Head Gasket/timing chain cover work - update 3/27/04 Complete!

[Lars]

Head Gasket/timing chain cover work - updated 3/13/04

Another update 3/20-3/21:

Last weekend we left off with getting the oil pans and timing chain cover off.

This weekend started out with replacing the timing chain damper which took about 5 minutes. After that it was time to start putting things back together.

Cleaning the oil pans and timing chain cover plus all the block mating surfaces takes some time. We used scotchbrite on all the aluminum parts and a small die grinder with abrasive disks on all the block and steel oil pan surfaces.

Friday night we got the oil pans and timing chain cover back on plus had some time to bolt up a few of the engine accessories.

Tonight (saturday) we cleaned up the gasket mating surfaces of the exhaust and intake manifolds. We then cleaned the block to head mounting surface for like the 5th time. Lots of rags, compressed air, brake cleaner fluid and oil for the cylinders.

It was time to put the head back on!

We slowly moved the head into the engine compartment using a cherry picker and dropped it into place with a little tricky manuevering. No troubles.

Next, after applying a little oil to each of the head bolts (as stated in the FSM), we got them torqued to their specifications and then did the 90 degree turning process. No troubles here either other than it's difficult to see the bolts located closest to the firewall. We had to use a mirror to see when met our marks.

Time for the exhaust manifolds to go back on. Some of the rear most bolts are a major pain to get to. Universal joint or flex sockets help.

We then moved to installing the cams, closely following the procedure layed out in the FSM. Got the timing chain mounted up and we are good to go. Installing the timing chain tensioner and the distributer were the last things we did tonight.

So far we have spent 5 nights on this.... and thank god the end is near. The 1fzfe engine is not easy to work on!

Regards, from Arizona,
Larry

 

[Lars]

Not sure if anyone cares but Im going to continue with my 'diary' in case some poor soul finds himself one day in the same shoes. Forgive any grammer or spelling errors as it's very late.

Spent about 8 more hours over the past two nights and it's finally done!!!!

Last night we put the valve cover on and got both the upper and lower intakes loosely mounted... PHH too (silicone hose and lined worm clamps from mcmaster). New plug wires and plugs went on as well.

Tonight we spent hours dealing with hard to reach bolts. Our hands and arms are completely carved up. One thing that makes this job easier it to have a large selection of ratchet sizes(short, long, 1/4", 3/8", flex head) and more important are the extensions... need lots of different lengths.

We remounted the radiator, shroud and fan, plus the battery and new belts. Plugged in all electrical and emissions equipement. I'm a little worried as some of my injector connectors were so brittle that the locking mechansims broke/cracked. I wonder if they'll hold tight.

Filled her up with oil and coolant and we cranked it over a few times with the coil disconnected to get some oil flowing. Enough of that, lets get it going!

Plugged the coil back in and she started on the first crank. I noticed smoke coming out of the tail pipe...... wtf. Is it coolant or oil? We hopped in and took it out on the street. I thought it was monsoon season looking back in the mirror as we drove away. Smoke..... and tons of it!

A mile or two later I pulled up to a stop sign and jumped out to smell the exhaust. Still wasnt sure if it was coolant or not. Got back in the vehicle and about 1000 yards later the smoke disappeared. Burns clean as can be now. Guess it just had to get up to a good temperature to burn off all the old crap. Runs smooth and strong.

Thats it... all done I hope. Just want to make sure no leaks happen over night and I'll be bringing it home tomorrow (and giving my friend his garage back after 4 weeks). I'll drain the oil while it's still hot. Im not sure whether to do another 'rinse' with crappy oil or refill it with the quality oil/filter.

It took us 7 nights to do this job... totaling somewhere around 30-40 hours. I spent over $1000. Half of that expense was a valve job and head work. Also, this was more than a standard head gasket replacement. I had the broken timing chain damper as well. I did not replace the radiator nor did I have to buy any tools.

It will probably take me a month of driving this thing before I feel confident in it. Afterall, I only put 1000 miles on it since I bought it. I really just want to be done with this string of bad luck and perhaps one day I can start modifying the 80 for the type of use I originally had in mind.

Regards,
Larry

 

[Beowulf]

Larry,
Thanks for the update. Let us know if there are any complications and how it's running after a couple of weeks!
-B-

 

[semlin]

Lars congrats on completing it, and I hope it works out for you. Although I have not suffered a 40 hour job yet, I know the feeling of having my modification fund depleted several times over now by unexpected repairs starting with a grenaded birfield within 1000 miles. Don't dispair. It's still pretty decent offroad stock

 

[Lars]

Thanks guys.

I'm still about $6k or $7k under what I was expecting to purchase an 80 for so the funds are there, it's just that I need to get some seat time in it before I start browsing the goodies at Slee.


So far so good. 8)

AC needs some work though.