Duramax Diesels Forum Truck of the Week
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Old 08-03-2018, 04:52 PM
DmaxLMM DmaxLMM is offline
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Default Ever Seen a New Engine Do This?

A couple months ago I had a well known and reputable shop put a built motor into my truck (motor was built my a engine builder that is well known in the diesel community, no costs were spared). Started burning about 2-3 quarts every 200 miles, so with about 3k miles on the motor brought it back in to the shop that installed the engine to get checked out. They reported that the turbos werent the issue (couldnt see oil in the exhaust or compressor), then continued on to do a compression test. Well long story short they pulled a head. Below are the pics. Initially the motor builder said it was to hot and the pistons melted, but it was just burnt oil on the edges of the piston, in the other photos you can see where the piston was cleaned and wasnt melted. Cylinder walls looks like hell. After the piston theory didnt pan out the engine builder said it must have been the injectors, since I have DDP injectors, and not Exergy, at this point I am loosing faith and it sounds like they are reaching for straws so they dont take blame. Currently having the shop that installed it pull it back out of the truck and bring it to a third party unbiased engine builder to see if they can figure out what went wrong. FYI, all 8 cylinders look the same. I am not going to mention business names for the time being till I see what the problem is and if they are going to make it right.

Engine Specs:
Callies Crank
Carillo Rods
Mahle Pistons
Billet Flex Plate
ARP Hardware
Alt Fire Camshaft
ATI Damper
CNC Ported Heads


Anyones opinions would be appreciated, specially if you have previously seen something like this.




Last edited by DmaxLMM; 08-03-2018 at 04:58 PM.
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Old 08-03-2018, 05:41 PM
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How hard was the motor ran? Broke in? What kind of exhaust temps did it see?
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Old 08-03-2018, 06:22 PM
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Piston to wall clearance too tight?
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Old 08-03-2018, 06:34 PM
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All 8 injectors would have to have been throwing a lot of fuel in there to wash the cylinders and cause that.

That looks like a machining issue like too tight piston to wall or rings upside down or wrong rings all together or oil starvation to the cyl wall.

Cast or forge pistons? What rings? Bored over? How big of injectors?
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Old 08-03-2018, 06:40 PM
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Quote:
Originally Posted by WVRigrat05 View Post
Piston to wall clearance too tight?
First thing I thought, too.
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Old 08-03-2018, 08:06 PM
DmaxLMM DmaxLMM is offline
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Default Ever Seen a New Engine Do This?

Quote:
Originally Posted by kubitza123 View Post
How hard was the motor ran? Broke in? What kind of exhaust temps did it see?


Shop broke it in. Motor was ran pretty easy, with the twins hottest it got was 1350 and that was for a couple seconds. Didn’t tow till about 2500 miles on motor and was about 12k. Never saw over tune 2 and tuning was by ATP...

Last edited by DmaxLMM; 08-03-2018 at 08:17 PM.
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Old 08-03-2018, 08:12 PM
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Default Ever Seen a New Engine Do This?

Quote:
Originally Posted by Chevy1925 View Post

Cast or forge pistons? What rings? Bored over? How big of injectors?


Cast pistons, rings came with the pistons from mahle, pistons were “thermal” coated (per recommendation of engine builder), .020 over. Injectors are 60%. S476sxe and a promax 64 for turbos...
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Old 08-04-2018, 12:24 AM
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Quote:
Originally Posted by DmaxLMM View Post
Cast pistons, rings came with the pistons from mahle, pistons were “thermal” coated (per recommendation of engine builder), .020 over. Injectors are 60%. S476sxe and a promax 64 for turbos...
Are all those piston tops the same color? Doesn't look so in the pics.

My first though is something mildly abrasive has eaten up those cylinder walls. And for certain your reason it was burning oil. If piston to wall clearance is correct, then I'm leaning towards coating adhesion issues.. There is some gritty looking stuff around the edges that shouldn't be there.
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Old 08-04-2018, 01:46 AM
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Looks lik a coating issue. Hard to tell with those pictures but it looks like small chips on the outside piston head. Be nice to see rings and what the domes of the head look like. Wonder if you have fine pitting around the edges of the dome?

Sucks sorry to read about this.
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Old 08-04-2018, 06:20 AM
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I agree with Kidturbo, looks like coating didn't adhere properly and acted like a cutting agent in your cylinder walls...
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Old 08-04-2018, 07:21 AM
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Daaang that really sucks DmaxLMM. The parts you have are a winning combo for sure. We have used the same components in many builds with excellent results. Except the thermal coated piston.


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Old 08-04-2018, 11:16 AM
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I would say she was built to tight myself.
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Old 08-04-2018, 12:13 PM
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If pistons are too tight, your typically gonna see some aluminum streaks stuck to the walls. Not as "clean" as this one. Recently saw pic of some big HP Cummins pistons and block where clearance was an issue and, it gaulded streaks into the block. This one looks more like a fine abrasive issue.

I'm guessing they carried the TBC over the edge and down to top ring, and it flaked off acting like sandpaper. Only time I've personally seen similar wear pattern, on a gas engine I rebuilt back in the late 80's. Machine shop bead blaseted the heads and forgot to wash them out. When I set the heads on, some of the fine shot material fell into cylinders, and damage looked very similar. Started smoking and used oil. Upon tear down we found that shot stuck to the rings.. My advice, measure everything, then break out the magnifying glass...

Very interested to hear what it is since I have two engines setting here ready to go with TBC pistons..

Last edited by kidturbo; 08-04-2018 at 12:19 PM.
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Old 08-04-2018, 12:25 PM
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It’s not tore down far enough in my opinion. It looks dusted to me but I would like to see a couple pistons out and cleaned up gently with some brake clean and a very soft brush.
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Old 08-04-2018, 01:49 PM
DmaxLMM DmaxLMM is offline
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Have any of you guys heard or seen thermal coating on pistons fail?


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