Pulling the unit injectors from a Cummins 855 Big Cam Engine - Project Brupeg Ep. 267

With the engine currently filled with a diesel/oil mix, we need to dive right in and find the fault. In typical Brupeg fashion we rip into it so we can figure out what has caused this to happen and any other faults that we find along the way will also be repaired as part of this.
This is a great chance to get this engine up to a standard we are really happy with. It was always in our plans to do a strip down and refresh so this may just jump start that timeline, and of course this is Damiens happy place, inside a lovely big diesel engine.
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Thanks for watching guys.
Jess, Dame, Snoop Dog & Baby Cat

[@tomwilliams8675]

I loved it, the look on your face when made the remark about engine versus motor 🤣😆😁

[@mikerowley464]

You are doing great. I have a suggestion to make oil changes easier. Take out the pan plug and replace it with a valve. You can then screw a hose (and even your pump) to it to drain the oil quite easily. Use the plug to cap the valve to prevent leaking into the bildge.

That's basically what I see on each NT855 on a canal barge in Europe. Some have it directly plumbed to a used oil tank with. Mine has an integrated manual sump pump, where I can pump the old oil right into an empty oil bucket to return to the oil supplier for recycling !

[@fonhollohan2908]

Great idea....

[@13kire]

Fumoto makes nice little valves for this exact application. Run them on my vehicles so I can drain oil without tools. Just flip the valve lever and drain

[@502bbb]

Damian, Those engines are much much easier (and the correct way) to turn over by using the accessory drive, it takes 1 & 5/16 socket to do it (34mm). The accessory drive is what has a belt on it to turn your alternator . Also as a couple of others have stated and you probably know by now that engine has no "hydraulic lifters", it has cam followers and a very precise thickness gasket that is what sets your timing (setting cam timing is a little to advanced to type out here in the comments section). Here is some good news though...I went out to the shop and got you some wrench part numbers that you need - the first one is for a 7/16 "spanner wrench" (in USA we call them adjustable ratchet wrench's) it is a gearwrench 85454 - that one is for the fuel pump bolts. The next two are for the compressor and accessory drive bolts MAC s244 & MAC s4.... You can thank me later for how much time these will save!!!

[@thefreshwater2727]

You guys are such a respite for me. My wife is on hospice and I’m here alone with her in the country. She sleeps 20plus hours a day and it gets so lonely. You two make my day each time I see a new episode. Love your humor and talents. Cheers and shalom. And THANKS!

[@ProjectBrupeg]

Tim I’m so sorry to hear that. Yes illness like that can be a real toll, I’m glad we can help in some small way. I’m really pleased we get to share this project with people like yourself. Jess and Dame

[@mikeday5776]

I know it’s a bit crappy for you guys, however, it makes for compelling viewing. Damien your a bloody star for getting it to this stage. Me, I’d have pulled my hair out and run off giggling into the sunset. And Jess, I know your right their with the same fierce grin as your other half. I hope your well, both of you. Hugs from me and Gloria.

[@mwolfer1]

5:04 Where I live we call this "redneck engineering", and it's not a derogatory term, but the admiring expression of appreciation for finding adequate solutions for temporary problems. Props to you!

[@robm.4512]

I’m Chief on a 40m ex-naval, ice rated, patrol vessel that’s now an adventure yacht. If we’re not going to be in service for more than a few days I always shut off the day tank outlet stopcock for the very reasons you’ve highlighted. If you don’t you’re leaving the system under pressure, albeit not much. I’ve been through a very similar situation to yours and after that I decided that relying on the shutoff solenoid valve for longer periods wasn’t quite the ticket. You have my sympathy! If you decide to follow suit, please please make a couple of proper warning boards to cover the engine start switch both in the engine room AND up at the helm station. Injector pumps don’t much like having their intake restricted !! Cheers, R. 😎👍🍻

[@leonply]

You took me back in time this week! I remember the Red Green Show, out of Canada. When you said that you were using duct tape to mount things, Red's show closing phrase came to mind. "If the girls don't find you handsome, make sure they fine you handy!" An excellent video and your progress is amazing. Well done you!

