Diesel Engine Cylinder head rebuilding

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00:00Eric say hi. Hello everybody. What this is is we build a lot of diesel motors and so we go through

00:12cores. A lot of times diesel heads are beyond repair. Yep. They've been resurfaced too many

00:18times. The deck thickness is too thin and what I mean by that is when you take metal off of a

00:23deck of a head there is a minimum thickness and that minimum thickness is basically that. That's

00:29what I'm talking about and a manufacturer will give you the minimum thickness on that head but

00:33just so you know what they're really concerned about give me a set of salient calipers. The

00:38thickness that we're worried about is not so much this much meat but it's this meat here in the water

00:43jacket and if you'll look in here in this water jacket it's the bottom of that to there. That is

00:50the actual deck thickness that you need to be worried about. So what we've got here is an

00:55aftermarket casting and an original casting. Six four power stroke. But what I want to do is I want

01:02to check on this head and see if this aftermarket casting brand new is as thick in this in this area

01:10as it is on this one. 1764. Actually that casting so I like that we're way so this casting here look in

01:21here look in here you can just see it. So what I'm talking about here is the thickness of the deck

01:27between the deck here and down here. When that gets too thin that's what causes this to warp and

01:33you'll look here this is a factory see all that and you go over here you can all your eyeballs will

01:39tell you it's thicker see what I'm talking about look how much metal is in there. So I really like I

01:46like this casting okay we've tried another aftermarket casting and we didn't we weren't as happy with

01:52them. I'm not going to throw out names here but to show what you should be looking for when you're

01:57looking at a good casting. So now we know that this casting has got a good thick deck. Yep. It's not some

02:02cheapy thin casting. We get these castings brand new and they're completely assembled. We call this a loaded

02:10casting which means it's got the valves the springs in here. They've set their uh recession heights.

02:17And what I mean by recession height is on a diesel the valve actually actually be recessed into the

02:22head. There is a depth that we measure and that depth uh intake and exhaust is supposed to be Eric?

02:2813 thou to 27 thou. Let's just see because this one we just popped out of the box. Yeah 13 to 27 thou.

02:35So that that's 28. That's it go to that one. 33. See that's too much. So there's a problem. We don't

02:44ever not disassemble a head. So we've already disassembled this one. You've touched the seats

02:50up. Yep. Uh faced the valves uh guides were all good and everything. Guides were good. So on this head

02:55actually recession was too uh high. So the valve was actually too close to the deck surface. Which would

03:00increase our compression. Would yep would increase the compression. So I actually had to cut the

03:05valve seat down uh about six thou on these heads to get the recession. Correct. And I see we've already

03:13put these up in the uh rottler and we've uh made our o-ring. Yep. So we'll o-ring the cylinder head.

03:18This is an upgrade that we do. And uh what else do we do when we get these new heads. So we disassemble them.

03:25We we we fix the recession problems. Uh resurface. I the decks are the are the decks on that head.

03:32What's the ar ra on that head. So it looks like these are like belt sanded almost. Oh let's look at

03:38that. Lay that down flat. Oh yeah. Oh this one actually was actually rotary. You can see

03:44the the rotary wave here. You guys have seen this before. This is a profilometer and if you'll watch

03:51here this little stylus is going to move. And while that's drawing in it's creating a picture here on the

03:59screen. And it'll give me an ra and ra stands for roughness average. And this surface and the surface

04:07on the block think of this as like a cheese sandwich. This is one piece of the bread. The block is another

04:12piece of bread and the cheese head gasket. Those two pieces of bread and that cheese have to be the

04:19right texture or you won't get the ceiling and the durability out of your head gasket. That's a little

04:25rough. 41 which is rough. So this uses a multi-layer head gasket which you want to be below 25. 25. So

04:33we will resurface. So there's another thing that these these heads as they come are not acceptable.

04:40What I'm trying to show you here is just because it comes out of the box does not mean it's ready for

04:45prime time. And certainly for for our product. And we've resurfaced this head. Yep this one has been

04:51resurfaced. So let's let's let's check the ra on this. And you'll notice on this head you don't

04:56have the waves in it. So it should be quite a bit smoother. But we're not speculating. This is science

05:02man. This is science. Drum roll please. 21. So our ra is 21. We want to be 15 to 25. We're we're in money.

