Cylinder Head Replacement

Post by **djm850** » 05 Feb 2010, 09:22

Well, for starters I had nothing but time to kill waiting for the head to come back. That said, it's not something I'd rush. I could be easily done over a weekend if you have your parts. After removing the manifold, I removed the rail injectors intact. I then removed the throttle body. I bought a brush from Home Depot. The brush head is about 4" long, cone shaped and has a rubber tip protector. It has a flex shaft that is about 20" long with a wooden handle. I sprayed throttle body cleaner in small glass jar and diped the brush and went to town on the inside of the manifold body and through each runner. After everything was broken loose, I poured about a half gallon of Simple Green in a large Rubbermade tub then filled with about 3 gallons of super hot water. Dunked the manifold body in and started the same process with the brush. Did a final rinse in some clean hot water, then dried it over time. Of course the throttle body is just time and more of the same, but I did remove the throttle sensor and Vac tree before cleaning. For the rail, I carefully removed the Pressure Regulator, the injector securing plate, and injectors (covering both inlets with some HVAC foil tape I had. I set the rail itself aside and did not do anything to it. Holding each injector with my fingers covering the inlets, I slowly and gently scrubbed the orange bodies with a toothbrush and straight Simple Green. DO NOT get anything in the inlets and BE CAREFULL not to damage either end. Really, this step is just for looks and unless you're planning to replace the O-rings/seats just leave the injectors fastened to the rail. That's pretty much it, reassembly is the opposite.

I actually enjoyed this job and would do it as a service.

Post by **djm850** » 05 Feb 2010, 09:30

boosted5cyl wrote:What happened to the motor. Looks like maybe a timing belt let go (not a lot of valve damage though), but then theres lots of deposits on the valves and what looks like coolant?!?

:S

Burned exhaust valves in #2 & #3. Look at the pics named for those cylinders. You can see the spots. I'm sure this was a long time coming condition, but the 'Italian Tune-up' set it off. Word to the wise, if you have high mileage and unless you know you're motor is "tight", I'd forgo doing it. It's just not nice on a senior citizen. Timing was spot on when the belt was removed. I had done a TB replacement 20k prior, including everything but the tensioner and Serp tensioner. I'll probably run midgrade gas in the future and maybe even a light fuel treatment per tank. No apparent coolant issues except for the heater core has a small leak. Overall I only have to top off the expansion tank about a 1/2 cup per year.

Post by **djm850** » 05 Feb 2010, 09:44

Messed around in my shop this morning cleaning the cams, a little touch up on the head, and did a dry run locking the cams into the top half with fordman's tool. Heading out to the garage where the car is to finish cleaning the block/pistons. Might even bolt on the head. Stay tuned.

Post by **JDS60R** » 05 Feb 2010, 11:03

Will you have to measure and set the valve clearance ?
If so could you please take pictures.

Post by **djm850** » 05 Feb 2010, 12:10

AFAIK, I shouldn't have to do anything but time it properly. It has Hydraulic lifters which have been in oil since removed iand labeled in order. The head/valves were rebuilt to specs. so I'd assume Clearwater knows what to do. If anyone knows differently, now's the time. The head will be bolted on tonight prolly around 4-5 Eastern. Finishing cleaning #5 piston now.

Post by **JDS60R** » 05 Feb 2010, 13:51

Excellent.

I couldn't find this before and knew that the valves in the 04-05 R were adjustable with different tappets so I was curious about the 850. I found this in VADIS saying that the 850'e were hydraulic and self adjusting.

Post by **charlyW** » 05 Feb 2010, 14:41

I cant believe that engine was running albeit roughly with that amount of valves burned out; I've never seen that many valves burned out in succession either and I've been rebuilding engines for over 8 years.

At last someone has posted a nice picture of the crank timing mark might be worth making that a sticky along with the cam marks so people know what to look for.

What injectors are those as they are different to the English stock ones, im guessing they're bosch.

Are the valves standard ones of large head ? Also I'm suprised you havent polished the ports after having the head in the shop

Charlotte

Post by **djm850** » 05 Feb 2010, 19:43

Yeah, I have a new respect for these motors. After the valves blew, I shut her down and the next day figured the worse via compression test. Fast-forward 3 days later I was towing. Cranked it over-n-over on a weakened Optima Red Top and it finally fired up. Drove it up on to the tow dolly. Towed it to the garage (hour later) cranked it up again and drove it into the garage. Hope my Cat isn't fried from raw gas.

The cam timing marks highlighted in red are slightly off. That's where they ended up under spring pressure after the belt was removed, but it's still pretty close.

The injectors are Bosch, but I've seen atleast 3 different types depending, on online parts sites.

Don't know about the valves, but the ones that were replaced seem to be the same as the original ones. I'm really just trying to get it back on road with as little $$ as possible since it's a daily driver.

Here are the pics from finshing the block cleanup and head bolt down.

: 1The Nasty.JPG (273.57 KiB) Viewed 3446 times

: 2Scummy #5.JPG (254.24 KiB) Viewed 3446 times

: 4Head Ready.JPG (282.42 KiB) Viewed 3446 times

: This stuff ROCKS! Get some!; 5GM stuff.JPG (291.17 KiB) Viewed 3446 times

: 6gasket.JPG (284.24 KiB) Viewed 3446 times

: 7stretch bolt.JPG (312.52 KiB) Viewed 3446 times

: 8Angle gauge.jpg (332.78 KiB) Viewed 3446 times

: 9Bolted down.JPG (314.21 KiB) Viewed 3446 times

Cams and top half tomorrow, stay tuned.

bright · Post by **bright** » 06 Feb 2010, 11:39

95 960

Thanks for recommending Clearwater for Heads rebuild. There's a place near the LKQ (Port of Tampa.) I never knew how far a rebuild could go, and whether there might be cam damage. People always made it sound like once a timing belt goes there is irrevocable damage.

I recently did my timing belt and so far so good.

It's a great price. I'll definitely keep them in mind.

NightTrain · Post by **NightTrain** » 07 Feb 2010, 10:53

Kudos to Clearwater, as well. I recently did the exact same thing as above, and it went pretty well. So far, so good.....

Cylinder Head Replacement

Re: Cylinder Head Replacement