Failed rebuild?

[Josiah Harder]

I had my engine rebuilt 30,000 kms ago and now I am being hit with everything under the sun. During the rebuild I replaced the oil cooler and EGR cooler for good measure since my oil sample came back showing coolant contamination. In the last couple weeks I also had to replace my entire manifold, the turbo actuator, the EGR valve and cleaned my DPF which is only 1 year old. Now I have codes for high crank case pressure only when doing a regen or when I come to a stop and the engine goes into its warm up mode for the emissions system. I had to leave the dipstick cap open to release pressure or I would get a STOP ENGINE IMMEDIATELY warning while it was doing regens. I had my truck at Kenworth in Ontario and they told me crank case pressure was measured too high for a new engine when under load during a road test. I will attach the invoice notes and engine codes for reference but for convenience I will quote the most relevant parts here. At idle crank case pressure readings are okay "1.2 InH2O" While driving under hard acceleration crank case pressure climbs to almost "16 InH2O" after coming to a stop and engine enters keep warm mode for regen pressure rises to "8-9 InH2O" Now before doing these tests they had replaced the crank case pressure sensor and ensured nothing was frozen or full of debris in the system but they did not replace my crank case filter because it is the non serviceable kind. They isolated both the air compressor and the turbo and still told me crank case pressures were too high and I must have an internal issue. So I drove 3000 kms to the shop in PEI Canada that originally did my rebuild. So im home now and they are now telling me they have opened a case with Cummins and that all my crank case pressure readings are within spec for a new engine. What am I supposed to believe here? I'm shocked Kenworth in Ontario didnt replace the crank case filter before doing all these tests but I was told it was non serviceable and didnt need to be changed. Now on top of all this my truck was asking me to do a regen once I got halfway home except it will not complete even if left over 2 hours. I stopped in Quebec on my way back and had a Peterbilt there do a regen for over 2 hours and they said the temperature is fluctuating too much. The shop here now is telling me the same thing and said my turbo is only getting around 78% closure rate which im told is insufficient to create the heat required to complete a regen. So ive ordered a new one now and am just hoping this will be the last thing I need to do. I am still worried about the crank case pressure readings and faults I was getting before so I told them to retest everything under load and under regen for high crank case pressure readings after they replace the turbo. Does anyone know what the acceptable values and tolerances are for crank case pressure in Inches of H20 for a newly rebuilt engine are? Was told Cummins has 2 sets of acceptable values for this measurement and that a newly rebuilt engine has a stricter tolerance.