4jg2 engine rebuild

[scruff123]

Hi all
just making a thread to post pics etc of doing my rebuild if anyone is interested.

no rings were broken every thing just worn out from 200k of bad oil changes before i owned it

so far i have engine out and all stripped down, hardest part was getting the liners out! ended up riggin up a sort of press with a old stand siting in the shed. just getting prices etc so hopefully have all parts end of january.

enjoy

ready to come out:

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got the block all stripped down ready to take the liners out, then pressed them out with a manual hydralic ram

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ground up a old flange to fit in and push the liners, worked well untill the last liner, so had to make another one out of 12mm x 40 flat bar, worked a treat

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[scruff123]

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oops. haha

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the liners

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liner removed

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[scruff123]

hey guys just sorting out what parts i need and was wondering do i need to get new head bolts? cheers

[pig75]

I used the old bolts on my 2.8. As long as there not pitted they should be fine

[scruff123]

I used the old bolts on my 2.8. As long as there not pitted they should be fine

ok cheers, yea they look still like new

[scruff123]

well i was cleaning up the block and fount this! in the cylinder wall not the liner it has coroded through were the coolant runs through one other cylinder has a pinhole.

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any sugestions on what i could do?? or will the liner seal it again? never had water in the oil before and never used any water so it wasnt leaking previosly with the old liner in

[geeves]

Engine reconditioner should be able to weld that up good as new and check the other bores but it could cost as much as another engine. I wouldnt take the chance of it not leaking.

[Demonic]

I used the old bolts on my 2.8. As long as there not pitted they should be fine

ok cheers, yea they look still like new

DO NOT, DO NOT USE OLD BOLTS!, for the last month (or 3) my truck has been in getting some major work done. we reused the old bolts and had 2 snap puting the head on, and this was b4 we had reached full correct torque. Although it says you can reuse them they do stretch.

If you unsure of the engine before you owned it i suggest new. Headmaster in wellie can do a full set for about $150.

[scruff123]

I used the old bolts on my 2.8. As long as there not pitted they should be fine

ok cheers, yea they look still like new

DO NOT, DO NOT USE OLD BOLTS!, for the last month (or 3) my truck has been in getting some major work done. we reused the old bolts and had 2 snap puting the head on, and this was b4 we had reached full correct torque. Although it says you can reuse them they do stretch.

If you unsure of the engine before you owned it i suggest new. Headmaster in wellie can do a full set for about $150.

cheers mate ill get new ones. good to be on the safe side

[scruff123]

well i was cleaning up the block and fount this! in the cylinder wall not the liner it has coroded through were the coolant runs through one other cylinder has a pinhole.

PC273026.JPG

PC273029.JPG

any sugestions on what i could do?? or will the liner seal it again? never had water in the oil before and never used any water so it wasnt leaking previosly with the old liner in

went and picked up my parts from isuzu parts specialists in auckland on saturday and had a good chat to the reconditioner, also found out when looking at the new liners that my old ones were cast iron so it has had a rebuild at some stage, that is why they were so hard to get out and also the reason for the hole in the coolant passage between bores, he said that with a little bit of corrosion and having to bore it out slightly to fit the cast liners results in very thin wall or a hole but because the cast liners are thicker and a press fit i dont need to worry. i am getting them to install the liners and machine the tops, hone them and remove/fit new camshaft bearings for $600, other parts i got were pistons, rings, all bearings, camshaft, gasket set, headbolt kit, engine mounts, cambelt, starter motor and full hose kit all for $1600, so that including machining and istallation of liners $2200 i thought was prity good.

will be gettin liners done in the next 2 weeks and then i can start putting everything together, will post pics etc of progress

[bozza72]

your at the same stage as me, block going to headmaster this week, will clean and check everything else while they are installing new liners

[geeves]

Ive seen iron and chrome liners on trademe The difference in cost is hardly any more than a cylinder bore

[bozza72]

Hi all can anyone tell me more about isuzu parts specialists in auckland ??
where do the parts come from ??
has anyone else had dealings with them if so whats there work like ??
cheers

[AirBender]

I used the old bolts on my 2.8. As long as there not pitted they should be fine

ok cheers, yea they look still like new

DO NOT, DO NOT USE OLD BOLTS!, for the last month (or 3) my truck has been in getting some major work done. we reused the old bolts and had 2 snap puting the head on, and this was b4 we had reached full correct torque. Although it says you can reuse them they do stretch.

If you unsure of the engine before you owned it i suggest new. Headmaster in wellie can do a full set for about $150.

Nothing can bet the new bolt..as well as for the engine rebuild kits. Using the old bolts could snap while you're driving it hard.

[scruff123]

Nothing can bet the new bolt..as well as for the engine rebuild kits. Using the old bolts could snap while you're driving it hard.

cheers, yea got a head bolt kit from isuzu parts for $85

[scruff123]

finaly got my block back, had to get a second hand block, the old liners in the original had a wider lip on the top than the new liners so they couldnt use it, they brout it up from auckland for $30 the nite i asked if it was ready wich i thought was pritty gud, got the crankshaft and pistons in etc, just cant do anymore untill i get some new conecting rod bolts, the old ones keep stretching, would it be because its on its 2nd rebuild???

also what do people use as a wieght for tensioning the timing belt?

heres afew pics, sorry bout the quality, couldnt find my camera so cellfone had to do.

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an engine stand would be nice haha

[scruff123]

my torque rench was faulty, that why i stretched 4 bolts. taking it back on monday

[scruff123]

been busy the past week every nite and my engine is finally up and running, everything went pritty well and it started up without to much effort. afew turns and she was away.
heres afew pics, didnt get a chance to take many step by step photos, too busy.

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[Captcol]

good job

[electrifying]

awesome work
Hopefully i will be able to do this some day (if the engine self destructs).