The Diesel Boys Maintenance Thread *4x4/4x2*

[bleedingfreak]

Mine doesn't creak when I grease mine.

[roadhog]

what speed does your van start to feel "unstable" at?

[bleedingfreak]

Depends on the road and the load boy

[roadhog]

with heavy load i would expect it to feel a planted to the road on a straigh and cornereing would have to be slow and breaking would be shoddy.

[Val]

140kmh.

Mine doesn't creak when I grease it either, it just doesn't last as long as yours.

[bleedingfreak]

[roadhog]

^^ i think it's earlier in theis thread or on a tiwaniese one i was reading beacuse of the hilux high enter of gravity alot of people were getting intoaccidents can't rem the particulars. but is common sence that a a larger vehicle you must be more cautious when driving it and it won't be as agile as a smaller vehicle.
anyone ever swap out their intercooler for an aftermarket one? if so whats the performance increase like?

[sweeks]

Ques... anyone running K&N air filters in their diesel engine?

Besides the obvious increased life span, do they significantly improve performance and fuel consumption?

[equipped2ripp]

yes, i have a K&N in my frontier. there's no BIG significant improvement in performance and fuel consumption, but you see slightly better mileage and acceleration. when the filter was brand new, it was a big difference. now it's more or less the same.

[sweeks]

How long have you been using it?

Have you ever serviced it with the recharger kit?

How much did you pay for it? I got a quote for $480 for the 1kz-te.

At the end of the day, is it worth it?

[roadhog]

in reviews K&N wasn't the top filter but i guess it's to only real drop in filter replacement is it possible to replace the intake system with say a cold air intake with a large cone filter?

[Val]

Roadhog, please do not use a Cold Air Intake in your diesel unless you want your van to sound like shiet.

[sweeks]

RoadHog ... I prefer not to do any modifications. All I want is to replace the filter.

[equipped2ripp]

i installed it when the vehicle was doing 44000kms or so. right now i just crossed 92000kms.

i've used the recharger kit a couple of times... every 15-20000kms.

i paid $550 for the filter. $480 is a good price for the 1KZ-TE.

at the end of the day.... it's economical in the long run. because the original filters are like $250 or so, and you need to change them every 20000kms. don't even compare the prices with the aftermarket ones for around $60... i've heard that the inside/paper walls collapse after a while. cheap thing no good, and good thing not cheap.

[sweeks]

The original filter is washable so I don't mind using it but if the K&N is going to improve performance over the long run I'll consider. Thanks for the info.

[roadhog]

what about tuning? was reading on a tiwanise forum that the new hilux they have a ecu for it that gives them 200hp. any one ever experiment to get more power or mor torque out of theire vehicle? tune it for you driving habits to give you the best performance.

[sweeks]

I have more than enough power. Personally I'm not into that and not going to interfere with anything esp the ECU. It might be small money but I don't have time for that kind of stuff. Besides that, a little philosophy of mine is ain't broken, don't fix it.

I'm still waiting for the opportunity to reach the top speed on my pickup.

[Val]

ah crap, oil is leaking from the "ferrol" in the oil gauge. Gotta get that fixed. Ppl if you're installing an oil gauge on a Diesel engine, I think you should use the high pressure gauges (160 psi), these engines put out a lot of pressure when cold.

[bleedingfreak]

sweeks, yuh right there boy. Diesels can get a bit complicated. Plus the obvious killer - prices of PARTS. My original air filter is washable as well. So I get 2-3 uses out of the one filter. Which is about 50K km I guess. I change/clean the air filter based on appearance.

I just really hate to see some fools put lowering springs on a 4x4 What's the point

But it's all about what you use your truck for. I know I like to handle some rough road from time to time, not be restricted by culverts, deep pools of water, flood, etc., etc.

[bleedingfreak]

[Val]

Also if you put a Cold Air Intake in your van, you risk the chance of hydrolocking when you decide to play hero in flood lol. Leave the stock airbox be please.

