ZMotorsports Shop Projects 2.0

[zmotorsports]

Holy cow Mike! you must have three clones with the same awesome skillset. You have accomplished much in the last couple of months while still working full-time. I've spent a couple of hours catching up and let me tell you I'm just in awe. I like a variety of work and feel somewhat proficient but you take it to a much higher level. Remarkable work my friend.

Thank you Paco. I've been feeling a bit overwhelmed lately but as of last week I took a breathe, slowed my roll and just decided to push on one project at a time until I get my feet back under me. I appreciate the comments but I don't feel as though I have been making much headway lately.

I am glad to have you back and thank you for following along on my projects thread and taking the time to post. I don't think you realize the value you bring to this forum and the insight that you share.

 

[zmotorsports]

Mike, how many miles on your son's LB7 and what issues is he having that is driving the injector change out?

Probably high fuel return rates or leaking externally into the crankcase. Pretty common with duramax injectors, especially the lb7.

I can understand LO dilution but how do you determine high fuel return rates? Is there a drivability symptom?

I've got about 225K on my LLY and plan on keeping it forever so I'd like to know what to look out for and expect.

My son's truck was not to the point of experiencing any oil dilution yet. He wasn't gaining oil nor any adverse running conditions. He had just detected a slight amount of hazing at the stoplight the other day on his way home from work and asked if we could diagnose it. I'm glad to see him so aware of his vehicles and wants to keep them in proper repair.

Upon checking his balance rates we noted that cyl #1 was very high @ 5.8 with cyl. #3 being the next highest @ around 3.8 and 4 being the cutoff point. All other cylinders were less than 1 so we immediately suspected two of the injectors were having issues.

One thing that was odd was when we were troubleshooting it and seeing the white smoke we noted that a couple of times after it has sat for a few minutes I could have sworn I noted a slight blue tinge to the smoke which didn't make any sense. My fear was we may have a cylinder going south such as an oil ring or something. Please read below with my next posts to find out what we found when we pulled the injectors.

 

[zmotorsports]

So yesterday we were able to get the injectors removed.

A little tip or suggestion is to use a 19mm tubing crows foot rather than a wrench. A wrench is too long to get on the high pressure line straight and therefore you will be forced to try and break the fittings loose with the wrench at an angle and high probability that you will round off the flats on the fittings. This eliminates, or at least greatly reduces, the chances of rounding off those flats.


All high pressure lines removed. I recommend replacing these lines as they can be (and usually are) filled with corrosion which will immediately find its way into your new injectors.


I have the actual injector pulling tool that straddles the injector and pulls straight upwards, but I seldom use it because it is more likely to pull the cups with the injectors.

Here is another little trick to remove the injectors without pulling the injectors cups out in the process. After removing the hold down fastener, use a high pressure line and thread it onto the injector. Tighten the fitting with a 19mm wrench, then use the wrench to twist the injector clockwise and counterclockwise as much as the hold down will allow. This is only probably 15 or so degrees but it is enough to break the O-rings loose from the cups.


Next grab the high pressure line and pull the injector straight out of the bore while catching the hold down clamp with your other hand.


And the injector is out, easy peezy. Now remove the high pressure line and go on to the next injector.


This is injector #3 and alerted me to an issue with all of the oil film on this injector compared to any of the others.


Here you can see the torn or damaged O-ring that was allowing oil to get past.


At this point the engine is to the point where we can adjust the valves before we commence putting everything back together.








That was the stopping point yesterday afternoon as we had to close up the shop early. My wife and I had arranged a small party for my in-laws who are celebrating their 50th anniversary this week and we wanted to get family and friends together to celebrate.

 

[protegeV]

The one good thing about the injectors under the rocker covers is there usually isn't much issue getting them out of the bore.
I did injectors on an lly in a kodiak 5500 landscaping truck and half the injectors had so much external corrosion it felt like they were welded in. Found out about a trick with peppermint oil after much cussing and gnashing of teeth. Worked like a charm.

 

[rmack898]

Found out about a trick with peppermint oil after much cussing and gnashing of teeth. Worked like a charm.