[@dickdegraaff5452]

Dear Jess and Damian. It must be very early in the morning with you right now but in particular Dick loved your latest vlog because he loves to work with engines. He admires Dame a lot since he seems to have a lot of technical skills. We wish you lots of success with the rest of the refit of Brupeg and wish your both families all the happiness of the world plus we send you ❤️ from the Netherlands. Best regards, Willeke and Dick de Graaff

[@Leosarebetter]

Your patience Damien is amazing, I would have had a spanner throwing exercise when I was half way through....

[@ColinDH12345]

I don't have the means at present but I wish I could pay for the fuel pump refurb, I really do. Love your videos and your journey. Thanks for taking the time, it is appreciated.

[@ProjectBrupeg]

Thanks Colin

[@abbbee8918]

That engine needs to be 100% reliable

[@merlinglennon5370]

On a hydro locked engine, one thing you can try, as long as the crankshaft bolt doesn't back off, is turning the engine counter clockwise. The cylinder that is full, that is on compression will now be on intake. With valve overlap, fuel, coolant, or water will go into the exhaust at TDC. Then remove spark plugs or Injectors if diesel, then crank over with with a bar clockwise at least 4 revolutions, then the starter to clear out. I have used this method to get vehicles in the shop , so I could repair them in my bay

[@rickrutledge7361]

Amazing to me the similarity of the hardware on that diesel motor (oops…engine) to the hardware on aircraft. I Maintained avionics systems on fighter jets for many years in the USAF. Love this channel. Learned a lot watching you troubleshoot, Dame. Can’t wait to see Brupeg on her first trip. Keep up the good work!

[@aviationsafety9082]

Us navy retired avionics technician here living in the Philippines

[@mickralph4623]

Nice work Damo!

[@ProjectBrupeg]

Thanks Mick

[@mickralph4623]

@@ProjectBrupeg You are amazing! You get knocked down and you get up again. Every time! We'll make a QLD'er of you yet. I wish I could do more to help your project, but I am really enjoying your ride.

[@AW-Services]

A general household cleaning spray bottle trigger with it's dip tube is great for emptying cylinders or bleeding brakes Getting a vacuum fluid / oil extractor is an affordable way. Like the reverse of a garden sprayer with various size suction tubes

[@laurapitre5797]

Next time you need a curved wrench just heat it with your torch until it's bright red where you need to bend it and then hit it with a hammer until it's at the right angle. We've done it many times at our shop.

[@RamBabu-ev9wl]

Good job

[@nigelwalton4769]

Damo your intros get better and better as your hair gets longer and longer. Cheers for sharing!

[@mikebills9343]

🤞🤞looks like you’ve saved a few quid there , and re use that old diesel mixed with engine oil , just filter it first , it all helps .

[@bobadam7021]

I usually laugh out loud once or twice per episode, but this one had me rolling. I really don't understand why subscribers aren't flocking to this. You should easily have twice as many.

[@MyPinky1986]

I love the intro! lol keep up the good work 👍

[@brucethecurmudgeon8538]

You can just dump that oil/fuel mix into your diesel tank. The oil will dilute and burn just fine.

[@McTroyd]

Glad to hear it (probably) isn't the pump. Curious to hear what you found in Cylinder 5. 👍

[@buellb0y]

Just a suggestion. Add an electric solenoid valve to the fuel supply and return lines, linked to the engines main power switch, along with emergency bypass valves.

[@Hissmannen]

This may be the best epidode of Brupeg since you started. In my eyes atleast. Best part was that smile att 28:35. Awesome work dude !

[@ProjectBrupeg]

Thanks so much for saying this. Cheers Dame

[@googies12a]

Get hold of an oil extractor vacuum pump. It'll take all sorts of liquids out easily. Love the videos, keep up the work!!

[@ryanchapman293]

You can undo the mounting flange between the compressor and the block then rotate the compressor and the IP just enough to get a normal spanner in there.

[@kenholt8297]

That Cummings motor 🤣🤣is a beauty!! Well done Damien.

