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The pre-cups are supposed to be a light press fit. I have seen a center punch used to improve the fit of the cup. Pick two spots outside of the fire ring of the head gasket just outside of the precup bore and mark two indentations with the center punch. This will retain the precup.

I've reused head bolts successfully on the 6.2 engines. The key is renewing the sealant on the threads and the lubricant under the head.

Mine did and I'm very confident that it was original.

I saw the title and was going on say something about the flyback diode and now realize that is unnecessary.

The intake bolts should not have sealant. I do see silicone on the water manifold gaskets which should not be there. The fuel supply hose is certainly not original. The manifold gaskets are marked like Fel-Pro but the don't have the plastic locating pins on the ends.

The hardest part about doing the injection pump is getting the intake manifold bolts out. They're the double ended ones and if the bolt breaks loose before the but does you have to figure out how to get a wrench under th fuel like bracket. I make sure to torque them during assembly and then a...

You're symptoms are exactly what happened to mine. It ran that way for a few thousand miles and then started getting worse quickly it blew out the water passage at the end of the head gasket, that's where almost all of these go. Option 2 is a crack between valves. I have seen these pinned. I...

The doors are part of the duct. If they're open you're disrupting the airflow. The set does not radiate heat through the doors in any meaningful way.

There pumps fail primarily in two ways. They leak fuel at the throttle shaft or they won't start when pump is hot. Losing power is a fuel starvation issue. How is your fuel filter?

No, they connect to the original oil cooler pipes by oil sample valve.

When I made oil cooler hoses I believe I used this fitting. The compatible hose is expensive, 221FR. I had some scrap which helped ease the pain. The engine side is NPT thread so I suggest using adapters to JIC flare.

Make sure you use Viton o-rings if you want them to last.

That amount of scratching on the skirt is definitely not normal for a professionally built engine but it is also not anything that would cause a failure. I believe you are correct that it's caused by debris from the failure.

The wrist pin bosses are pulled out of the bottom of the piston. That indicates to me that it failed under tension. We usually see this when a piston seizes. I see no indication of heat under the crown and the cylinder walls have no scuffing to indicate overheating. I don't think this engine...

As a fleet operator with nearly 2 million hours of diesel engine operating experience, just drive your engines. You want to warm them up quickly.

If you want a black undercoating check out Daubert Nox-Rust 121B. I believe it's the same product GM is using to coat the frames on some of their heavy duty trucks. It's well priced. It can be applied over existing coatings and rust. https://petroleumservicecompany.com/nox-rust-x-121-black/

Use anaerobics anywhere you can. Silicone is very permeable and can seep oil. Silicone glues the parts together which makes disassembly difficult. Silicone is more difficult to clean up. Silicone contaminates surfaces for painting. Silicone makes chunks that can clog things up. Anaerobics are...

I don't see any indication of a blown head gasket. When they do fail on these engines it's at the rear water passage so that should be cylinders 7 and 8 that are affected. With multiple valve kisses and the brutal amount of damage, this has to have been an overspeed event.

I guess auto trannies mostly slip, they don't drop out of gear suddenly. A transfer case might. I have had a transfer case with worn shift forks that would drop into neutral. I don't know if that's possible under load or not.

With multiple pistons hitting valves this is looking like an overspeed event. Have you had a look at the transmission? It's possible something broke in the transmission which caused the engine to unload suddenly.