You can't just say something like that and walk away.

 

[Firstram]

You can't just say something like that and walk away.

Right?

 

[protegeV]

You can't just say something like that and walk away.

Right?

Lol. Sorry guys.

I got a bottle of pure peppermint oil and poured it down the sides of the injector. The orings had turned hard as rock and the injectors stuck in the bore. The oil softens everything up. You let it sit for about 3 hours and besides smelling real good, the injectors popped right out. You let it sit too long and everything starts to harden up again.

 

[Bob Heine]

I dropped one of the retainers which found its way into the black hole that vehicles seem to have. I need to dig in and locate it once I get the front end up off of the jack stands.

Mike, I find the best way to locate a lost part is to order a new one. As soon as I have the new part packaging torn apart and thrown away, the old part comes out of hiding.

 

[fnieto]

Good one Bob, so true....
Great educational write up Mike, I always learn reading your threads.
Thank you.

 

[zmotorsports]

Mike, I find the best way to locate a lost part is to order a new one. As soon as I have the new part packaging torn apart and thrown away, the old part comes out of hiding.

Good one Bob, so true....
Great educational write up Mike, I always learn reading your threads.
Thank you.

Thanks guys.

Bob, I'll be stopping by my local GM dealership today to see if they have a clip as well as ordering a couple of new fuel lines that we may as well replace while we are at the high pressure pump (CP3). I thought the same as you Bob, if I pick up a new retainer, I'll more than likely locate the hidden one.

Again, thanks for following along and commenting guys, I really appreciate the comments.

 

[zmotorsports]

Talk about a kick in the balls. Yesterday was the warmest day of the year so far @ 75-degrees and today when I arrived home it was 51 and I had to start the shop heater up again before beginning work. The news is actually saying we’re supposed to have 1-3” if snow on the valley floor by morning. Yuck! I was hoping we were done with that white **** for the year. Pat, I think you jinxed me this year. [emoji12]

First order of business was to adjust the valves. With no injectors in their bore there is no compression so rather than lie on my back trying to get a socket on the balancer I simply reinstalled the A/C compressor, slipped the belt back on and turned it over with the alternator pulley nut.


Tools required for adjusting the valves.






Tighten until there is resistance on the feeler gauge, .012” in this case.


After running through the valve adjustments, I like to roll the engine over a half dozen revolutions or so then run back through with the feeler gauge and double check each rocker.

Next was to clean the injector bores in preparation to accept the new injectors. Years ago I took this tapered punch and cut it off so the tip would barely fit into the .375” nozzle hole in the injector cup. As I apply some pressure it will create a seal so I can spray some brake wash into the injector cup then chase it with compressed air to clean the cup. This works great and keeps anything, including brake, wash from entering the cylinder bore.




Last task of the evening was to clean the lower rocker boxes and upper valve covers so they are ready for reinstallation. I start removing the old sealant with a razor blade.


The upper valve cover has a groove that needs to be cleaned out to accept the new sealant. I start with a cotter pin tool to remove the old sealant from the groove.


Followed by a small wire brush.


Just prior to going into the solvent tank I wipe the sealing surface with a rag and brake wash then scrub the sealing surface with a small piece of Scotchbrite. I buy the 3M Red Scotchbrite in a 2” x 25’ roll and cut off a small piece at a time as needed.


Out of the solvent tank, dried and ready for reassembly.


That’s it for tonight.

Thanks for looking.

 

[shortykorte]

Snow? Too bad you don’t have a Rumba snow vac. lol. You could always move to Florida....preferably down the block from me.
Thanks for the tip on the scotchbrite roll. Didn’t know that was available.



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[zmotorsports]

You could always move to Utah Shorty, cuz I don’t think there’s a snowballs chance in hell I’m moving to Florida. lol


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[gearhead1960]

Mike,
Your attention to detail is one of things that sets you above everyone else in your repairs. I can see why when you closed your business there were alot of unhappy customers. I've done my fair share of wrenching but on the jobs that I can't or won't do, your eye for detail would keep me coming back, no matter the price. Kudos to you for never compromising.

