Oswego's Build

[Oswego]

So the engine is done and 100% buttoned up.

Got most of the gas out of the tank, but ran out of time Saturday and it's been raining since. Dang "quick disconnect" fuel lines have a very ironic name. I'm sure they are quick and easy when new, but add 11 years time + half a swamps worth of dried mud to the inside of the clips and they become a total PITA. Had to keep hitting them with air as I picked out the mud and dirt so the quick disconnect buttons could even free up.

Only things left now is to install the new fuel pump and put the tank back in.

 

[Oswego]

Fresh squeezed organic unicorn juice is now available

couldn't get the filler tube off the neck until we dropped the tank so slow and steady milking with 1/4" tube . wish I had known 1/4" tube fit past the anti siphon junk - I would of drained the tank years ago

 

[Oswego]

Dropped the tank this morning to drain the rest of the turpentine and put in the new fuel pump. I was not impressed with the amount of rust I found under it.... looking like Ill get a new frame the more and more I look at it.

this ring had me worried due to how people had talked about it being a pita, bnut I must have been lucky. Few turns of my strap wrench and it popped right off. Once the old pump was out I got cleaned out the inside but it only had a few specks of dirt in it.

also found out why my sending unit wasn't working.... orange wire was completely severed and the yellow + black was half gone as well. I have no idea what did it. Either a foreign object like a stick or a hungry rodent. The sheathing was torn/chewed and that sheathing is pretty darn thick

maybe tomorrow she will turn over

 

[balakay]

Yep, that's definitely worthy of a new frame.

 

[Oswego]

Funny thing is the frame is A-OK up by the cats where everyone else has issues.

All I know is after fighting all the rusty nuts, bolts, and brackets....Ill be happy to get a new frame. Every bolt is a fight, but we got lucky and only sheared two in the entire process so I consider that a win.

Also got my URD Y pipe on with O2 sim then added the upper O2 extensions and plugged up the top header bungs.

Truck turns over w/no codes but has yet to fire up. Not sure if no spark or no gas. Ran out of light so called it for tonight. Tomorrow Ill investigate.

We purged all the fuel lines in the entire truck so I'm not quite sure how long it will take to prime if thats even a thing on a injected motor

 

[AlienXtx]

It will take a few seconds

 

[Oswego]

Since I got out of the shower Sat night after typing my days summary here I haven't touched the truck. Started shacking with a bad chill after my shower and was thinking sunburn or illness so I took my temp and sure as shit I had a 103* fever. Been wiped out and bed ridden ever since. I was wondering why I had no power in my arms and legs while working on the truck

Came into work today because this is where I got sick (more sick kids were brought in last week) and I really DGAF at this point who here get's ill when they all bring their dam sick kids to work.

 

[Oswego]

this is today...had my fingers crossed but really wasn't expecting it to fire up. keep your volume down

time to start investigating when I feel better

 

[Anathollo]

this is today...had my fingers crossed but really wasn't expecting it to fire up. keep your volume down

time to start investigating when I feel better

Weird, it sounds healthy.

 

[Silverback]

Sounds expensive.

 

[Silverback]

How big of a PITA was it to drop the tank? I need to replace my sending unit (I'll do pump at the same time).. my fuel gauge doesn't read right. Assume its all the shit fuel over the years.

 

[tex]

Did you put gas back in the tank?

 

[Taco Loco]

Did you put gas back in the tank?

Oh that’s a blonde question there,

 

[tex]

Oh that’s a blonde question there,

Thanks for picking up on the intended delivery

 

[Taco Loco]

OB Scan for any error codes.
It’s hard to tell in the video, but if the key is turned on, without starting it, you should hear that fuel pump. If you don’t hear the fuel pump, check the fuel pump relay.

 

[Taco Loco]

Thanks for picking up on the intended delivery

, I’ve seen it happen before though, maybe he didn’t add enough fuel, didn’t think @Oswego was a blonde

 

[Oswego]

Weird, it sounds healthy.

But you can hear me wheeeeeezing in the background

How big of a PITA was it to drop the tank? I need to replace my sending unit (I'll do pump at the same time).. my fuel gauge doesn't read right. Assume its all the shit fuel over the years.

So I'm now not so certain I needed a new sending unit. My wires were cut. By what, I have no idea, but maybe the leaf springs mixing around? The wire is in a bad spot. Maybe it's common

The Haynes manual actually had a pretty good write up for tank removal and fuel pump replacement so check that out.

