Builds Rolling Project : 1992 LC BJ-73 VM 2.5 TD (1 Viewer)

[theMYTE]

Hello all, somewhere to keep a catalog of my 73 LC journey. I've got some backdated content to post up first...

I've had a chequered history into 4x4's due to what's been available locally at the time, but I've been trying to build a daily 4x4 rig that can go anywhere for sometime now. From a 4x4 Renault Saviem, 2 door Range Rovers (complete projects), to an early LWB G wagon (very slow and too clean to 4x4).. finally I have my first LC (what I've wanted all along).

The truck : 1992 LC BJ-73 VM 2.5 TD

The brief:
Keep it relatively original to look at, with subtle modernisation mods.
Functionally needs to be a good tourer with no bounds, not planning to hard 4x4 it but needs to be capable (it already is).
Modernise the interior, making it more comfortable for longer journeys. Sleeping arrangement inside. Off-grid power etc.
Generally, get to know LCs and how to fix them.

List of jobs (some completed):
Previous to me, it's had a recent (~2 yr ago) part resto. DONE
Fix an intermittent fuel issue. DONE

Air leaks​

Recondition injectors​

Clean fuel tank​

Get it running mechanically tip-top

Exhaust leaks​

Swivel hub rebuilds​

Gearbox issue​

Interior

Sound deadening​

Audio upgrades​

Draw system​

Ta,
MYTE

 

[theMYTE]

Resto pics

 

[theMYTE]

The full story and problem (just incase someone experiences the same issue) there is a TLDR below:

I purchased the vehicle and drove it back ~200km. It was mostly motorway driving and on one of the long hills under load it had some slight dips in power. The rest of the journey was fine.

After driving around locally a few times all seemed fine, max distance was 30km. Then I realised the fuel gauge wasn’t reading right and ran out of fuel (or so I thought), I filled it up but I noticed air in the system, causing power issues. I bled the system and noticed a small leak in the fuel filter drain plug. I replaced a rubber in the drain plug and fitted a new filter. Then bled the system again.

It drove fine on the first test drive 15km and I put the problem down to the old rubber seal. I then took it on a second test drive, shorter distance but faster roads. It suddenly cut out of power, you could hear the turbo stop spooling and my foot was flat on the floor. On hills it was crawling up, just about made it home. It felt like there was no power but it wasn’t clear if it’s a turbo boost or fuel problem.

I bled the system…again to make sure, visually checked the fuel lines for leaks and the air inlet ducting for leaks or loose connections but I couldn’t see anything obvious. I checked the turbo and there wasn’t any play at all. There is still air getting into the fuel system on the inlet line to the filter, on idle it’s not coming out the outlet of the filter but thought that may change under load. I did also notice air leaking from the second injector, where it sits in the head, when I bled the line there was fuel that leaked out sitting in the injector seat, bubbles were appearing showing there’s a leak here (obviously not the cause of air in the system).

It idles fine and driving the first 1-2km all seems fine, you can hear the turbo spool and no power issues. But it seems once the engine is warm the turbo stops spooling and I’m in the same position, foot flat to the floor crawling home. Even if I cut the engine and sit for 5mins, start back up, the power loss is still there.

TLDR
Problems to investigate:
- Air leak in the fuel system
- Air leak between the injector and head
- Turbo issues, stuck waste gate?
- Fuel starvation

I replaced any clips I thought might cause an issue - this solved the air in the system.
Then the injector leak - I re-cut the injector seats and replaced the crush washers. I also has to flatten one of the injector shoulders as it was slightly damaged.
When doing this I noticed one of the injectors had been glued in! I noticed something when I purchased the vehicle but the engine was hot and I couldn’t really make it out, thought it was oil or dirt.. the seller didn’t say anything when I mentioned it.
I just need to re-cut the seat and the problem was solved.
All injectors got rebuilt.

 

[theMYTE]

Whilst working on the engine I noticed some dirt pass though the clear fuel line, this lead me to flushing the lines and cleaning the fuel tank where I found the root cause!
I'm not quite sure where this gunk came from, it could be something to do with the glue that was used around the injector but would that get into the fuel system and fed back to the tank in the return idk

 

[theMYTE]

First test drive, what a difference! Definitely added a few extra bhp

 

[Felde]

Whilst working on the engine I noticed some dirt pass though the clear fuel line, this lead me to flushing the lines and cleaning the fuel tank where I found the root cause!
I'm not quite sure where this gunk came from, it could be something to do with the glue that was used around the injector but would that get into the fuel system and fed back to the tank in the return idk
View attachment 3896178View attachment 3896183

That looks like diesel pest to me. Basically microorganisms that grow in diesel tanks that have been sitting for a longer time. Root cause is biofuel that's added to most modern diesel brands in Europe.
It's an infection, so it will grow back over time, if not treated. I recommend to swap the filter (likely you did that anyways already).
There are diesel additives available to sanitize the fuel system.
Cheers Ralf