Let the Rebuild Begin!

Hey everyone, so as I said in my last post, I am rebuilding the 4d55 engine for my truck. I pulled the engine in a pretty short amount of time, probably less then an hour but who's counting right? Love the older rigs with very little extra to take up space!

Of course we had sunny weather for the past 2 weeks and all of a sudden it starts snowing for a few days and is also 20 degrees... It's actually the most snow we have had in this area in a long time!

I'll let the pictures do most of the talking:
http://i95.photobucket.com/albums/l1...ps42f545e2.jpg

As it sits, in all of its glory...

http://i95.photobucket.com/albums/l1...ps28247b72.jpg

Starting on the passenger side.
http://i95.photobucket.com/albums/l1...ps3b195035.jpg

http://i95.photobucket.com/albums/l1...ps408ed9fd.jpg

With the Head off:

http://i95.photobucket.com/albums/l1...ps97b06b97.jpg

Oil pan removed. Started getting a little worried here because there was quite a bit of metal in the bottom and on the pickup when I first took it off. You'll see why...

http://i95.photobucket.com/albums/l1...ps5f12bc19.jpg

One of the reasons for the metal in the pan: This is the number 4 rod journal.

http://i95.photobucket.com/albums/l1...psec544a18.jpg

Here is the 3rd rod journal: The rest looked great.

http://i95.photobucket.com/albums/l1...psd71e6278.jpg

http://i95.photobucket.com/albums/l1...ps97b06b97.jpg


I tried to get a good shot of the lip at the top of the bore, it's pretty big. Also, every one of the pistons had a broken ring. I don't know if that is from removal over the lip or what, but the wear plus or minus the rings is definitely why the compression was less then 100 psi per cylinder. The lip is big enough to get your nail stuck easily.

http://i95.photobucket.com/albums/l1...ps4402739c.jpg

Knowing that my crank is probably going to have to be turned to be used, I decided to pull apart my spare block. The spare block came with the truck, but was seized up. Well, I unseized it, and I think I will clean this block up and as long as the cylinders can be cleaned, I will use this block. There is literally no lip at all at the top, and the bearings actually looked brand new as if someone put it together and then never ran it. So, everything will get replaced for peace of mind, but just thought it was interesting.

Here are the pistons/rods from the seized block. Also forgot to mention that, on the 3rd rod from my main block, the bearing was seized to the rod cap and had turned itself so that it was out of the normal configuration if that makes sense...

http://i95.photobucket.com/albums/l1...psfb169fc6.jpg

It looks ugly now, but I should be able to clean this block up really nicely. I noticed it also has a block heater, where my other block did not.

http://i95.photobucket.com/albums/l1...psefcac086.jpg


More pictures to come. For now I am going to get everything as clean as possible to make some good measurements and then finally get everything ordered to get this thing on the road again! I spoke with Mike Warme a few weeks ago and I am going to be buying the parts from him. I have not heard back from him in a while, so if you are reading this Mike, I am finally ready to go!

Any advice that anyone has would be greatly appreciated throughout this build. Also, if anyone has the adapter setup or can recommend something that works for setting the proper timing on the injection pump, that would be great!

~Kyle

awesome start! cant wait to see this progress :)

Seems there is always one part of the engine that gets a bunch of wear marks, never fails. Looks like your pistons have also worked very hard with scuffed cylinders and you mentioned broken rings. I hope all goes good for you on the build. Make sure you run the proper oils on the first start so it will last for many miles.
Keep us posted with your status, we all like the happy endings.

That's not bad... this is how my last one started

Attachment 8321

I think you are right BradMph. Every engine I have ever done had some sort of weak link. I am currently waiting on a call from Mike Warme about the parts and then when those get in it will be off to the machine shop, and then we start the fun stuff!

~Kyle

LSR Mike, were you able to complete your build? Any tips or suggestions that you learned along the way?

~Kyle

Quote:

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Originally Posted by diablodude64

I think you are right BradMph. Every engine I have ever done had some sort of weak link. I am currently waiting on a call from Mike Warme about the parts and then when those get in it will be off to the machine shop, and then we start the fun stuff!

