What to do with a blown up engine

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Don't go a rebuild, it'll never be the same and never as good as it was originally. For me, once it happened I lost all faith in the vehicle and was glad to finally sell it. My advice, if you've been considering an upgrade anyway, cut your losses and offload as is. Or at least weigh up what you could sell it for as is V what you will realistically get selling it after fixing it and is it financially worth pouring $10k into it.

Why not?
My D4D did the injector and melted a piston. Had the block machined oversize and fitted a new aftermarket cylinder head and baileys injectors. Removed the motor myself ( big job ) and had the engine done at a local shop.
Total cost was $7500 ish. Labour would add $3k.
Now over 50000 km and other than sorting out the injectors with Matt from BDG all good.

Car now has 250000 and other than the engine and usual maintenance cost very little.

dhr - did you have a tuning chip fitted?

Rusty.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Had the block machined oversize and fitted a new aftermarket cylinder head and baileys injectors.

Hey Rusty,

What aftermarket head did you use? ...did you also use aftermarket over sized pistons?

How many km's have you done on the rebuilt engine? I think you're also running the manual mapper now and have fully blanked the egr? So you would have done most of the rebuild km's on a small diameter 6-7mm plate and minimal km's on the full blank?

Lots of questions, but it would be interesting to get a more detailed understanding of your rebuild and how you've survived the egr mess!

Best

Mark

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Mark

Too long a story to type.
Don't remember the brands that where used only that the engine re conditioner has never had one fail. Bore is 0.5 mm oversize.

On the EGR had used a catch can after injectors at 150000km and 7mm for a few months and after the third clean have gone 100% block.

Happy with the way it is running and would line up for a second trip to WA tomorrow if the funds permitted.

Rusty.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Mark

Too long a story to type.
Don't remember the brands that where used only that the engine re conditioner has never had one fail. Bore is 0.5 mm oversize.

On the EGR had used a catch can after injectors at 150000km and 7mm for a few months and after the third clean have gone 100% block.

Happy with the way it is running and would line up for a second trip to WA tomorrow if the funds permitted.

Rusty.

Hey Rusty,

Third clean, holy moly! ...egr is a nightmare!

Nice to hear you're confident in the rebuild and that it's worked out.

I'm with ya on WA, just need to win lotto!

Best

Mark

[Anth120playdo Banned Find all posts View Profile Close Anth120playdo]

Hey Mark, only 1 clean required once plated, don't stress, Russel has some spare time to play with the vehicle, he just cleans & inspects every time he gets bored.

Russel the reason not to rebuild is, so many people are not so lucky, more often than not with rebuilds, people are having oil leaks& oil burning afterwards. It's good that yours has worked out well!

A long motor from Toyota has new injectors & waterpump, with what we now know, plated & regularly serviced with diagnostic, it will go forever!

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

You two are funny He He.
Alan.

We try.

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

My engine blew at 73K. It's now done another 87K after new short motor and head check. Current injectors have done 45K. It's still as strong as ever and performed admirably during the Tas GTG which included a lot of kilometres towing the CT over some pretty hilly terrain. I even passed a Discovery (not towing) going uphill towards Hobart with my CT in tow- got to be happy with that. As #### said, regular monitoring of the injector feedback values restored my confidence in the product.

[dhr29 Junior Member Find all posts View Profile Close dhr29]

Thanks again for all your valuable input, after listening to all your experiences and talking to my mechanic I have decided to cut my losses and sell the car as is.
It has been a great work horse and doesn't owe me anything, but it is time to move on.

And Rusty yes it did have a chip but it was only on level 3 out of 10, it also had an oil vent tank.

[Rusty62 Advanced Member Find all posts View Profile Close Rusty62]

Another motor gone towing with a chip.

Denso have a lot to answer for with the failure rate of these injectors.

Rusty.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Another motor gone towing with a chip.

Denso have a lot to answer for with the failure rate of these injectors.

Rusty.

Hey,

Toyota and Denso are ultimately responsible, they both know about the problem.

How long can you expect to get out of after market injectors with decent seats that don't leak?

I'm sure that any poor soul who has been through the wringer with this problem and lost money will be keeping a very close eye on their injector values. Even with better Baileys injectors they will still cop a flogging with the basic CRD design and poor quality diesel in Australia. You will be treating them as consumables, so how long can you expect before shelling out more bucks? 80,000km max?

