Preventative D4D maintenance/measures.

[SWR Banned Find all posts View Profile Close SWR]

Gday roo
Yep!!... Another "HUGE" read for those none mechanical minded out there that want to learn the truth on facts!.... That is what is supposed to separate a forum from a dealership and workshops!... Un-bias truth with no hidden agenda's!... Lol
I haven't bought fuel injectors off these guys (http://www.amayama.com/) as i bought mine from someone that i "thought" i trusted and like most people i believe i also got shafted (Reconditioned) and for this i am now on a mission to pay back the favour to the industry as a whole with facts based on truth!
There is still quite a few good/honest guys (Like your self roo) trying to make an honest crust but i feel the industry is becoming a tad greedy and miss-leading in the fine detail of wording and cashing in and taking advantage of the average go-blogs hard earned cash.
I have ordered parts from these guys and they do look extremely authentic! The packaging i got for the washers etc. was all in Japanese and look's very authentic!
If you are ordering from these guys three weeks wait is not out of the norm so ordering up-front would be a smart move! Lol I also used paypal to hide my credit card details but i am like that with everything.
Toyota sell parts just like any other car manufacturer but they like all the other manufacturers also pay others to make them so i guess the rule applies globally EG: Toyota mark-up from denso and denso mark-up from who-ever and maybe who-ever from even someone else.... Lol What ever the story they are better priced and work just as good as denso/toyota and look extremely identical as a few other guys have pointed out with the parts they have bought
I also found out with intense research that the copper coated seating washer for the fuel injector is actually a heat shield washer and one of main cause for injector failure is microscopic silka particles in the fuel!.... High flow 2 micron filters play a critical roll as well as keeping out that water or shall we say moister.
Silka is the aquiverlent of sand paper (Microscopic particles) running at very high speed (More relevant at high fuel pressures) through the fuel system & causes extremely abnormal wear on the injector ports and high pressure fuel pump etc.
Average life of a common rail diesel injector "can" be up to 300,000km but it can also be as low as 60,000km with poor filtration of the fuel given its environment.. (Dry sandy environment and poor fuel storage).
This is a must read if you want to understand your D4D despite this is mainly referring to commercial!... Also ignore promo as i put it up for the informative information!
https://www.hyprofiltration.com/clie...&%20Slides.pdf
I believe the fuel passing through the injector acts as a coolant to help dispearse heat for the injector but on the flip side of the coin one of the many contributions to life reduction of the fuel injector is the heavily reduced sulpha (500PPM to 10PMM = Parts Per Million)... sulpha being a good lubricant... Also the return fuel to the tank heats the tank fuel and can cause condensation in the fuel tank on cool days. So many variables with the fuel algae and bacteria etc. Not forgetting the very high fuel pressures just add to the big picture in the extreme circumstances.
Ever noticed how stock standard highly abused d4d's in the mines and desert are living longer than the average pimped-out diesel suburban despite the commercially run D4D's having the odd's stacked against them from a percentage point of view?
This is also a good read on engine stress. Admittedly its on boats but the same rule applies!... "Engine stress".
http://www.mvdirona.com/TechnicalArt...neOverload.htm
I believe the main reason for the turbo intercooler being re-located is for the ever tighter emission laws to scavenge as much cool air as possible for the manifold intake cooling with minimum heat absorption exposure as possible... Intake air (heated via turbo compressor) and EGR (Exhaust Gas Recirculation) will always be cooler than peak-duration combustion temps and the min 84 deg Celsius temps that are being pulled from the coolant radiator when the thermostat opens (also being compromised with the heat from the a/c condenser and turbo/exhaust temps will always climb very high in the engine bay when stuck in traffic or the poor air flow due to high RPM in low gear EG: driving sand dunes or climbing steep hill in low gear with engine under heavy load.
Just sharing my thoughts on it all and manufactures will always re-configure the engine management as technology changes for the better.
Cheers

[Corigator Avid PP Poster! Find all posts View Profile Close Corigator]

Have you guys hear of Twitter?

[mackayvx Advanced Member Find all posts View Profile Close mackayvx]

Have you guys hear of Twitter?

Twitter? What?

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

I'm intrigued. Will have to price up the parts in Japan.

[mjrandom Out of control poster! Find all posts View Profile Close mjrandom]

Twitter? What?

It's how feathered friends communicate. Strictly for the birds.

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Yes an Adelaide member has bought these injectors, DocK, the same guy that had them fitted for $400, I have already linked to his post in this thread where he talks about it.

