1999 4.0 OHV replaced headgasket - folded over the gasket?

[RussAdams]

I'm bummed again.

I went to put the intake manual back into my 1999 4.0 OHV and saw a large gap between the drivers head and the block.

I replaced the heads on Wednesday, 8/1/2024 and it was way too hot outside. I kept making mistakes. Put the gaskets on wrong. Set the heads on them, and realized my mistake. Did not put the bolts in yet. Picked the heads back off. Flipped the gaskets the correct way. Put the heads (exhaust manifolds were attached, so very heavy for me) back on and torqued them down in three stages, following the diagram in the manual.

Today I go out to put the intake manual back in and see this:

Darn. Look at the size of that gap!!!

Here's some closeups of that area:

I'm thinking I must have folded the gasket over when shifting the heads around.

This can't be right, can it?

I'm ordering new gaskets and head bolts.

Comments greatly appreciated!

Russ

 

[SenorNoob]

Definitely not right. I hope you find an obvious cause when you take it back apart. Were the heads and block checked for flatness?

 

[RussAdams]

Definitely not right. I hope you find an obvious cause when you take it back apart. Were the heads and block checked for flatness?

I did check the flatness. .006 on the driver's head between the middle and outer cylinders. SHOULD be ok to run that way.

 

[RussAdams]

Well I definitely folded over the headgasket when I was installing it.

I am replacing with FelPro gaskets.

Took the passenger head off just to be sure I didn't mess it up too. It was OK, but I cleaned and replaced both.

Moral: DON'T work on the car in 95 degree weather with heat advisories in effect.

 

[SenorNoob]

Ouch. At least you found it. To people more knowledgeable on the subject than myself: Would it being folded and torqued down cause damage to the flatness of the head?

 

[Broosedamoose]

I doubt it would affect it.

 

[pentode]

Well I definitely folded over the headgasket when I was installing it.

View attachment 114805

View attachment 114806

I am replacing with FelPro gaskets.

Took the passenger head off just to be sure I didn't mess it up too. It was OK, but I cleaned and replaced both.

Moral: DON'T work on the car in 95 degree weather with heat advisories in effect.

Dang. I feel your pain. I do some of my worst work in extreme heat. I don't know how you Southern guys do it.

Ouch. At least you found it. To people more knowledgeable on the subject than myself: Would it being folded and torqued down cause damage to the flatness of the head?

I'm not an expert engine builder nor metallurgist, but I know a bit about both and my money is on you're fine. You won't have bent the head.

 

[RussAdams]

Dang. I feel your pain. I do some of my worst work in extreme heat. I don't know how you Southern guys do it.

I'm not an expert engine builder nor metallurgist, but I know a bit about both and my money is on you're fine. You won't have bent the head.

The weather here (20 miles or so west of DC) in summer is worse than it was when I lived in Sarasota Florida!

My driveway, where the Ranger is parked, faces west-ish. By 1 or so pm the sun is blazing down on the black hood. I really shouldn't even try to work on it once the sun clears the house.

Thanks for the encouraging words about the head! I'd have been more worried if it was an aluminum head like on my Audi.

 

[RussAdams]

August 17, 2024 update:

Everything is back in the Ranger with the exception of the front exhaust and catalytic converters.

Running smoothly!