Petrol defender head gasket fiasco - Defender Source
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  #1  
Old February 12th, 2016, 12:06 AM
DocB
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David
1989 D110
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Petrol defender head gasket fiasco

After following advice from multiple sources, I decided to reuse the head bolts when rebuilding the top end head gasket replacement. Well it didn't turn out so well. The center bolts (part number 554622) are definitely stretch bolts. They wouldn't seat all the way down, with about 3/4 inch of clearance when fully tightened. Pulled them out and they measure a little over 5". The manual shows them at 4.1"

Anyone ran into this issue before? Now I'm trying to overnight more stuff to get her up and running to drive to work next week lol
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  #2  
Old February 12th, 2016, 06:56 AM
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Mike
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Yea, when I looked at my bolts I found some specifications that said they could be re-used as long as they were in spec. Forget where I found that information. Didn't feel comfortable re-using them so purchased new. They were not too expensive. Just a pain waiting for them to get here.
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Old February 12th, 2016, 08:49 AM
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No head bolt stretches 9 tenths of an inch/20% of its length. You either have the bolts in the wrong holes or there is something completely screwed with your ruler.

Stretch head bolts have flanged heads and do not use a washer. What you have pictured are non stretch bolts with spacer washers. I don't remember the last time I worked on a 2.5 petrol (its been many years) but are you certain the rocker assembly/or pedestal doesn't bolt on under those center bolts ? This appears to be an assembly error not a bolt issue.


As Pendy says "advice is only as good as the person applying it. Don't make me give you bad advice".
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Old February 12th, 2016, 09:08 AM
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Did you blow out the bolt holes with air? They could be filled with oil or cleaning solvent.
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Old February 12th, 2016, 09:26 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Did you blow out the bolt holes with air? They could be filled with oil or cleaning solvent.
x2 on this.
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Old February 12th, 2016, 10:20 AM
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Quote:
Originally Posted by Jymmiejamz View Post
Did you blow out the bolt holes with air? They could be filled with oil or cleaning solvent.
This was my first thought. Before we replaced the head I used a screw driver and rag to clean it out. I'm pretty sure it's not this.

------ Follow up post added February 12th, 2016 07:27 AM ------

[QUOTE=Uncle Douglas;714227]are you certain the rocker assembly/or pedestal doesn't bolt on under those center bolts ? This appears to be an assembly error not a bolt issue.
[QUOTE]

Yup, I think I'm an idiot. The manual is written a little funky and says not to place the rocker assembly until after the head bolts are hand tightened, and then calls the cylinder head bolts "rocker retaining bolts", even though the parts catalog says otherwise.

I'm at work not so I cant way for sure, but I'd bet that there is a pedestal that does under those and it will fit fine

ps-i love you guys lol
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Old February 12th, 2016, 10:54 AM
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Quote:
Originally Posted by DocB View Post
Yup, I think I'm an idiot. The manual is written a little funky and says not to place the rocker assembly until after the head bolts are hand tightened, and then calls the cylinder head bolts "rocker retaining bolts", even though the parts catalog says otherwise.

I'm at work not so I cant way for sure, but I'd bet that there is a pedestal that does under those and it will fit fine

ps-i love you guys lol
It says:
Quote:
88. Place the cylinder head in position and engage all the cylinder head bolts and washers except those used to secure the rocker assembly.

89. Insert the push rods into position ensuring that the ball-ends fit correctly into the spherical seats in the tappet slides.

90. Fit the rocker shaft assembly ensuring that the hole in the front and rear rocker bracket locates properly in the corresponding dowel in the cylinder head. Also, make sure that thc ball-end of all the rockers fit into the spherical seats of the push rods. Evenly tighten the rocker shaft
retaining bolts to the correct torque.

91. Tighten the cylinder head and rocker shaft securing nuts and bolts strictly in the sequence
illustrated to avoid distortion of the cylinder head.
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Old February 12th, 2016, 12:26 PM
DocB
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Ok am an idiot. I cannot confirm or deny of drinks were consumed during the rebuild process lol
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Old February 12th, 2016, 10:45 PM
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Quote:
Originally Posted by DocB View Post
Ok am an idiot. I cannot confirm or deny of drinks were consumed during the rebuild process lol
Nah man. See my signature line. Been there, done that.
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