I note another non mechanic, (IT GUY) took around 6-7 hours to fit a set as a DIY project, being a non mechanic and his first time I would imagine a good operator could cut that time down a bit, so depending on the hourly rate; $400 isn't that far off the mark.

Cheers Andrew

[sacred cow Member Find all posts View Profile Close sacred cow]

Skywalker,

Never heard of "silka". Do you mean "silica"? There would have to be something radically wrong with the refining process if all silica was not removed before the fuel was delivered to the customer.

Glenn

Gday roo

I also found out with intense research that the copper coated seating washer for the fuel injector is actually a heat shield washer and one of main cause for injector failure is microscopic silka particles in the fuel!.... High flow 2 micron filters play a critical roll as well as keeping out that water or shall we say moister.
Silka is the aquiverlent of sand paper (Microscopic particles) running at very high speed (More relevant at high fuel pressures) through the fuel system & causes extremely abnormal wear on the injector ports and high pressure fuel pump etc.
Average life of a common rail diesel injector "can" be up to 300,000km but it can also be as low as 60,000km with poor filtration of the fuel given its environment.. (Dry sandy environment and poor fuel storage).
This is a must read if you want to understand your D4D despite this is mainly referring to commercial!... Also ignore promo as i put it up for the informative information!
https://www.hyprofiltration.com/clie...&%20Slides.pdf
I believe the fuel passing through the injector acts as a coolant to help dispearse heat for the injector but on the flip side of the coin one of the many contributions to life reduction of the fuel injector is the heavily reduced sulpha (500PPM to 10PMM = Parts Per Million)... sulpha being a good lubricant... Also the return fuel to the tank heats the tank fuel and can cause condensation in the fuel tank on cool days. So many variables with the fuel algae and bacteria etc. Not forgetting the very high fuel pressures just add to the big picture in the extreme circumstances.
Ever noticed how stock standard highly abused d4d's in the mines and desert are living longer than the average pimped-out diesel suburban despite the commercially run D4D's having the odd's stacked against them from a percentage point of view?
This is also a good read on engine stress. Admittedly its on boats but the same rule applies!... "Engine stress".
http://www.mvdirona.com/TechnicalArt...neOverload.htm
I believe the main reason for the turbo intercooler being re-located is for the ever tighter emission laws to scavenge as much cool air as possible for the manifold intake cooling with minimum heat absorption exposure as possible... Intake air (heated via turbo compressor) and EGR (Exhaust Gas Recirculation) will always be cooler than peak-duration combustion temps and the min 84 deg Celsius temps that are being pulled from the coolant radiator when the thermostat opens (also being compromised with the heat from the a/c condenser and turbo/exhaust temps will always climb very high in the engine bay when stuck in traffic or the poor air flow due to high RPM in low gear EG: driving sand dunes or climbing steep hill in low gear with engine under heavy load.
Just sharing my thoughts on it all and manufactures will always re-configure the engine management as technology changes for the better.
Cheers

[AJ120 Out of control poster! Find all posts View Profile Close AJ120]

Take a chill pill Roo and settle down for a bit. I don't know what you charge, I don't know how long it takes you. I don't care how much you charge or how long it takes you, I never mentioned you or your workmanship or your prices or anything else to do with you. This thread isn't about you!

I was commenting on the fact that a guy in Adelaide had the job done for $400 and he is happy with it, another member did it himself and says it took him 6-7 hours, so on that basis the guy (in Adelaide) who is a diesel expert could be expected to do the job in less time and charging $400 seems to be in the ball park.

If you do more or better or different then thats fine, what you do has nothing to do with my comments.

Cheers Andrew

[D4D Addicted PP Member Find all posts View Profile Close D4D]

Wow I just read this thread for the first time today, what an entertaining read.

I love my D4D*

* I had my fingers crossed when I typed that

[Bushbasher Out of control poster! Find all posts View Profile Close Bushbasher]

What's the going rate for a finger!

[JRB Lurker Find all posts View Profile Close JRB]

Roo, you've made me question my timings - I don't think I would have done it quicker than the pro's... And you're right I guess, time must fly when I'm having fun.

The first photo I took was at 10:37:


At 18:00 (last pic I took), I was about to install and torque the fuel pipes:


So I'm gonna have to say it would have taken me maybe 10 hours, but I can't say for sure cause I stopped taking pics. It's definitely tight under that EGR cooler. I remember I unbolted the power steering reservoir to get some room to move.

