Head gasket repair

my deuce started running like sh!t, and we suspected a blown head gasket.
Tore into it yesterday AM and here is what we found....this is the rear head, cylinders 5&6:

It actually didn't run that bad, all things considered.

Pulling the heads was a chore....the intake and exhaust manifolds are a major PITA to try to remove; so we pulled both heads, intake, exhaust, turbo, etc as a unit. This mass weighs about 400 lbs.
I should have snapped a pic of the gantry crane we built to pull it.
It had to roll, span 8 1/2 feet to clear fenders, and needed a lifting point at least 10 AGL.
We got the heads off, deck cleaned, new gaskets on, and heads tripples torqued and called it quits for the night.
then we hadto reconnect the turbo to intake, intake plumbing, install the water manifolds from intake to heads, replace the injectors, adjust the valves, reinstall the intake manifold flame heater system, reinstall all the air lines that were in the way, reinstall the fan, radiator, and grill guard and some other misc. stuff .

We completed the project in record time....7 hours start to road test. I don't think the depot maintenence people could come close to that

Turbo/intake

Heads on, rockers next

Installing rockers( that would be member Bomar76 in the pic, big thanks to him for helping out!)

[2]myself installing water manifolds that go from intake manifold to heads[/2]






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[2]Another shot of me hard at work.....notice we just stand in the engine compartment to work on it.[/2]






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[2]Valve lash adjusted (Intake .010, Exhaust .025 ) injectors and return lines in, and closing it up...[/2]






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installing the fan.
WATCH THOSE KNUCKLES! :smilewinkgrin:

No bandaids needed...but close.

Last item.....we are ready to road test!

all put together and running like a top

overall i would rate this project a 5 out of 10. not real hard.. just lots of tedious work. forgot to take the cam with us on the road test. but she runs great. [2]
Head gaskets run about $75 each for these things , but I found a complete NIB engine set (8 billion gaskets in set) for $140!!!!
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Again big thanks to Bomar 76 for all his help and quick thinking for our homemade gantry crane. ( wish i had snapped a pic before we tore it down :banghead: )




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Great post Baja - thanks for sharing. I had no idea the heads were split like that (as opposed to just having one).

That was a pretty quick repair there guys! Had you een planning on it and had the gaskets on hand? Good job guys!

Great set of pictures! Should be good for an article in MVM. Forum managers, why not stick this in the reference section?

Thanks,

I don't think the depot maintainence could do better than we did!
I bought a COMPLELTE gasket set (all 8 billion gaskets) from Safran for only $140 + $10 shipping - it was a steal over buying just the head gaskets.
If it wouldn't have been 90 degrees and 100% humidity I would have taken step by step pics for a tutorial.
The deuce suddenly exibited severe problems.....extreme smoke, loss of power, and the most telling - backfiring. Sure signs of ablown gasket.

yeh I started to do the same thing then a sleeve was cracked so orderd new sleeve and piston set then my block was cracked
so in go's new engine(when I get it, do we have any members in PA who might be able to help) but thoes heads are a paine
to get off I herd its a bed a idea to pull heads with manifolds some thing about they dont set back on right?
hey guys I NEED TO KNOW WHAT COLOR THAT ENGINE IS thats the color I have been looking for.