Need some guidance

[Vistablue3v]

I was planning on installing Ford performance Hot Rod Cams, and a high output P1sc procharge kit, with upgraded blowoff valve, and an upgraded fuel pump! In the process of installing the Cams something went horribly wrong and I’m unsure what we did wrong since we followed all the instruction for the Cams!

We decided to start the car just to make sure the cams were installed right and head a dreadful noise! Upon inspection a valve had broken and dropped into cylinder 4 and damaged the top of the piston head!

I already have a parts list of what I need including a new head!

My main question is, the kit I was planning on installing only puts me around 450hp it was my buddies kit that he sold to me that’s the only reason I know for a fact, plus our cars have almost the exact same in reference to stuff done to it)! But I wasn’t planing on doing rods or pistons for a while if ever! There’s no damage to the cylinder wall of any kinda, and all other cylinders and walls are untouched!we hand cranked the engine with no issues either!

What would yall do? I want it to be drivable again and not have to worry, but I also don’t want to spend a fortune, especially considering my buddy ran the kit with a stock bottom end for over 2 year without a single issue!

The picture was before we cleaned it out, and checked the cylinder wall, so those pieces that look like metal was just dust!

 

[Dino Dino Bambino]

You're lucky the damage wasn't much worse.
The cheapest route would be to replace the damaged piston with a new stock piston and rings, plus your replacement cylinder head, and throw everything back together again.
However since you've gone this far, it's an opportunity to upgrade all of the rods & pistons with forged units. You can then have more peace of mind when boosting the engine. A set of Gen 2/3 Coyote rods are an inexpensive upgrade and a direct swap.
I'd suggest the reason why you bent a valve in the first place is because you either got the cam timing wrong, or the roll pin of the phaser wasn't properly seated in the cam nose causing the phaser to slip. It's a common mistake when people use an impact wrench to tighten the cam bolt.

 

[Vistablue3v]

This helps a lot, would you recommend just staying with the stock crankshaft as well? Also would you just pull the motor and do it or drop the oil pan and do it that way?

 

[86GT351]

This helps a lot, would you recommend just staying with the stock crankshaft as well? Also would you just pull the motor and do it or drop the oil pan and do it that way?

No need to replace the crank unless you want to stroke the engine for more Cubic Inches.

 

[Vistablue3v]

Awesome thank you! What would be required in order to install stock gen 2/3 rods/pistons/rings are they a legitimate direct replacement for the stock 4.6l ones? Same bore?

 

[JC SSP]

I think you should find out what caused the issue first before investing any more money.

 

[Vistablue3v]

Pretty sure incorrect install of the cams, most likely a rocker wasn’t seated properly, or potentially the phaser wasn’t seated 100% correct! To be honest not 100% how I could even figure out how the damaged was caused, any suggestions would be much appreciated!

 

[86GT351]

Pretty sure incorrect install of the cams, most likely a rocker wasn’t seated properly, or potentially the phaser wasn’t seated 100% correct! To be honest not 100% how I could even figure out how the damaged was caused, any suggestions would be much appreciated!

If all the other valve train components on that cylinder are good, it will most likely be an installation error that occurred. Sadly it happens. Just a costly mistake.

 

[MrBhp]

Valve spring keeper was out of place during cam install. The instant you put pressure on the valve, (at start up, probably) that valve dropped. The most common mistake with valve train work. When you start putting everything back together, you MUST check each and every one of the keepers. All 48 of them.

 

[Vistablue3v]

Do you think that piston would be fine? In your opinion?

 

[MrBhp]

Do you think that piston would be fine? In your opinion?

That is really hard to say from pictures. I've smacked pistons before. I've never hurt a piston to the point of pulling it. But that doesn't mean you are safe. You need a trained eye to make that call. Clean it up very good. Look for cracks. If there are no cracks, send it.

 

[Vistablue3v]

Thanks for the guidance! I may just reach out to a professional just to see cuz tbh I really don’t wanna have to pull the motor and do that I’m kinda lazy

 

[Dino Dino Bambino]

Do you think that piston would be fine? In your opinion?

Unless my eyes are deceiving me when I zoom in, the gouge at 6 o clock from the center was deep enough to perforate the top of the piston. Put a drop of oil onto it and if it disappears into the crankcase, this will confirm my suspicion.

 

[Vistablue3v]

It does not disappear and just sits there!

 

[GriffX]

My guess, if you installed the cam with all followers in place you pushed the exhaust follower at #4 out of place. The exhaust valve at #4 and #8 is so hard to see. The follower pushed on one side of the valve spring instead of the valve itself and the keepers came out.

 

[Midlife Crises]

That piston was smacked multiple times by the valve. I would not run it for fear of it breaking order load. I would not use the rod either. Especially if I planed spirited driving taking advantage of the cams.

 

[Autokyrios]

Yeah, I'm not experienced with engine builds but my guess is the top of the piston is important and damaging it compromises the integrity. My guess is it will eventually burn a hole through the top of the piston and then fun things happen.