 

[zmotorsports]

Mike,
Your attention to detail is one of things that sets you above everyone else in your repairs. I can see why when you closed your business there were alot of unhappy customers. I've done my fair share of wrenching but on the jobs that I can't or won't do, your eye for detail would keep me coming back, no matter the price. Kudos to you for never compromising.

Thank you for the comments, I am flattered. I'm definitely not the fastest wrench around but I try to deliver consistent and quality results no matter on my own vehicles or someone else's. It is nice to see someone recognize that because at times I was wondering if my clients appreciated the care I gave their rides.

I appreciate you taking the time to follow along.

 

[PhantomEB]

Damn I never seen feeler gauges like that!

Must have!!! Who makes the angled ones? Part number?

 

[LXCam]

It is nice to see someone recognize that because at times I was wondering if my clients appreciated the care I gave their rides.

I appreciate you taking the time to follow along.

In my world it’s a rare client that see’s any value in someone like yourself that takes the time to go the extra mile. I’ll spend countless hours detailing any assembly I’m working on just because I can’t live with myself slapping something together regardless if I’m getting paid for it or not.

Occasionally I kick myself in the azz for that ocd trait, but I like to sleep at night more. I’d tell you not to change your ways Mike, but it’s far too late to even bring that up.

 

[zmotorsports]

Damn I never seen feeler gauges like that!

Must have!!! Who makes the angled ones? Part number?

I don't have the part number as they are a bit worn. I'm pretty sure I got them from MAC about 25 years or so ago. I know my straight bladed feeler gauges are in fact MAC was well.

They definitely have their place for certain tasks.

 

[zmotorsports]

In my world it’s a rare client that see’s any value in someone like yourself that takes the time to go the extra mile. I’ll spend countless hours detailing any assembly I’m working on just because I can’t live with myself slapping something together regardless if I’m getting paid for it or not.

Occasionally I kick myself in the azz for that ocd trait, but I like to sleep at night more. I’d tell you not to change your ways Mike, but it’s far too late to even bring that up.

Thanks Cam. Yeah, I don't see myself changing any time soon. Actually I feel that my OCD seems to be getting worse the older I get rather than better and I have no idea why. When I do a job I have an image in my head of what the finished product or end result should be and it had better match or I'm not happy with the job or worse, with myself.

I'll admit I did have quite a few clients that recognized the care that I put into every job for them but I would not say that was the norm by any stretch.

 

[Firstram]

Nothing wrong with holding yourself to a higher standard. Paid job or a freebie, the only thing that makes it worthwhile in my book is the gratification I get from doing a good job. You always put your best foot forward and should find relief in that. I doubt pride is in your vocabulary!

I really enjoy your posts and the thoroughness in your work. Keep on keeping on

 

[zmotorsports]

Nothing wrong with holding yourself to a higher standard. Paid job or a freebie, the only thing that makes it worthwhile in my book is the gratification I get from doing a good job. You always put your best foot forward and should find relief in that. I doubt pride is in your vocabulary!

I really enjoy your posts and the thoroughness in your work. Keep on keeping on

Thank you for the comments. I appreciate the kind words and for taking the time to follow along.


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[zmotorsports]

I didn’t have much time tonight as I got out of work late. I only had about an hour and a half but at least made some progress.

O-rings installed and Sil-Glyde applied to them in preparation for installation. I also cleaned the hold down clamps and bolts in preparation.


Injectors installed with hold down fasteners torqued to 37 lb/ft. Also fuel return lines installed which included new gaskets and fasteners. Fuel return lines torqued to 106 lb/in at the injector and the bolt in the head @ 11 lb/ft.


Lower rocker boxes installed with new gaskets and new fasteners torqued to 89 lb/in. The socket head fasteners for the lower boxes were replaced with hex head flange style bolts.




Thanks for looking.

 

[gearhead1960]

In my world it’s a rare client that see’s any value in someone like yourself that takes the time to go the extra mile. I’ll spend countless hours detailing any assembly I’m working on just because I can’t live with myself slapping something together regardless if I’m getting paid for it or not.

