Howdy Skoolie Family! Welp, Its been a rough past month-and-a-half, but things are looking up!
We missed both Skooliepalooza and the Florida Skoolie Swarm due to mechanical issues, but was finally able to get things back up and running!
A little background: On the way back from Montana in October, I was getting some DTC's (Warn Engine light). It was a 333 code (ICP above or below desire pressure). I was able to reset the code underway using the Scanguage and it would run fine for a bit, then show up again under load. We were ablr to make it back to Texas without any problems, just had to clear the codes quite a bit, but other than that, the bus was running OK.
Made it back to Texas and started to troubleshoot. Decided to replace the ICP sensor and the IPR (Injection Pressure Regulator) Valve since they were the cheapest things to start with. Replaced those and figured we would be good to go! WRONG!! started rough and never smoothed out. Crap. Still throwing 333 Code. Going through the troubleshooting, figured the next logical thing has to be the HPOP (High Pressure Oil Pump). Ordered it and swapped it out. Started her up and STILL not running right.
Crap. OK, next step would be to check the injectors. Maybe have a leaking O-ring that is not letting the pressure build up. OK. Pull the injectors, clean them up and put in new O-rings.
Well, since I have the engine all tore apart, might as well rebuild the air compressor since I noticed a slight oil leak from the head. OK. Wait for parts. Get the compressor head rebuilt.
Since I was rebuilding the compressor head, also figured it would be a good idea to get a new dessicant filter for the air dryer and a new purge valve which was also sounding like it was on its last leg... great! Air system with lots of new parts!
To get the compressor head rebuilt, had to remove the HPOP again. OK, really learning a lot about the DT466E . As frustrating as it has been, really been learning a bunch about the engine. As I was removing the HPOP, I had another look at the IPR valve (removed it as it was easier to get the HPOP off with it off). Something did not look right. I compared it with the original IPR Valve that was removed. The "new" IPR Valve was not the same size. It was about 1/8" longer than the original. What the hell? I went back and looked at the order history... looks like I went cheap and ordered the cheapest one I could find online. MISTAKE!
I went and ordered another one from a more reputable business. When it arrived, I compared it with the original one and it was the same size. OK! PROGRESS!
Now to put everything back together and hope to hell I don't have any extra parts laying around.
Allrighty - got everything re-connected, re-wired, and re-torqued.... Needed to turn the crankshaft a few times to make sure and squeeze any oil/diesel (that I didn't get when I sucked out the cylinders with a vacuum pump) to prevent any damage due to hydro-lock.
With a VERY nervous wife, finally ready to attempt to start it back up. Since the oil lines and fuel lines were removed, it took quite a bit of priming and cranking before we got any action.
Moment of truth.....SHE'S ALIVE!!!! There was much smoke and fanfare, but the engine finally settled down and seemed to be running OK. Hooked up the laptop to check the numbers.... SWEET!! They seemed to be looking OK... revved it up, pressure numbers looked good! Time for a test drive - Took it out for a bit and ran great! A few little sputters at idle, but the longer its ran, the smoother it got - just needed to work out all the air bubbles in the oil and fuel lines...
So - lessons learned - DO NOT cheap out on certain parts. Had I not went cheap the first time with the IPR Valve, I probably would not have had to get a new HPOP. Since my bus is a 1998, I figured "what the hell" it is over 20 years old - couldn't hurt, right?
Either way, I got her running again and we couldn't be happier.
All is right in bus world again.
Cheers!!! Now on to more adventures!
John and Beeks