Posted by NCWayne on August 16, 2013 at 18:59:06 from (98.21.228.82):
Got one of the 4024 Deere engines, also called a 2.4 liter Powertec engine that was brought to me with the cooling system full of oil, and with the coomplaint that the engine had everheated.
Since there was oil in the coolant, but not coolant in the oil, I first checked the oil cooler and it didn't appear to be leaking. Since the cooler appeared to be OK, and the engine had overheated, I went ahead an pulled the head. The machine shop said there were no cracks, but that it did need to be surfaced, which they did. I also found the thermostat was messed up and stuck about half way open/shut, and then as I started to put the belt back on I found the water pump bearings were sloppy (but it wasn't leaking yet).
Longer story short, I finally got it all back together and running. Even after all that has been done there is still oil getting in the water just as soon as it gets warm. I swear it makes me think of a head gasket leaking, especially since the oil cooler didn't appear to be leaking, but everything on the top end appeared to be OK when checked. I'm almost wondering if it's not the oil cooler but that it takes being 'bolted in' and warm before it leaks. Wouldn't be the first time I've run into something crazy like that....
Beyond the oil leak, whoever designed this engine had way too much time on his hands, and way to few brains in his head. I mean this thing has a funky L shaped 'accordian' type seal between the front cover and the head. I mean seriously the space it has to fill is at least 1/8 to 3/16 wide, so trying to seal two pieces setting that far apart with nothing more than a thin piece of rubber settin flat against one of the faces is just plain stupid. The gasket sets in a groove in the rear of the front cover, but it simply sets flat against the end of the head so there is really nothing to put pressure on the seal other than the seal itself. I mean the cover is located by the front of the block, the head is located by dowels, so there is absolutely NO way to put more or less pressure on it to make it seal. That said the manual simply says put the gasket in it's groove on the front cover and assemble. It says basically the same thing in both the head section and the front cover section, so it appears to go together 'dry' with no sealant of any type. As many engines as I've built over the years I have never seen a rubber seal call for another sealant since silicone, etc will often make a rubber seal leak instead of helping it seal. Anyway, take a guess what's happening with the new seal...if you guessed it's leaking then, 'ding, ding, ding' you win a prize.
Funny thing the head bolts are one time use only so there's no pulling the head again. Heck, head bolts, gasket, and a thermostat was more than $400 the first time around so I'm not going there again. Even if I did, how do you seal a rubber seal that's supposed to be sealing a gap as wide as the one between the head and the cover?
Ultimately I'm no on here asking, has anyone here worked on one of these pieces of junk, and seen, or heard of one having this problem? I would really appreciate any help any of ya'll can offer. Thanks, Wayne
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