Hello!

This page, and the project itself, is dedicated to Richard Thomas Jean. I suspect he would have approved of what I'm doing to his truck. Uncle Richard, I wish you could have seen this.
Special thanks to:
- Seth Emerdinger, for making a school autoshop project out of rebuilding and magna-fluxing my cylinder heads and going through the turbocharger;
- Trevor Emerdinger, for providing muscle, an extra hand, and encouraging thoughts when needed, and for understanding when the truck wasn't ready to go on our summer trip;
- Jim Basaker (my dad), for providing moral support along with the occasionaly-needed dose of common sense;
- Dave Shanks, for lending me his air compressor, other assorted tools, knowledge, patience, and moral support;
- Gene Luo, for helping me out on acquiring the turbocharger assembly;
- Calvin (towcat on TDS), for allowing me to harvest various trucks for parts (notably the timing gear cover and injector pump drive gear cover) for this project;
- Cameron (Radcam on TDS), for providing me with a diagram on how the turbo assembly goes together and for giving me a spare turbo boost gauge;
- Bill Miller, for allowing me to use the oil cooler pressure tester that he built himself, for only the cost of shipping;
- Pete Clark, for providing updated diagrams when my made-in-1983 shop manual wasn't accurate or detailed enough;
- Mel Agne, for taking the time to write up an article on head gasket replacement that provided such an excellent reference for myself as well as countless other people;
- and all of the BOOB men of TheDieselStop.com
I couldn't done it without all of you. And another special thanks to Robin Davis (my girlfriend) and Jan Wolski (my mother) for putting up with me, the cluttered driveway, the greasy fingerprints, and the lovely smells of carburetor cleaner, PB Blaster, and diesel fuel permeating the air throughout this project.
Pictured above is my 1984 Ford F-250HD pickup that I inherited in 2001. This truck is equipped with a 6.9 litre International-Harvester indirect-injected naturally aspirated diesel engine, along with a 4 speed Borg-Warner T-19 manual transmission and four wheel drive. Sitting on the hood is my girlfriend, Robin.
Contained in this page will be a series of writings and pictures illustrating a project I began in June 2004 and completed in September '04. This project includes:
- Removing and re-installing the left and right cylinder head
- Rebuilding both cylinder heads
- Removing and replacing all 16 hydraulic valve lifters
- Removing and replacing the timing gear cover on the front of the engine
- Removing and re-installing or replacing the camshaft
- Removing, replacing O-rings on, and re-installing the engine oil cooler
- Removing, flushing, re-installing, and re-charging the air conditioning system
- Installing an ATS non-wastegated turbocharger
- Cleaning and re-painting all parts
Please click on the links below to navigate through the page. Thank you!
Introduction to the project
Before the project begins
Removing external parts and accessories
Removing cylinder heads
Heads, gaskets, and the block after head removal
Removing timing gear cover and camshaft
Cleaning the piston tops
Cleaning the ins and outs of the engine
Final engine block cleaning with compresed air
Oil cooler disassembled
Parts ready for painting
Final painting preparation
Parts after painting
Installing BajaGringo drains
Installing the camshaft
Re-installing the camshaft
Assembling and testing the oil cooler
First steps of modifications for the turbocharger
Comparing the stock head bolts to ARP studs (lengthy!)
Installing the cylinder heads
Installing the head studs
Installing the valvetrain
Installing the intake manifold and injector pump
Assembling and installing the turbocharger
Last touches on engine assembly
Installing radiator
The Finished Project