Occasionally I kick myself in the azz for that ocd trait, but I like to sleep at night more. I’d tell you not to change your ways Mike, but it’s far too late to even bring that up.

Cam, I agree and think you have to be there yourself as you describe to appreciate the detail that I pointed out. The non "gearheads" just don't understand nor do they want to. Sometimes, I think you do it for yourself. No one else.....

 

[gearhead1960]

I didn’t have much time tonight as I got out of work late. I only had about an hour and a half but at least made some progress.

O-rings installed and Syl-Glide applied to them in preparation for installation. I also cleaned the hold down clamps and bolts in preparation.


Injectors installed with hold down fasteners torqued to 37 lb/ft. Also fuel return lines installed which included new gaskets and fasteners.


Lower rocker boxes installed with new gaskets and new fasteners torqued to 89 lb/in. The socket head fasteners for the lower boxes were replaced with hex head flange style bolts.




Thanks for looking.

Mike,

I've not been on GJ long but found and have read through your threads with a variety of enjoyment, envy, thoughts and emotions. I'm certainly envious of your shop and your skills, but this work you are doing for your son has brought about a train of thought I must share. Hopefully, it's not too mushy... I wish you a long and prosperous retirement (when you actually reach it) with your wife and family. I must say, it just struck me that long after you have moved on to another plane, your son will always have a great memory of you and your skills and love in being there for him. I have 2 sons and can only hope that they feel the same about me.

 

[bmxdad]

Why the new bolt style? And why Syl-Glide, why not regular grease?

 

[zmotorsports]

Mike,

I've not been on GJ long but found and have read through your threads with a variety of enjoyment, envy, thoughts and emotions. I'm certainly envious of your shop and your skills, but this work you are doing for your son has brought about a train of thought I must share. Hopefully, it's not too mushy... I wish you a long and prosperous retirement (when you actually reach it) with your wife and family. I must say, it just struck me that long after you have moved on to another plane, your son will always have a great memory of you and your skills and love in being there for him. I have 2 sons and can only hope that they feel the same about me.

Thank you very much. I appreciate and thank you for taking the time to follow along on my projects and especially for the kind words. I hope one day my son is able to look back on our time with pleasant thoughts and not just of me working. I hope he realizes one day just how fortunate he was to grow up in our family because to him it was just growing up. I don't think he thinks anything of it other than a normal childhood but my wife and I know different and his childhood was anything but normal.

I was joking with my future daughter-in-law last night as she was commenting about their children and if they would be able to walk on my lawn. I told her they will always be able to play in our yard but I won't let anyone else walk on my lawn and then jokingly told her to make sure she stays on my stepping stones when she walks on it.

She had also made a comment about how I will be their children's only grandfather due to her dad's passing 8 years ago. I told her I would try to honor that responsibility and take it to heart. She said if it is anything like how I've treated and raised my son she would be the one honored and I got kind of emotional. I told her she will have to put up with modified and custom built strollers, bicycles, go-carts and all the way up until they are driving and she said she could live with that. I don't think she quite has any idea of what she is marrying into yet.

I appreciate the thoughts and comments and thank you so much for sharing them.

 

[zmotorsports]

Why the new bolt style? And why Syl-Glide, why not regular grease?

I like to replace the banjo bolts on the return lines because they can get debris and corrosion in them much like the high pressure lines. These particular bolts are ones I have used before when I bought injectors from this vendor and I think it is their way of quickly identifying their bolt compared to the OEM.

I like Sil-Glyde and have used it for nearly 30-years now. I started using it when I first became an industrial maintenance technician and was doing a lot of hydraulic ram rebuilding/repacking. One of the hydraulic shops we worked with turned me onto it vs. grease or oil and I have used it on nearly every O-ring I have replaced now over that 3-decades of work. I feel it helps upon reassembly and eliminates the possibility of rolling an O-ring and/or tearing it.

Thanks for stopping by and checking on my projects.

