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Thread: Can a member help me with lapping leaky injectors?

  1. #1
    Well it hits on 7 of 8... WarWagon's Avatar
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    Default Can a member help me with lapping leaky injectors?

    I don't have the tools to mess with injectors and the local shop is just costing me money without standing behind their work. I now have 2 leaking body injectors from them. They pump them up on the stand without the return lines and can't see the leak because the return fuel coats the injectors...

    So shop recommendations or a member that can correct this by lapping them would be helpful.
    Not enough room in sig for all the stuff I have that LeroyDiesel.com sells.

    2003 Dodge Ram 3500 SLT QC LB HO Cummins 6 speed handshaker w/ Pacbrake. Factory 3rd pedal anti theft.

    1993 Chevy "Patch" K2500 6.5 Diesel LB project beater... Now a 6.2 re-power w/6.5 NA heads. Gapless rings. Walbro FRB-5. A-Team Turbo. ARP head studs. 6 banger Trans tune chip I think I have changed, replaced, or tightened every bolt and nut on this thing!

  2. #2
    Registered User ak diesel driver's Avatar
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    A sheet of glass and some really fine wet or dry will do it.
    96 gmc k2500 4" exhaust, marine inj, #9 resistor, GL4, turbomaster, duraterms,-1.94 TDCO,FTB, remote pmd, isspro pillar gauges, lift pump relay added ,141 block, 2 1000 w block heaters, 2 150w glue on oilpan heaters, 2 150w glue on transpan heaters, 97 K47 air filter , IP replaced at 229k ,gear drive set awaiting install, Parts for intercooler waiting to be installed

    94 k1500 excab sb 6.5 plow truck. Fisher plow w/engine driven pump, F intake, h/m turbomaster, plowing chip by Buddy, remote PMD w#9 resistor, Duraterms

    96 k3500 CC 6.5 dually
    94 k2500 excab lb 6.5 parts truck
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    75 Vette built 383 needs work
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  3. #3
    Registered User bison's Avatar
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    I use a sheet of glass with a sheet of crocus cloth on top.use diesel as lub and swirl the parts in a figure 8 patern.
    98 GMC 2500 HD 6.5 F auto ext 4x4 engine rebuild at 268.000 km,Provent Oil seperator,Vacpump deleted,TM,all gauges,5th wheel.currently at 307.000 km
    95 GMC 2500 6.5 F auto ext sh bx 4x4 ,relocated PMD,OPS,extra glow and aux LP manual switch.In cab fuel gauge.CDR vented at 307.000 km to the atmosfeer.presently 405.000 km
    Wife's d dr.Soon to have pyro,boost,chip and TM
    89 GMC 2500 6.2 auto ext 4x4 relocated OPS 700.000+ KM denoted to ranch duty.
    95 chevy 2500 6.5 F st ext .parts truck .
    2 spare 6.5 F blocks,
    1 is a powerup project, the only 506 block in existence with no outer main cap bolt holes.

  4. #4
    Registered User NVW's Avatar
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    Leo
    * 95 GMC 3500 4x4 dually, VIN "F", 4.10 gears, 4L80/E trans, 405,000km, 3" downpipe, 4" exhaust, FSD mounted on heat sink in bumper, #9 resistor, 3 pillar gauge's, High Idle kit, Bosch marine injectors, Bosch Duraterm glow plugs, Leroy's ATT chip, ATT, GP overide, K47 airbox, FTB, Racor fuel filter, fuel pressure gauge
    * 98 Chev. 1500 4x4 VIN "S", 3.73 gears 250,000 km, (needs work)
    * 97 GMC C3500 VIN "F", 4.10 gears, 5 spd manual, 324,000 k (parts)
    * 04 Yukon Denali, 6.0, 196,000 km.
    * GMTD ScanTech
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  5. #5
    Recruit midniteplowboyy's Avatar
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    Quote Originally Posted by bison View Post
    I use a sheet of glass with a sheet of crocus cloth on top.use diesel as lub and swirl the parts in a figure 8 patern.
    What he said.
    1992 6.5TD K2500 4x4 5spd 3.42's reg cab, Feed Truck, fully cranked DB-2, straight piped factory 3" exhaust, boost and pyro, 3/8" feed the beast mod, 3500 rear springs, flat bed, 2000lb T&S trip hopper feeder, K/C Daylighters, 3-1/2" receiver hitch