[@renerichter7296]

There are no decompression bolts on a Cummins Diesel? You have been a great inspiration for me while rebuilding my old steel boat…I like your ironic comments lately! Keep going! Cheers from Germany

[@djmini2numpty141]

firstly, felt your heartache when the thought of reconditioning the fuel pump first entered your mind, what struck me was that no matter if that was the case, it is waht it is and lets move on.. ( mums fav saying) . i couldnt help but feel the weight lift when you figured that the solenoid was more likely the culprit. keep going, as i know you guys will, the end is nigh :)

[@thestruggler3338]

The above view of the rockers with the orchestral soundtrack was begging you to hand crank that motor as fast as you can.

[@JulianBuss]

I enjoy every episode, but this one is a star. Very interesting and entertaining at the same time. Having a truck engine in my boat as well, although not as big as yours, I‘m very interested in learning how such a beast work. You just made me donating for the first time 👍

[@ProjectBrupeg]

Thank you so much Julian

[@keithk2926]

To clear the cylinders out rotate the motor backwards,fuel clears out the exhaust,cheers from California

[@jeanhawken4482]

Amazing workmanship

[@quarlow1215]

Nice catch on the injectors. One of my trucks had that problem only the reverse as you mentioned. It would lose its prime every night. I couldn't afford to do the injectors so I finally adapted a caterpillar hand pump to work in line. Then I'd just give it 20 pumps in the morning before starting it. If I sat for 3 or 4 hours it would roll over a bit before firing. That lasted me a year till I could fit them done.

[@justinbouvier132]

Yep. It is a curved mac wrech that i keep in my shop just for that bolt.

[@khallingstad]

Awesome video

[@rodneynikora358]

A fan enjoying the mqdness so cool 😎 👌 😀 😊 😄 😍

[@bobd9775]

Dame I use hydraulic hose with Banjo fittings. Replace the drain plug with a Banjo bolt. Do the same for the generator, hook them up to a manifold attached to a reversible pump.. Now you can remove the old oil to a bucket and pump the new oil in the same way

[@cjhooker4955]

28:38 thumbs up!!!!

[@bally1213]

Another great video, well done to you figuring out that pump 🙈👍

[@wildwestcoast8095]

Thankfully these problems are getting fixed on land you will have piece of mind on the ocean.

[@iaingray36]

Great diagnostic and practical video👍

[@johnmorrison1180]

Boy o boy is there anything that Damien won’t tackle, carpentry, design & fabrication, welding, heavy diesel mechanical, electrical installation, mechanical restoration, all with a cheerful attitude and taking the time to film and explaining it to us as well. Of course behind every good man there is a wonderful woman, but I’m curious, just what is Damien’s background, mechanic? marine engineer? mechanical lecturer? Brupeg is one of the best channels on utube, a no nonsense presentation! I look forward to every video.

[@ProjectBrupeg]

Thanks John. Started out with competitive dinghy sailing and then mucking around with cars including spray painting at panels shops, then onto precision machining building custom close ratio gearboxes for classic race bikes. From there I started a bus company and then met Jess. We ran that company for a few years then moved to Aussie and onto a yacht. We lived and worked on the boat for five years then brought brupeg. So it’s been a lot of things but nothing for long enough to be qualified in any one thing.

[@johnmorrison1180]

Thanks for taking my inquiry seriously and providing that answer, a well rounded background, I wish both of you every success!

[@ProjectBrupeg]

Thanks for being a part of this journey.

[@cannon440]

I had the exact same problem of the fuel filling the oil sump on a 30kwh Hercules white diesel engine. It had a Roosa injector pump which was easy to replace the O-rings.

[@jeverich]

Good work! Continually blown away by what you’re pulling off with just two people. I know it’s an added cost, but I’d highly suggest switching over to a water jacketed exhaust manifold. There may even be a different “marine” turbo cartridge that will work a lot better for your application, too. Another thing, make sure that there isn’t a “fresh air” and “sea air” aftercooler. “Fresh air” after coolers will destroy themselves in short order in a marine environment… leading to a trashed engine. I’m no expert in 855s (Cat 3406 Guy)… but I’d also suggest you talk to someone about variations between truck engines and marine applications. I guarantee the injectors are different, possibly even the cam.

