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dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

The cams are fine, which was a surprise. All the rockers have been more or less damaged like this. Now here is the strange part. According to the documentation, the engine has been replaced in 2007, at 77K miles I also found a stamp on the exhaust side of the intake cover that states 01/28/07). The truck now has just under 144K miles. That would mean that this much was done in just under 67K miles!? The rest of the truck is in spotless condition, so I am really confused on how the hell did this happen to the engine in relatively short time! :ALONE:

kjjet · **Posted:** Tue Mar 26, 2013 8:59 am

dragand021 wrote:

The cams are fine, which was a surprise. All the rockers have been more or less damaged like this. Now here is the strange part. According to the documentation, the engine has been replaced in 2007, at 77K miles I also found a stamp on the exhaust side of the intake cover that states 01/28/07). The truck now has just under 144K miles. That would mean that this much was done in just under 67K miles!? The rest of the truck is in spotless condition, so I am really confused on how the hell did this happen to the engine in relatively short time! :ALONE:

That is confusing. But working at a Stealership for years, I can tell you when they say "engine replacement" that could be lots to things. Short block, long block, Head or used combination. You never know.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

Another update. The tools from Hexus have arrived, thank you. I locked the cams, timed everything, and still could not complete the full turn. Pulled the intake cover off, removed the rockers, still no go. Then, I pulled the head and found... There is no mechanical damage on any valve or pistons, however, I found a loot of soot and garbage. The cylinder #1 was the one that was blocking, and it was all because there was almost an 1/8" of sooth on both the valves and the piston. Soo bad news, now the head is off, the good news, it seems like no damage to the lower parts. Now, a dilema. Since I have the head off, should i replace the valve stem seals and possibly spring, and do a valve job? Probably should, since I have everything off. Whadda ya think?

Cyl 1

Cyls 2 & 3

Cyls 3 & 4

Hexus · **Posted:** Thu Mar 28, 2013 7:14 am

Take a straight edge, like a carpenters square and put it across your head (the one off the engine please, haha).

Make sure the head isn't warped, and the valves should seat so they don't stick above the surface of the head, this is a good way to check for bent valves.

LMWatBullRun · **Posted:** Thu Mar 28, 2013 12:31 pm

I suggest you consider head studs. A few hundred bucks there is cheap insurance against head warping.

GreenDieselEngineering · **Joined:** Sun Jun 07, 2009 5:10 pm **Posts:** 1111

That engine was suffering a lot. Hopefully a good cleaning and all will be well. You will need new head bolts, we have stock sets 40% less than mopar.

kjjet · **Posted:** Thu Mar 28, 2013 1:21 pm

I would clean things up and inspect things real well. If you have a good local engine shop, you may consider having them take a look at the head they can determine if its warped or if you need a valve job.

jeepdan · **Posted:** Thu Mar 28, 2013 7:04 pm

GreenDieselEngineering wrote:

That engine was suffering a lot. Hopefully a good cleaning and all will be well. You will need new head bolts, we have stock sets 40% less than mopar.

What is the major cause of carbon build up like this?

Hexus · **Posted:** Thu Mar 28, 2013 8:40 pm

EGR valve, US Diesel.

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kjjet · **Posted:** Thu Mar 28, 2013 9:04 pm

My take on the cylinder build up:
As the Rockers started to wear from the EGR, the valves open less. So the engine could not effectively burn the fuel and exhaust un-burnt fuel from the engine causing the build up.

Or Just EGR! in short.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

That's exactly what I was thinking, plus the exhaust valves not opening completely, even more soot to mix in.

I took the head apart and will drop it off at the machine shop tomorrow, see what they say. For the first time EVER, I saw the head where the intake was dirtier then the exhaust! :-)r

LMWatBullRun · **Posted:** Fri Mar 29, 2013 11:43 am

jeepdan wrote:

GreenDieselEngineering wrote:

That engine was suffering a lot. Hopefully a good cleaning and all will be well. You will need new head bolts, we have stock sets 40% less than mopar.

What is the major cause of carbon build up like this?

EGR.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

The head cleaned and inspectd, pressure tested, all OK. Will start reassembly next week. More pictures to follow.

Hexus · **Posted:** Sat Mar 30, 2013 4:58 pm

Did you end up using the VM.1089, or just the VM.1053 and VM.1052?

Just curious, I got the 1089 to go right in, others here have voiced some complaints or like using a hex key....

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

I couldn't get the VM1089 to go in, so I lined it up with a 1/4" allen, then I used the small wrench to lock it with the VM1089, wanted to make sure I had the clear path, so I don't damage the flyweel or the tool. I will use the tool once I start putting it together, as the allen has a bit of play, and it is hard to see if it is really lined up correctly. I don't have a lift, just the stands, so I crawl under to do it.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

Getting there. Last night, a looong day of work, the head is back on, the rockers in place, the cover is on, the timing..... DONE!!!!! Thank's to all the help from KJJET and Hexus, you guys are the best. I may take a rest today, but tomorrow should be throwing a match in the furnace. Couple of pictures of the head and the block/pistons, after the cleaning and before assembly:

kjjet · **Posted:** Thu Apr 04, 2013 10:18 am

Looking Great! Glad to help.

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

I am too tired to post the pictures now, but I must share the news. The little tractor lives another mile! Got it all finished this evening. At first, it was cranking but would not start. After tinkering with it, we found that the sensor at the end of the fuel rail and the injectors have the same plug, and we got them wrong on the first try. I read the codes and it was telling me that there was a fuel leak. Once we got them right, it was cranking ok, but still no start. On the second try, my friend (a former mechanic) loosened the feed to the fuel rail, it sprayed a little and started like a champ. Runs surprisingly smooth and really good.

Thanks everyone for your help.Hexus, I will be shipping your tools back most likely on Monday.

:BANANA:

Hexus · **Posted:** Sat Apr 06, 2013 7:26 am

It tickles me a little that you left the Turbo and the Thermostat on there when you took the head off, man that must've been a bit unwieldy and heavy, but I understand the whys.

I spent 2+ hours trying to get all of the Thermostat Gasket off of the darn thing when I changed mine. It's in a weird spot and you can't get a good razor on there to really get at it, no scraper, just a small flat head screwdriver and just thinking about it... :furious:

Congratulations, sure is satisfying isn't it? Don't forget an oil change around 1000-1500 miles to get your assembly lube out of the oil filter! My filter was pretty nasty after 1400 miles, even though they were shortly after the rebuild and interstate miles, you could tell the filter was pretty gummed up with it.

Glad to have helped!

dragand021 · **Joined:** Mon Mar 11, 2013 11:52 pm **Posts:** 34

I took the head off with the turbo and the thermostat attached. Once the head was off, I removed and cleand everything, then I put it all togther before I installed the head back on. Yes, very heavy, butbeasier to clean and assemble. My secret weapon... A shop crane that we have, I used it for both the head and the intake cover installation, much easier then muscling them in.

After it started, I had it running for about a minute, then shut it off and put everything else back on, the hood, grill, bumper, headlights... Here is the test ride:

http://m.youtube.com/#/watch?v=qlxVzmL_ ... lxVzmL_bDI

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