Is it standard procedure to replace all the pistons if one burns up?

 

Not really, the other five were in perfect shape. If you need one, let me know, I still have them in the shed if they will work in your engine. I just preferred to have all new ones but the five old ones would have worked just fine.

 

The only update I have so far is that all the injectors are still intact. The tech said this is promising because a destroyed cylinder usually takes the injector with it. Hopefully we'll know more tomorrow...

 

Ok... the tech tested the 6 injectors he pulled out of the truck; said they were popping at 400 bar instead of 300 bar and one of them wouldn't pop at all. I relayed this information to Rip, who then spoke to Don M. Don suspects something isn't quite right with the "testing" but Rip overnighted a new set of injectors anyway. (Great guy to do business with!)

This morning the tech tested the new injectors and claims that 4 of them pop at 400, 1 at 380, and 1 at 420... Now, I highly doubt that Don is building bad injectors but the tech claims there is no variable in the test or test equipment that could cause these high pop-offs.

So now Rip is overnighting my stock injectors (which I had returned to him for core exchange) for the tech to try out tomorrow. (Did I mention that Rip is a great guy?)

Unfortunately, all this hassle with the injectors leads me to believe that the problem with my truck lies deeper than the sticks. So tomorrow, when the tech tests the factory sticks and puts them back in the truck (assuming they test good), the truck will likely still run like crap and the next step in troubleshooting will be to pull the head and see what he finds.

I miss my truck.

 

go here for a replacement motor.

www.car-part.com

 

So it looks like I'll be rebuilding or replacing the engine... #6 is done. If I go the rebuild route, I may do a little bit of work while the engine is out, maybe a PDR cam and head, but there's still a lot of details to sort out and options to consider.

I'm waiting on quotes for both replacement and rebuild from a couple people... so we'll see what they come back with.

 

CTD99, When you say #6 is done, can you describe? I know serveral trucks that just have had 1 of the pistons replaced, even oversized without a complete rebuild. And are running fine without any problems.

 

Honestly, the engine isn't even apart. I've thrown $1200 at the thing in labor for troubleshooting because the tech at Cummins thought it was a fueling problem and not cylinder damage. Turns out one of the injectors was bad because the "knock" went away with the stock injectors but the truck still runs very rough. Tech did a blow-by test and found 8 in/lb @ idle and that went up to 30 in/lb as revs increased. So he says that's a sure sign of cylinder damage and I had that information confirmed by a 3rd party as well.

I just assume it's #6 because from what I've read and been told, that is usually the first to go; and because the truck threw a code for misfire in #6.

I know that I could have the one cylinder (if it is only one) sleeved and I guess it's also acceptable to have one oversized piston but I figure since the engine has to come out of the truck anyway, might as well do them all. I don't know... I just can't wrap my head around replacing just one piston.

We'll see what develops though, I have no idea which way I'll end up going with this repair.

 

The head can be off in 2 hours, for a guy who know's what he's doing. $1200 and not fixed, sounds pricey. I would have the head pulled and then make your decision.

 

That doesn't make me feel good... the tech at Cummins says it's an ~8 hour job to pull the head. Can't say I have the highest confidence in my pals at Cummins right now... and needless to say, I'm leaning towards having another party finish the job.

 

Joel, did Scheid determine what caused your #6 to burn?

-Kent

 

If you burnt a hole in a piston and the cylinder wall is still good slap a piston in there, new berings, put the head on and be done with it. You wont regert it I've done that several times on old 6.2 chevys after burnt glowplug riuned piston. one is still running 8 yrs later ,friend uses it as a farm truck.

JED

 

Chrysler warranty pays 5.9 hrs. to replace the head gasket, (that includes reinstalling the head). Customer pay is usually about 1.5 times the warranty time, 8 hours labor to remove and reinstall head is about the "going rate". That being said, 8 hours to just pull the head is pretty high. Unless you are committed to having them do the work I'd be looking someplace else.

 

Here's what #6 looks like...



another...



and the head...



I'm still debating how much to invest in the rebuild... whether I just want to get it running again or build it up.

 

I would build it up a little since its already torn apart. I practice that routine on all my vehicles, while I'm in there............. Man sorry to see that, but it could be a blessing in disguise?