Rerebuilding a Diesel Engine

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Jonathan_Ferguson

Jonathan_Ferguson

★ is in the wrong locale
10 Year 15 Year 20 Year
Joined
Jul 2, 2003
Threads
132
Messages
950
Location
Glen Waverley, Victoria, Australia
Website
jonathan-ferguson.au
On the first day of driving my freshly rebuilt 2L, it wouldn't restart after a Toilet stop 97km into the journey, I gave it a final try before the RACV chap was to spray Start Ya Bastard into it, fortunetly it started. Then just shy of 400km, again it wouldn't restart and this time the RACV chap in Bendigo sprayed Start Ya Bastard into it. - No worky. My Hilux was put on a Tow Truck and stored at the RACV depot for a week, where they left the interior light on killing the battery and losing my spare key. Then the following Friday my father and I hired a Trailer and trailered it back to Melbourne, where I was able to check over the work I had performed, nothing wrong with the work I had done, but I noticed that the outer mesh of the Air Filter had heaps of white powdery corrosion on it, then the Car was put on a Tow Truck and delivered to the Engine Builder who found the problem(when they got the Engine started, they found that some of the Injectors were leaking lots of fuel down onto the ground :rolleyes: They didn't fix this, so I had to drive to Dandenong to the Diesel workshop there, where they put different Injectors in with the correct washers). The wire held on by a nut, that controls the fuel control valve, was loose. - So either the Engine Builder or the mob that rebuilt the Injector Pump made a huge boo boo causing me to throw more than $6,000 down the drain. :doh:

So two and a half years on I'm starting from scratch, again.
I can't afford to do anything but throw further money at a Diesel Engine, as I'm already too far down this path. This time I will supply the parts for the rebuild, and I plan to hotrod the Engine where I can.

Who makes Roller Rockers for the 2L, or is OEM the only option?
Where can I get a new Camshaft from besides Toyota?
Where on the internet can I find details on the availability of oversize Pistons?

On the Hotrod portion, all I can think of to improve the Engine other than forced induction, which I can't afford nor justify, is a gnarly Camshaft.
What Intake and Exhaust durations can I choose from, aswell as the Lobe Seperation Angle?
Also, should I have the Camshaft installed on centre, or at the same angle as stock(unless stock is on centre)?

Keep in mind fellas, my current budget is $3,600
To keep this rebuild on budget I'm only replacing the bits that live in Oil, as the Ether could only of leaked out of the Cylinders down into the Crankcase contaminating the Oil, creating poor performance and fuel economy. :cheers:
 
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Turbo Charger
No more than 12lb boost put a pyrometer on it so you don't melt the engine,other than that there is very little on options to Hot Rod It.
If you want hot rod swap a V8 or V6 into it for 3600 you could go aalong way with change left over for a tank of fuel.
 
To save money and being more convenient, can I reuse the Rockershaft and Rockerarms?
Also, are the 2L Roller Rockers able to be resurfaced to be nice to a reground Cam?
 
Jonathan_Ferguson said:
... and I plan to hotrod the Engine where I can.
Click to expand...


:confused: see your last quote.



Jonathan_Ferguson said:
Who makes Roller Rockers for the 2L, or is OEM the only option?
Where can I get a new Camshaft from besides Toyota?
Where on the internet can I find details on the availability of oversize Pistons?
Click to expand...


If the head is shim-under-bucket, I don't think you can.

Unle$$ you do with a higher compression ratio, I would not bore it unless you absolutely have to. Save some liner (and machine shop $$) for the next rebuild.





Jonathan_Ferguson said:
On the Hotrod portion, all I can think of to improve the Engine other than forced induction, which I can't afford nor justify, is a gnarly Camshaft.
What Intake and Exhaust durations can I choose from, aswell as the Lobe Seperation Angle?
Also, should I have the Camshaft installed on centre, or at the same angle as stock(unless stock is on centre)?

Keep in mind fellas, my current budget is $3,600
To keep this rebuild on budget I'm only replacing the bits that live in Oil, as the Ether could only of leaked out of the Cylinders down into the Crankcase contaminating the Oil, creating poor performance and fuel economy. :cheers:
Click to expand...



If you are adding any power, you are stressing the bits you didn't replace, that are original, and prolly wore out, even more.

If I was in you shoes, and was contemplating the build of a 2L (not that I know ANYTHING about them) I would focus on longevity and forget the, "hot rod". I have a feeling you're gonna blow it up soon after you blow yer budget on it.

2L and "hot rod" don't belong together IMO.


And Jonathan, I would talk to a mod about moving this to Diesel Tech. I bet you will run into A LOT more guys that know more about this motor there.


(I wish I could trade ya a stock, running 4.3 V6. But you are way to far away :frown:)



OPPS, forgot! Do you have any experience with a fresh 2L? You might get all the hot rod you need, once it's been rebuilt.
 
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This is the graph of my Engine 2 years and 2 months after its first rebuild. 38.09 RWHP

Hilux said:
If the head is shim-under-bucket, I don't think you can.

Unle$$ you do with a higher compression ratio, I would not bore it unless you absolutely have to. Save some liner (and machine shop $$) for the next rebuild.
Click to expand...
The original Rockers do have a roller type Camfollower.
I don't plan to have the engine rebuilt for a third time, also, I don't know how far the Cylinders were bored out last time.

Hilux said:
OPPS, forgot! Do you have any experience with a fresh 2L? You might get all the hot rod you need, once it's been rebuilt.
Click to expand...
From the seat of my pant, the Engine had the most power at 290,000km which was before it had, had a rebuild.
 
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Does the Connecting Rod Bush care about side to side movement on the Gudgeon Pin/Wrist Pin?
Assuming that the diameters of the Conrod's small end, Conrod Bush and Gudgeon Pin are the same and that the only difference between 2L and 3L, other than the 3L Piston being 0.07874" over, is the width of where the Conrod Bush lives. - Could I use the 2L Conrod Bush that lives nicely in the 2L Conrod but is narrow inside the 3L Piston, or could I use the 3L Conrod Bush that sits outside the ends of the 2L Conrod but is the correct width for the 3L Piston? :clap: Either of these scenarios OK?
 
Went and spoke to the Engine builders today, all that the Engine needs doing over is the Bores need to be rehoned as there's no crosshatching visible and new Pistonrings fitted because they never bedded in. - Even getting a notice from the EPA about the big black cloud emanating from the exhaust of my Hilux, no carbon got past the the first compression ring, which is just plain amazing.

It was suggested by the Engine builder, through my father, that I could Turbocharge my 2L, but on doing research, there aren't any kits available for the 2L, only for the 3L and 5L.
| DTS |
Safari Diesel Turbocharger System
In talking with the Engine builders today they said that to make a 2L-T like setup a 3L Head would need to be modified to fit on my early 2L. :hhmm: Also during my research last night the 3L and 5L have their Heater hoses run above the Exhaust manifold then across the front of the Engine, whereas the 2L has its Heater hoses run above the Rocker cover where the Intake piping would run to and from the Turbocharger's compressor. The only option for a turbocharged 2L is with one of these and to reinvent the wheel.


Oh, and kids, don't let your Engines inhale Ether. :D
 
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