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  1. #1

    Help After Engine Rebuild

    Hello, I have a 2003 XLT 1200 i just rebuilt the motor on. This was my first rebuild and need some guidance. I got it all back together and it fired right up so i hooked it up to the hose and when it it it was spraying water out the head gasket. I pulled the head and am looking for guidance on howto proceed. I am worried about water getting into the case. Should i rip it all back down? also i have attached a picture of the new cylinder are these markings normal? also #3 looks "dirty" compared to #1 and #2 should i be concerned? any help is appreciated!
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    Last edited by aloosen; 04-27-2015 at 09:45 PM.

  2. #2

    Join Date
    Nov 2009
    Did you pressure test motor before you dropped back in ski?

  3. #3
    i did pressure test and it passed with flying colors dropped less than a pound over in 20 min. Could the hose pressure have been to high?

  4. #4
    Did you use a torque wrench on the head bolts?

  5. #5
    Yes torqued to specs per the manual

  6. #6
    OzarkYamMonster's Avatar
    Join Date
    Oct 2012
    Lake Of The Ozarks
    Hello I feel your pain! However, just a thought is it possible you may have installed the gasket incorrectly! It is possible. Ask me how I know. Even the correct torque on the head bolts will not stop the water from having to blow out somewhere under pressure if gasket is on wrong. Good luck

  7. #7
    powerstroke specialist mikegp's Avatar
    Join Date
    Mar 2011
    Quote Originally Posted by aloosen View Post
    Yes torqued to specs per the manual
    i have seen head bolts stretch few mill , check all your bolts to make sure they are the right lent .

  8. #8

    problem solved

    I get the idiot award today! After looking at the photo below from after the rebuild I see I had the gasket on wrong I swapped it and fired it up again and no leaks! Did a compression test and it is the same across all three cylinders (80psi on all three but I think that is due to a cheap harbor freight gauge) so this weekend take it to a lake and see how it goes! Thanks for all the input I could have never done this without the forum!
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  9. #9
    dockwalker's Avatar
    Join Date
    Mar 2010
    On the water near Belhaven,NC
    Did any water get into the engine? (on top of piston or down on crank) .I'd run it on the hose for a good while to make sure it's dry(with some rpms) until you can run it.Rust forms fast.

  10. #10
    I like the engine indoors pic =). Reminds me of the weird looks my wife would give me when putting mine back together on the coffee table around christmas time.

    Glad you found the leak problem! I was getting a little worried myself with the problem you were having as I just fired my engine up the 1st time this weekend on the hose. Dunno how many times I kept pulling the plugs checking for water in the cylinders. Have fun!!

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