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stillthinkin · 03-11-2016, 05:48 PM

I got some bad news from Cummins CalPacific shop today, my overheating problem appears to be a blown head gasket or a cylinder sleeve has cracked / began to leak into the cooling system.

Background: I was returning to southern Ca, from the Jan 2016 Quartsite show, when I noticed the engine temp gauge was a little high. nothing came of it and I checked oil and coolant at the next stop.
Great experience at "Q" by the way, not my first visit to the big tend but it was my first stay at La Posa South in the circle of Monacos. I had a great time.

The next motor home trip was February and at the first hill I encountered the engine temp went to red line almost immediately. I pulled over and was suprised that, at idle, the engine temp just as quickly would drop to 180. I called some friends (Harry Martin and Bill Willard) for advice and eventually limped over the hill to my destination. Water and oil was always fine.

After changing the thermostat and washing the radiator (twice) I attempted a trip to Phoenix....not good. I made it 40 miles and new it was still going to over heat at the first try to put a load on the the engine (hill or long grade). Yesterday I noticed 2 exhaust gaskets were leaking, #2 quite a bit. I dropped it at Cummins fearing a blown head gasket and they "dropped the other shoe" by telling me it could instead be a cylinder sleeve ruptured or cracked from erosion (pitting).

That sleeve comment from them made me think back to the thermostat change I did, because I wondered why the thermostat seat on the block was so pitted and erroded on a 2007 with 39K miles. I've had extended life coonant in it since 2014.

I'll know the news in a few days after their tear down.

Happycarz · 03-11-2016, 10:08 PM

That sucks! Mark, sorry to hear that.

10Boomer · 03-12-2016, 02:57 AM

Quote:

Originally Posted by stillthinkin

I got some bad news from Cummins CalPacific shop today, my overheating problem appears to be a blown head gasket or a cylinder sleeve has cracked / began to leak into the cooling system.

Background: I was returning to southern Ca, from the Jan 2016 Quartsite show, when I noticed the engine temp gauge was a little high. nothing came of it and I checked oil and coolant at the next stop.
Great experience at "Q" by the way, not my first visit to the big tend but it was my first stay at La Posa South in the circle of Monacos. I had a great time.

The next motor home trip was February and at the first hill I encountered the engine temp went to red line almost immediately. I pulled over and was suprised that, at idle, the engine temp just as quickly would drop to 180. I called some friends (Harry Martin and Bill Willard) for advice and eventually limped over the hill to my destination. Water and oil was always fine.

After changing the thermostat and washing the radiator (twice) I attempted a trip to Phoenix....not good. I made it 40 miles and new it was still going to over heat at the first try to put a load on the the engine (hill or long grade). Yesterday I noticed 2 exhaust gaskets were leaking, #2 quite a bit. I dropped it at Cummins fearing a blown head gasket and they "dropped the other shoe" by telling me it could instead be a cylinder sleeve ruptured or cracked from erosion (pitting).

That sleeve comment from them made me think back to the thermostat change I did, because I wondered why the thermostat seat on the block was so pitted and erroded on a 2007 with 39K miles. I've had extended life coonant in it since 2014.

I'll know the news in a few days after their tear down.

Keep us posted, I know that's not the news you wanted to hear.

Duoglide1 · 03-12-2016, 10:10 AM

We are hoping for the best for you Mark, very sorry to hear about this. Hope to see you at Q again next year. Frank.

2007 Monaco Executive 45' 525 ISX

William Willard · 03-12-2016, 06:12 PM

Quote:

Originally Posted by Happycarz

That sucks! Mark, sorry to hear that.

2X -- Bill Willard

stillthinkin · 03-13-2016, 12:34 PM

Thanks for the support. Yes, I'll see you all at Quartsite next year!

I'll post more info after the engine tear down and they call me in for a walk through. Right now I'm guessing that in the 6 years the original owner had it, it never had a coolant change (23K miles). I had it a year or so before I changed the coolant to the 5 year extended service type.