    1993 6.5TD C3500 2x4 4L80 3.21's 4door, Play Truck, fully cranked DB-2, WH1C Holset Turbo, 24x12x4 I/C, 4" Exhaust, 0.010 thicker Head Gaskets, ARP Head Studs, Pete Jackson Gear Drive, Fluidampr, Bosch Marine Injectors, HO Water Pump, Amsoil Bypass Oil Filters and Air Filter, fuel filter housing mod with 3/8" fuel lines, Gauges(Pyrometer, Boost, Fuel Pressure, Water Temp in each head, Oil Temp, Trans Temp and Trans Pressure), BD Torque Converter, Transgo HD Shift Kit, 3.21 gears, U.S.Gear Underdrive, rear 4link Air Ride,22" Alcoa's and 305/40 Tires. BROKEN CRANK!!!, Damn Dorman pulley . Getting a P-pumped 12valve Cummins, RTO-6610 Road Ranger 10spd, 14" double disk clutch

    http://www.thetruckstop.us/forum/album.php?albumid=286

    1994 6.5TD K2500 4x4 4L80 3.73's reg cab, The Stabbin Feed Wagon Max-E-Tork Heath chip, manual GP overide, Flowmaster 3" downpipe, straight piped factory 2-3/4" exhaust, posi-lock actuator, 3" body lift, flat bed, remote hydraulics, hay spear, 2500lb T&S trip hopper feeder, 33-12.50 front/14.50 rear-16.5" super swampers on 9-3/4" and 12" rims, backup camera

    2004 6.6TD K3500 4x4 Allison 3.73's 4door, Towing Truck Ranch Hand brush gaurd, Ranch Hand wrap around rear bumper, B&W turnover hitch

  6. #6
    Stand Your Ground 3500GMC's Avatar
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    X3.. Used wet or dry sand paper 600 to 1200 to 2000 grits. Took some time, be patient. Lap both sides of the cup washer in there too.

    The piece with the two holes- photo.

    DSC01713.jpg
    '93 GMC Sierra SLE K3500 RCLB 4L80E 4.10 axles, lockers, JB8 13x3.5 brakes, 4X4 SRW 1TON, 6.5TD now a fully ported big valve '82 6.2 turbocharged, mandrel straight pipe w/ warpspeed x-over, Fluidampr, tweeked DB2-2831-4911 IP, Battery relocation, H/O W/P, CDR elim custom vent, PYO wheels w/285-75 Dick Cepek FC-II's - Quasar Blue and Argent Silver two tone.

    ...and other various GM cars and trucks


  7. #7
    6.5 nut job/addict
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    The pop tester can't produce the pressure and volume that the ip does on a running engine. The pop tester only goes to the pop pressure. The ip can be running 4000 psi or more.
    I use 1000 grit wet or dry sandpaper on a piece of glass with diesel fuel for lube.
    Barry



    I am not on the Heath Bandwagon

  8. #8
    9 11 Never Forget Brooklyn Tow's Avatar
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    Never heard of that kind of "lapping"..........learn something new everyday!
    Louis

    96 3500HD Dynamic Wrecker....3" DP to 4" Exhaust....Severe Duty Fan Clutch....D Max 21" Fan Blade.

    Member#2 Massive Blowby Club
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  9. #9
    Registered User bison's Avatar
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    Quote Originally Posted by Brooklyn Tow View Post
    Never heard of that kind of "lapping"..........learn something new everyday!
    Stick around
    98 GMC 2500 HD 6.5 F auto ext 4x4 engine rebuild at 268.000 km,Provent Oil seperator,Vacpump deleted,TM,all gauges,5th wheel.currently at 307.000 km
    95 GMC 2500 6.5 F auto ext sh bx 4x4 ,relocated PMD,OPS,extra glow and aux LP manual switch.In cab fuel gauge.CDR vented at 307.000 km to the atmosfeer.presently 405.000 km
    Wife's d dr.Soon to have pyro,boost,chip and TM
    89 GMC 2500 6.2 auto ext 4x4 relocated OPS 700.000+ KM denoted to ranch duty.
    95 chevy 2500 6.5 F st ext .parts truck .
    2 spare 6.5 F blocks,
    1 is a powerup project, the only 506 block in existence with no outer main cap bolt holes.

