Engin Rebuild

[Dscholz]

Ok, haven't posted here in forever but here it goes.
I have a 2005 4x4 2500 QC LB with the G56 transmission, owned since new, pretty much stock, just a drop in non-oiled aftermarket AFE air filter, X-Monitor gauge to watch EGTs and boost pressure with cool down timer. I developed excessive pressure/smoke coming out of my oil cap when it was removed and blow by tube spewing oil and smoke but no check engine light. I shut the truck down, killed the cool down timer. Had it towed to a shop that I had just had replace the injectors 6 weeks prior as I had 237k miles on original injectors and it was probably time. They checked their work and said it wasn't injectors, I didn't think it was either. Options were to spend $1k to do a compression check or $11k to do an engine swap. I chose option 3, tow it home and pull head to see what's going on and confirm my suspcions.
Just finished pulling the head today and it looks like it is cylinder #3, scored sidewall, so I'm thinking broken ring(s). Just wondering if there is any shops in the Sacramento area that anyone would recommend to rebuild it or should I just buy a rebuilt one from someone like DFC in Edmonton? Looking for any thoughts or opinions that anyone has, I just wasn't expecting to have to do this level of engine work this early in this trucks life.
Thanks for any input,
Dan

 

[Darkbloodmon]

Ok, haven't posted here in forever but here it goes.
I have a 2005 4x4 2500 QC LB with the G56 transmission, owned since new, pretty much stock, just a drop in non-oiled aftermarket AFE air filter, X-Monitor gauge to watch EGTs and boost pressure with cool down timer. I developed excessive pressure/smoke coming out of my oil cap when it was removed and blow by tube spewing oil and smoke but no check engine light. I shut the truck down, killed the cool down timer. Had it towed to a shop that I had just had replace the injectors 6 weeks prior as I had 237k miles on original injectors and it was probably time. They checked their work and said it wasn't injectors, I didn't think it was either. Options were to spend $1k to do a compression check or $11k to do an engine swap. I chose option 3, tow it home and pull head to see what's going on and confirm my suspcions.
Just finished pulling the head today and it looks like it is cylinder #3, scored sidewall, so I'm thinking broken ring(s). Just wondering if there is any shops in the Sacramento area that anyone would recommend to rebuild it or should I just buy a rebuilt one from someone like DFC in Edmonton? Looking for any thoughts or opinions that anyone has, I just wasn't expecting to have to do this level of engine work this early in this trucks life.
Thanks for any input,
Dan

Following, any indication as to why cylinder 3 broke a ring?

 

[CVR222NV]

I agree with DBM you need to determine what caused the ring in #3 to go. I lost rings and piston in #4 when an injector went out at 207,000 miles. I'm using DFC Diesel for my rebuild and should be getting my motor back in the next couple of weeks. Great to work with so far although it has taken just a little longer than they estimated but not too bad. I have a thread on the rebuild progress you can check out.

 

[sag2]

I would be suspect of the injector in #3. You will know when you pop the piston out if it is the ring or not. If the other cylinders look good, I would run a hone through #3 and see how bad it is. You might get away with a new piston. There also might still be a shop around with a boring bar that bolts to the block and they can cut it in truck. Being it is #3 there is plenty of clearance for one.
If you were capable of pulling the head, getting the piston out is not that much more work.
Whatever you do, don't mix up the injectors until you confirm the cause. Otherwise you will need to have them all tested.

 

[Tuesdak]

Whatever you do, don't mix up the injectors until you confirm the cause. Otherwise you will need to have them all tested.

Just saying IF one of these replacement injectors burned down one hole in the engine: Why would the other ones be any better? Yes it can be just one bad one, but, what if another one is borderline bad? The shop may have already mixed them up. I wouldn't risk a fresh rebuild without testing all 6 injectors and neither would the shop that rebuilt my engine.

@Dscholz What did you use for injectors? Rebuilt, new, and from whom? Who did the shop get them from if they supplied them? Did the shop pull the injectors and have them tested? As they wanted $1000 for a compression test I suggest they didn't.

You may have a warranty claim for your engine from the shop and injector supplier. You should proceed carefully if you want them to cover the cost of the possible bad injector(s) and engine. The shop may not know the situation and maybe would like an opportunity to warranty their work/injectors. Invite the shop to the party and ask who they would like to have test the injectors.

Don't forget Cummins has reman engines available as well as other places mentioned on here.

 

[Dscholz]

Darkbloodman - I have no idea what caused cylinder 3 to break the ring. I would love to figure out why it broke so I don't have it happen again. My 12 valve is still running strong after over 300k miles and I haven't replaced injectors in that one yet. My 24 valve, I put the Fass titanium fuel pump and filter on about 30k miles ago, hoping to extend the life of the truck and motor.
CVR222NV - I will look for your post on the rebuild. How did you know that your injector failed on your #4 cylinder?
Sag2 - My injectors are still in the head in the correct order so I am happy to take one or more of my injectors to get them tested to see if #3 is bad. Testing would be cheaper than new replacements, but I know that testing only means they are good during the test, no guaranties.
Tusedak - The shop said they only used the Bosch injectors from Bosch, that is why I took it to them to have it done, I was short on time and hadn't done injectors yet and didn't want my truck down long. Now it's down for a while. I don't think they had the old ones tested. I like your idea to ask the shop if they'd like to have the injectors tested. I doubt they will want to warranty the engine since I have torn into it but it will say a lot if they are willing to at least participate in the testing and possible fix.
I was hoping to have some local people chime in with advice on shops and good or bad experiences in the area so I can figure out my next steps.
I was going to look at the numbers on the injectors to see if I can figure out if they really are Bosch remans and when they were done. Any advice on the next steps is greatly appreciated or if I should post pictures or things to look at/look for. Let me know. I am even willing to talk on the phone if someone wants to contact me to talk me through something but I don't see pm's on here anymore - as I said it's been a while since I've posted here.

 

[Tuesdak]

Possible they may have gotten knock off injectors. Regardless ask them what they would like to do now that you discovered the engine problem. "You touched it" excuse isn't acceptable esp. since they wanted to charge you. You have merely diagnosed it further and are at a point they can step in over the injectors and testing.

https://www.turbodieselregister.com/threads/fake-bosch-injectors.270036/

 

[CVR222NV]

Pretty much laid out in the thread but the consensus was over fueled due to injector going out:

Remanufactured Engines | Turbo Diesel Register