Hilux 2.8D problems after head gasket replaced

[RandomBrad]

Hi all,

Some background: My head gasket was leaking a bit of oil so I took it to a mechanic for a gasket replacement. He removed the head, had it skimmed, shimmed and the engineers replaced the exhaust guides and valve stem seals. He also did the timing belt while he was in there. I got my bakkie back and the thing is far from right!
All filters, oil/fuel/air are new. It's not using water or oil.

1st off, no. 1 injector was leaking so I took it back and that was sorted out with new seals.
I am battling to start, even when warm (it used to start on it's 1st swing);
blowing loads of grayish white smoke;
absolutely no power (yes, yes I know it didn't have power to start with!), but seriously I can't get more than 70km/h out of it now??
One hell of a noise which sounds like a pre-detonation / knocking or something similar or what sounds like an exhaust leak even though there isn't one!
fuel consumption has gone from around 8.5km/l to 2km/l... so it's using loads of diesel for no power!

I took it back to the mechanic today telling him that I thought he'd buggered up the injection timing when replacing the belt. he took it all apart again today and verified that the timing was correct (or at least he convinced me that it was correct).

What now? Can anyone point me in the right direction?

Thanks,

Brad.

[Family_Dog]

Not good, Brad. Suggest you PM this thread to Hoppy for some good advice.


-F_D

[doppies]

Jammer as 'n werktuigkundige jou voertuig so opfoeter, maar dit kan na my mening nie 'n groot fout wees nie, daar word iets mis gekyk. Eerstens, begin by die dieselpomp. Is jou pomp nie ''geswop'' nie ? Is jou dieselpomp se timing nie verander nie ? Ek dink die setting vir die 2:8 is 0.75 mm. Is die delivery valve met spring op elke injector pipe terug gesit. Is die injectors se pressures reg. Nou kom ons by die belt timing, kry 'n tweede opinie. Is die shims op die valve's korrek ? Laat 'n ordentlike werktuigkunde na bg punte kyk.

[Rebel 4x4]

Jammer as 'n werktuigkundige jou voertuig so opfoeter, maar dit kan na my mening nie 'n groot fout wees nie, daar word iets mis gekyk. Eerstens, begin by die dieselpomp. Is jou pomp nie ''geswop'' nie ? Is jou dieselpomp se timing nie verander nie ? Ek dink die setting vir die 2:8 is 0.75 mm. Is die delivery valve met spring op elke injector pipe terug gesit. Is die injectors se pressures reg. Nou kom ons by die belt timing, kry 'n tweede opinie. Is die shims op die valve's korrek ? Laat 'n ordentlike werktuigkunde na bg punte kyk.

Hi Brad,

Reading this - the starting issue....thought it could be the glow plugs....but reading further thinking a setting on the diesel pump might have gone out after re-doing the head. I could suggest a guy that's excellent working on SFA's in PE.

[doppies]

Wat my pla is dat dit nie nodig is om enigsins die dieselpomp los te maak as die top afgehaal word nie. As die top geskim is, dan moet jy die top ook ''linebore'' waar die camsaft loop, anders loop jy die gevaar dat jou cam met 'n kromming loop en breek dan gewoonlik in twee. As jy linebore gedoen het, moet jy ook die valve shim tot standaard clearence.

[Frederick]

Klink vir my ook soos dieselpomp en/of injectors. So ver my kennis strek moet die 2 altyd saam getoets en gekalibreer word.
As daar dan aan gepeuter is sal jy die simptome kry.

[Kaaskrul]

Valve clearance is nie reg nie.
Daarom start hy ook swaar.

Laat dit doen, en hy sal reg wees.

[RandomBrad]

Thanks for all the help guys!

The mechanic's shop is right next to my office / workshop. I popped in there every few hours during the 'operation' to see what was going on as well as to have a look at my pistons / bores etc. The injector pump wasn't removed and it's timing marks are all lined up perfectly. The camshaft pulley and the pump pulley are sitting on their marks perfectly too.

