Engine/Transmission (1994 - 1998) high pressue with KDP jig, what goes?

[PCline]

Does anyone know what's the first to go if you (OK me) use too much air pressure with the KDP jig? I used the jig last night and manage to have two pressure gages give me bad information.



Needless to say I put too much air pressure on the tool and heard a small "pop" (like a hose popping off a fitting) followed by what can be best described as air flowing through a thin walled pipe. For the life of me I couldn't pinpoint where the "leak" was.



Does anyone know what might have happened? With my luck it will require tearing the top end off or somthing crazy like that.

 

[Rammin On]

Most likely you popped the tappet cover gasket ... . if you did you need to remove the injection pump to replace ...



For those that do the jig fix ... USE NO MORE THAN 3 PSI ..... 2 is better .....

 

[illflem]

That's why the NW jigs come with a valve and hose to add air pressure though the dip stick tube with the blowby left open. Even with 90 psi air you can't do damage. One other fellow who overpressurized ended up with four leaks by the time he was done, none were expensive to fix but took a lot of time. By your description of the sound you may have blown the return oil hose from the turbo, low down on the engine under the oil filter.

 

[BPINE]

Check the side cover gasket, it is along side the pump on the block and is where you would access the lifters. I hate to say it but this happened to me. If you look with a flashlight you will see the gasket popping out and white where there is no paint. When you do a KDP I don't pressurize the engine at all and it works fine. I use a radiator hose attached to the oil filler pipe and don't plug the breather.

 

[WDaniels]

You guys know more than me, but I pulled my tappet cover off to do my KDP and I'm telling you that it would take a trememdous volume of air to pop that gasket. That cover has a direct flow tube that is... . what, 7/8 of an inch maybe even an inch or so in diameter flowing out of that cover. It would take a huge volume of air to pop that gasket. IMOH.

WD

 

[Rammin On]

The side cover gasket that BPINE refers to is what I'm talking about ... tid the tappet cover. I've seen this happen more than you can guess ...





Illflem ... WTF ???? 90 PSI ..... even the blow by tube won't stop problems ... but the turbo hose is a good place to look ... .





W Daniels ... why did you remove your injection pump to do the KDP? Did you already trassh the timing case?

 

[illflem]

Rammin, I probably shouldn't have said that but with a shop type compressor I doubt if you could ever pressurize the engine beyond a few psi with the blowby open before you ran out of air. Now if a guy were to hook up to a diesel powered 400 cfm unit that's another story. I tell folks to adjust the airflow into the dipstick tube so that the pressure only slightly lifts the unscrewed oil fill cap, no need for a regulator or gauge.

A vacuum cleaner on blow duct taped to the oil fill tube will also blow the chips out if a person doesn't have a compressor. No danger of blowing gaskets there.

 

[bighammer]

Dipstick tube to block connection? (Just to guess something different )

 

[SRehberg]

high pressure with KDP jig, what goes?

When I did my fix, I used the breather for the input of the air, used a 15lb pressure guage, set the regulator for approx. 2psi, then left the dipstick pulled out some as a safety. The chips were no problem and the pressure remained in a safe range. Illflems method is the safest without a guage, as it doesn't take much for the debris to come out as you drill/tap. My 2cents

 

[Rammin On]

Yes ..... Bill's method is the best to use without a regulator . . the kit I send around has a regulator setup included. Always make sure the dipstick is pulled out of its seat before applying pressure. CPFF has also provided a neat little safety valve that sits atop the oil fill tube. I'll take pic of that and post it when I get a chance.



WOW Bill thanks for clearing that 90 PSI issue up ..... you were scaring me for a moment .....

 

[PCline]

No doubt about it. It's the side cover gasket. I finally got a good look at it yesterday and I can see the gasket popped off and the unpainted portion of the exposed cover. I've got a lot of work ahead of me. Any words of wisdom towards that task would be appreciated.



I hope at least one person reads this thread and avoids the same problem.

 

[WDaniels]

Rammin on,

Sorry I took so long to respond, I forget where I post and it takes me forever if I ever find it again to respond. Old age creeping up on me.

yes I trashed my gear case. I was coming to a stop when she let go and I heard it. I opened my hood and there was a gaping hole in the top of the case and the dowel pin on the ground under the truck.

 

[WDaniels]

Pcline,

You will probably have to pull your fuel heater and pump as well as you injection pump. It is much easier to pull the filter housing off to reach the pump/heater. Make sure to get new "O" rings for your banjo fittings on your filter setup. I didn't and they seeped pretty good. Hope it goes easy for you.

WD