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Hello, I am new to the site…
I recently identified a coolant leak at the site were the turbo to exhaust manifold gasket is on the starboard engine on a cummins 6CTA 8.3M. The leak appeared to only occur when the engine was operated above 2000 rpm. The gasket on the port engine was not leaking. The engines have about 1660 hours on them.
I employed a cummins mechanic to change the turbo to exhaust manifold gasket on the starboard engine to correct the issue; and had him also change the same gasket on the port engine as maintenance. I was present when the service was done and noted that the surfaces on the starboard turbo and exhaust manifold were fairly clean with not much additional cleaning required and that there was soot build up on the port surfaces which required more cleaning than the starboard side. I had red RTV and RectorSeal #5 ready at time mechanic came (as I had reviewed the how to on this site prior to the repair) and I asked the mechanic he he used the products during the gasket install. The mechanic advised me that per Cummins approved service he installed the gasket dry and uses anti-seize on the stud threads.
After the install of the new gaskets, new coolant was added to both engines and both engines started immediately leaking coolant out the bottom of the gasket. The leak occurred merely while the coolant was still being fully topped off and with no other pressure to the system. I spoke to the service supervisor and asked if the gasket could have been installed wrong thus causing both engines to leak, but he advised that the mechanic had properly installed the gaskets. The service supervisor and one of the cummins mechanics suggested that the exhaust manifolds and turbos on both engines be replaced. I again spoke to the service supervisor and he has now suggested/agreed to send out the mechanic to disassemble the turbo from the manifold and to have the mechanic use a straight edge and feeler gauges to measure any gaps to see if the surfaces are warped.
I did contact another company who is also an authorized cummins warranty repair facility and did not go into any of the details other then I had a leak at the turbo to exhaust manifold and he told me two separate times during the phone call that there are “8 ways to install the gasket, but that only one way will make it so that it does not leak.”
How would I be able to tell, at the time of removal, if the new gaskets were improperly installed? Also, is it likely that the turbo and exhaust manifolds on both engines could be warped? the vessel is a 2001 Riviera and I have been running this vessel for over 7 years and have never had any overheating or other major coolant issues.
Any suggestions or thoughts as to what could now be causing both engines to now leak coolant would greatly be appreciated.
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