OK, I have a customer that had a problem of oil consumption and slight loss of power... 2006 Cummins with 80k pretty much stock other that a edge juice with attitude.
Truck had serious blowby issues so i told him he more than likely had a broken ring, He got the money together and came to the shop and 830 am saturday morning, the truck on a trailer so by 9am im elbow deep in this venture...
well i started to take some pics of the job and there are DIy's on here to remove injectors
http://www.dodgeownerforums.com/smf/index.php?topic=2461.0after you get the valve cover off and coolant and oil drained your ready to rock
Remove the 26 head bolts, disconnect the Downpipe and Injector Rail feed line on drivers side along with wiring harness's. The Injector return line is on the rear of the head i have no pic to show it because you can barely get your hand and a 3/4 wrench back there let alone the Droid to get a pic...sorry
I pulled the head with the turbo and manifold still on, easier this way in my opinion... you should end up with something like this
now you loosen the motor mounts and pic the engine up as high as you can get it, almost 4 inches you have to go to remove the Oil pan. then you will see this
You have to remove the oil pickup and block stiffner plate and you will see this
Now you can remove the rods and pistons, I barred the engine over till each one was at the bottom to make it easier to get to the bolts, and then push the pistons up through the top. You may find yourself having issues getting them out, so push them back down and hone the top of the cylinder a minimal amount to remove any debris at the top of the cylinders
when you get the pistons out it should look like this
Now is the time to Remind yourself CLEANLINESS IS THE KEY... Take your time and clean everything
I used my expanding hone to clean the cylinder walls up then sprayed everything down with solvent and blew dry then repeated
now with everything out you can inspect everything and this is what i found
Number 1 and 6 the top rings were cracked, luckily the cylinder walls were not tore up so a mimimal amount of honing was performed... Before Honing remove the bottom oilers that shoot up into the bottom of the pistons...
now clean all of the components
install new rings and upper and lower bearings REMEMBER never touch the bearing surface that will contact the crank, i wear gloves and use some kind of assembly lube when putting all back together.
now put pistons back in the same hole they came out of
torque the rods to spec
I also removed 3 of the main caps to make sure the mains were not bad, and reinstalled and retorqed the caps.
now you reinstall the head and hook it all back up
sorry for such few pics, there are more here
http://s239.photobucket.com/albums/ff207/04cumminsram/in%20frame/but it ran at 145am sunday morning... !