Greetings everyone. I have finally passed a barrier and can start moving forward again on this engine. Although I did find one more thing to correct before continuing. Anyway, here is my progress on cleaning this engine.
While using Easy-Off oven cleaner, I first realized the spray pattern was far too wide. So I switched the cap with a Blaster aerosol can. This provided a straight stream of oven cleaner that did not get all over parts I didn't want to expose to oven cleaner.
Oven cleaner did a good job of removing the carbon. By the end of 3 cans, the inside surfaces of the block were clean. As mentioned before, I rinsed everything with a solution of vinegar and water to neutralize the oven cleaner.
I tried Jeep dealership before starting and they do not stock oil galley plugs anymore for our 2005 diesels. Item #11, Chrysler p/n 04723211 showed 1 in stock on the east coast of the mainland. NAPA brought some from across the island but they were too small, 15mm. O'Reilley has 8 in stock but they're in Texas. The $0.49 part carries $23 in shipping. The end of the oil galley measures 0.710" (18.5 mm). If push comes to shove, I can still use my original plugs with a good gooping of Permatex gasket sealer. I don't really want to go there I'd worry for the first 10,000 miles.
This is the front of the engine right after pulling the first Freeze Plug style oil galley plug.
A closer picture shows a solid coating of carbon.
Got a Universal Gun Cleaning Kit for $12 and it did it's job perfectly. The rods were long enough to clean all the way through the block.
I had the block upside down on the stand but turned the picture upside down so the block would be recognizable. Unfortunately that showed the surplus cleaning solution defying gravity and flowing upward.
With the block upside down, the brush bristles are visible as they pass the oil jet hole.
Shaft of the brush is also visible through the same hole.
Since the gun cleaning kit rod is smooth and round, it can be chucked into a drill for better performance. I'm sure this method took an hour off the job.
The first end result was a clean oil galley clear through the engine. The engine stand is partially visible at the far end of the oil galley. After seeing this image larger on the computer, I realize it needs some more cleaning. Particles of carbon are still attached to the oil galley walls.
The second end result is actual oil shooting up through all four of the jets. Had my wife take the picture and I realize it caught something I didn't expect. The jets of oil seem to pulse. I imagine this is caused by the low oil pressure from the drill only spinning the crank at about 500 RPM. Also noticeable in this picture is some of the jets need to be aimed. I'll have to make a cardboard target that mimics the hole in the piston; when oil shoots through a small hole when aimed correctly.
Regarding the 'one more thing to correct', I found a section of an O-ring laying against cylinder #1 sleeve. After examining it with a Jewelers' Loop, I concluded it is a section cut from a cylinder sleeve during installation. One of them did feel a little odd while going in, but I don't remember which one it was.
Dean.