Just got truck back together after a full rebuild. Rebuild required boring to 0.040. After about 200 miles engine was hydrolocked with coolant in the rear drivers side cylinder, pulled glow plugs and cleared cylinder. Pulled engine and head but don't see any issues with head, gasket, or cylinder. What would capitation look like in the cylinder? Trying to decide how to proceed, any ideas would be appreciated. Thanks
Fill the block with coolant, roll the piston in question to the bottom of its stroke then let it sit over night. if it fills up with water, you probably have a crack, or cavitation. I have seen a lot of different cracks where the cylinder leaked, but the cavitation monster isn't as big as a lot of people would have you believe. Chances are that one of the head gaskets leaked. Especially if you had every thing checked before you re-assembled the engine. Cracks happen from overheating usually. New head gaskets don't always show up as leaking. If there were no problems when you assembled it, then it didn't cavitate or crack in 200 miles. Unless in that 200 miles you seriously overheated it.
Engine never got hot, and everything was checked by my machine shop before assembly. I am running turbo pump and injectors though without a turbo so it is possible that the EGT were high prior to installing pyro.
Bigger diesels have replaceable cylinder liners so liner erosion is easy to see from the coolant side when the liner is removed, like so:
The erosion holes are much smaller on the inside of the cylinder. Unless there's some sonic type equipment that exists nowadays, it's impossible to inspect the complete coolant side of cylinder walls (where the erosion starts) because they're not removable and they're part of the block. If you DID have a cavitation problem but not yet into the inner cylinder wall, and then the cylinder was bored out, maybe the boring would take out enough material to allow leaks into the cylinder. There again, how would the machine shop know?
Chances are your problem is one of the much more common ones Oldrebuiltdodge mentioned above.
Using a turbo pump and injectors won't cause high EGTs by themselves. You need to over fuel by either lugging the engine, or chocking off the air. I'm with old rebuilt on this one, I am thinking head gasket.
Thanks for the info guys. There was a small spot in the rubber coolant passage that looked suspicious when we disassembled so I will hope that was the source and reassemble and hope for the best.
Update, finished replacing head gaskets, did both to be safe, and reinstalled. Filled with coolant and let set. After 24 hrs radiator is low and have coolant in oil pan and in #8 cylinder. Guessing #8 cavitated due to boring out. Question is can I sleeve the engine , likely do the 7 that are not already sleeved, and then bore back out to 40 over so I don't have to scrap the new pistons i already have?
I wouldn't hesitate to sleeve the block if I could find a machine shop that knows what it is doing. I might have a problem with .040" over though
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