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Wanted to post up a problem I'm having. I have done several searches but really no luck. I am gonna list the symptoms, my test and findings. Please feel free to comment and post ideas. Sorry for the lengthy post but I felt it would be better to include all the important info. Thanks in advance.

My problem is with my 05 SRW truck. It has 190,000 miles but a good strong running truck av 16+- mpg. Last week I Went to the Cummins store to get a lift pump for the 98 flat bed. Truck ran fine. When i came out of the store and started the truck it had a rough idle. When I gave it pedal and dove it was fine. Drove approx 20 miles to the house. Pulled it into my shop and started investigating. looked for the frayed wire around the oil filter but no luck. I didn't drive the truck again. The next morning on the way home from work I picked up a bottle of HEAT in the red bottle. I poured it in and went to bed. When i woke up around three in the after noon I started up my truck. It was still idling rough and wile I was checking and shaking wires The truck started to knock. I shut it down Immediately but first taking note of water temp and Oil pressure all normal.
I figured it was the Heat additive so I drained my tank and drained /changed fuel filter. No luck. Still Knocking with gray hazy smoke and loss of power.

Things I have done:
Checked oil and oil pressure----Good No coolant in oil
pulled valve cover and checked rockers----- all good
made a fuel pressure gauge and hook up----8.5-9 psi idle
pulled serpentine belt of and started truck ----still knocks
Probed the entire motor with stethoscope and rod. Knock is at front of motor.

Things I'm gonna do:
Pull fan shroud and pull Timing cover
Remove Injectors and have them tested cleaned.

One thing I have noticed is a little oil around my EGT spud nut in the exhaust and a little oil around the exhaust and turbo mount.

Here are some pics of the fuel pressure gauge and connections. I used my Banjo bolt on the cp3 pump and tig welded a AN-4 plug to the top of it and drilled a #70 drill (very tinny) serves as a needle valve. Then made up a AN-4 gauge and hose.


 

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did you see any white smoke when your started? The truck may have an injector sticking open would potenially give you rough idle and fuel knock.
 

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Discussion Starter #3
did you see any white smoke when your started? The truck may have an injector sticking open would potenially give you rough idle and fuel knock.
Yes. It puffs heavy white / gray smoke and It dose sound like a fuel knock like when we shoot either to our tractors just continuous. That's why I drained the tank thinking it was the Heat fuel additive.

Is it possible to unhook each injector and test run the motor kinda like spark plugs? Or could this damage something? Thanks
 

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Yes you can disconnect the wiring for the injectors one at a time to find out which one is the problem. With that many miles I suggest you remove all of them and get them tested. And thanks for listing all your questions the first time. Nothing worse then having to pull them out of someone.
 

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You say you checked the rockers but did you confirm that all the push rods are straight

Bent push rod(s) can give a knock tick and puff smoke
 

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Discussion Starter #7
Good to see ya Rum.
pulled the #1 Injector this ev. and plan on pulling the rest in the am after work. Yes all the push rods and valve train was checked. Thanks.
I noticed a little puddle of fluid leaking from an exhaust joint. looks to be raw fuel. I figure #1 injector leaking or continually open. I also inspected the Injector and found a dent on the tip. I cant see anything in the motor doing this??? I did buy this used and know there was some prior motor work performed and could be caused by human error.


I also like how my Intake Rockers are stamped USA and my Exhaust Rockers are stamped INDIA. :confused013:
 

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did you get any rail pressure measurements while knocking?

you're going to be pulling the head. something hard hit the end of the nozzle.

Cummins has manuf. plants all around the world, one of the largest in India. plant that produces a particular part for the lowest cost and still meets Cummins tight specs gets the incompany contract for that part.
they build the 5.9 for the world market.
 

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Discussion Starter #9 (Edited)
Nope no rail pressure. Dose this have to be done with a electronic gauge?? I still can do it just need to cap off Rail.
Wish I could barrow a BORE SCOPE from work for the day.
 

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Any chance of a dropped valve seat?
 

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Discussion Starter #11 (Edited)
D45 could be. That would explain the ding on the injector. Gonna take a closer look at the valves and try to inspect inside cylinder.
 

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Discussion Starter #12
Just got home from work. Used my digital dial caliper to check valve retainer height between the two #1 exhaust valves and there is a .133 difference. Checked the #2 exhaust valves and there is only .005 difference. Tells me the valve seat is out on the rear exhaust valve in #1 cylinder. Well I'm pulling the head.:doh: Dose this make sense?
 
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Just got home from work. Used my digital dial caliper to check valve retainer height between the two #1 exhaust valves and there is a .133 difference. Checked the #2 exhaust valves and there is only .005 difference. Tells me the valve seat is out on the rear exhaust valve in #1 cylinder. Well I'm pulling the head.:doh: Dose this make sense?
could be worse, you could have to pull the cab to pull the head...hope the bottom end is good, head should be a cheap(er) fix
 

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Discussion Starter #14
could be worse, you could have to pull the cab to pull the head...hope the bottom end is good, head should be a cheap(er) fix
No Problem with the cab, I will let Bronco cut a section out with his SAW ZAW.



I picked up a magnetic fishing tool that would fit in the injector nozzle hole hoping to fish some fragments of something but nothing found..
 

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magnet doesn't work on stellite valve seats

Stellite alloy is a completely non-magnetic and corrosion-resistant cobalt alloy

not unless you got one of those NASA Roswell cobalt titanium special magnets with the alien writings on them. they'll stick to the outside of one of those flying saucers Powered By Cummins:thumbsup:

even rarer are the Martian magnets made in Mexico that pick up aluminum piston chunks, very expensive:confused013::google: IT
 

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Discussion Starter #16
Didn't know the valve seats were made of stellite.We weld a little stellite here at work use it mainly for Hard face. Didn'T even get a splinter. Guess that's a good sign. Meaning valve sill in tact. Head will be off in the morning and will post findings and pics then. Thanks.
 

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Discussion Starter #17
Finally had time to pull the head. Took a minuet to figure out how to get the last 4 push rods out of the block. Chrysler engineer's you are sneaky!
#1 piston is beat all to hell. Cylinder head not too bad should mill out/off. Gonna do a Dy-pen check this weekend.
1 exhaust valve bent and missing valve seat. Looks as if i get to do a rebuild.
with a 190,000 will probably do an entire rebuild.??? In rail would be easier and faster.
Here's some pics.


 

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damn! that sucks. :( add a turbo to your list.
 

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You said knocking--not hammering! Was the valve seat totally gone?

Randy
 

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Discussion Starter #20
yes seat was gone. The knock sounded like I had just sprayed either in to the intake, A fuel knock in the head. well it was in the head all right. Haven'T looked at the turbo yet.
 
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