Im planning on personally rebuilding my 1-HDT next winter. This will be the second engine I have rebuilt, ever. I know this will be a large and costly undertaking, so I want to get a head start on gathering any parts, tools, and collective knowledge that might help me, while starting a thread to document progress. I'll be updating the following.
Here is my reasoning for a rebuild:
What I've already done:
Other plans (budget providing):
(Really) high-level plan of attack:
Tools to buy (incomplete list, some may change depending on level of machinist involvement):
Random Build Notes
Removal
1HDT engine removal
Questions outstanding (need more research):
Anyone out there perform a 1-HDT rebuild? Any advice? Things you wish you knew? Tools specific to the 1-HDT you wish you had?
Here is my reasoning for a rebuild:
- Below-spec compression on #3, low-end compression on others
- Slobbers oil through breather
- Double check BEBs were actually replaced, and/or 100k km refresh
- Fix ring or head blowby
- Opportunity to get ahead of anything starting to rust in engine compartment
- Opportunity to replace all the hoses
- Opportunity to rebuild horribly leaky PS system
- Opportunity to buy more tools
- Get it all over with at once
- Possible rugrats on horizon, may be now or never
- Something for me to do, and a learning opportunity
- Afterwards, I will know EVERYTHING about this truck
What I've already done:
- New turbo
- New injectors
- Rebuilt IP
- Fresh timing belt and water pump
Other plans (budget providing):
New manual tranny (h151f): Auto tranny is sticky until warm, and suffers on mountain passes. Current engine smoky when in drive at idle, but clean when in neutral. Hoping rebuild will solve that, but if not, a manual tranny should help.- Sticking with upgraded auto tranny
- Rebuild TC with higher high and lower low gearing.
Higher gears should help with h151 5th.TC currently has loud but undiagnosed rattle.- Fix rattle, look in to lower lo possibility
(Really) high-level plan of attack:
- Pore over manuals
- Create budget to ignore
- Purchase tools
Remove TCRemove tranny- Remove engine, TC and tranny as one unit
- Block and head pulled apart, measured and sent to machinist
- Purchase rebuild parts
- Purchase tranny and TC parts, if budget allows
- Clean, clean, clean.
- Paint stuff
- Rebuild TC
- Install wholesale valve body and tc (rebuild whole tranny if in budget)
- Rebuild engine
- Install engine, TC and tranny
- Tig weld stainless exhaust
Make necessary tunnel/crossmember changes for stickshiftInstall stickshiftInstall TC- Drive in to sunset
Tools to buy (incomplete list, some may change depending on level of machinist involvement):
Tranny jackPress (or borrow a friend's)- not necessary?- Calipers
- Inside calipers
- Dial indicator with bosch fittings for IP timing
- Plastigauge
- Engine stand of sufficient capacity
- Assembly lube
- Ring grinder
- Aviation sealant
- Piston ring lube
- Number punches
- Liquid teflon
- Loads of beer
- PS box rebuild w/ 105 sector shaft (parts ordered)
- Reco PS pump
- New PS lines
- New radiator
- New ac radiator
- 12v starter
- New u joints, balance driveshafts
- New engine/tranny mounts
- Wholesale valve body and tc
- All the sensors
- oil press
Thread Size on Oil Pressure Sender - water temp
1HDT water outlet with temp sensor port - tranny temp
HDJ81/FZJ80 Tranny Temp Gauge - gauge
- oil press
- coolers
- tranny
- ps
- Rebuild TC, Underdrive lo
- Rebuild kit
- Performance version, ceramic pistons
- Adjustable wastegate actuator: Adjustable Wastegate Actuator TOYOTA CT26 14BT DYNA 17201-58020
- Newer (stronger?) turbo oil assy 15407-17020 ct26 turbo oil supply line leak possible solutions.
Sequoia alternator- not bolt on, amperage likely unnecessary
Random Build Notes
- Weight of engine, a442f and tc is ~1000lbs or 1/2 ton. Engine hoist not to extend beyond 1 ton.
- Hot tank
- Pocket port
- Grease main/cam seals for longer life
- Where to use loctite?
- Keep list of parts to order during teardown
- Studs in block?
ARP2000 1HZ 1HD-T DIRECT FIT HEAD STUD KIT — DIESELS UNLIMITED - New rod bolts?
- Port head?
- New valves seats?
- Does oil pump need replacing?
- Check wastegate, 15psi spring?
- Cerakote ceramic coating
- Engine colors?
- Stock color (ceramic), polished raised lettering on valve cover
- Black block
- Black heat shielding
- Zinc or 'burnt bronze' headers
coat turbine side of turbo?Heat blanket
- OEM squeeze cast pistons? (ask engine australia)
- I vs H beam rods: weight?
- Exhaust ideas:
- Are you using a torque plate?
- Rebuild head? Work with shims before?
- Magnaflux for cracks?
Removal
1HDT engine removal
Questions outstanding (need more research):
- Can pistons from later model 1-HDTs be used? Are there any other modifications to make for this to work?
- Use pistons for correct year.
- Are there any other parts that can be swapped for greater longevity?
- What gear ratios should be used in the TC?
Anyone out there perform a 1-HDT rebuild? Any advice? Things you wish you knew? Tools specific to the 1-HDT you wish you had?
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