Iron Maiden DIED !!!! ...burnt hole in the piston

[SRXy]

Man...I'm so sorry to hear about this....sad days indeed...but all is not lost I'm sure!

To sort out your turbo...give Turbo Exhange a call. There website is http://www.turboexchange.co.za/contact.html. They have branches all around the country....I had some pretty good service from them when they sorted out my Turbo. The Cape Town branch seem very knowledgeable....

I have my injector nozzles replaced for R1800 last year....best money I've spent in a long time!

[tour de frans]

Jip,you can send the pump in for service and tests ,and you can send the injectors with.The diesel shop will tell you if they can service them and maybe fit new tips.Or if you have to replace them with new one's.Recon injectors are just fine.
Do the pump now,to avoid fiddleing afterward that will cause a oil leak.When you fit the fresh pump while building the motor,its easier to do the pump timeing.
Two things about your built/parts.The M/parts full gasget set do not include the 2 o-rings for the vacuum pump.If your pump are under the injector pump and not on the altinator.I have used several gasget sets from them and did once find 2 o-rings.If your set do have them,DO NOT USE THEM,they are the right size or it will look so,they are to thin and create a oil leak after 10 or so thousend kilos.You can buy those o-rings loose from a sparesshop or bearingshop(SKF,Bearing Man)
The injector copperwashers are not complete aswel.No need to worry,the diesel shop supply the right one's with the complete injectors.If not ask them for the right washers.
I will look at your list on Monday and let you know.
Good luck again and ask your enjineering shop to take good care of your parts
Rgds
Frans

[Ross]

Eish Cedric,

I`m a little late onto this thread, but man that is very very k@k luck! I`m very sorry to hear of the problems, but on the up side we are very fortunate to have such great expertise on the forum. I wish the Iron Maiden a speedy recovery, I hope you get her back up and running again very soon.

And Frans.....thanks for sharing you insights and knowledge, I learned a lot from reading through this!!!!

[ricster]

I'll take the pump and injectors in for service probably tomorrow morning.

Frans, yes my pump does sit under the injector pump. I'll check and get the correct O rings for that. I can't remember if I added head bolts to the parts list I sent to you. I noticed a lot of greay silicone Sealer on a lot of gasket places. I assume this is a gasket maker type silicone. What kind and brand should I be using?

Oh yes ....any tip on getting the old green paper gasket that is well and truely stuck on certain parts off???

Well the good news is that the block is out and in at the engineering shop. I didnt manage time wise to get the crank out before sending it, but he said he will take it out and mic it to let me know the bearing sizes..... hoping for standard !!!!.... but hey.... if I didn't have bad luck ..... I wouldn't have any luck...

I found out that the head was done by Dastek in Pta about 70-80 000 Km ago. The Turbo was done by CRD.

[ricster]

I found some more info on the diesel pump. Stamped in but not very clear is the following:
864 R000745
pump no 104660-47.80
NP-VE 6/10F 2000RNP 181
licence BOSCH

[tour de frans]

Hey Ricster.I have not been at my office yet,will be there tommorow and look at the fax.I know its there,my secretary told me.
The green gasget on the timeing cover can be removed with a blade or a baby grinder with a soft disk.(flapper wheel).I know it is hard work to remove that specific gasget.
The sealer for the gasgets,I use sikaflex.The grey sealer sold by partstores are ok too.
Your injector pump are the std one for turbo,and should deliver enough feul for 125-130kw on the flywheel.
Rdgs
Frans

[ricster]

Thanks Frans.

I'm hoping to get the sizes of the crank and all other measurements today. Then I can make sure which bearings to order.

[ricster]

Ok.... The crank is standard and in good condition. The old bearings were still looking good too. Don't worry, I'm going to replace all bearings.

So now I need to order:
6 x semi finished sleeves
6 x keystone pistons and rings
1 x set standard main bearings
6 x set big end bearings
6 x set small end bushes (my existing gudgeon pin size is 30mm)
6 x Precombustion chambers
1 x full gasket set
x Head bolts..... can't remember how many, I'll have to count, unless someone knows off hand.

The enginering on the block and head complete but without re-assembly, but will include matching sleeves to pistons will be R3700.00 + VAT.
The diesel pump, i will get the quote tomorrow. Recalibrate will be about R 1300 and recon injectors will be about R 425 each. I'm hoping the pump is fine and that it is just the injectors that are finished. But we will see tomorrow.....

Frans, the engineering shop asked me to comfirm with you (I told them "my chom in die Kaap is die guru van Patrols en as hy se so is dit so" ), What is the piston protrusion height (deck height) allowable on the motor. He mentioned something about 0.07mm, but wanted to know if that should be dropped to 0.03-0.05mm. They are going to put new precoms in, so the head will need to be skimmed. He says, looking at the machining marks on the head, as if the head has not been skimmed before, but there is a black permanent marker note on the face of the head that says 0.3mm. This indicates that the head has been skimmed. I think that is why he is asking regarding the piston protrusion (deck height). I like this guy, as he isn't one of those okes that is too proud to ask for an opinion, or a "know it all".

[ricster]

I'm a bit confused again. They mic'ed the gudgeon pin (small end) and this is 30mm not 28mm as was mentioned. Do you think the con rods were changed or is the '99 TD42 standard small end supposed to be 30mm? I assume then that I won't need the 30mm small end bush, just the standard smallend bush for that piston.

[tour de frans]

Good Day
The sleeve protrution are between 0.02mm-0.09mm,so 0.07mm are just fine.I will go with the higher number because the head are going to be skimed flat.(precoms)
The small end bushes,I dont know the year models or when or what enjine came with 28mm and 30mm pins.You are lucky to have the 30mm one.But do replace them anyway.
Someting else;measure the camshaft lobes.If the head were gasflowed,who knows maybe the cam are cut.The std sizes are Intake lobe:41.71-41.75mm and exhaust:41.88mm-41.92mm.Check it for what its worth.
Rdgs
Frans