Blown headgasket

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My '90 has popped its headgasket, anyone have any experience pulling the head for this? I am looking for the wisdom that experience supplies. I have extensive automotive experience but not on the Cummins. Engine is stock, non-intercooled. Thanks, Bill

 

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I have changed the head, and the first thing you need is the service manual. I can offer some tips that worked for me, in addition to that reference. The head weighs about 150 lb, and I used a cherry picker to lift it. I ran a chain from an exhaust manifold bolt hole to an intake cover hole. Put the pushrods into slits cut in a piece of cardboard so they are kept in order. Keep the rockers in order too. Get new black (not the gray--they swell and leak--valve cover gaskets. Scrape the surfaces carefully and very thoroughly, then check for flatness with a quality straightedge. The finish on the block and head must be very smooth, and very few shops can get that quality of smoothness. I finish torque the bolts to 110-120 ft lb, bacause I found too much variation trying to torque them to +90 degrees as the manual said. You might buy a few extra of the medium length bolts. They seem to get the hottest and be most likely to lose their heat treat and stretch too much. you can tell, because they won't come up to torque fast like good bolts will. You can leave the alternator and belt attached, just gently remove the top bracket. I removed the exhaust manifold from the head and pushed it and the turbo a bit to the side. This works, but it might be a wrestling match to align the manifold perfectly afterwards. Be sure the manifold is flat and smooth, and that all replacement exhaust gaskets are the same thickness. You should do a valve job at the same time. You will probably find the 5/16" valve guides are worn out and need bronze wall inserts.

Hope this helps, Joe

 

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I thought of a few more things. Try to clean out the head bolt holes--some will be filled with oil, for example. You don't want that stuff being displaced onto the deck surface while the head bolts are being tightened. I clean the head and deck surfaces with lacquer thinner, and put the head gasket on "dry" meaning with no additional sealers. Check the valve seats in the head for cracking, especially between #1I and #1E.

 

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I'm pulling this thread back to the top to help with the current problem with a head gasket.

 

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Well I came back from the Cummins dealer, $1600 poorer and now have a fresh head and 6 new injectors, and a fist full of gaskets. I guess it is time to put it all back together.

 

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Good luck. Make sure the head and block surfaces are super clean and dry--I finish the process with lacquer thinner. Turning the engine over a bit at a time helps you make sure no "crumbs" remain hidden between pistons and walls. Get all the oil and stuff out of the head bolt holes. Be careful to anti-seize the exhaust manifold bolts and torque them in order to prevent breaking an "ear" in the future.

Helps if you have a cherry picker to lower the head into place.

Best wishes,
Joe

 

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Been working on my 89 this week and hope to have the head off by Saturday. Just workin a little each day after work. I assume I should remove the injectors before pulling the head?? So far I've remove the heater hoses, radiator hose, intercooler boost tubes(Banks) and Intake. Mine had water(coolant) in the air intake hose and aircleaner box and in the boost tubes and intercooler!!!! Any explanations???!?? I would appreciate any tips to hop this thing up while it is down. I am taking the head to a reputable local shop to have it checked and get valves or anything else that it may need. I have 140,000 on it should I look at the injectors? I really expected something else to fail first like the GETRAG, but not the head gasket. I don't run it that hard but I have towed @15,000 lbs. behind it about every other weekend for 11 years and I have monkeyed with the pump. I turned the fuel up and adjusted the plunger. It will make 30 pounds of boost and I never get it over 1150 deg pre turbo. I am curious as to why it let go.

thanks
Don Peters


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1989 D 250 Ice blue met. 5 spd 3. 54, 140,000, Banks stage III powerpack straight exhaust, pump adjustments, still looking for more power ON HOLD DUE TO BLOWN HEAD GASKET!!
1999 3500 4x4 Chassis cab Emerald green ISB 5 spd 4. 10 K&N Filter straight exhaust 9 ft flatbed WARN fenderflares,Let the BOBMing begin!!! 275hp injectors installed, boost and pyro gages, awaiting results of those who have purchased the VA box.

 

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Well, I have a friend that has a 40' x40' garage where big red currently rests (fix a lot of cars in there). Right now he is waiting on a 2001 3500 4X4 quadcab. He was tired of me disappearing in the distance on him in his Chevy 6. 2 I guess. I teased him about the weenie automatic. Anyway, we have a cherry picker to put the head back on. I am in the cleaning phase now, getting the block real clean, and cleaning the bolt holes out. I didn't take the injectors out at all till the head went to the Cummins shop. I don't have a long straight edge, so I ordered one to check to make sure the block is nice and flat (and am hoping I got one of the "new improved" headgaskets to stop the gasket leak problems). I am hoping so bad that the block is flat, as I do not want to take this engine apart any further. I agree that the last thing I thought would go was the head gasket. The engine is essentially stock, only the Banks exhaust, the K&N filter, and a Racor fuel filter added on. Since the engine does not have an exhaust pyrometer on it I figure I will have to put one in now. The next hurdle is that there is a leak in the cab from the top somewhere, so as soon as it runs again, into the shop it goes. I intend to post again with the question can I put the '91 and newer grille on the '90 beast without major surgery?

 

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I hope to pull the head off mine tomorrow. how many miles did yours have?? Mine has 140,000. How much are gaskets?? Should I pull the injectors before removing the head?? You cannot put a 91 grille on a 90. I looked at doin my 89 that way when I installed a BANKS intercooler. The bulkhead is different as well as headlight location etc. I used the stock grille and cut the back out of it. Good luck. I too hope my block is true. Any pitfalls I should be aware of?? Any help is greatly appreciated. You can email me if you'd like to talk off line about pricing etc. Why do you think yours blew?? I don't have a clue.


later
Don

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1989 D 250 Ice blue met. 5 spd 3. 54, 140,000, Banks stage III powerpack straight exhaust, pump adjustments, still looking for more power ON HOLD DUE TO BLOWN HEAD GASKET!!
1999 3500 4x4 Chassis cab Emerald green ISB 5 spd 4. 10 K&N Filter straight exhaust 9 ft flatbed WARN fenderflares,Let the BOBMing begin!!! 275hp injectors installed, boost and pyro gages, awaiting results of those who have purchased the VA box.