Dropped Valve Seat Repair w/Pics (part deux)

a_d_a_m

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Zack blazed a trail with this thread. I followed in his foodstamps by doing it myself.

Anyway - the #8 cylinder overheated because I was dumb and didn't do a cooling mod. So I had to spend today ripping it all apart. I had some help along the way but for the most part this is me being a dumb wrench-spinnin' Polack.
Anyway, here's the carnage.


































The guy in the blue shirt is my friend Cam who just came over to hand me wrenches, and the guy in the white shirt is my friend Dave who pissed me the F off but was right in his judgment. He asked me about my timing tensioners/guides and if I wanted to change 'em. I didn't but I'm glad we decided to - the passenger side was actually roached. Most people never have issues with them but I apparently did (despite my usage of synthetic oils and religious changes).

Anyway, that's that. Not sure what shop I'm sending the head to or how much it'll cost or when it'll be back together...but half of the hard work is done. :D

More to come later on.
 

Zack

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Get the timing stuff from ford unless rockauto sells ford parts.
Need a cooling mod? I have a few ready to ship.
 

RICH17

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For being such a large car it sure does seem tight under the hood.
 

a_d_a_m

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Get the timing stuff from ford unless rockauto sells ford parts.
Need a cooling mod? I have a few ready to ship.
Will do - and apparently I might have a connection with Ford parts (not that it's that difficult) so I might get that (as well as a head changin' kit-er-oo) for cost.

How much is your cooling mod? I was gonna buy from Travis, but...well, drop me a PM I guess...

For being such a large car it sure does seem tight under the hood.
No doubt. My fat ass couldn't stand under the hood, but my buddy Dave was able to get between the radiator and the engine to help me get the head out. DAMN that thing was heavier than expected. He let go and I was just "OOF, ummm, okay, gonna go set this thing down."

Food stamps :bowrofl:
Honestly didn't think someone would notice but I'm glad you caught it!!!
 

a_d_a_m

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Not yet. The head went to the shop last week and should be back early next week. At that point I've got a wedding that I'm in so I don't know when it'll be all back together.

I had one bent valve that needed to be replaced, in addition to the seats.
 

massacre

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Good luck with the install. If you get in a jam, this is the site to ask so you're in good company.
 

a_d_a_m

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Oh trust me I know - Zack and Travis both have a hand in my car, and I'm sure I'll be consulting them both in the coming weeks...
 

a_d_a_m

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Well, the chains are back on, new tensioner arms, and everything looks timed properly. Got the cylinder head on (talk about a PITA with only two people - ended up getting lucky and a neighbor stopped over to help out).



That was yesterday. Ran into a snag this morning. Went to torque the intake down to the heads, and one of the bolts was going in just fine. I thought it was bottomed out because I was getting resistance, but it turns out it was actually...well, I don't know. Damn thing snapped.

Instead of getting the car running today, I spent all day dickering around with EasyOuts. Couldn't get dickall done with those. The bolt snapped right at deck height so I decided to try drilling it out and tapping it again. This actually worked. So, I've got a $9 unexpected expenditure on this project, the M6 tap.

Need to go get another M6 bolt for the intake to replace the one I snapped, but the lower part is on anyway. After that, I've got the following to do: plenum, throttle body, crossover tube (need to un-seize the cap in it too), alternator, power steering pump, water pump pulley, crank, serpentine belt, cooling fan, reservoir, wipers, cowl. Connect the fuel lines, injectors, and toss spark plugs back in w/coils.......


Since starting this project, Zack's number has gone toward the top of "most frequently called numbers". Holy shit. Dude got us set on the right course more than once. Believe it or not, Zack, I think I got this from here........I think...........................thanks.
 

a_d_a_m

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More progress today.

First of all, I don't think I posted it yet, so here's how I keep my bolts all in one place and know where everything goes and sort of in what order. I'm really not a fan of bagging or taping everything. This system, in my opinion, is superior for a shadetree mechanic like myself who really doesn't know what he's doing:


Got the following done today: plenum, throttle body linkage, throttle body, plugs, coils, coil covers, EGR, vacuum lines, injectors plugged in, random electrical connectors hooked up (no idea what they do!), alternator placed and mostly mounted (aside from the bolts on the top where the crossover tube goes).

This is what it looks like now:


Still need to figure out how to unseize the crossover tube plug (gonna try heat since I actually broke my new 1/4" ratchet!), then install new O-rings on the tube. Those are the big projects. After that, I'll do the water pump pulley, crank pulley, 3 PS bolts (it's currently held on by the one impossible bolt that's above the PS line), electric fan, reservoir, PS reservoir.

After that, just a few little plumbing things like burping the coolant, hooking up the fuel line, and it should be ready to fire.
 

musclemerc

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Thats a great idea, I normally bag and tag all my hardware.

Looking good Man!
 

Zack

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I throw all my bolts on the floor and havent gotten them mixed up since 2003.
 

a_d_a_m

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Not much progress today. Woke up after working midnight shift and tackled the crossover, unsticking the plug, cleaning it up, and installing new O-rings. All it took was a little bit of heat, after all.



The next few things require the car to be pushed into the driveway, so I'm gonna wait until Sunday when the weather's supposed to be actually decent to do that. Hoping to fire it up Sunday or Monday.
 

a_d_a_m

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IT RUNS! After forgetting to hook up the crank sensor and a couple vacuum lines (Zack, again, saved the bacon), I finally got her FIRED UP! So much powah it knocked the camera over!








I......there are no words.
I think I'm gonna go cruise some more.
 

a_d_a_m

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Update:
I seem to have created a leak at my crossover tube. Apparently heating it with a torch so I could unstick it cracked the welds that connect the cap to the tube itself (and no, I didn't heat the cap). I noticed a little weeping out of there so I cleaned the area and patched with JB Weld.

I thought I'd done okay, but then I drove the car again and noticed a puddle after I parked it for a while.

Further investigation shows that it is now weeping out of the cap. I suspect the O-ring I used (part of a variety pack I had laying around) is too small in diameter and does not seal the area properly.

I am going to hit up a parts or hardware store in the next couple days to see if I can find one that does a better job of sealing that area off.





Other than that - the car runs AWESOME. Haven't enjoyed driving it this much since I've owned it. (and yes, I'm keeping an eye on the coolant level)
 

MMBLUE

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Great job Adam. Better when you do it yourself.
 

a_d_a_m

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I agree. Glad I didn't farm this one out (other than the phonecalls/texts to Zack).

Speaking of, he suggested Teflon tape on the threads as a workaround for the O-ring. Apparently the O-ring has squared off edges and might be a difficult thang to find.

So I've taped the threads and will take it to work. Hafta see how it works/doesn't work.
 

a_d_a_m

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Never did get the coolant leak fixed and wasn't happy with JB Weld holding things together. Called in a favor with a buddy at a dealer in Buffalo and got a crossover pipe for $120.

Other than that, the car's running awesome - been driving it around, just checking the coolant level every once in a while since it's merely weeping.

Not sure when I wanna do my first oil change - was thinking 1000 miles, but that would put me into 2013 as the car gets stored in the winter.....
 

Jon01

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Glad to hear you got it back together and is running well.
 

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