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 Post subject: Re: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Sun Dec 28, 2014 12:26 am 
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Posts: 291
flman wrote:
taroo wrote:

I did not use alignment bolts and I do have a problem. When I was turning the crank to realign the TB tensioner I hit a hard stop. A HARD STOP! I am at a loss though I did have a 8mm socket go missing and am afraid it is in the intake at a valve....

I have no choice now but to pull the valve cover and now the head off to find out why I am hitting a hard stop and see if my missing 8mm socket is the cause.

Does anyone no of another reason for a hard stop if it is not my 8mm socket?

Lastly, where do I get the alignment bolts for the intake?


That is why I asked about alignment bolts, yes it is painful, but I think you nocked a rocker out of place and that is your bind, so you will have to pull in back apart. I have the VM alignment pins for the intake. You may just have the timing off, but if you can get the crank locked and see if you can turn the cams it would be a good test. But I am betting 10 to 1 you knocked a rocker out of place. All you need is 2 bolts the same size as the ones that bolt on the intake and cut the hex off so you can put the in the center for alignment.


Well...thanks...I so hope it is a rocker that I knocked off and not my 8mmin the cylinder! I checked the timing after calling Geordi and I moved it one tooth in each direction to no avail. Still have a hard stop. I will pull the valve cover off again and turn the crank and hope to not have a hard stop. If I can turn the crank Freely I will go to 90 ATDC and reinstall the valve cover that has the locking pins installed. What a pain!

_________________
2005 CRD Limited
SEGR
WEEKS Kit (removed EGR, FCV),
Gen 2 Fuel Head
GDE Eco Tune
ARP studs
Etechno (7v) Glow Plugs
F37
Kap 193 thermostat
Carter Lift Pump (Modified wiring harness)
Fumoto (CRD-108)
Bypass oil filter (2 micron)
Samco
Provent
Sears P-1 Battery
Secondary 2 micron fuel filter


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 Post subject: Re: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Sun Dec 28, 2014 9:57 am 
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Joined: Tue Jul 29, 2008 6:34 pm
Posts: 2543
Location: America
taroo wrote:
flman wrote:
taroo wrote:

I did not use alignment bolts and I do have a problem. When I was turning the crank to realign the TB tensioner I hit a hard stop. A HARD STOP! I am at a loss though I did have a 8mm socket go missing and am afraid it is in the intake at a valve....

I have no choice now but to pull the valve cover and now the head off to find out why I am hitting a hard stop and see if my missing 8mm socket is the cause.

Does anyone no of another reason for a hard stop if it is not my 8mm socket?

Lastly, where do I get the alignment bolts for the intake?


That is why I asked about alignment bolts, yes it is painful, but I think you nocked a rocker out of place and that is your bind, so you will have to pull in back apart. I have the VM alignment pins for the intake. You may just have the timing off, but if you can get the crank locked and see if you can turn the cams it would be a good test. But I am betting 10 to 1 you knocked a rocker out of place. All you need is 2 bolts the same size as the ones that bolt on the intake and cut the hex off so you can put the in the center for alignment.


Well...thanks...I so hope it is a rocker that I knocked off and not my 8mmin the cylinder! I checked the timing after calling Geordi and I moved it one tooth in each direction to no avail. Still have a hard stop. I will pull the valve cover off again and turn the crank and hope to not have a hard stop. If I can turn the crank Freely I will go to 90 ATDC and reinstall the valve cover that has the locking pins installed. What a pain!


My LTD ate a 7mm but I know it is down in the frame some where, I am not sure why you would need an 8mm with the head of intake off except for maybe that exhaust tube support in the back of the head? Did you pull the skid plate?

OTOH if you did drop a socket in, I would think you could pull it out with a magnet just by removing the ARP nuts and washers, and lifting the head with the exhaust manifold in place? I wish you luck, sounds like this job is kicking your azz? :banghead:

_________________
2006 LTD Bright Silver loaded with all the needed mods, CCV intact.
Proudly supporting CRD vendors, and their development of quality parts and accessories.
Equipped with HDS thermostat, plenty of heat, faster warm-ups, increased fuel mileage.


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 Post subject: Re: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Sun Dec 28, 2014 10:09 pm 
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Joined: Sun Apr 27, 2008 2:14 pm
Posts: 291
taroo wrote:
geordi wrote:
After you spin the fuel injection pump to fill the rail, rotate it around so the timing mark lines up with the raised mark on the inner timing cover, just below the bolt at 8 o'clock. This sets the pump in time with the cams which are pinned (right?) and then everything has proper time.

Check, recheck, check it again to ensure everything stays in time as you are reassembling.


