I chickened out and am paying someone to do the head gasket, but thought I would share the pics and experience so it might help someone down the road.

My gasket wasn't actually blown. Head bolts stretched and/or nuts loosened. there was cylinder to cylinder leaks as well as the coolant coming out behind the heat exchanger

here's the leak




here's the old gasket




everything off





head

 

Based on what the mechanic suggested:

1. Head gasket set- P/N 4089649 213.00 includes turbo/exhaust manifold gasket, manifold bolts and gaskets, injector washers, etc

2. 4 turbo studs and nuts

3. 26 head bolts

Bolts P/N 3920779 6 @ 3.35
3920780 14 @ 4.43
3920781 6 @ 7.22

4. exhaust manifold $350

5. Upper and lower radiator hoses

6. new belt

7. Updated Thermostat for 89-93 models and gasket
Cummins Part# 3802968


and from searching here:

8. oil cooler 3957544 $279

9. fuel heater gasket
Cummins P/N 3913695

10. Oil Psi Sender
Cummins Part# 3923200


total is $1100 from cummins +$140 for hoses and belts at napa

 

Ouch... Your oil cooler looks good, your whole side of the motor looks real good, very little rust... Is your cooler leaking??

 

no cooler leak. wiped it with a clean rag a few times looking for the initial leak.

 

Well, on my dump truck.. the line that runs around back of the cooler and loops to the elbow rusted through.. It was a bugger to find out where it was coming from... That whole cooler deal is a PITA, if it leaks again I am tossing it on both of my trucks..

 

yes it is. My one line rusted out (coolant) this summer and i ended up replacing it with rubber hose. It is so tempting right now with the downpipe out of the way to just pull the whole thing out.

 

If you're going to spend 350 on a factory exhaust manifold, might as well spend 450 for a 3 piece.

But why, is it cracked?