[@ProjectBrupeg]

Yip we have a Cummins genius we work with. Injectors are cam are actually the same but fuel pump is different (hence we changed it a few months back, turbo and exhaust are different but it’s possible to run the one we have. We do plan to change it over but most likely when the current turbo dies

[@jeverich]

@@ProjectBrupeg awesome! I knew you already did your research, so much of this can’t be Google’d, and we need info from the experts. The build is coming along. The setbacks are frustrating, but it will all be worth it!

[@michaelecullimore9677]

I worked on Cummins V6-200M, VT600M, VT1710M during my 31 year USCG career as a machinery technician.

[@shawnchurch316]

You should install a solenoid valve on the fuel line right before the pump as a backup to the pump mounted solenoid. In the United States I can purchase oem cummins injectors for ntc400 engines for about $150 usd each. I once had to change 2 injectors on a ntc400 on the side of the road on I80 on Donner pass in winter. The engine was in a 80 ton grove crane.

[@paulibbertson1636]

How high is the fuel tank above the engine?

[@ProjectBrupeg]

Top is about 1.5m bottom is about 100mm above the pump

[@MotorSailingforOldDudes]

Bugger Damo. A job you didn't think you had. Just did the same dancing with some plastic water tanks. Hang in dudes.

[@rolandtb3]

Great instructional video and tool modifications. Enjoyed the diagnostic analysis.

[@dc1544]

that bottom drain plug is where we install a drain hose so we connect it to our pump setup and it sucks all the oil out. makes it super easy after the install.

[@tomwatson6827]

The Cummins fuel pump is a suction pump that dont need head pressure to the inlet of the pump to operate. If you have a fuel tank higher than the engine it is recommended to use a float tank. A leaking fuel solenoid valve can cause a small amount of fuel to the injectors when engine is shutdown. enjoy your videos. keep up the good work.

[@ProjectBrupeg]

Hi Tom We think this is exactly what happened. We have three ball valves in the fuel supply line at various points between the tank and the engine and not one of them was closed when we shut down. the fuel solenoid valve was open slightly which caused the injectors to leak and the engine to fill up.

[@tomwatson6827]

@@ProjectBrupeg What did you do with the jake brakes you removed. Are you going to sell them?

[@ProjectBrupeg]

Gave them to the guy I brought the fuel pump off.

[@cobamanuele5030]

I thort you droped the nut in the sump but it was just the rod falling to 1 side. Haha

[@johndavidson4974]

Very disappointed there was no #8 fencing wire used in the making of the extraction gadget. You two make me very proud to be a Kiwi, keep living the dream.

[@jamesread11]

Nice work dame 👍 just as well u found problems now even if it’s delaying the launch, you wouldn’t want to hydrolock at sea and possibly knacker a ConRod

[@ryanstip751]

With the old Cummins you can go ahead and dump your used oil and fuel straight into your tank the oil will help lubricate the top end of your diesel engine. Over here in the states back in early 2000 we switched over to ultra low sulfur diesel in which took the oil out of the fuel that was lubricating our engines. Since then with new Engines new technology it lubricates other means. I would also go ahead and circle back to that check valve you very well could be getting fuel coming from your fuel tanks and going back into the injectors as well. And on that Commons the other possibility is that manual override on the injector pump. I've seen both cases in my past. I'm a old diesel mechanic Marine proportion as well as truck back when they're real engine not computers

[@bobuncle8704]

Having rebuilt my own injectors on my 6.0 L powerstroke, I have a better understanding of this process. I was able to get in rebuild kits for all 8 injectors for around $800🇨🇦, and then about 10 hours to clean and rebuild them. This was much better than the $3800🇨🇦 For a set of remanufactured ones. I will say it was much more work getting to my injectors, but your reinstall and setup will be more work.

[@ProjectBrupeg]

These are fairly simple injectors. Just had a call with the fuel shop guy and they are back in the post on there way here. They were in good condition, nothing needed to be replaced, they tested 10cc lower than new but are within spec now they have had a clean up and test again

[@bobuncle8704]

@@ProjectBrupeg nice

[@jossmaxwell00]

Excellent process of trouble shooting there Damian. Great episode and i hope the refurbed injectors solve the problem.