Everyone I read up on had differing opinions. People talked it up so much I was more concerned with the tank than the engine.

Here's a quick to do list for ya:

Tools needed (all of this is off of memory while being sick )

17mm socket with some extensions

3/8 or 1/2 ratchet

long sharp/new #2 Phillips head

small dead blow to tap in screw driver (if needed)

dental pick (only if needed to remove mud)

fuel quick disconnect tools in 3/8" and 5/16" (forget which one worked - bought a cheap multi pack)

strap wrench

compressed air (to blow out mud you loosen w/dental pick)

headlamp (hard to see on top of the tank but below the bed)

ratchet strap

second set of hands for install (not really needed for dropping it)


* make the truck safe


*empty gas from tank


* remove rear exhaust pipe/muffler from y pipe and hangers (you’ll need to sit in this spot later to unhook and then later reattach the filler neck and vent)


* remove ds rear tire (I didn't do this and was angry/frustrated I did not)


* disconnect fuel filler neck clamp w/#2 Phillips. tip - the screwdriver does NOT go in the hole in the bracket - that's an optical illusion. Tap into place w/deadblow to insure great fit – you can NOT strip this screw.


* disconnect vent fuel "quick disconnect". Its next to the fuel filler neck clamp


* disconnect supply and return lines in front of the tank. Also supposed to be "quick disconnect". These by far held me up the most. Mine had 11yo mud cemented in so the buttons on the sides were frozen. Took allot of picking, tapping, cussing, and compressed air to free them up.


*fasten ratchet strap under tank so it can’t drop


*remove tank strap bolts and then cotter pins and tank straps so the entire tank can be turned freely while resting on the ratchet strap


*now that you can access the top of the tank, remove the filler neck rubber hose from the tank (prob slid off by itself at this point). Remove the plastic cap covering everything. Now the fuel lines, evap, and douche connector is accessible). Remove the evap line and douche connector.


*drop the tank


*grab strap wrench that’s long enough and turn lefty loosey while unlocking the tabs as you get to them J


(before I started the above I spent 20 minutes washing and scrubbing mud from between the tank and white cap – that said I still missed a ton of mud some of which fell into the tank upon removal so do this if need be)


*remove pump from tank


*dance a jig


BTW – the gas lines are under pressure so be mindful when first disconnecting them.

Did you put gas back in the tank?

Yes sir, 5 gallons and not one drip of leakage....good news is my fuel gauge now works again and isn't stuck on "E" with the light on like it was for 3 years prior to the engine blowing

 

[Oswego]

OB Scan for any error codes.
It’s hard to tell in the video, but if the key is turned on, without starting it, you should hear that fuel pump. If you don’t hear the fuel pump, check the fuel pump relay.

Would codes register even if we never get it turned on? We did have it plugged in and checked for codes and had none. Then checked just about everything we could including throttle response. We reset that with no luck.

You can hear the pump come on and smell gas when its turning over.

, I’ve seen it happen before though, maybe he didn’t add enough fuel, didn’t think @Oswego was a blonde

what little hair I have left is turning grey, but was never blonde to begin with. Although waiting for 4+ years to fix this was surely a blonde moment in my life

 

[Taco Loco]

Would codes register even if we never get it turned on? We did have it plugged in and checked for codes and had none. Then checked just about everything we could including throttle response. We reset that with no luck.

You can hear the pump come on and smell gas when its turning over.



what little hair I have left is turning grey, but was never blonde to begin with. Although waiting for 4+ years to fix this was surely a blonde moment in my life

Some codes can be triggered without actually running, while many of the codes will not register without the engine running.

Discount battery, turn key on and hold brakes for 30sec, reconnect battery...this truck has been sitting for awhile...might try starting it with the other keys if your truck is equipped with those RF keys for anti theft.

 

[Oswego]

Some codes can be triggered without actually running, while many of the codes will not register without the engine running.

Discount battery, turn key on and hold brakes for 30sec, reconnect battery...this truck has been sitting for awhile...might try starting it with the other keys if your truck is equipped with those RF keys for anti theft.

Both good ideas Ill try so thanks - this is the kind of little annoying thing I think and pray is holding me up.

Just in case someone way smarter than I reads this and can put 2 and 2 together - The new engine was almost identical to the old, but it is 2 years older then my old engine....only differences I noticed were oil pan for 2wd vs 4wd and the quick disconnect leading from the fuel rail to the intake had a different end terminal on one side so we had to clean and reuse my old one. Other that that the engines have seemed to be identical in every way.