One thing the Master Mechanic told me is that he has seen electrolysis destroy an engine - he thought from lack of a good ground (engine to frame I thought he meant). I'm now wondering if because my motor home sat in storage for 1.5 years, with batteries connected and solar charging, does that mean electrolysis could have been erroding enging components? Does that mean for long term storage I would power down and disconnect batteries?
Any thoughts on electrolysis?

Thanks - Mark

stillthinkin · 03-17-2016, 11:00 AM

The Cummins shop called me last Tuesday and asked me over for a look at the engine. They found no problems with the head gasket but said the head surface should be trued up - I agreed.
The next step is to pull all pistons and remove / replace all cylinder sleeves.

I ordered a new stainless surge tank from Source Engneering in Oregon, should be here on Monday. Mine was leaking at the filler neck.

I attached pics, hope they work.
Mark

windsorbill · 03-17-2016, 06:18 PM

Mark,

Now that it's torn apart, did you get a good explanation what exactly happened? Was it lack of coolant maintenance? Did you ever find out what the electrolysis is he's talking about?

stillthinkin · 03-19-2016, 03:30 PM

Windsorbill,
I didn't get a good explanation yet. When asked how it happened the service manager said maybe because you got it hot. I think it got hot because exhaust gases were being pumped into the coolant (via leaking sleeves at the head) at an increasing rate.
Its the weekend now, I'll wait to talk with the two mechanics for an answer on why it happeded at 39K miles. They think by the end of next week it will be done.

My surge tank arrived early from Source Engineering. Looks smaller, but looks good. I'll take it to them Monday for them to install when they are ready.
Thanks, Mark

stillthinkin · 03-26-2016, 10:37 AM

The engine repair was completed yesterday, Friday, on my 07 Camelot. List of parts:
- New hoses, belts, coolant
- Water pump and thermostat
- 6 new cylinder sleeves, rings, gaskets
- Head resurfaced, head gasket
- New surge tank from Source Eng.
- New oil an Filter
- Radiator flushed (water only to look for debris)

Symtoms were over heating and loss of power. Runs strong now and mechanic said it was very quiet at idle - I took that to mean some diesels rattle and clack.

Notice in pic of the cylinder sleeve the heat burn marks on outside. This is exhaust gases getting out of the cumbustion area and into the coolant. The cause of all this was the sleeves slipped or moved somehow. when I asked how or why, no one knew.

Note in pic of old surge tank - gasses bubbling out at idle, non stop. Failed official gas test too but when they saw that they knew it would.

I asked about dusting and got an immediate, "no way," the cross hatch inside cylinder sleeves show a good surface for mating to piston rings.

I am taking a short trip next week. Looking forward to a well running rig!

Mark

windsorbill · 03-26-2016, 05:44 PM

Mark,

Glad you're back up and running. Which shop did the work? Colton?

stillthinkin · 03-27-2016, 09:14 AM

Bill,

Cummins Cal Pacific in Ventura did the work and have done work for me since 2006 (prior Fleetwood DP). They have two RV sites if a traveling customer needs overnight work done. I live local so I just dropped it off.

I'm happy especially with the prompt repair on such a big job, and the technical expertise. Now, if it continues to run well for the next 200K I'll be very happy

Mark

abrasv · 03-27-2016, 03:21 PM

Quote:

Originally Posted by stillthinkin

Bill,

Cummins Cal Pacific in Ventura did the work and have done work for me since 2006 (prior Fleetwood DP). They have two RV sites if a traveling customer needs overnight work done. I live local so I just dropped it off.

I'm happy especially with the prompt repair on such a big job, and the technical expertise. Now, if it continues to run well for the next 200K I'll be very happy

Mark

Mark, what were the $$ damages to you on this adventure. Reason I ask is I am just going to look at an '06 Camelot next week. Not saying it will happen but always plans to be prepared.

Jim