05:15Yep perfect. We're in money. So uh so these heads besides putting the wires in and getting them

05:22reassembled. I like this casting. Yeah so far so good. Yeah I've never found just so everybody's

05:26aware I have never ever I don't care if they're coming you know not even gas heads diesel heads

05:31whatever I'm buying from a manufacturer loaded head or unloaded the head's never right. When you guys out

05:37there are buying stuff to build your stuff with it ain't right. And I mean every man every manufacturer.

05:44So if you want it to be right find a good machine shop this is the kind of stuff you want them

05:49looking for to make it right. All right today we got a 6.4 power stroke head. We're going to be o-ringing

05:55the head with the stainless steel wire. It's 41 thou thick. We cut a groove in the head that's 32 thou deep

06:05and the groove wide is 38 thou. So we got about a 3 thou press fit for the width and then the wire will

06:14stick up above the head about 8 to 9 thou. You want to make sure you have a nice even 90 degrees surface

06:22on this wire. I haven't cut this yet it's probably hard to see on camera but I'm going to file this

06:28down until it's flat because when you cut it with a cutter it will leave kind of like a peak.

06:34So I'll file it down here. You want to make sure you deburr the edge a little bit because when you

06:48file it flat it will leave a burr on the edge. So you just want to deburr the sides. Now we're going to

06:54take the wire and get a rough idea of how big this o-ring is. Cut the wire. That's probably a little big

07:07but it'll do. You start an end point where a head bolt or a head stud is because that's going to have

07:13the most clamping force. So I'm going to start my wire right next to this head bolt. I'm going to take my hammer

07:20make sure it's nice and soft so you're not ruining the deck surface.

07:35And then before you get to the end here

07:38you're going to take your cutter and you don't want to cut too short here. You always want to leave it longer if possible.

07:45Cut it and then same thing we're going to file it flat

07:48just enough to where it slips down in there nice and tight.

07:56And then while you're filing that there's going to be shaving so I'm just going to take some

08:00compressed air, blow it down in there.

08:05Then take my hammer and knock it down in.

08:12There we go.

08:13All right so we're back we're going to go ahead this is uh

08:15our aftermarket head got our our stainless steel o-rings in here and we're going to go ahead and

08:21assemble them now and then we'll vacuum check it and then this head is ready. It was not ready when

08:28it came in the box assembled from the manufacturer. I'm not here to be picky I'm here to do it right.

08:34Valve stem seals in it's also the lower spring seat that's all in one so make sure you put some lube on

08:40there all over the valve guide and where the seat is

08:57that's all over the valve guide and then I have these marked. I mark them just because

09:14sometimes seat heights are different stem heights are different so I mark them.

09:18He marks them because he's good. He's accurate and he's thorough.

09:28Is there a top and bottom to that spring? I'm looking. Now remember a top and a bottom the bottom

09:33would always be your tighter coil but this spring is this equal so there is no top and bottom on that spring.

09:38So while we're having him do this I'm going to give you a little terminology. Spring, retainer,

09:58stem seal and that's your spring pad is built into that one and these are keepers

10:04and obviously there is a top and a bottom. All right, so we got a keeper holder here.

10:13So we'll go to our valve, lower this, press this tool on there and release.

10:18So we got all our valve springs in. I'm going to take just a rubber mallet and lightly tap

10:33all the valves to make sure all the valve keepers are seated.

10:38And that just ensures that you won't drop a valve in your motor and you don't want that.

10:50So now we're going to vacuum test this. This is our vacuum tester.

10:58So this is our gauge here. Right about there is almost like perfect vacuum. So if I stick

11:03this on my palm, that's a perfect seal. And if I stick it on the valve here or on the intake,

11:13I get basically the same exact result. And then I can check my leak down.

11:17I turn the vacuum pump off and there's no leak down. So I'm just going to do that to every cylinder

11:22and check them all.

11:35All right. So we finally finished this six four power stroke head with the O rings. Again,

11:42this is a brand new casting. Again, check your new parts. Not every part is going to be correct.

11:50Like this was so check your recession, check your stem height, check your vacuum,

11:56and also check your deck surface because 80% of this head was not correct. So this head is

12:01good to go. We're going to send it off to our customer.

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