- Joined
- Mar 7, 2010
- Messages
- 979
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well, the old girl is back up and running tonight
I have over the last couple of weeks replaced the turbo with a new green wheel Gturbo from aus, fitting that was pretty straight forward, new exhaust manifold studs made that easier too, a word of advice though is to fit the new inlet pipe to the turbo before bolting the turbo in place, it’s a bloody tight fit to stretch it on!
Although I already had a 3" stainless exhaust, the connection flange to the turbo was the original (21/2"?), so I made up a 3" outlet flange and modified the downpipe & bends to suit.
also gave me the opportunity to clear out some of the Egyptian desert sand & Russian mud from various nooks & crannies on that side of the engIne bay.
then thought I should get the injection pump & injectors refurbished, so I removed the pump & injectors and sent them off to diesel bob for the once over, while waiting for him to work his magic, and the truck was in bits, I fitted a new water pump, flushed through the cooling system and cleaned about 1/2 a ton of dirt, sand, mud & muck from the radiator, a/c rad, intercooler & auto box cooler fins, even though it didn’t run hot, it was amazing the muck I got out with the airline.
So back comes the pump, looking like a brand new one, had been speaking with diesel bob while he had it, and he completely rebuilt it, replaced numerous bits of its innards including a piston, he modified the fuel pin & upgraded the fueling etc to take into account the other engine / turbo mods, he was extremely thorough & wouldn’t send it back out to me until he was 100% happy with pressures etc etc.
He also refurbished the injectors.
fitted the pump & injectors today and spent ages with the dial gauge & Toyota SST to ensure the pump timing was spot on, fitted the injectors & reconnected all the pipes, vacuum & fuel pipes etc, on went a new cam belt & fuel filter, a check over that the intercooler, water & fuel pipes were tight and the moment of truth, time to fire her up. Reconnected the batteries and pumped through the fuel, and with some trepidation turned the key with no 1 injector union cracked open.
bingo , after about 5 seconds of turning over she fired, tightened the injector union & let her tick over for a minute before revving up a bit.
Absolutely gobsmacked at how smooth & quiet it was running.
let her warm up and didn’t even get an airlock on the heater pipes! started up a few times and called it a day with a smile on my face.
tomorrow will just tidy up and refix sone pipes & wiring, adjust the tick over a bit, have a good clear up and take her for a test run and adjust the boost to around 22 psi while checking the egt’s etc.
Still can’t believe how smooth & quiet it sounds, prIor to this work I had no issues with starting, running etc, I just fancied doing it, the truck has only done around 200,000 miles, with some tough expeditions under its belt so thought it would benefit.
Will report back after I’ve given it a test run tomorrow, but as I said, so far Ive got a big grin on my face
Andy
I have over the last couple of weeks replaced the turbo with a new green wheel Gturbo from aus, fitting that was pretty straight forward, new exhaust manifold studs made that easier too, a word of advice though is to fit the new inlet pipe to the turbo before bolting the turbo in place, it’s a bloody tight fit to stretch it on!
Although I already had a 3" stainless exhaust, the connection flange to the turbo was the original (21/2"?), so I made up a 3" outlet flange and modified the downpipe & bends to suit.
also gave me the opportunity to clear out some of the Egyptian desert sand & Russian mud from various nooks & crannies on that side of the engIne bay.
then thought I should get the injection pump & injectors refurbished, so I removed the pump & injectors and sent them off to diesel bob for the once over, while waiting for him to work his magic, and the truck was in bits, I fitted a new water pump, flushed through the cooling system and cleaned about 1/2 a ton of dirt, sand, mud & muck from the radiator, a/c rad, intercooler & auto box cooler fins, even though it didn’t run hot, it was amazing the muck I got out with the airline.
So back comes the pump, looking like a brand new one, had been speaking with diesel bob while he had it, and he completely rebuilt it, replaced numerous bits of its innards including a piston, he modified the fuel pin & upgraded the fueling etc to take into account the other engine / turbo mods, he was extremely thorough & wouldn’t send it back out to me until he was 100% happy with pressures etc etc.
He also refurbished the injectors.
fitted the pump & injectors today and spent ages with the dial gauge & Toyota SST to ensure the pump timing was spot on, fitted the injectors & reconnected all the pipes, vacuum & fuel pipes etc, on went a new cam belt & fuel filter, a check over that the intercooler, water & fuel pipes were tight and the moment of truth, time to fire her up. Reconnected the batteries and pumped through the fuel, and with some trepidation turned the key with no 1 injector union cracked open.
bingo , after about 5 seconds of turning over she fired, tightened the injector union & let her tick over for a minute before revving up a bit.
Absolutely gobsmacked at how smooth & quiet it was running.
let her warm up and didn’t even get an airlock on the heater pipes! started up a few times and called it a day with a smile on my face.
tomorrow will just tidy up and refix sone pipes & wiring, adjust the tick over a bit, have a good clear up and take her for a test run and adjust the boost to around 22 psi while checking the egt’s etc.
Still can’t believe how smooth & quiet it sounds, prIor to this work I had no issues with starting, running etc, I just fancied doing it, the truck has only done around 200,000 miles, with some tough expeditions under its belt so thought it would benefit.
Will report back after I’ve given it a test run tomorrow, but as I said, so far Ive got a big grin on my face
Andy