Best

Mark

[AussieAndy Find all posts View Profile Close AussieAndy]

Wowee.......

I'm sure if you ask anyone who is actually in the know how long you get out of your injectors depends on a lot of things. How good is the diesel you are putting in your tank, how good if your filtration system, how you drive the car (what fuel pressure the computer wants) and if you have a chip (once again fuel pressure) are some of the more important things.

So in the prefect world we are gentle on our car (computer is only asking for lower fuel pressures), we don't have a pressure altering chip (or any chip for that matter), put clean "town" diesel in from newish high turn over servos and regularly change our fuel filters. Suddenly we have a vehicle with 175,000Km on the clock and the injectors are still within spec, all be it only just.

In the not so perfect world we push our vehicle (computer wants higher fuel pressures more often), we have a chip that alters fuel pressure and we have it wound up as far as it goes, do lots of outback touring and get some questionable diesel and rely on toyota to change our filters when they want to. Now we have a vehicle that wears injectors out a lot quicker and is possibly looking for injectors at 80,000Km or sooner.

Obviously if the injectors go out of spec and go unchecked too long they will begin over fueling and will eventually cause damage. This amount of time will also depend on the above mentioned things as well as long runs/engine heat soak.

So I ask the question how are Toyota or Denso responsible for excessive wear and tear caused by factors outside of their control? Sure these injectors are susceptible to what many consider "premature wear", but now we all know about the "issue" we can continue on with routine maintenance and call injectors what they always have been, and that is a consumable component the needs periodic maintenance or replacement.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

So I ask the question how are Toyota or Denso responsible for excessive wear and tear caused by factors outside of their control? Sure these injectors are susceptible to what many consider "premature wear", but now we all know about the "issue" we can continue on with routine maintenance and call injectors what they always have been, and that is a consumable component the needs periodic maintenance or replacement.

Hey,

According to your definitions above of "excessive wear and tear" and "factors outside of their control", how many Europeans driving a Prado or a Hilux fall into this category, and why then would Toyota issue a European wide "Customer Satisfaction Campaign"?



Denso made the original injectors, they were sold in Toyota vehicles, and Toyota has accepted responsibility for their failed design by putting in new injector seats.

Best

Mark

[AussieAndy Find all posts View Profile Close AussieAndy]

Yes, SEATS!!!!!!!

This has nothing to do with the wear of the injectors. We are talking about a cracked piston issue here aren't we? Not a seized due to blocked oil pick up? Two seperate issues completely.

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Really, is that all you can expect out of these motors?

Hey,

I meant changing the injectors every 80,000km, not the motor!

If you have new injectors with decent seats that don't leak, and drive your Prado as a 4wd in various conditions, then I'm sure you can put plenty of km's on the D4D with regular injector changes every 80,000km. I've also seen the figure of 80,000km from #### (an expert in these matters). You will also need to do some work on the egr system, and either reduce the egr flow with a small diameter plate or block it completely.

Have a look at these threads so you can get an idea of all the issues surrounding the injector problems and egr in the D4D;

Issues with the original Denso injectors;

http://www.pradopoint.com/showthread...-seats-Egr-Scv

Reducing the egr flow;

http://www.pradopoint.com/showthread...-000k-of-facts

Blanking the egr;

http://www.pradopoint.com/showthread...Diesel-Engines

Best

Mark

[Whitey Shockie Maker of the Month Award Find all posts View Profile Close Whitey]

Yes, SEATS!!!!!!!

This has nothing to do with the wear of the injectors. We are talking about a cracked piston issue here aren't we? Not a seized due to blocked oil pick up? Two seperate issues completely.

Hey,

Do the original Denso copper seats leak fuel? If the pistons are cracking/holing due to small fuel droplets/puddles forming on top of the piston from fuel leaking through the injector/and or seats, then isn't it possible that piston cracking/holing has occurred earlier than it would have from an aged and worn leaky injector? ie, leaky copper seat can cause piston cracking/holing even with a young injector?

...or is it strictly oil leaks that form the puddles on pistons that eventually cause cracking/holing?

Either way, fuel or oil has leaked through the seat?

Best

Mark