Okay folks,
I did contact my mechanic to see what he would charge for this job. His quote came to $425. Which is probably not that bad, but I am a frugal sort of person... usually.
So, after much debate, and plenty of research, I've decided to tackle this myself.
Day one: Removed underpans, plastic injector cover, intake manifold, battery terminal. Plugged intake ports, EGR pipe and plenum tube with paper towles and put underpans on a drip pan to let the diesel drain out of them.
Tomorrow: I will set the IM to soak with Marine Clean, and start cleaning/inspecting the injection pump, lines etc to better determine what is leaking.
There was diesel all over the side of the engine and the underpans were soaked. I did see diesel around the tops of the DVs on the topside, but there was a significant amount of diesel that may have been leaking from behind the SOV as well.
Thursday/Friday: I plan on replacing all o-rings and return lines with viton, changing the filters, running a couple cans of diesel purge through the system.
I also plan on cleaning and checking the EGR to ensure that it fully closes (was getting a lot of whistling from the turbo lately and the EGR did stick one cold night) and replacing all the vacuum lines/connections that actuate the EGR and turbo wastegate.
After all this I think I should be good for a while... I hope.