[roadhog]

^^^
lol run one them nice snorker things they have on the land cruisers

[roadhog]

if your van smoking i found this on united diesel

Black smoke
This is due to a air to fuel ratio imbalance, either the fuel system is delivering too much fuel into the engine or there is not enough clean air (oxygen ) a few things to look for :

Faulty injectors (injectors need attention at about 100.000 to 120 000 miles)
Faulty injector pump
Dirty air cleaner
Turbocharger or intercooler faulty
Problems within cylinder head, valves clogged up due to faulty EGR (exhaust gas recycling unit)
White smoke
Normally means that the fuel injected into the cylinder is not burning correctly. The smoke will burn your eyes.

Engine/pump timing out
Fuel starvation to the pump causing the pumps timing not to operate correctly
Low engine compression
Water/petrol in the fuel
Blue smoke
The engine is burning engine oil

Worn cylinders or piston rings
Faulty valves or valve stem seals
Engine over full with engine oil
Faulty injector pump/lift pump allowing engine oil to be mixed with the diesel

[roadhog]

DRIVER
ENERGY EFFICIENCY
TIPS


DIESEL ENGINE
DIAGNOSTICS

Most diesel engine problems are related to the injection system. As such diagnosing diesel engine problems requires knowledge of engine and injection system operation.



This brochure provides you with the guideline to troubleshoot various diesel engine and injection system problems.

DIESEL ENGINE DIAGNOSTICS
Diesel engine problems that are most frequently encountered may be identified as follows

1. Excessive Exhaust Smoke

2. Engine Knocking

3. Engine Missing

4. Hard Starting

5. Lack of Power

6. Poor Fuel Efficiency

7. Fuel Leaks

8. Clogged Fuel Filters

These potential problems are briefly discussed below.


1. EXCESSIVE EXHAUST SMOKE
Excessive diesel smoke is due to incomplete combustion, normally caused by faulty injection system or other engine troubles. A small amount of exhaust smoke is normal during initial start-up or rapid acceleration.


Type of Smoke
Abnormal Exhaust smoke may be black, white or blue. Each type of smoke indicates engine problems and these are discussed below:


Black Smoke


Excessive black smoke is caused by a rich air-fuel mixture. This may result form problems with the injection pump or infection timing, which may in turn be clue to a choked air cleaner, worn fuel injectors, adulterated diesel fuel or the engine itself.


White Smoke


White smoke occurs mainly during cold starts, when the fuel tends to condense into liquid and does not burn due to cold engine parts. The most common reason for white smoke are in-operative glow plugs low engine compression, a bad injector spray pattern, late injection timing or injection pump problems.


Blue Smoke


Excessive blue smoke indicates problems from low engine compression and/or worn piston rings, scored cylinder walls or leaking valve stem seals The blue smoke is caused by crankcase oil entering the combustion chamber and being emitted after partial combustion through the exhaust


2. ENGINE KNOCKING
All diesel engines produce a "knocking" sound when running. In a diesel engine fuel ignites when infected into the combustion chamber. This rapid combustion produces very high pressures generating a rumble or dull clattering sound Abnormally loud "knocking" may be due to diesel engine miss.


3. ENGINE MISSING
A diesel engine miss results from one or more cylinders not burning fuel properly. This is caused by injection system problems which include:

Faulty injectors
Clogged fuel filters
Incorrect injection timing
Low engine compression
Injection system leaks •
Air leaks
Faulty injection pump


4. HARD STARTING
If diesel engine does not start it may be due to:

In-operative glow plugs
Restricted air or fuel flow
Bad fuel flow solenoid
Contaminated fuel
Injection pump problem
Low battery power

A slow cranking speed is a common cause for starting problem. Being a compression ignition engine, a diesel engine must crank fast enough to produce sufficient heat for combustion