 

[sanddan]

Thank you very much. I appreciate and thank you for taking the time to follow along on my projects and especially for the kind words. I hope one day my son is able to look back on our time with pleasant thoughts and not just of me working. I hope he realizes one day just how fortunate he was to grow up in our family because to him it was just growing up. I don't think he thinks anything of it other than a normal childhood but my wife and I know different and his childhood was anything but normal.

I was joking with my future daughter-in-law last night as she was commenting about their children and if they would be able to walk on my lawn. I told her they will always be able to play in our yard but I won't let anyone else walk on my lawn and then jokingly told her to make sure she stays on my stepping stones when she walks on it.

She had also made a comment about how I will be their children's only grandfather due to her dad's passing 8 years ago. I told her I would try to honor that responsibility and take it to heart. She said if it is anything like how I've treated and raised my son she would be the one honored and I got kind of emotional. I told her she will have to put up with modified and custom built strollers, bicycles, go-carts and all the way up until they are driving and she said she could live with that. I don't think she quite has any idea of what she is marrying into yet.

I appreciate the thoughts and comments and thank you so much for sharing them.

A BIG to you MIke!

 

[zmotorsports]

A BIG to you MIke!

Thanks Dan and thanks for stopping by.

I hope when you and your wife start traveling in that bad *** RV of yours that you will get to my little corner of the country in your travels.

 

[Yarz]

I told her she will have to put up with modified and custom built strollers, bicycles, go-carts and all the way up until they are driving

I hope these builds will be featured here too!

 

[zmotorsports]

I hope these builds will be featured here too!

Of course they will, I can't think anywhere more fitting.

Thank you.

 

[zmotorsports]

Tonight’s progress includes the installation of the injector wiring harnesses then the upper rocker covers, new injector high pressure lines and retainers.


While we were in it this far we opted to replace the low pressure fuel lines as they are getting a bit hard and “crunchy”.




Lastly before closing up the shop for the evening I bead blasted the thermostat housing.


Touched it across the belt sander to make certain the housing was flat and installed it along with two new thermostats.




Maybe I shouldn’t have bead blasted it as it stands out too much now but it had some ugly discolorations on it.

Thanks for looking.

 

[ryan in louisville]

Damn I never seen feeler gauges like that!

Must have!!! Who makes the angled ones? Part number?

It's a MAC FG275, only $19.29 on the MAC website.

 

[hbabler]

Thanks for posting all these things in your thread. It’s one of the first things I look for when I visit the site. You do some amazing work. Watching you do the injectors on this LB7 reminds me of the time I did mine. You are doing a much more thorough job then I did.
Keep up the excellent work!

Hudson

 

[zmotorsports]

It's a MAC FG275, only $19.29 on the MAC website.

Thank you for sharing that information, mine had worn off the tool.

Thanks for posting all these things in your thread. It’s one of the first things I look for when I visit the site. You do some amazing work. Watching you do the injectors on this LB7 reminds me of the time I did mine. You are doing a much more thorough job then I did.
Keep up the excellent work!

Hudson

Thank you very much for the comments Hudson and thanks for following along. I'm glad you find my work, posts and projects enjoyable.

 

[sanddan]

Thanks Dan and thanks for stopping by.

I hope when you and your wife start traveling in that bad *** RV of yours that you will get to my little corner of the country in your travels.

Might be as soon as this fall.

 

[zmotorsports]

Might be as soon as this fall.

Awesome. I am happy for ya, and a little envious if truth be told.

 

[Finallygotit]

Great work Mike! When do you plan to fire that girl up again?

 

[zmotorsports]

Great work Mike! When do you plan to fire that girl up again?

Thanks Dan. I was hoping this weekend to finish up the engine and then get to work on his steering upgrades next week but it depends on how much time I get to work on it over the weekend. No time tonight and only part of the day tomorrow.

 

[zmotorsports]

I was able to round up the last molded fuel line for my son’s LB7 today. I sourced it from my local GM dealership.


On the way home from work I swung by my local NAPA and picked up my filter order that I called in earlier in the week. This week they had their annual filter sale and it definitely pays to take advantage of it. I generally stock up for the year to save a few bucks.




Happy Friday everyone. I hope you all have a great weekend.