Been About 2 weeks since i last updated the build thread. And a busy two weeks at that.... so after i pulled the coolant cap and found that crap and under my valve cover oil fill cap. I stopped driving it until i got my priorities straight. My buddy was comming down for 4 days and i figured what better way to entertain a guest..
So lets get down to the nitty gritty. I ordered a new head from clearwater cylinder head in Florida (btw best customer service ever) They even gave me free freight shipping on an 80 lb head since im military. maybe they will do a jeep forum discount. Since it was expected to be here by tuesday my buddy kyle and i got down into it. Let the images begin.
First things first, I got a bunch of parts bags together and placed a bunch of soak-em-up underneath the front end.
Drained the coolant, and since it hadnt been turned over in about 2 days i wasnt to worried about the fuel pressure. disconnected the battery and used a 5 dollar tool from pep boys. 3/8" i believe. its 2 sizes on each end. just got the smaller of the two they offered.
Disconnected the fuel line
removed the airbox,and hose to the throttle body to give me some room to get in there.
started to pull the injectors. 12 years old and the heat in the south has gotten to them. with little pressure after sliding the red tabs up to unlock them this happened. TO EVERY SINGLE ONE!!!
Let me state, That before i did anything. i took about 20 photos from differnt angles and i did a 3 minuite video explaining to myself while panning the camera what lines went from this point to this point and what components they were attached to.
Much credit deserved to the6nightmares, because his thread on replacing his head helped me SOOOO MUCH. Thank you again sir.
Then i started ripping stuff out,
Disconnected the exhaust manifold from the downpipe. I dont have a california equiped 2000 xj, so i dont have two more precats up their thank god. At first they would not budge!!!! but i blasted them with some pb blaster. came back 5 minuites later and it took almost no force to break them free. glad i didn't have to use a saws-all
Wonderful sword of extensions to reach it from the ground while my buddy held a 15mm box end wrench on the nutplates from the mani down.
After that i Disconnected all vacuum lines, Throttle cables, and sensors secured to the side of the head, belt, Power steering pump (dont disconnect lines) a/c comp (dont disconnect lines, just 4 bolts on top and 2 attached to the head.) Took out the tension pullet bracket. And water pump. Disconnected all the radiator hoses. Basically anything that was in the way. Common sense stuff. And got a neighbor to help me lift it up and out. Pulled the head bolts which took some pb blaster and a cheater bar. #14 wont come out so you just have to lift it up and wrap some painters tape around the shaft so it doesn't catch. lifted up the front end of the head and intake/exhaust mani and slid a cargo strap underneath it. they stood on the side and front lifting from their and the back of the head. while i was sitting where the air box was guiding the mani's and moving lines out of the way. (dont step on your steering system....)
Okay so then the head was out, but my new one wasnt here yet, So what else can i do!!!!! First things first. It was a mess, and their was coolant in the piston chambers so i cleaned that up first. Shop vac-ed the pusher rod seats and stuff. then stuffed paper towel in the pistons chambers and the exhaust down pipe so it could stay debris free for now. Until then We started Tearing the top end apart.
I used a box to keep all the pushrods, rockers,bridges,headbolts, and valve cover bolts in order. I marked the box (front,rear,pass,driver) to avoid any confusion later.
My best friend looking grim while we tear it down on his tailgate.
I plan to strip down and clean the exhaust manifold and intake manifold While i inspect them for damage
remember where everything goes!!!!
So while it was pulled apart i ran to my auto skills center on base and sandblasted the exhaust mani and intake mani
Then i cleaned them all off with the air compressor and simple green and let them dry completely.
picked up a can of vht 1300-2000 ceramic header paint (a little more silver than i wished for)
While those baked in the oven we decided to address the issue of my dirty engine compartment. Yes i know it will get dirty again. However. Their was alot just sitting in their driving me crazy... So we went simple green crazy
2 hours and 3 different bake temps later we were still cleaning in the engine compartment, and wandered to other areas.
half cleaned lol
So it was all cleaned up and My buddy left. We wrapped all parts in trash bags and stored them in the jeep, filled open areas of the motor with shop rags. and covered the block with trash bags.
Closed the hood and tarped off the opening to my carport so no weather could get in anywhere i dont want it
Good thing, It rained allllllllllllllllllll week. Head came in tuesday though.
pics of old vs new.
