cat head bolts

No matter what the issue is, the shop is lacking somewhere in setting up the liners.

Don't know if maybe you want to consider a new shop or at least bring it to their attention how important proper liner protrustion is

 

A CAT shop rebuilt his motor the mechanic should have filled out a spec sheet where he checked the liner protrusion. Mine was and I have that spec sheet in front of me now. As Haney said the correct way to check the liners are measured and recorded on the spec sheet at 4 different points. Variation is checked from each to the other to make sure everything is in spec. Surely they can pull this up and show him where they checked? The mechanic has to fill out the paperwork and file it with the service manager. Here's what it will look like:

Liner Projection:

1A .043
1B .043
1C .043
1D .044

sum .173

avg .043


2A .044
2B .044
2C .042
2D .043

sum .173

avg .043


3A .043
3B .044
3C .043
3D .044

sum .174

avg .043


4A .042
4B .044
4C .044
4D .045

sum .175

avg .043




5A .043
5B .044
5C .043
5D .045

sum .175

avg .043




6A .044
6B .043
6C .044
6D .045

sum .175

avg .044



Max variation each cylinder

Max 1A-1D .044
Min 1A-1D .043
variation .001

Max 2A-2D .044
Min 2A-2D .042
variation .002

Max 3A-3D .044
Min 3A-3D .043
variation .001

Max 4A-4D .045
Min 4A-4D .042
variation .003

Max 5A-5D .045
Min 5A-5D .043
variation .002

Max 6A-6D .045
Min 6A-6D .043
variation .002


Max variation between cylinders:

Avg1 .043
Avg2 .043
variation 0

Avg2 .043
Avg3 .043
variation 0

avg3 .043
avg4 .043
variation 0

avg4 .043
avg5 .043
variation 0

avg5 .043
avg6 .044
variation .001



Max variation average of one cylinder head

max avg 1 thru 6 .044
min avg 1 thru 6 .042
variation .002

 

Thats pretty even. Did you have a counter bore done on it with those readings?

 

I don't think so. When I get to my stop later I'll look at the work order and see for sure. What does it mean to counterbore one? He did tell me the first owner had shimmed #6 (I think it was #6) at some point, which I didn't know that had been done, and there was no record of it having been done at a CAT house.

 

Shimming requires counterbore.

 

You mention above #6 Shimmed.. also above you state 3 times head gasket blown at the rear. I'm seeing a trend here.

Cutting counter-bores for shims is usually done in the Chassis and when the engine is out its "mostly" but not always Inserted so no shims required.

Leaking Injectors and or seals causing hydraulic-ing and or water entry doing the same can play havoc on the head gaskets.
I've seen many guys fit new liners in a counter-bored block and do liner heights insisting its perfect and a week later pull the head again due to water entry. Cracks in the counter-bores are also hard to see and get missed all the time.

98% of the time is human error that leads to these repetitive failures and they are costly!!! Depressing and you will develop a hatred for an engine type.

If the Counter-bores are Cracked then it will never be any good until its inserted or the Crack cut out and a thicker Shim inserted.
Also if the Liner flange is cracked it can be very hard to see and inadvertently gets re used at times.. If there is fretting on the deck then there will be corresponding fretting on the liner flange so you don't want to be re-using the liners unless they are perfect on the underside.

 

Randy will stay out of the ecm if you tell him to, at least call and ask a few questions he's a great guy. Also I thought of something else to think about, if they cut the deck and the head maybe your headbolts are bottoming out now.

 

I didn't know that. I'm amazed at what they can do with the motor inside the frame, I had no idea, learn something every day. Apologies to OP I didn't mean to derail or jack his thread. I think you have me confused with him. Not sure if he had to shim bore #6 or not. It was done on mine.. My whole reason for posting was his motor was overhauled by a CAT house. Their mechanics have procedures for checking to make sure everything is acceptable and in spec. They document that they check that stuff. Now whether the mechanic who worked on his motor cut corners or not I guess we'll never know but there is a paper trail there they are SUPPOSED to check that stuff as part of the routine. For what it costs they #### well OUGHT to check everything before slapping it back together.. A REAL tradesman of any kind always checks/double checks everything and ought to be proud of their work anyways. Since it blew another head gasket tear down, diagnosis, and fix is/was all courtesy of CAT. If it blows again they have to eat another one. If it got to that point and I was OP I'd do one of two things. 1) ...go to another CAT house, a different one from the ones who did the job, and speak with the service manager in detail about what I'd been through. I'd ask around and try to find out who was the best mechanic in that or any other given CAT shop and insist that's who do the work. Talk with the mechanic and give him details about everything that had happened - service managers do that but they sometimes leave out important little details. Then hope for the best.. The good thing here is it's not a shade tree mechanic who screwed up it... or 2) light a stick of dynamite and toss it under the truck

 

I went through similar issues. Out of frame, block decked and protrusion checked on assembly to have head gasket go 70000. Shop thought it was just gasket because they don't seem to be of same quality that they used to be. New gasket to make I another 50000. Turned out to be #6 liner under side of liner not true. Cat claimed it was "in spec" but replaced and got 110000 now. I use cat parts but a different shop due to cats spec range being to broad. Just my .02 Good luck