Okay...putting the valve cover back on is a pain in the rear!!!! It took me forever to avoid any of the rockers even after sticking them down with a little grease. I sure hope I got a clear install.

Was installing the fuel system and broke the plastic tip where the injector return fuel line goes into the "block"/manifold to go back to the tank. It is a little plastic block that returns the fuel pump, fuel rail, and injector fuel to the tank. Anyway. the stealership does not have it and has to order it but can get it online for a third the price. Meanwhile I am trying to JB weld the parts to get me by as want to get this job done and behind me.

Will try to start without tuning the fuel pump by hand or with a drill. I assume others have restarted with the starter alone and not used any form of filling the rail by turning the pump manually?

Doing all four jobs at once is not for the faint of heart but at this point I can say that the TB change alone is not a big deal. The ARP studs are a larger job. The WEEKS Kit is not that bad and I highly recommend getting rid of all the components. I am using a piece of half inch copper pipe with a cap soldered on to plug the line at the block and the thermostat. But have logs of room now to install a bypass oil filter system...woohoo!!

More later...hope I can get this thing running and that none of the rockers are off.


Whew...pulled the valve cover back off and the crank turns freely! Guess I knocked a rocker off when installing the valve cover therefore causing a bind. Will make some alignment pins to reinstall and use #2 monkey grease to hold down rockers.

Questions- can I reuse the new copper crush washers I put in with the injectors yesterday? I think so but want a second opinion.

Believe new timing is easy as a) crank at 90 ATDC. b) fuel pump witness marks lined up. c) pins in cams so they is fine. Install TB and all should be in time. Let me know if I am missing something.

I can know do a TB and ARP in my sleep!

_________________
2005 CRD Limited
SEGR
WEEKS Kit (removed EGR, FCV),
Gen 2 Fuel Head
GDE Eco Tune
ARP studs
Etechno (7v) Glow Plugs
F37
Kap 193 thermostat
Carter Lift Pump (Modified wiring harness)
Fumoto (CRD-108)
Bypass oil filter (2 micron)
Samco
Provent
Sears P-1 Battery
Secondary 2 micron fuel filter


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 Post subject: Re: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Sun Dec 28, 2014 11:07 pm 
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Joined: Tue Jan 05, 2010 6:34 pm
Posts: 77
Location: Media, PA
Personally I would reuse them. They are brand new should not be an issue. I took the valve cover off twice. Once for the ARP studs once for a headgasket. I did not use the tool either time. Just two guys very carefully lowered the valve cover down together. Guess I got lucky. I helped someone do the same job and he made some dowel pins or something similar to lower the cover on. It was pretty smart and effective.
Make sure to follow the tightening sequence of the valve cover. It does not sit exactly flush and as you tighten it down it will put some pressure on the rockers. Glad you figured it out. Good luck.


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 Post subject: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Tue Dec 30, 2014 12:47 am 
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Joined: Fri Apr 02, 2010 3:14 pm
Posts: 2294
Location: Sumter, SC
I would NOT reuse the injector washers. They are crush washers and they deform when you torque the injectors in. You may be lucky and be ok reusing them but chances are you'll have leaks and loose compression. For few more bucks, it's not worth the hassle imo.

_________________
2005 kj CRD, samco, suncoast tc, provent, Kennedy lift pump, GDE ECO full torque, 2nd gen filter head, 245/70/16 a/t tires, mopar light bar, fumoto oil valve, OEM Skid Plates, ARB Front bumper and HD OME, tru cool LPD47391 40k GVW tranny cooler (stock cooler delete), FF Dynamics e-fan and shroud, rocker arms replaced, HDS2 190F thermostat.


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 Post subject: Re: TB, WP, ARP, Weeks simultaneously-Questions
PostPosted: Sun Nov 01, 2015 12:35 am 
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Joined: Fri Dec 10, 2010 1:18 pm
Posts: 17
papaindigo wrote:
You can replace that fuel return block with a brass one per an old email to me from fxjr73. Here's that photo of my brass return block. I did run into one issue with this. The largest diameter fuel line had a plastic inner lining which was molded to the fuel return outlet/inlet. I couldn't pull it off, so I had to bend and break the lining. I clamped the remnant of the hose tightly around the brass outlet/inlet, but I'm going to replace that fuel line. In fact, I may just replace all of them.


Image


We did this repair to day and thanks to the ones who came up with it. This was cheaper than the plastic thing the engineers ($108.00 dealer price.) came up with. The other flat hex head shown is hard to come by, only a few might have it. It is also known as #3122 flat hex head junction. Good luck.


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