Rebuilding a common rail ctd

[dzldodge]

I recently became involved in a project for a friend of mine. He is rebuilding his 2004. 5 CTD. It’s a long story of how he got there but I’ll try to keep it brief. Basically at about 240k’ish miles, he noticed increased oil consumption. He really did not know what to do. Life was throwing him several curveballs and worrying about his truck was not one of them. He just monitored the oil level and kept going. This led to more and more consumption and leakage. Then another issue popped up. It started running poorly and was diagnosed as a bad #6 injector. With it replaced, there was little improvement. Additionally, we gave his truck the nickname “Puff the Magic Dragon” because of the amount of blowby coming out of the oil fill cap. It literally looked like a Choo-Choo train while running. Again life prevented him from doing anything about it until “POOF !!!”, the turbo blew a seal. The engine was running on as much 15w-40 as it was diesel. It was embarrassing watching the truck drive down the road.



At just over 260k, that was the last straw. Since it had so many issues, a rebuild is in order. He needs assistance and enlisted myself and a friend to help. The friend has a fully equipped shop. The three of us had the engine out and torn down in one very long day. The root cause of the problem seems to be broken piston rings at #1 and #6. Of course, it needs a turbo as well. The plan also calls for injectors as well as all the regular consumables like hoses, t-stat, water pump, etc. We’re even doing the Larry B’s starter contact thing since it is out.

My job in all this is to find out what is the best course of action. For that I am enlisting the help of the TDR. What I am hoping for is help regarding what tricks to do during the build. Not to make more power (of course that wouldn’t be a bad thing either) but to make it run as reliably as possible for a long long time.



So far, the turbo has been dropped off to a local diesel shop for rebuilding. I believe they are going to do the injectors as well. Also, the block, crank and head were dropped off at the machine shop today for evaluation. He is after a completely stock rebuild. No crazy power adders like my truck, he says. Are there any machining issues, tricks, etc that we need to be aware of. Should the CP3 be replaced at same time? What about the FCA too? The cam looks fine but the some of the lifters are crowned from wear. The friend with the shop says they can be machined. Is that true?



Any advice, tricks, solutions, etc would be greatly appreciated.



Thanks

 

[Shadrach]

Check out my thread from a couple of years ago. Although there are some internal differences between our engine they are basically the same https://www.turbodieselregister.com...lding-my-5-9-Common-Rail&highlight=rebuilding One little trick I did was to install dual piston cooling nozzles. To do this all you have to do is replace the plastic plugs that are behind the upper mains bearings with the old style nozzles ( Cummins p/n 3937214 ) This will give you more oil squirting at the under side of the pistons and it won't hurt the oil pressure The only other internal mod I did was a cam upgrade, as that was the perfect time to do it. Of course do the lifters as well. Shad

 

[seafish]

Be EXTREMELY wary of buying or using rebuilt injectors... . they RARELY function well.
I think almost all here will agree here that if you can afford it, go with brand new bosch injectors from a reputable dealer, like TC Diesel, here on TDR, or maybe Exergy.

 

[sag2]

At that mileage you could have gotten away with a set of rings assuming the cylinders were not scored. The crank should be fine, the head could probably use a little freshening. Was your friend running an aftermarket air filter?

 

[TCDiesel]

The CP3 bushings as well as the seals need to be replaced, the unit if it qualifies can be freshen up to like new condition and run another 250k trouble free miles. as suggested stay AWAY form Re-done CR Injectors. I have stop calling CR remans, BC in most cases they are NOT.

 

[dzldodge]

Shadrach – I did see your post and it was great. We are looking into the nozzle thing. Hopefully, it will fit in the budget. I know how that sounds… build a Cummins on a budget. HA HA !!



Seafish – I got an update/clarification today on the injectors. The guy rebuilding the turbo is getting the injectors not rebuilding them. He ordered them today. I’ll try and find out from where and update.



Sag2 – He’s been running a K&N plus an Edge EZ box for years. Both are coming off.



TCDiesel – What is involved in “freshening”? I’m guessing that is a reman unit.



Thanks for all your help and suggestions.

 

[TCDiesel]

Yep... ... ... ... .....

 

[rscurtis]

Looks like the K&N strikes again. I remember a rally that Buzz Chew Chrysler-Dodge held for LICROC in the late '90's. They hosted a rep. from Cummins, Bosch, and many aftermarket suppliers of air filters and the "magic black boxes" of the era. The vendors were on one side of the field, and on the other was the Cummins rep. showing the worn out rings and scuffed pistons, as well as the Bosch rep. with his damaged VP 44 parts.

 

[Shadrach]

Not to worry. Putting in the second set of piston cooling nozzles is NOT expensive, even though they are genuine Cummins parts Shad