On my 92 6.5TD I had severe blowby from about every orifice. Pulled the engine and now its on the stand ready to be opened up. I pulled the glowplugs and they look like the tips are melted or severely carbonized. I'm begining to think that the engine got a bit too hot at times. Any suggestions on where cracks or damage to heads or block might be due to exessive heat? If I can rebuild it, I think I might upgrade the cooling system. Its supposed to have a 97 water pump on it. Is there a part number that I can verify this?

Should have HO cast into it

You can look at the part number sticky and it might have a list of a couple different high output water pump part numbers.

If it has a high output water pump, without the HO cast into it, it is just a rebuilt one. The regular ones can be made to flow as much as the HO pumps, so only way to tell is from manufacture. It can be very hard to tell, if it were me and had the engine out on a stand, I would replace the pump anyways.

I should have asked, how far apart are you planning on tearing this engine down?
To fully check for all cracks it has to be to the block.

The glow plugs will swell from normal use. Not a sign of overheating. A compression test or cyl.leakdown test will help determine if there is cracks. Was the cooling system overpressureing? Coolant in overflow jug black or oily? Coolant in oil?

No there was no coolant in oil or vice versa when it ran. Just severe blowby and engine not starting no visible probs on drivers side. This a.m. I will tear down the right side as a matter of fact I'm gonna do that right now. They say curiosoty killed the cat. They are falling all over the place at the moment.

What did you find when you tore down the right side of the engine?

Those old GP (9G) have a history of swelling which if it is not changed, will look like melting and breaking off.

Upon tearing the rest of the engine down, I have found nothing. Everything looks good real good. All pistons are good both heads look good although I haven't tore them down yet. Block (599) is exelent no cracks. The bores are mirror smooth with no crosshatching left and a little ridge. I think the massive blowby is due to the bores. I didn't pull the cam yet to check those bearings. I'm contemplating replacing those when I get the crosshatcing done not sure if I'm going to hone or bore it the micrometer will make that desicion. (I've yet to look for a shop here in E IA). Crank looks good #3 and#4 mains had a small scratch, the journals unaffected. All bearings are std. Exept the rearmost which is .0013. All in all I'm happy with what I've found. I did find the reason for not starting. All but 2 of the inj (marine) were plugged ( The prev owner used waste oil for fuel). I plan on replacing the marine pump and inj with a normal DB2 that I have anyway even tho the marine pump is good.

Another ? Should I relpace the pre charge cups? And what about puttig hydraulic cement in in the water jacket as Heath Diesel does? Maybe that's overkill. I need all the help and suggestions I can get.

Another ? Should I relpace the pre charge cups? And what about puttig hydraulic cement in in the water jacket as Heath Diesel does? Maybe that's overkill. I need all the help and suggestions I can get.

You won't need to replace the precups unless they have large cracks in them (over 3/8" long if I remember correctly)

Yes, you can partially fill the block, but you need to have the engine bored after that is done. DO NOT block fill after it is bored out.

The lack of crosshatching isn't good, as a smooth cylinder wall will let by oil.

If the cylinder is round and "small" enough to just get it honed then that would be a good option, but then you can't block fill it.

That bearing labeled ".0013" is strange, I have one bearing in my engine like that too (might have been the rearmost as well) It doesn't seem like a regular oversize to me... maybe I'm the only one confused about that though.

That bearing labeled ".0013" is strange, I have one bearing in my engine like that too (might have been the rearmost as well) It doesn't seem like a regular oversize to me... maybe I'm the only one confused about that though.

Factory defect/screw up. Correct a machining problem with an oversize bearing on the factory floor. Done with lifters and only a splash of paint identified the oversize lifter bore.