First time rebuilding a diesel - Diesel Truck Forum - TheDieselGarage.com
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post #1 of 4 (permalink) Old 05-28-2013, 02:43 AM Thread Starter
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First time rebuilding a diesel

Newbie here, I recently picked up a 24 valve Cummins 5.9l complete, only missing injection pump, in need of a rebuild (melted piston) and I have some questions:

First what is the best way to remove melted aluminum from a cylinder wall? I want to avoid over boring if possible

And my last question for now, how did pieces of melted piston rings end up in adjacent cylinders? This seems really weird this would happen, for me, but it deffinitely happened while the engine was running (pieces embedded in pistons)

Thanks in advance
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post #2 of 4 (permalink) Old 05-28-2013, 03:36 AM
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You can sleave the bad cylinder. Last one we did was about 300 to get it done. Then just get a new stock piston.

As for the extra parts in another cylinder? good Question. I don't have a clue but it does happen.
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post #3 of 4 (permalink) Old 05-28-2013, 11:05 PM Thread Starter
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Well i used a ridge reemer to remove heavy aluminum build up from the cylinder walls, it worked good, then i ran a drill hone through the cylinder to try to remove the scratches, i'm trying to avoid boring, but i'm not sure that is possible, whats a good rule of thumb to go by when determining whether i need to bore the cylinder? The scratches are vertical in the cylinder, not too deep, but the hone wont remove them
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post #4 of 4 (permalink) Old 06-04-2013, 01:08 PM
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Your call, vertical scratches will cause the engine to burn oil. You might get by with cast iron rings but they won't last more than 40 or 50,000. If you have gone to all this work why not just go ahead and fit it right and have a sleeve installed. With a sleeve you can just install one new piston and go back stock. Stock Cummins pistons are about 100 dollars each, so if you bore the block out to the first over size and install a complete set of new pistons, that will cost more than a sleeve.
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