I have some updates coming, however, I am working on using a more stable image hosting service since free services could dissolve at any moment. I was using Flickr, and trying to move to Google Photos since I pay for storage, yet Google doesn't seem to allow me to link an image. I'm all ears if anyone has any suggestions.

 

imgur is what I use. It's what reddit uses, is free, and can host original sizes. Plus, the URLs are short.

 

Thanks, I have the app on my phone, I'll have to look into that further since I know Reddit isn't going away and imgur was developed by someoen at Reddit iiirc.

 

Been a while and now time to get crackin!
Some updates...
ECU was sent to Diesel Toys in TX for an ECU tune. Deleted the EGR and Immobilizer as well as added their mild tune to give more power and more MPG. After running the engine using TechStream I determined injector two would be failing soon, so sent the Injectors off to Baileys Diesel Group in Australia. After speaking with Simon, he told me that the main bearings are not a concern (as I was going to replace the mains) in these engines, but to switch out the hard fuel lines due to the mileage. So, new injectors (Stage 1 15% more flow), valve cover gaskets kit, fuel hard lines and suction control valve for the injection pump.

Valve cover off, the black gets on everything, its worse then anti-seize.


Injectors getting sent out to Baileys Diesel Group, going Stage 1 which has a 15% higher flow for a future mild tune.


Intake manifold nastiness. There is a butterfly valve on the circular cylinders, with about an 1/8" of soot and oil tacked onto it.


To deal with the black death...
Made a parts washer out of some bits we had laying around UnHoly Motorsports.


First pass with the parts cleaner, that is soot in the sink, about an 1/8" thick. This is all due to the EGR, cancer to diesel engines.


Engine back on engine stand for cleaning and maintenance. Will be rotating the engine to clean the intake ports on the head.


More to follow

 

Did some cleaning on the head intake runners and welding the EGT bung into the exhaust manifold.








Welding on the cast manifold for the EGT bung

 

Just welded that to the cast iron? How well did that work? I assumed you kept it hot while you worked?

 

What solvent did you use to remove the EGR gunk?

 

Yep, used a MAP gas torch and had the heat(voltage) cranked on the welder. I never realized just how thick the manifolds are, now I see why many guys just NPT tap the manifold.

 

I bought a gallon of Sea-Foam, worked really well after letting it soak. Many of the 1KDs I've seen getting an EGR cleaning seemed to be much dryer than what I had, most seem to flake and scrape out. However, My mess was a black gooey substance that needs to be agitated to get removed.

 

deleted

 

I'm having trouble figuring out where to put some updates, the build thread or the swap thread....
Anyhow, I am going to leave the engine specific stuff here, and update my build page with the install shenanigans.