layback40 wrote:
Dean, I spent hours reading through all of this thread. A bit worrying in places. You are very tenacious & never give up. You never posted a pic of the head face when it had been fixed. Would be interesting to see the after pic & compare with the before. Your old piston would make a good paper clip holder at work. Give visitors something to start a conversation about.
layback40,
Here are some pictures to synopsize the entire project (before and after shots). The events that took place are:
1. Previous owner did not replace the Water-in-fuel sensor.
2. New owner (me) did not realize it was missing.
3. Got water in fuel.
4. Tip blew off injector #3 allowing unregulated water and fuel into cylinder #3.
5. Water split into elemental components (H20) causing a Hydrogen explosion in cylinder #3.
6. Cylinder wall was a weak spot and blew a chunk out.
7. Post-explosion implosion sucked an exhaust valve into the cylinder and bounced it around a while.
8. Took 3 days to get my hair to lay back down again.
Tip blown of injector #3
One exhaust valve stem sticking up higher than the others (toward the back)
Cylinder #3
Piston #3
Bottom-side of #3 cylinder head
Repaired head
cylinder #4
repaired cylinder #3
cylinder #2
cylinder #1
Cylinders and piston tops
cylinder #1
cylinder #2
new #3 piston & sleeve
cylinder #4
Put the head and cam shafts back on yesterday, and got the timing belt installed.
I have seen several ideas about installing the cam gears, but this is the style I like.
idealistically, arrows pointing toward each other
arrows slightly lower but belt tight across top
When the arrows come together the engine is in the timing position
Fuel pump timing
Notch in gear at mark on engine
Crankshaft timing
Crank at 90° (my engine is tilted)
Timing gear tension
notch aligned with spring
Dean.