5. LACK OF POWER
·Lack of engine power may be caused by

Slack throttle cables

Incorrect governor settings

Clogged fuel filters

Dirty air fillers

Low engine compression

Other factors affecting combustion


6. POOR FUEL ECONOMY
Poor fuel economy may be due to:

Fuel leak ·

Dirty air filter

Corrected injection timing

Leaking injectors


7. FUEL LEAKS
Leaking fuel lines or loose connections can adversely affect the performance of a diesel engine Pinpointing exact locations of fuel leak become much more easier when the engine is on Since fuel is injected at high pressure extra care must be taken as the leaking fuel can cause serious injury



If signs of fuel leakage are detected use a piece of cardboard to find the leak, move the cardboard around each fitting If there is a serious leak, it will strike the cardboard and not your hand, thereby avoiding serious injury to your hand


8. CLOGGED FUEL FILTERS
Other than the main filter installed in the fuel line for draining water, diesels have sock filters fitted in the fuel tank and some times in the injector assembly as shown below For optimum performance these filters must be kept clean.



DIESEL TESTS
Diesel Compression Test
Diesel engine compression test is similar to compression test for petrol engine. In diesels compression pressures are in the range of 3,000/ 4,500 psi Readings in each cylinder should be in the range of 50 to 75 psi of each other


Cylinder-Not-Firing Test
The resistance of each glow plug increases as the cylinders fire A no change in the resistance of any particular cylinder's flow plug will show that the cylinder in NOT firing. Pyrometer, a temperature sensing device can be used to detect temperatures at exhaust of each cylinder to confirm the NOT firing cylinder.


Injection Pressure Test
An injection pressure test uses special valves and high pressure gauge to test the following

Injector opening pressure

Injector nozzle leakage

Injection line pressure balance

Injection pump condition



Due to the versatility of this tester it helps in quickly locating bad nozzle, clogged injector filter or faulting pump.



DIESEL INJECTOR SERVICE
Most diesel engine problems are associated with the injection system Major injector system components have been discussed in driver energy tips No. 4 titled "Understanding and Maintaining Diesel Vehicles" In the following section information is provided on the proper functional characteristics of the diesel injector


Injector Opening Pressure
Typical diesel injector opening pressure is approximately 1,700 to 2,000 psi (pound per square inch) of opening pressure is not within service manual specifications, rebuild or replace the injector.


Injector Spray Pattern
Some diesel injectors make chattering sound during operation while others do not. However, all nozzles should make a swishing or pinging sound when spraying fuel.



As shown above there should be a narrow, cone shaped mist of fluid. A solid stream of fuel, uneven spray, excessively wide spray or spray filled with solid droplets indicates that the injector needs service and or replacement

DIESEL INJECTION SERVICE TIPS
1. Wear safety glasses when working on a diesel injection system.

When in doubt, refer to a service manual for the make of vehicle being serviced. The slightest mistake could upset engine performance or cause engine damage.

Always cap lines or plug fuel end fittings to prevent entry of foreign matter.

Never drop a diesel injector or injection pump. They can be damaged.

Remember that high pressure inside a diesel injection system can cause serious injury.

Some diesel injection systems must be bled (air removed) after repairs.

Clean around fittings before they are disconnected.

Adhere to all torque specifications. This is extremely all the more important on a diesel engine.

. Never use a bent, frayed, or kinked injection

line. Place a screen mesh over the air inlet when the engine is to be operated without the air cleaner. Rags and other objects can be sucked into the engine. Also, do not cover the air inlet with your hand with the engine running or injury may result.

Check fuel filters and water separators periodically. Water can cause extensive corrosion of injection system parts.

[bleedingfreak]

[bleedingfreak]

[Val]

Bad is joke

[bleedingfreak]

^^ Yuh in a real mess there Val

roadhog, good info. Had the problem with the glow plugs already. And well, the black smoke from the clogged strainer.

[roadhog]

where would i get a nice hydraulic jack that would be easy to use for a good price?

[bleedingfreak]

^^ You can get a 2 ton jack for $150-200... that'll be sufficent.

When yuh getting the vehicle