DIY Head Replacement Help Please!

[den 22]

I'm pretty sure the head has gone, and I've searched the forums for details about how to replace the head myself but I'm not getting very far.
Does anyone know of any threads or links which include pics and instructions or tell me where to start as perfect planning prevents p*ss poor performance...
Before I buy a new head can anyone tell me the difference between an original and a modified head? Is it just a changing of the waterways or do they also go from cast to aluminium? I'm looking to keep costs to a minimum so can I get away with buying a new cast head as I've heard they last for about 70k.
Any help gratefully received.
Den.

[BUSHWHACKER]

There's a write-up at the bottom of this page....

http://www.hiluxsurf.co.uk/php_lib/v...at=1&submit=Go

[den 22]

Cheers bushwaker i obviously wasnt looking hard enough! Using those instructions, what sort of nightmare job is it to do mainly on your own? Im guessing same as always getting apart is easy, its puting back all the bits is the hard part
Got any ideas if the modified heads are cast or alloy?
Den

[BUSHWHACKER]

I would say getting it apart is the hardest job.
The new heads are cast the same as the originals, but with re-designed waterways.

[den 22]

Whats so hard about getting them apart? Are there any obvious ways of telling by looking at the modified head that it is a modified version. What about serial numbers? What do u reckon about fitting non modified head? Loads of questions!!!

[DaveD]

Whats so hard about getting them apart? Are there any obvious ways of telling by looking at the modified head that it is a modified version. What about serial numbers? What do u reckon about fitting non modified head? Loads of questions!!!

I've always found the getting apart bit the worst bit as everything is usually locked up tight..............putting bits back on after you've given em a clean is the good bit..........

[Koi]

Fit a non modified head at your peril

You need to fit the redesigned head and a genuine one at that, only place I know that guarentees them to be the modified one is Stevo (add at top of page).
Now way of telling a modifeid head apart from an old one, well there is if you take the head off and use a micrometer to measure the the thickness of the wall on the waterways.
70k on a new head???? don't think so, like all things fit it corrrectly, regular maintainance and it should go on for far longer than that. Hell theres guys on here with well over 100,000 on the clock and still going strong.

[Guest]

I've always found the getting apart bit the worst bit as everything is usually locked up tight..............putting bits back on after you've given em a clean is the good bit..........

I found that getting a set of ratchet spanners makes getting the exhaust manifold bolts undone easier, and you need a 3/8 or 1/4 drive ratchet with extension bars and u/js to make the inlet manifold easy to undo.

Personally I leave the turbo attached to the exhaust manifold and undo the manifold from the head leaving the exhaust manifold in situ. same for the inlet, undo it from the head rather than removing all the injsctor pipes from the pump to remove the inlet manifold.

the head sometimes sticks on to it's locating dowels (actually raised waterways) and can be a pain to get off.

Also the fan bolts can be a pain.

And the bottom pulley bolt on the 2LT engine is a pain and needs to come off to get the front cover off and get the timing belt off.

Apart from that, taking it slow and easy for a first time expect around 5 or 6 hours to get the head off and 4 or 5 to put it back on. If you have any problems it may take longer. First one I did took 14 hours start to finish.

[den 22]

Sorry for not being clear. I meant that the un-modified heads seem to last around 70k before the dreaded cracks arrive . I realise the better ones last much longer. So its a question of time do i fit it my self or do i go to work and pay for someone else to do it who knows what their doing!

[sumo]

where abouts in suffolk are you? cos I am doing a head swap at the moment (well I will be putting it back on next weekend when it gets back from stevo) I have just sent a 2lt head back to him,if you had shouted earlier maybe we could have done a deal and you would have all the stuff you need right here in suffolk.Never mind,but I strongly suggest you use stevo cos he realy is a very descent bloke.
I know cos I aint half caused him some greif this week.

[den 22]

Sumo - we're about half an hour up the A12 from you in Yoxford. How's the work on yours going so far? Is this the first time you've had to change one? Yes - it's a shame we didn't know earlier, however I've been in denial for a while about having to change it.

[sumo]

Sumo - we're about half an hour up the A12 from you in Yoxford. How's the work on yours going so far? Is this the first time you've had to change one? Yes - it's a shame we didn't know earlier, however I've been in denial for a while about having to change it.

So far the jobs ok,but no work on it this weekend,as we had a bit of trouble finding the right head(1st gens are so unique that everyone is different)and Iv'e not done anything this big for over 15 years so its quite a steep relearning curve but help is only a phone call away and if you shout loud enough some one will offer a hand(will cost you mucho beero but its worth it)

[den 22]

Hi Sumo, got your head yet?