[@BenJaminLongTime]

I dont care about boats, mechanical things or your personalities, I only have been watching for years for the bikini scenes, keep them coming thanks.

[@elaynewhite069]

I really admire your determination,stay mentally healthy.

[@MargaretLeber]

Love the Infinite Improbability Drive badge.

[@ProjectBrupeg]

Your the first to notice it Margaret! We love that movie

[@redbovine]

I cut my teeth working on those for 10 years. It is one of the easiest engines to work on.

[@ProjectBrupeg]

Yip. It is a nice engine to play with

[@clydedecker765]

"Balls deep" ... 🤣🤣 Cylinder no 5 wonky and a screw loose on the fuel pump ... fuel tank higher than the engine... Can't wait to see the results - without the bikini. SO long to wait....

[@sparkey9098]

That oil fuel mix and dilute it with more fuel and thow it back in the tank it’s practically new oil extra lube for the motor ect

[@fuggnut]

Well rebuilding this boat will make you know every inch of it so when you have an emergency at sea you will be more relaxed and efficient at fixing the problem. Imagine all the people that do not have that advantage, you can find some of those boats resting on the bottom. I bet you never thought you would be telling people how injectors work lol. Nice job, hope you find the leak so you don't have to go through this again.

[@matthewsellers82]

We left a small transfer pump (like you're using) permanently connected to the main sump outlet with the pump's outlet hose capped, just in case oil leaked by the vanes in the pump. With this setup oil changes became SO much easier and cleaner. Hit the switch oil out, hit reverse and pump new oil back in.

[@SuperDriver379]

A tip for spinning over a hydrolocked engine is you can open the valves as you apply pressure at the crank and find your cylinder that’s full. This is easier with two people. But I suppose it’s late for this advice now. If only I’d have known when you were scratching your head on it, maybe that could’ve saved you some time.

[@grimreaper6112]

you need a tool to open the valve and when several have fuel in them you will need several people and you would need to spin it fast enough to get the fuel out the exhaust valve

[@badger003]

Just love a bit of trouble shooting, great vid, keep up the good work

[@marcjordan29]

Twice engaged in pedantry! This guy and his motor! 😜

[@Altoid777]

Hang in there...You will triumph.

[@kimkeam2094]

Peltor, a company that makes vacuum systems to remove oil use a bicycle brake outer to insert the hose down the dip stick right down to the sump base. Gets all the oil and works well. To attach it to your pump, just have 1&1/2M of brake tube attached to a larger hose until it fits your inlet.

[@ry6346]

Lol motor vs engine with a cheeky smile 😁

[@sparkyprojects]

We made it easier to drain oil from generators where i worked, we added a valve, if you do the same, always put a plug in the end of the valve when not in use, you don't want accidental draining.;)

[@CutTimeBrony]

Not gonna lie, I def would of pumped that straight into the day tank instead of carrying it out of the boat lol

[@curthazlett595]

Just got our injection pump back from the injection shop 145$ to change and supply the shaft seal. It was much cheaper than expected!

[@ProjectBrupeg]

That’s staggeringly good value

[@Nodularguy1]

You could put that oil/diesel mixture right back in the fuel tank. The Diesel will burn it right up.

[@DorsetSaferRoads]

Still watching the video so don't know if you fixed it yet.... Good way to stop the hydrolock is to wind up the adjuster on the exhaust valve so it opens the exhaust valve a little that effectively removed the compression allowing you to turn the engine over and push the diesel out.

[@PBarrPrince]

Just a note: I love both of you letting your hair grow out. You look quite pretty/dashing! 👍

[@jerrydutra3225]

Good ol duck tape 👍

[@codemonkey2k5]

LOL!!!!! I freaking love your sense of humor!

[@jamarie1972]

I would say British ingenuity with the spanner but this time I’ll give it to you Kiwi 🥝 ingenuity ( sorry wrong kiwi ) Great work, such a positive attitude to all you do. It must seem strange talking to yourself but we do appreciate your devotion both of you. Cheers guy’s also that Motor will look lovely with a new coat of paint.

