Dropped valve head repair
 

4G63 Dropped Valve Head Repair


The Subject head is a 1G 6 bolt head.
This head had extensive work done to it and would cost way more to replace than repair.

The head was loaded with SuperTech +1mm valves, and duel valve springs and Ti retainers.

How the head looked when I received it.

Attachment 4581

A closer look at #4 cylinder, the one that dropped the valve.

Attachment 4582

Yes it looks pretty beat. But it is fixable.

First thing to do is disassemble the head and get a parts list going.
At first look, I thought the 4 valves in the #4 cylinder would be the only ones needing replaced.
It turned out only 4 valves of the 16 could be used.
Attachment 4583

The SuperTech duel springs and Ti retainers tested fine and will be used. About half of the Ti retainers had be rubbed on.
Attachment 4584
At this time it was decided to install bronze guides, to replace the stock appearing cast iron guides.
Attachment 4585

The bronze guides installed.
Attachment 4586

Once the head was cleaned, a couple small cracks were found in #1 cylinder.
Attachment 4587

The seats were cut out
Attachment 4588

Then the head was pressure tested, using 35psi in the water jacket.
The head did not leak.
So work progressed by removing the 4 seats in #4 cylinder.

Attachment 4589

New counter bores were cut, and oversized inserts were installed.
Attachment 4590

Some grinding, polishing and blending was done to smooth out some of the damaged area in the combustion chamber.

Next was to mark the spots to be welded.
Attachment 4591
What it looked like once back from the welder.
Attachment 4592

Also to note is the spark plug inserts were installed in cylinders #1 and #4 before welding.

From this point a bit more blending was done to smooth out the welds and a full valve job was performed.

As the seats were cut,
Attachment 4593

Valve tip height was checked and set to the proper specs.
Attachment 4594

Spring installed height was measured and set to 1.550 @ 85lbs
Attachment 4595

New 3g HLAs were installed, along with the followers and cams.
Attachment 4596

Bottom of the head.
Attachment 4597

Close up of #4 cylinder after repair.
Attachment 4598

Head thickness after repair and rebuild. 5.159
Head build # BBB 744