2011 Navistar International DuraStar DT570 engine.

[edgart]

Good day, Friends.

I’m troubleshooting a 2011 Navistar International DuraStar DT570 engine.

About a year ago we performed an in-frame overhaul (All parts and labor for the in-frame overhaul were supplied and performed by the authorized Navistar dealership/service center.)

-replaced the cylinder head,
-installed new pistons and cylinder liners,
-resurfaced the block deck,
-and fitted new gasket sets, among other items.

After the overhaul the truck sat in a yard for seven months without being run.
When we tried to start it one morning, the engine fired, produced a loud bang, and shut off; it has not started since.

Upon teardown we found:
-one cylinder liner shattered,
-liner debris that damaged the cylinder head and the affected piston,
-coolant mixed with the engine oil,
- a fragment of piston ring in the oil pan.

Question:
Could this failure be due to a factory-defective liner, or where would you focus the diagnosis?

[Rawze]

That is a clean break all the way around. - It looks to me like it rusted together, or 'ringed' itself while sitting due to dry conditions, and then went 'Boom'.

Was a second oil change performed after the first crank to flush all the chems and sprays that get used (and end up mixing with oil) during the rebuild?... before it was shut down for that long?

After sitting for so long and not being run after a fresh overhaul ... Did anyone bother to turn the engine by hand over a couple revolutions before cranking it?.

Were any preparations done at all to prevent rusting, dry start, etc.,. to allow for it to sit that for long in storage?.

[edgart]

Good afternoon SR

No second oil-and-filter change was performed after the initial post-overhaul startup.

While the truck was in storage, the engine was started a couple of times per week to keep the batteries charged, no drop in coolant level was noticed during that period.

No lay-up preservation procedures.

Given this information, would you still attribute the failure to cylinder-liner rust bonding/seizure, or do you see another likely cause?

[Rawze]

(07-31-2025 )edgart Wrote:  ...
Given this information, would you still attribute the failure to cylinder-liner rust bonding/seizure, or do you see another likely cause?

without seeing more evidence, I would not know those answers.

[edgart]

Good day SR.

I’m attaching the additional photos supplied by the “specialist” shop.

Further background:

Over the last three years the engine has undergone two in-frame overhauls.

On both occasions the dealership diagnosed overheating due to a cooling-system failure. Hoses, radiator, water pump and surge tank were inspected and showed no issues.

Something fundamental is still wrong with this engine, and the dealer hasn’t located the root cause. I therefore rebuilt it again and put it up for sale, but the same failure occurred with zero miles driven.

During the sale process, each prospective buyer was fully briefed on the engine’s history and given copies of the work orders and invoices so they could make an informed decision; there was no intent to mislead anyone