Verb: – to take apart (a piece of machinery or equipment) in order to examine it and repair it if necessary.
synonyms: - service, maintain, repair, mend, fix up, patch up, rebuild, renovate, revamp, recondition, remodel, refit, refurbish, modernize.
Ok where to start.
Remembering I am a newbie and this is my first 4x4 bakkie…
After finding my dream 4x4 (done 205k km and almost no rust) (I have always loved the shape, height, look and feel of this model ,since I saw my older brother’s one about ‘99/’00 {when I started high School} ) ..And driving it back 3500km from North Western Mozambique to Durban, …I realised a few things.
1. The Carb definitly needed an overhaul as well as new distributor and cables. (>20L/100km)
2. The clutch needed replacing (starting to slip badly)
3. The steering play needed to be fixed.
Other than that , it drove like a dream, … or so I thought.
My luck with vehicles ….
My long term plan is to put on an aluminium canopy and R.T.T and kit it out for the bush and overlanding trips. But first I need to get the engine and mechanics checked and tuned.. this is where my fun begins.
So I take it to our mechanic , had a compression test which came back fine, and got the carb overhauled and a heavy duty clutch put in, got the brakes and wheel bearings checked and the propshaft checked and replaced the universals, replaced the belts and hoses and checked the diff, transfer box and gearbox.
When under they noticed a small leak from a water jacket at the back of the engine. So removed it to replace the gasket. This is where it goes from a dream to a nightmare.
Upon opening it you could immediately see the corrosion near the bottom around where the gasket needs to sit, (apparently due to sitting for prolonged time and lack of anti-freeze?) and this now needed to go for aluminium welding to be able to fit the gasket properly. No problem, so the head comes off to go to get welded and bam …unbeknown to me the head was in fact blown.. and cracked and there was signs of previous welding having been done inside, and the cam shaft badly worn in places. Funny as it ran well – just a gas guzzler :? .
So here we are now looking for a new head and camshaft and and and … instead of my minor fixes im going to need to do some major ones. But before I go on I thought I would get some advice from all you seasoned Hilux professionals as to what to do next.
As it is open now I decided I might as well do a complete overhaul and try get it back to as close as new as possible, and as I am a newbie I want to make sure I get everything done and not leave anything out.
I want to put a list together of what would need to be checked, replaced and changed, in not only the engine but throughout the cab as it is almost 20 years old and not having much history on any previous services or work done, I want to do it right as I plan on keeping this guy for the next 20 years if I get that far
I will write down what I have been told/understand so far but will greatly appreciate any additional information that I may have omitted or gotten wrong. And rough prices will help if you have.
Thanks.
Engine: 1995 22R 2.4 petrol (not sure of what has to be done to engine from inside out?)
Heart:
Replace head?
cam shaft?
big ends ?
conrods?
timing chain?
seals
gaskets
valves, stem , guides & seals?
reamed& rebored
oversize pistons?
oversize rings ?
…..?
Brains: ?
General Organs:
Overhaul carb (done)
replace distributor cap and cables (done)
new spark plugs (done)
replace thermostat
check radiator, clean and flush
replace water hoses
replace water pump
replace Fuel pump & filter
replace oil pump & filter
replace fan belts and bearings
replace air filter
check alternator / recondition
check starter motor / recondition
check airconditioner & filters
Spine & Joints:
heavy duty clutch and seals (done)
replace prop shaft centre bearing & universal joints & check balance (done)
check gearbox, check mounting & replace seals
Check diff & transfer box & seals
Check Engine mountings
Check Cv joints and seals
check exhaust system / manifold & gasket
Grease all lubricate all nipples ,points etc
Feet:
Replace brakes and check
Check Wheel hubs, replace bearings & seals
New tyres & Spare
Skin:
paint with stone chip where necessary
respray
Finished Testing:
Compression test?
dyno test?
Well this is off the top of my head so please if I have missed anything your help will be greatly appreciated, especially in regard to the actual engine and components. Thanks in advance all.
