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Figure 3-1. Custom copper cylinder head gasket. The engine block and head were resurfaced at a local machine shop by removing 0.08 mm of material from each surface to ensure trueness and even clamping force. The second step taken to improve combustion chamber seal was to install stainless steel combustion chamber O-rings around each cylinder in the engine block (Figure 3-2). The machine shop cut a 0.89 mm deep groove around each cylinder to allow a 1.04 mm diameter stainless steel wire to be installed. The wire protruded 0.15 mm above the engine block deck and was pressed into the copper gasket when the cylinder head was fastened to the engine block. The contact between the stainless steel O-ring and the copper head gasket created a high pressure seal to prevent combustion chamber gases from escaping. However, the copper gasket alone was not sufficient to seal the coolant and oil passages between the engine block and cylinder head. Sealants such as Hylomar® and Permatex® High-Temp Red RTV Gasket Maker were initially used to try and seal fluid passages through the head gasket. Unfortunately, neither sealant was successful and oil and coolant leaks both externally and into the combustion chamber were found. Eventually, 34PDF Image | WASTE HEAT RECOVERY FROM A HIGH TEMPERATURE DIESEL ENGINE
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