So Friday night before my weekend i stayed up late in the carport by myself cleaning and prepping as much as i could.
scrapped and cleaned up
Also with my new csf 3 row i could wiggle it forward and backward. I didnt like that. I also didnt like the 1.5" gap between the radiator and the radiator support. Allowing air to pass over instead of through it and wiggle around. Id rather not. I Saw someone else on here use a pool noodle to fill the gap. However pool noodles will melt very easy if in contact with a hot surface. So i picked up some 3/4" copper pipe insulating cover. 1$ at walmart for a four pack. and it took one piece. Has sticky open ends and is already slit down the middle. Trimmed off a few inches and spots for the radiator support to slide back in. PERFECT FIT. And no more wiggle. Satisfied 1$ customer here.
Tried to clean out the threads to the best of my ability. But im not buying a tap or w/e it is. So i stuffed an electronics compressed air straw in it and blasted it out.
Good enough for government work
Messy carport Drove me insane.
Also when i pulled the head last week i kept all the tools i needed in a wash bucket so i didnt have to re-find them when the time came for the install.
Also that night i wired my Rampage h4 housing with my e-autoworks Harness.
While i had the radiator support off i cleaned one of the bolt holes and used it as a ground on each side of the grill for my ground on the harness.
I left the old harness right where it was and just unplugged it from the headlights. The E-autoworks one plugs in on the passenger side to get a signal from the headlight switch.
Stock harness is black connector. Male on aftermarket plugs into it. And the female plugs into your new h4 bulbs.
Each light has a ground.
The harness is wired perfect.
The positive cables fit perfect on my military style battery terminal and the relays mounted on their Included L-bracket on the left side where the throttle thing thing is. w/e its called. youll find a spot to mount it close to the battery.
Just a shot of where i ran the wire. Much easier with the radiator support out
messy carport shot...
Ill update the install of the head tomorrow. I have class At 6:45. Yeah Military!!!!!!!
Well my other buddy showed up Saturday to help me Put it all back in, mind you neither of us have motor work in out history except on aircraft. Principals transfer but not the knowledge.
Here he is Cheesing while we lined up the int/exh mani gasket and put them on.
Then we put the headgasket on and very gingerly with 3 people lifted it up and in. dropped into place perfect thanks to the alignment dowels or w/e on the engine block. Pretty impossible to mess up.
Dont forget the high temp Sealent on #11 Bolt. Red stuff.
Now time to start hooking Everything up. I put the spark plugs in while he put the throttle body back on. (new gaskets on everything) Then we put the fuel injectors back in. I replaced the o-rings on them too. Cheaper through o-reilys than online.
New water pump.
put the power steering pump back in.
Tentioner pulley and bracket.
Ran the belt.
Poured oil over the head/rockers and whatnot. (about 3/4 of a quart) then installed the new valve cover gasket and valve cover. Then put the rest of the oil in. Cheap penzoil since im changing it in a week or so anyway. Hooked up all my vacuum lines and throttle cables. Coilpack/rail thing thing. plugged in all electrical connectors and radiator hoses. Also while everything is pulled out. I flushed the radiator with about 5 gallons of freshwater, and flushed and backflushed the heatercore like 8 times each way. Stuff was still comming out. (rusty sediment) I had no heat btw.
So i get it all hooked up and the moment of truth is here.
Battery cable hooked up.
Key in (aux power comes on) first good sign.
fuel pump pressurizes.
Its going to smoke alot just so everyone doesnt freak out like i did, it went away though. Probably from the vht header paint. or maybe just the new head and all that jazz. Either way. Victory. So we let it get up to operating temp and pressurize. No leaks!
Old housings before the harness upgrade
While that warmed up we installed the rampage housings.
Took it for a ride around the neighborhood to a dark dead end to get a beam pattern idea in the dark
Here it is for yah. AMAZING (pictures do it no justice.)
Easily 4x as bright. And soooooooooo Much clearer. They put my 2006 jetta's hyperblue lights to shame
Now it sits in my driveway/2 miles to the afb until next weekend when my goodies go on
4.5" x series. drop brackets. IRO HnT and my retread 265/75/16s
Guess who's brakes caught on fire last night!!!! my jeeps -_- left caliper stuck didnt even notice really while going like 55 down a back road. as i pulled into the afb i saw a reflection in the glass of the security forces shack. HOT ORANGE ROTOR. Which then proceeded to emit flames luckily the cop their let me use his fire extinguisher inside.
Got some Premium Centex rotor's and some ebc's yellow, new calipers and new brake lines. I Plan to install my lift kit, and that **** tommorow. Wish me luck. hopefully i can get it done in 9 hours. Me and a buddy, Teaser pics.