~Kyle

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I have been waiting on Warme since October.;)

I talked to Mike yesterday and brought some of my parts in to the machine shop. I have to take a few more measurements and then it will just be waiting for parts.

Kyle

Quote:

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Originally Posted by diablodude64

I talked to Mike yesterday and brought some of my parts in to the machine shop. I have to take a few more measurements and then it will just be waiting for parts.

Kyle

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How did the little brown truck look? I am flying in to pick it up on Friday.

Quote:

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Originally Posted by 4D55 Performance

How did the little brown truck look? I am flying in to pick it up on Friday.

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The truck looked decent, has a few things that I'll need to take care of but otherwise it is pretty solid. You're flying in to pick up a truck where?

Kyle

Alright everyone, it has been too long and an update is due.

SO, I received some of the parts so far and everything needing machining or cleaning is at the machine shop. One of the boxes of parts, I am told, was damaged during shipping so the shipping company returned it. Mike Warme has been awesome too work with, and of course re-sent everything right away, including a set of 0.040 pistons. Originally I had ordered the 0.030 pistons, but unfortunately the cylinder bores wouldn't clean up at 0.030 so the 0.040's will be needed.

As soon as the parts arrive I will be headed to the machine shop to finish everything up. I cannot wait to get this thing back together! Actually, I have trip planned for the engine break-in so I don't have much choice but to get it going in the next couple weeks!

Here are a few more pics:

I cleaned up the rusty block as much as I could before brining it in.
http://i95.photobucket.com/albums/l1...ps3e0b6e55.jpg

Here are the pistons that I removed from the seized block. One ring from each was broken... Everything else was perfect!
http://i95.photobucket.com/albums/l1...psfb169fc6.jpg

Here is the first installment of parts:

http://i95.photobucket.com/albums/l1...pse62441c4.jpg

Gawd I hate shipping companies. They bust your stuff up, cost you money, they ship it back, cost you the shipping fees, then they blame it on packaging which their own package inspectors rate the package and always give a fail rating. This kills the automatic insurance of damages and your out a pocket full.
I hope your experience has been better then mine with....what's that doing back at my house so early surprises.

How much did this kit cost you?

Quote:

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Originally Posted by Diesel mightymax

How much did this kit cost you?

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I think I am in at just under a grand right now.

did you get all parts from mike? what is that big peice of cast?? timing plate or water pump??? :S

Quote:

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Originally Posted by 4D55 Performance

How did the little brown truck look? I am flying in to pick it up on Friday.

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When you first posted this I thought you were referring to the truck I just picked up, as it is also a little brown truck! I saw your video the other day, and I am assuming that is the one you were actually referring to. In which case, that thing looks pristine man!

Quote:

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Originally Posted by coyotefiveoh

did you get all parts from mike? what is that big peice of cast?? timing plate or water pump??? :S

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I have some of the parts. The last box should finally be here today! Then I can finally put this thing together and get you guys some updates! That big piece of cast in the lot of new parts is the oil pump assembly.

where did you get your machining done at? Im also in Portland.

The machine shop is B&M Engine Services off of 77th. Everything looks good so far that I have picked up. I am now just waiting on the block and they said that should be done tomorrow most likely!

Kyle

Turns out the first block had two cracks in the cylinder liners, so I had to bring the second block in and this one looks promising (crossing my fingers). Also, the head I brought it won't clean up without taking too much off, so I am bringing in my second head and also crossing my fingers that it is good....

Holy crap, I have never had this much difficulty in any of my past builds. Does anyone local or close to Portland Oregon happen to have any spare blocks or heads that you wouldn't mind selling? Feel free to text or call me at 541.324.4278 if you do. It's pretty urgent so you know i'm serious!

~Kyle

There was one in Oregon city a couple days ago on Craig's.

I can't find it now.

Good luck with the second block!

Ill let you know if i find anything.

Quote:

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Originally Posted by 4D55 Performance

I have been waiting on Warme since October.;)

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I'm still waiting on you Spencer. Do you need to take a math class?? :grin:

Okay everyone, it's been a little while so here is an update. So everything went well with the original block and head of course... It only took 3 weeks to figure that out!

