1hd-ft engine rebuild

[Cptsideways]

Your EGR cleaner..... did it make the coked up stuff all gooey? smoke may well have been caused by that leaking down.

Where you have your lump in situ, I'd line all the pistons up, fill the bores with oil & wait to see what happens. It will be fairly obvious which ones have the best seals. If only one leaks as such just pull that one & so fourth.

 

[dellboykev]

all the baked on carbon in the inlet is pretty gooey but i think it is from oil in the breather from the blowby number one leaks the quickest then number 6 all the others drain pretty evenly but while i have it apart i might as well change all the rings because i am doing the bebs so taking the pistons out and honeing the bore isnt much more work

 

[StarCruiser]

The thought I have had, which may have no weight to it at all, is,…

If there was a lot of sticky carbon round the rings, could it be that the EGR cleaner loosened it and gummed up the rings?

Or am I just being hopeful?

Guess it won't be long before we see the cause.

Good luck with it and hope it turns out to be something that's (relatively) easy to fix.

 

[dellboykev]

there is no gunk in the cylinders apart from the carbon ridge and some carbon on top of the pistons the engine specialist i took it to thinks it was ether a snapped ring or a stuck ring as there is no damage to the cylinders it will probably be a stuck ring so i will see how much gunk is in the piston groves tomorrow

 

[StarCruiser]

Fingers crossed for you Kev.

 

[frank rabbets]

I have seen "smudged" lands between the piston rings. If the ally between the rings touches the bores with no oil the ally drags over the top of the ring trapping it tight and causing poor compression. It's possible to retrieve pistons if not too bad.

 

[dellboykev]

got the pistons out today and this is what greeted me this in number 3 and is the worst but all of them have cracks so im on milners now ordering a full set

 

[StarCruiser]

Oh well you know the answer now at least. Jeez, thank god I don't have an EGR valve nor need to spray EGR cleaner in. Do you really think it is the cleaner that's done it?

 

[frank rabbets]

Hydraulic damage probably caused by the egr cleaner washing that loose oily soot in the intake manifold into the chamers in my opinion but at least it was not bad enough to break a rod. Problem is other lands on other pistons may be damaged and even with the pistons out there is no way of telling if they are cracked.

Even though you can see the original diagonal honing marks there will be some glaze which needs busting before new piston's rings will bed in.

Really unfortunate but well done for persevering . Really interesting. Keep the pictures coming.

 

[dellboykev]

i do think it was the egr cleaner it causes slight diesel knock when you use it but when i used it on the cruiser it caused quite bad diesel knock so that is how i think it has happened all the pistons have cracks between the lands so i am going to replace all 6 number 3 was just the worst and i could pull a piece of the piston off the second ring on number 3 was jammed and the bore has more of a glaze in one place than any of the others i have already honed the bores ready for the new pistons but milner wont have them until next year, oh an the head on this engine weighs a ton

 

[StarCruiser]

Have you tried Amayama for the Pistons? Seems if you're gonna have to wait, you may as well see what genuine Pistons cost and wait for them if within budget.

 

[StarCruiser]

You can see where the lower ring has been flapping back and forth by its wear pattern.

You've probably already done this but with the Smart it was recommended that the bores be thoroughly scrubbed with soapy water and a (bog) brush to ensure no grit remains anywhere in the bores. Also flush so that no grit remains in any of the water or oil channels.

I've got to say this is rotten luck and personally I would probably consider putting a claim in to Wynns for the costs involved via a friendly solicitor (don't even consider doing it without). It would probably take ages but could well be worth a try.

 

[frank rabbets]

I took my bonnet off first so I could use a block and tackle on a railway bolted to my garage roof to get the head off. I would not have been able to without this. Did you just lift yours off ?

It's worth a quote from Toyota for the pistons. They have good offers on some 80 parts at the moment.

 

[dellboykev]

I have checked amayama they are £130 each milners want £215 for a set of aftermarket ones I have Karl on the case so I will see what he comes up with I will give Toyota a bell tomorrow but my local dealer tell me it's too old and fob me off more often than not. You are right about the wear pattern star cruiser it looks like 1 end of the second ring was jammed out and the other end jammed in there is wear on the broken piece of the piston where it has been moving between the rings. to take the head off i had to sit on the radiator slide it on to my lap spin around and have my two lovely assistants take it off me being very careful because i left the injectors in god knows how i am getting it back on

 

[frank rabbets]

Do you know of "toyoDIY".com ? You can get the piston part number for your car by putting in the chassis number. Then your local dealer may find it easier lol. If you need a hand pm me your chassis number.

I was going to say to check the bore for aluminium rubbing. It leaves a mark a bit like a pencil on a piece of paper. My friend had one so bad you could actually see bits of aluminium stuck to the bore in a smooth layer. He was unaware of this and seized a piston after the rebuild !! In effect the bore was smaller and the engine gradually stopped as the piston expanded with heat and no damage was done. If you've glaze busted I expect it's OK especially if you can see the original factory honing marks beneath.

Yes I don't know how to get the head back on. Dropping the edge on the gasket is no good. Perhaps a pole with the head suspended in the middle with one person each side of the car and another guiding it directly onto the dowels. I think there are dowels?

 

[clivehorridge]

Have to say, a good move to get to grips with this properly Kev, and not to trust in the bottom end being "OK" without checking.

When this is back together, it will run like a new engine..

If you're on concrete, I'd hire a small hydraulic engine lift, to replace the head. Otherwise, knock-up a tripod or a "swing" frame from borrowed scaffold tubes and clips.

Usually, a local builder will be happy to lend (give) you some bits and pieces enough for that. A cheap nylon pulley set from halfrauds would be enough for a head.

 

[dellboykev]

to put the head back on i will probably do what frank said and have a pole and a person each side of the car while i guide it on milner have just rang me and they wont have pistons until February and toyota want £200 each. i have inspected the pistons properly and took the rings off chunks have fell off every piston i have also taken the pistons off the con rods

 

[frank rabbets]

If you've left the camshaft on some of the valves will be open. Make sure you don't rest the head on them. Can't remember now if I had to take my shaft off to get at the head bolts or whether I took it of unnecessarily.

 

[frank rabbets]

PS I had a nightmare getting the valve gear on. I used a piece of string pulled tight underneath the rockers etc to keep them horizontal.

 

[dellboykev]

i had to take the rockers and cam off to get to the head bolts all that is left in the head is the injectors and valves im not really thinking about putting it back together now with all the trouble im having finding pistons. speaking of pistons check this out im amazed it was still running