ok guys tell me if im missing something... a few months back my w250 started running real bad at work so i pop the hood and see fuel leaking from every shaft on the pump.So my first thought is ok orig. pump quit.(towed it home)so on friday I installed a new pump and injectors,as i cranked the engine over start it and i start closing injector lines it starts to fire.....OH NO! I say, I can hear it firing into the intake... after its running 5-10 min.I relies ,I have a blown head gasket.... so over to cummins I run and go to work after an hour I have the head off and see the gap between #4-#5 and stuck in the exhaust valve of # 4 is a 3/4" piece of the fire ring and # 5 piston is wet with fuel. after cleaning the block and head, visual inspection I reasemble it ...its now 11 pm and I have it running ,BUT it is real ruff .ok maybe valves are out .will work on it sunday. ok now its sunday and I recheck the valves ,...valves ok ..the engine is shaking real bad ... recheck timing ... nope its ok too.so I start cracking lines open and this is whats got me
thinking #5 is not right.
first ,if I open 5 the engine seems to do nothing if I open 6 the the miss in the exhaust gos away and the engine smooths out. all others lines will make the engine stumble. I have swapped the injectors thinking miss matched but no change.reinstalled old injectors ,no change .it idles ruff but out at hwy speed its fine.no smoke at idle or WOT . boost is at 38 psi. lots of fuel at each injector... ....

Am i missing something???.my next test is cyl. compression test

I hope I dont need to start looking for a new motor.
PS. all this happened on a warm engine under light load .it ran fine on the way to work after I started it the next time things got bad to worse

 

hmmmmmm so I take it you are not going to be needing to install the 3200 gsk??? hmmm well... hope all is good sounds to me like you have had a failure if the ring was in the valve

 

I already installed the 3200 spring before i put the pump on. and the ring... is the fire ring from the head gasket not a piston ring when i cleaned the block all 6 bores still have cross hatch in then from top to bottom>(as far as i could see that is)

 

Did you check the head real close for crack's while it was off. That would cause a compression leak into the intake.

 

What about the fire ring that you found in the valve! intake or ex.?

Did you remove the vales and check for damage the seat area?

I don't now what the fire ring looks like, or what is made of but......could have a part of that fire ring got nocked or blown back into the intake, and is now back in the syl or valves?
The reason i say this is i had a v10(dodge truck) that to piston came apart and made one he**l of a mess! rebuilt the motor and washed and flushed the intake,before i put it back on i shock the intake to make shore that there wasn't any thing left!.........it ran for 2 week and stated to knock, pulled the left side head and there was chunk of piston ring inbeded in the Piston.....a new manifold went back one that baby!!!!!!! just my.02

 

It sounds like you hurt the valves on #5. I can't believe that the problem is in the bottom end from your description of the cylinders. Do a leakdown test on #5 to confirm. You will be able to hear air leaking out the intake or exhaust if you have a poor seal on a valve.

 

Was the fire ring missing or damaged on the headgasket?

 

I am with Dave. If cracking number 5 makes no change, that cylinder is not firing at idle. You did not damage the injector tip (since you swapped them around) so it must be bad compression. Also makes sense that it goes away at high rpms.

That stinks!

 

You didnt get 5 and 6 switched at the pump did you? My buddy just did his engine and after borrowing some injectors from me and pop testing his old ones it turned out he put the lines on wrong. Just a thought, i dont know if 5 and 6 swap easy but whatever ones he missed swapped pretty easy according to him.
-RATCHET-

 

thats a great idea. I didnt see any or any head gasket pieces in the head ,when I pulled it there was 3/4" of the head gasket gone on both sides of #5 and #4 one part was stuck in the exhaust valve the rest must of gone through the turbo ( I looked real close turbo is fine) I didnt pull the valve that had the ring piece in it but at a quick glance it looked ok ....maybe not now just a note ...with all the miles this thing has on it it still has very little blowby,so maybe...hopefully its valves

Ill do the leak down test this week end and get back with you all!
Thanks

 

one more thing the cyl. with the head gasket stuck in the exhaust valve was #4 not #5

maybe the rest of the gasket damaged #5 valves

 

well now what? I did a leak test today and noda, all 6 cylinders hold air . I was really surprised how tight this engine still is.I could not hear any air leaking from exhaust, intake ,or pan ,I pulled the air horn, turbo and oil fill plug to hear for air and could not hear a leak one.

PS.dont ever leave a 1/2" drive ratchet on the alternator when putting air in to a cylinder, that sucker will fly

 

Reminds me of the time I smacked my dumb head spinning a cross type lug wrench.

 

Have you checked out Ratchet's suggestion?

You swapped injectors around without moving the miss, so it all leads back to the pump. Maybe a sticking DV?

 

well I dont think its a question of injector lines being swapped.as i took them off in groops of 3, and 5 and 6 are too far apart to fit . I left all the clamps on so all I had to do was put the front half on then the back half and inorder for the lines to swap I would need to bend then purrdy good.and the firing order lines up 153624.

so back to the pump? can I swap DV? you now ...like i did the injectors? cant hurt since I moded the pump already and theres no warr.

and with it running good above Idle would DVs cause that?...Im shootin in the dark hear.maybe there is a problem somewhere else and the new injection system is just amplifiying it??

also I pulled all 6 injectors and from the looks of it all 6 are firing (tips are black and dry)