DDP, the quality of reman injectors is iffy at best and failure rates are quite high within the first few months of driving. With the bad reman coupled with the high miles on your oem injectors, it will likely be best for you to buy a complete set of NEW Bosch injectors from a reputable distributor like TC Diesel or Exergy. Of course,that us assuming that you have about $2000 to spend on them.

03 Melt Down

That's what I meant. It seems whoever did this injector rebuild may not have been the best. I'm on my way to being finished with this my injectors are sent to a very reputable test shop. I'm just gonna throw a couple used pistons in there and run it!