Pulled this down today on a heavy knock complaint from a Freightliner step van with the Common Rail ISB 04 EGR engine. Odometer showing 63k. Oil had 2 gallons of coolant in it. #1 piston came apart and the skirt was laying in the pan. The dome is melted and looks to be from a washed down cylinder. Injector nozzle was not broken off and was still intact. Pretty good crack in the block on the #1 wall. Rod and mains looked normal. Headgasket showed good sealing area around ports and cylinders. A little more driving and the rod would have found its way out.

 

Ouch, that looks like an expenisve bill.

 

Cummins is picking up the bill, so, this is what they want us to get: Bare block, new head, new rings, 1 injector, new bearings, and 1 piston and rod...thats it. IMO a reman is in order, however, if they can save a dollar by piecing it together that is what they will do.

 

Yeah. I havent seen carnage like that since I help my dad rebuild and Old Detroit 8V92 out of a 1973 Kenworth. Good Old screaming Jimmy haha.

 

Any idea what caused it?

 

Wow, i would think you need a total rebuild...

 

you just won the worst piston pic.

 

Suddenly I feel better about mine...

 

he says "washed down cylinder" so my guess is the injector stuck open and washed the oil off the cylinder wall causing no lube=lots of heat and a melted piston?????just my geuss

 

Ooops, missed that. Thanks,

 

I'm thinking new long block if it's my truck. Cummins is out of their collective mind.

 

Monty , hopefully you did include a turbocharger, you may not see any damage on the turbo, but the turbine blade is toast, also make sure you inspect the EGR valve and the cooler for metal contamination, if not.... that new turbo or engine won't stand a chance when you fire it up. progressive damage will cover all the components. Cummins has always done business in replacing only what is needed, warranty will only bring the engine back to the condition is was in when it failed. most likely cause of that failure was when the supply passage in the injector leading to the upper plunger area got blocked with debris from the fuel, which allowed the needle valve spring to lift the needle and continously feed fuel into the cylinder. getting to be more and more common from techs not praticing clean care when servicing the fuel system. and that mean fuel filter changes. The melt down was the result of overfueling.

 

Monty, is the customer willing to pop for the difference for a complete overhaul? Just curious thanx

 

Dude theres not way I would put that motor back together.
They ought to be buying you a new long block at least. My moneys on a cylinder wall crack(s).

 

Pourin, he said they were getting a block and a new head and 1 new piston, thats why I asked if the customer was willing to spend any extra money on a complete overhaul kit. Now would be the time and it would be much cheaper now rather then later.

Tim