Engine Dead

[Monroefiredog1]

Hi All,

I have a 02 2500 CTD that I have had for many years with no real problem. THen about 2 years ago it got a little hotter than it should have. It really didn't have the power after that, although it still ran pretty good. I decided to pull the head and have it checked. And while I was that far into it, I had an oil leak on the tappet cover, that I was going to repair also. Long story short, got it all back together and it would not run right. I kinda figured that the key-way on the injection pump was sheared a little. Took it all back down, found nothing wrong. Put it all back together, still would not run. I was just standing there looking at the engine, when I noticed a bubble from the #5 exhaust gasket. AT this point I think that it's either the block is warped, or a crack in the #5 cylinder wall. I have since started to pull the engine, it is now ready to lift out. My questions is what do you guys recommend at this point? Take it to a machine shop and let them check it, and repair it? Find a used engine? I have come to learn a lot on this adventure about the 5.9. I purchased a 5.9 with 147,000 miles on it. But when I got to looking at it closer it is a 2002 5.9 that was rebuilt by Cummins in 2016, however, it is only a 190 hp 5.9. I had no idea that a 5.9 Cummins engine could have this much less hp. I also learnt a lot about these 5.9 applications. I was not aware that Cummins rebuilds these engines for these older trucks on an ongoing basis. Anyway, I was just wondering what some with similar engine problems would do? Thanks in advance for you help.

 

[BoeingDiesel]

Think the first thing I'd do is pull the dipstick and check for coolant contamination. Sounds like you have a fairly good idea of what you're doing but are you sure the key way was properly oriented?

 

[Monroefiredog1]

Think the first thing I'd do is pull the dipstick and check for coolant contamination. Sounds like you have a fairly good idea of what you're doing but are you sure the key way was properly oriented?

Hi Boeing, Thanks for the input. When I took it down the 2nd time there was nothing wrong with the key, but I replaced it with a new one anyway. It's acting just like it did the first time. Do you have a lot of experience with these engines? When I saw the bubble from cyl 5 I just figured that water was getting into that cylinder. Any other ideas?

 

[BigPapa]

I assume you put the correct key in it. They aren’t all the same.

Is the bubble coolant? It would mean you at least have an exhaust leak there.

 

[Monroefiredog1]

I assume you put the correct key in it. They aren’t all the same.

Is the bubble coolant? It would mean you at least have an exhaust leak there.

Big papa, Yes I put the correct key in it and yes the bubble was coolant.

 

[Monroefiredog1]

Think the first thing I'd do is pull the dipstick and check for coolant contamination. Sounds like you have a fairly good idea of what you're doing but are you sure the key way was properly oriented?

Boeing,
Yes I am pretty sure the key way was in correctly, I read the service manual and I made sure that it was the way the book said, and I even got a new key, yes it was the correct size. I did pull the dipstick but it didn't show any mixture as of yet. It was only ran for like 15 min or so. And of course it had new oil too.

 

[BoeingDiesel]

Monroe, where did you get the 190-HP info from...something isn't matching.

 

[BigPapa]

I even got a new key, yes it was the correct size.

It's not the size of the key, it's the offset. The VP pumps take a specific key for proper timing depending on the key code on your pump.

 

[BoeingDiesel]

^^^ What Scott said. Begs the question which direction was the arrow on the key pointed...toward the case or the pump? You've got a lot going on here.

 

[Monroefiredog1]

^^^ What Scott said. Begs the question which direction was the arrow on the key pointed...toward the case or the pump? You've got a lot going on here.

Boeing, I made sure the key was pointing right. The 190 hp 5.9 CTD is from the Cummins data plate that's on the timing chain cover.

 

[BoeingDiesel]

First of all, there are a lot of members on the TDR that are far more qualified than me to lead you on this. I suggest you take some pictures of the #5 exhaust etc and post them...it can only help. Since the '02 was still subject to the 53 block issue I'd check both sides of the block for the # and hopefully that isn't the issue in your case. Good luck!