  10. #10
    Stand Your Ground 3500GMC's Avatar
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    Post #6 said the 'the piece with the two holes'... Should have read, 'the piece with the three holes'... You know what I meant.
    '93 GMC Sierra SLE K3500 RCLB 4L80E 4.10 axles, lockers, JB8 13x3.5 brakes, 4X4 SRW 1TON, 6.5TD now a fully ported big valve '82 6.2 turbocharged, mandrel straight pipe w/ warpspeed x-over, Fluidampr, tweeked DB2-2831-4911 IP, Battery relocation, H/O W/P, CDR elim custom vent, PYO wheels w/285-75 Dick Cepek FC-II's - Quasar Blue and Argent Silver two tone.

    ...and other various GM cars and trucks


  11. #11
    Registered User buddy's Avatar
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    So the injectors are actually leaking out of the threaded body part? Something is not sealing the high pressure away from this area like it normally should?
    94 6.5TD C1500 ECLB w/ 50 gallon aux tank/box; 235/75R17 tires on Alloy wheels; 3.42 gears; A-Team Turbo; 4" Aero Turbine 4040 muffler to 5" Aero Turbine 5050XL muffler to 6" tip before rear axle; FSD heatsink, marine injectors; "F" intake; SynBlend 10W-30 oil; Walbro FRB-5 w/ 12 micron prefilter; Feed The Beast; WMI and Propane fumigation; OPS extension & relay; 110K original miles; Engh GMTDScanTech
    Near Future: Battery relocation, Amsoil Nanofilter behind headlight, and stereo upgrades
    Veterans of America Club, member #18

  12. #12
    6.5 nut job/addict
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    Quote Originally Posted by buddy View Post
    So the injectors are actually leaking out of the threaded body part? Something is not sealing the high pressure away from this area like it normally should?
    There is no actual seal. It is metal on metal. The surfaces are ground "flat". "Flat" is a relative term. "flat" could be + or - .05 or .005. The surfaces distort over time especially with all the heat cycling. The sanding them trues the surface enough to make a seal again.
    Barry



    I am not on the Heath Bandwagon

  13. #13
    Registered User buddy's Avatar
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    Although, would fuel normally be in the area of the threads to make its way to the return nipples? Or would that normally spit out above the threads? Does fuel spill around the outisde of the nozzles normally to cool them in operation? I am just wondering if its normal to have fuel in that area, and if there is any other explanation. Should the body have some thread sealer and torqued to a specific value?
    94 6.5TD C1500 ECLB w/ 50 gallon aux tank/box; 235/75R17 tires on Alloy wheels; 3.42 gears; A-Team Turbo; 4" Aero Turbine 4040 muffler to 5" Aero Turbine 5050XL muffler to 6" tip before rear axle; FSD heatsink, marine injectors; "F" intake; SynBlend 10W-30 oil; Walbro FRB-5 w/ 12 micron prefilter; Feed The Beast; WMI and Propane fumigation; OPS extension & relay; 110K original miles; Engh GMTDScanTech
    Near Future: Battery relocation, Amsoil Nanofilter behind headlight, and stereo upgrades
    Veterans of America Club, member #18

  14. #14
    6.5 nut job/addict
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    No thread sealer. Torque spec is 65 ft. lbs. There should be no fuel get to the threads if the surfaces are lapped close enough. I would imagine that the return fuel does somewhat cool the nozzle but the fuel is really not all that cool after being pumped to a high pressure.
    Barry



    I am not on the Heath Bandwagon

  15. #15
    Stand Your Ground 3500GMC's Avatar
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    Total metal on metal seal, yes. Thats why we take our time with the lapping process.

    In the pic, these are the parts that are totally responsible for sealing up FUEL inside the injector. Note the small hole in the inj TOP. This is where the main pressurized fuel flows. On up in the injector TOP there is the return passages.

    Also, using a sealer on the threads would be asking for trouble. It simply isn't needed.

    DSC02569.jpg
    '93 GMC Sierra SLE K3500 RCLB 4L80E 4.10 axles, lockers, JB8 13x3.5 brakes, 4X4 SRW 1TON, 6.5TD now a fully ported big valve '82 6.2 turbocharged, mandrel straight pipe w/ warpspeed x-over, Fluidampr, tweeked DB2-2831-4911 IP, Battery relocation, H/O W/P, CDR elim custom vent, PYO wheels w/285-75 Dick Cepek FC-II's - Quasar Blue and Argent Silver two tone.

    ...and other various GM cars and trucks


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