Valley Gasket to BIG

[oistylin]

Hello-

I am doing a head gasket repair and got the AB #STC4082BK kit. I am in the process of replacing the valley gasket and I swear the damn thing is 1/2" too big width wise. I pushed down in the middle and finger tightened the bolts and I won't even be able to get the injectors bolts in the holes. Overlaps the intake holes by about 1/4" on either side

Has anyone else this problem? or did I really mess something up?

2004 bosch 4.6

Thanks.....

 

[kwmnh]

can you post a picture please,
with the valley gasket on the block.

 

[I HATE PONIES]

Have the heads been planed several times?

The injectors don't bolt down through the valley gasket.

 

[oistylin]

Ok must e the intake that bolts in then, the car has 58k and am guessing this is the first head gasket repair.. Machine shop said they barely took anything off. Images include front-left/right bolt holes

I keep getting an error when uploading

http://www.opticimpulse.com/disco/IMG_0754.jpg
http://www.opticimpulse.com/disco/IMG_0756.jpg
http://www.opticimpulse.com/disco/IMG_0757.jpg

Thanks

 

[oistylin]

I just went and measured the old and the new and they are the same... so the machine shop took off a 1/4' on either side? It wasn't even that bad, I just took them in because I did not want to do this again in a year.

How bad is it then?

 

[wheelen disco]

Is it fliped around

 

[oistylin]

I did try flipping it around, it appeared the same...

 

[discostew]

what is under the intake between the rubber end seal and the intake gasket. looks to be the same color as the endclamp ?

 

[kferg]

I just did the valley gasket on my '95. I don't think mine lined up perfectly either but it was not off that much. I should say my heads have never been off so they are factory original. I did not have any problem with the bolts and they probably pushed the gasket into alignment better. No leaks or problems so far.

 

[Dan B]

Just did HG job on my 04 with the same AB kit. I had the same findings - seemingly a little too wide valley gasket. Just take your time. I found that it fitting fine after shifting the lower intake around a bit, and lining up a few of the intake bolts at a time.

BTW. Considered putting sealant around the coolant passages (even the back ones that are blanked off). This is not the first time I had to replace a valley pan gasket

 

[pdxrovermech]

did you tighten the end clamps down? that will help pull the center of the gasket down and give you some more clearance on the bolt holes. sometimes you just need to apply a little pressure on the bolt while starting it with a socket and ratchet.

 

[MarkP]

Looks normal to me. Finger tightening the end clamps does not pull the gasket down. Use a little hylomar on the gasket water passages, arch the gasket sides a little more to better fit the valley, center gasket on block, depress in center and ensure side to side centering, carefully place intake, check gasket and if needed push down edges into valley to align better, apply pressure to intake to further seat gasket, tighten end clamps some more, add intake bolts, check gasket alignment, torque in correct sequence, torque end clamps.

Done.

 

[KyleT]

typical britpart quality.....

 

[kwmnh]

it will align itself with the lower intake bolts on.
put the clamp hand tight, use rtv on the clamps (both sides) and where the water holes go (both sides).
then put all the lower intake bolts and youll be alright.
after you torque the lower intake bolts, torque the clamps, done.

 

[oistylin]

Thanks everybody for the help and guidance.

Ended just shaving down the end clamp gasket ends where it meets the heads so it was more even. Also added some right stuff sealant. And your right it did get pulled down more once tightened also used the intake bolts to align the valley gasket evenly. Once everything got in I felt a lot better about it... no worries anymore.

Now I just need to put the alternator back on and hook up all the extra connections.

2 hardest things with the job, removing and re-installing SAI and the Coil Packs (made sure to put in some new 8mm wires as well).

I have yet to start it up but so far a major mechanical accomplish for myself.

The community rocks, thx for the tips and help