I'm starting to think that the valves have been shimmed incorrectly and the exhaust valves are not closing properly which is why half burned diesel is coming out the exhaust and also the noise which could be the diesel mixture still burning on it's way out the exhaust (using the exhaust system as a combustion chamber??).

Does anyone suspect injectors? Could they suddenly fail after working perfectly just by being taken out and put back in? Would the engine do what it's doing if just one injector was bad?

Really appreciate the help guys!

Brad.

[Kaaskrul]

VALVES.

[Mars]

VALVES.

+1

[Hoppy]

Have the injectors checked, installing them incorrectly IE; with the wrong washers or not torquing them with the right tube socket on the right hex can cause this.

The firing order might be wrong, it is fairly easy to get it wrong and it will cause those symptoms.

Make sure the timing is correct, there is two sets of marks on the cam gear, use the bottom ones, if the injector pump is on the mark and the belt slips over, you've got it wrong, the pump gear needs to be held in place for the belt to slip over

The pump itself might be faulty, but it is unlikely as it was running before

Do a compression test, the wrong thickness gasket can cause this

[Rebel 4x4]

Keep us updated, would be nice to see what the problem was.

[RandomBrad]

Took her in to a diesel mechanic this morning. He heard the truck coming from 3 blocks away and came outside with his coffee to see what was making all that noise! He said 1st thing he does is check the basics i.e. compression, timing etc and then if necessary he'll dig deeper.

Now I'm kicking myself for not going to him in the 1st place. Why does learning a lesson always cost money?!!!

I'll keep you posted...

[MOFASA]

School fees are never cheep....
My Dad toldo me that many years ago and i thought he was joking...
Well lets just say I now know just how expensive some of the school fees can be.....

Hope you get it sorted out soon with not to much extra cost...
If its the previous mechanics fault BILL HIM.......

[Rebel 4x4]

Unfortunately to find the right mechanic you have to go through the "school fees" This is when you live in the arm pit of South Africa, called Port Elizabeth.

Off the topic, you came right with the ally canopy?

[RandomBrad]

School fees shcmool fees.

I went round this morning to check on progress. Compression: perfect, totally equal across all 4. Timing: completely out. Reason: crank pulley is keyed to the crank with a woodruff key. Over time this little key had buggered up the keyway in the pulley. A previous owner had broached a new keyway in the pulley which obviously now makes the timing mark on that pulley as good as useless.
I'm busy machining a spacer disc for him now to space out the v-belt pulley for the alternator / p/steering pump cause it's wearing away the timing cover. Once that's done, he'll put it back together and we'll see what happens?

Thomas: I'm waiting to see what this whole exercise costs me before I buy the canopy... shot for the help!

[doppies]

When the previous mechanic remove the top, he should notice this serious fault on the pulley, otherwise he is blind. You have to remove the pulley first and timing cover and belt. Eish, they became only new part fitters. The pulley also act also as a vibration damper and it is best to replace the pulley with a new one. Once the inner part of the pulley loosen from the outer side, the timing mark became invalid and start to damage the crank nose up to a point where the cranck nose complete broke off.

[LouisZ]

Mmmm, he have replace the crank or machine it to correct the diesel timing, and that is that.

[ChrisF]

at least you now know what was wrong.

hoping you get this resolved soon.

[doppies]

Maybe it's better to replace with a good import, and sell your old engine.

[Hoppy]

Kry julle nog 2L/3L/5L imports? ons kry hulle nie meer nie.

[doppies]

Ek het maar altyd my masjine by John Dauth in Brackenfell gekoop, maar hy het nou Paarl toe geskuif by Paarl gearboxes. Hier by ons in Whk is die ouens mal met pryse. Het lanklaas 'n L engine gekoop,sal probleem wees as hulle nie meer beskikbaar is nie.

[MOFASA]

So the previous mechanic is a DUMB A$$ for not seeing the pully had a different set un BEFORE he stripped it......

I say BILL him the new mechanics fees as its his fault you hed to take it there in the first place.....