[@eddief3326]

you can also blow air into the injector holes to blow fuel out . it will also dry up with the injector out. and blead off.

[@wandahelmer1038]

Filter those precious gallons back to the tank!

[@walle226]

Awesome stuff!

[@simonilett998]

Yep, on a gravity fed system, if your shut off solenoid bypass valve is leaking, and one of your injectors has a leaky lower oring, you'll get diesel into the cylinder with the leaky injector oring...For shizzle. Or, if the centre oring and upper oring is leaking, the fuel will pass upwards into the oil/lubrication gallery, and potentially back down the oil gallery into the sump. Plenty of silicone grease, or oring lube is your friend, and go gently when installing the rebuilt injectors into those sharp edged injector bores, seen many orings shaved in the past by the sharp edges👈🤣👍🇦🇺

[@MrTallpoppy58]

Great episode Dam, love the detail and hope I it sorts it's self out soon without too much pain and of course looking forward to seeing your ENGINE running. I am off now to your patreon page / murch shop to put a bit of my money where my mouth is.

[@ProjectBrupeg]

Love it Adrian. Thanks so much for the support mate

[@matui6983]

Definately needs a 6L3B/8L3B Gardner in that engine-room.

[@jamesbrown145]

You need a ‘half moon’ spanner to get the pumps off. For some reason the big stores don’t stock them any more

[@linc11]

I had a feeling if your fuel tank was above crankshaft height , a non return valve is recommended in the return line , for depending where the crank stops an injector can be left partially open and return line fuel can drain back into the sump by siphoning assuming the return line is in the fuel in the tank , this maybe worth a thought

[@chrisparola3949]

You need to make an inverted barameteric loop line so the override fuel would have to climb above the loop to get to the injector pump

[@tamaralee4108]

Aeroquip makes fittings for what they call the FLOCS (fast lube oil change out system) system. That might simplify your quick oil change set up. For the engine fuel oil return, if the fuel return were routed to discharge at the tank top, then it couldn't siphon back into the engine. I know you have multiple tanks so that might not be possible.

[@ProjectBrupeg]

Thanks I will check them out this week. The return goes back to a single primary tank, it’s plumbed in at the top of tank so it should in theory break any siphon

[@edwardferguson.lasvegasnev1612]

Yes indeed duck tape is your friend .😄

[@fonhollohan2908]

It's good your taking care of these issues before launching the boat as you said the engine or motor hahahaha whatever the hell it is, lol is the heart of Brupeg with that said, She has to be reliable you can't take chances like that. You need a motor that you can surely count on.

[@ProjectBrupeg]

That's the plan!

[@peterkelly250]

Hi Dam, you said that in a truck, the tanks are lower than the motor, so the problem you have would not be seen in a truck. So the design may not be for fuel supply with head pressure and the seals are not design to hold against pressures. In a truck the pressure may be zero or slightly negative. A independent electric shut off valve on the fuel line maybe at tank so opens with ignition circuit and closes when the motor stops may solve any issue in the future. Just a thought.

[@ProjectBrupeg]

We swapped the fuel pump over to a marine pump so any seals I suspect would be capable of head pressure. We do have valves in the feed but I stupidly didn’t turn them off and at the same time the solenoid on the pump was cracked open slightly. These two things combined allowed the issue to happen

[@peterkelly250]

@@ProjectBrupeg I heard you say about you have shut off valves that were left open. Electric ones can be motor reliable then ones driven by grey matter especially in my case

[@primeusante7224]

Sad to see that there is not more than 10% that smash the like button!

[@sidekickbob7227]

It's 25% at 4K

[@thebigchuckster]

I think the lads over at SV Seeker fabricobled up a sump vacuum/extractor to do oil changes. If I find the video I'll post a link.

[@neilfairless4589]

Fingers crossed you have the issue cracked Dame.

[@nicolasmejia1736]

You make me interested in diesel mechanics

[@ProjectBrupeg]

They are a hansom lot I agree😆

[@caseystringfellow2066]

Mate, AllDiesels in Molendinar have an 855 on the shelf. Dyno’d done. It was for another boat.