As I posted here, #1&2 were quite bad, in my uneducated opinion, and obviously the source of the smoke on startup when facing downhill.
http://www.pradopoint.com/showthread...l=1#post382831

Anyway, the first pic there is of the injectors that I sourced from Amayama. I know it's not the best quaility pic, but maybe it will help you determine if they are legitimate (I believe they are!)


Jeremy

[JRB Lurker Find all posts View Profile Close JRB]

... As for the quaility of the injectors (and indeed my own work), I guess only time will tell.

Toyota did run their diagnostic tool when they reprogrammed the compensation codes, and they said there were no issues.

[Dueler120 Senior Member Find all posts View Profile Close Dueler120]

Wow, im praying to the Toyota gods that I dont have to try and do this! Hats off too JRB for taking it on though ;-)

Cheers,

[JRB Lurker Find all posts View Profile Close JRB]

I take the EGR cooler right out and replace all gaskets. Pretty well the same as what Toyota Global Services tell you to do.

The best I could get my hands on was a Hilux GSIC manual. I'm guessing the Hilux's don't have EGR coolers, cause I can't remember reading that I had to remove it.

I did take it off eventually to clean it, but I think that was a waste of time cause all I really did was spill coolant everywhere - and it really wasn't that dirty.

I wanted to take the intake manifold off; going by how dirty the TB and elbow was, I'm sure that is absolutely caked too, but chickened out cause I couldn't see the bolts to remove them (again probably because of the limited space). I might try some of the EGR cleaner some have been talking about before I do the next oil change.

Toyote Service when they entered your compensation codes for your injectors would have done a pressure test to check for any leaks. You can do this through most diagnostic tools so they would have done this.

I was actually pretty impressed with Toyota on this one. I was initially quoted $200 by a Diesel injector specialist to enter the compensation codes. I rang Nunawading Toyota they quoted me 'time only', $80, then fit it in that day between the bigger jobs. When I picked up the car the service guy said he'd had the mechanics run some tests and everything came back ok - he then asked if I was a mechanic. Haha.

I always do a full flush of the coolant system as and check the valve clearances as well.

I wish I had owned some feelers at the time cause I know the clearances were only 'audibly' checked at the 80k service (not Toyota). As I'm coming up to the 120k mark, it would have been a really good time to check them.

It's also fun cleaning out those injector ports in the head as well.

Rag wrapped around a screwdriver, plenty of carby cleaner and elbow grease. I'm not sure if it's the offical way but it worked for me. I was pretty cautious as I'm sure scratching the insides would be bad. Used the aircompressor and a bit of thin tube to blow out any oil that pooled in the injector clamp sockets (if that makes sense?).

I also got a new #1 clamp like you have recommended in other threads. It looked the same (visually) as the one I pulled off, but I replaced it nonetheless.

How long did it take to get the parts from this company

Do you have a phone number for this mob?

All my ordering was done online and correspondence via email. Payment was via Paypal, which was one of the main reasons I felt comfortable in ordering - can lodge a claim if they turn out to be fake.

Paid on the 15/11, and installed on the 01/12, so a good couple of weeks.

what torque wrench did you use?

I've got a couple of Norbar 'Professionals' (though only needed the smaller one). They were certified when new (a couple of years ago now), and I've hardly used them and treated them well, so hopefully they're still close enough.


Jeremy

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Gday sacred cow

sacred cow Skywalker,

Never heard of "silka". Do you mean "silica"? There would have to be something radically wrong with the refining process if all silica was not removed before the fuel was delivered to the customer.

Glenn

Yup! My spelling mistake!

Was supposed to be "silica" and not "silka". I will pretend that it was spell-check that changed it!... Lol

Better known as a hard grain of sand or quartz at microscopic levels.

"Apparently" dust particles as small as 6 to 7 microns (Bearing in mind that there is 1,000 microns to 1 x millimeter) is more than enough to cause abrasive/ abnormal wear to a high pressure fuel injectors... Not common with injectors that run 3,000psi but can be critical when running 20,000+ psi..... Better known as liquid sand paper when running at high pressures.

Unless you can guarantee that your servo has clean tanks and you don't live in the out-back where dust is air born everywhere i don't think the refinery can guarantee something as small as 6 - 7 microns?... That's friggin small!!

I think it is more for the guys in the bush and provided that you don't any of those dodgy private servos in Sydney! Lol

Cheers