Block back on the engine stand ready to go back together!
http://i95.photobucket.com/albums/l1...ps24f46bfa.jpg

Painted:

http://i95.photobucket.com/albums/l1...psf25b9e26.jpg

Nice cross-hatch in those bores:
http://i95.photobucket.com/albums/l1...psb13d05cc.jpg

Bottom end almost complete:
http://i95.photobucket.com/albums/l1...ps3dc6b9e2.jpg

Pistons and rods installed:
http://i95.photobucket.com/albums/l1...ps77494cc9.jpg

Oil Pump installed:

http://i95.photobucket.com/albums/l1...ps6c72c867.jpg

Front assembled:

http://i95.photobucket.com/albums/l1...ps3fc5f3d6.jpg

Ready for the head:
http://i95.photobucket.com/albums/l1...psd8ba397b.jpg

Head assembled and ready to go on the block:

http://i95.photobucket.com/albums/l1...psbcf78306.jpg

Oil pan painted and installed:
http://i95.photobucket.com/albums/l1...ps5311df01.jpg

Timed and ready to go in the truck:
http://i95.photobucket.com/albums/l1...psf1f77521.jpg

http://i95.photobucket.com/albums/l1...psc2a1e1a4.jpg

I'll get a video of it running so that you don't feel left out!

As it stands, I got everything back from the shop around 6pm and had the engine 95% complete by 2am and the next day I had it in the truck and running by noon! It started up and ran awesome! I have just under 800 miles on the truck now and so far the only issue I have is the glow plugs that I bought a couple months back are bad. Also, I have a small oil leak from the oil pan but will take care of that this coming weekend.

I drove from Portland to Medford Oregon and got just under 40 miles to the gallon. Totally insane! I did a quick city mileage test and was getting 26 miles to the gallon. This seems crazy for a 4x4 but, I won't complain!

Kyle

Looks great! Mind me asking how much you budgeted for the rebuild?

Thank you! I don't mind. I did everything except the machining. But the breakdown is as follows:

Machine Shop: $395
Engine Rebuild Parts: about $800
Clutch: $80.41

So a grand total of about $1,275.41

Thanks. How does it drive? Torquey? Laggy? Top speed?

Quote:

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Originally Posted by noahwins

Looks great! Mind me asking how much you budgeted for the rebuild?

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Keep in mind that this is not a full rebuild nor is it even close. A full rebuild will set you back at least 5-7K. A full rebuild would address the injectors, injection pump, turbo, oil pump, alternator, pullies, starter, etc. These are the expensive parts of the rebuild.

Also make sure you put a new radiator in your truck. If you don't you'll overheat the engine.

I'd say it depends on what you define as an engine. If everything is by extension then I guess i'll let you all know when I finish painting the truck and replacing every nut and bolt. I would say pretty close to a full rebuild but to each his own. I did however put a new oil pump, new injectors, and alternator on the truck.

The turbo is next on the list to be rebuilt. Stay tuned.

Also I've been running that same radiator since the first start and have not had any issues. Maybe i'm lucky, but what is your reasoning?

Kyle

diablodude64

do you have any parts left over from this build? I'm gathering some parts and have been going to the picknpull but if you have any wouldn't mind getting from you. FYI Ive tried contacting you through craigslist with no reply?

Do you have a video yet would be good to see running.

Hey man, I am incredibly sorry it has taken this long to get back to you. I am on the Formula SAE team at my school and we have been working overtime to catch up with our build so I haven't had very much free time, and when I have it's already 10 pm.

If you are still interested in some of those parts, I do have quite a bit of spare parts.

Also, I will get a video up as soon as possible!

Kyle

All good just wasn't sure if it was going to spam mail or something I'm not in a rush, Just wanted to know what the deal was.

I need to get my truck running. But am trying to collect all the extras needed. Can you send a photo or two of what you may have as far as parts. Or IM me your number and a good time to come check out your stock.

What school are you attending?

Diesel mightymax

Where did you get all your parts from?

Quote:

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Originally Posted by TV97

Where did you get all your parts from?

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Hi TV97, This is a rather older thread and it might be past it's time. If your needing parts for your truck...RockAuto.com, car-part.com and Ebay are very good location places for parts. You can also check Craigslist for your area and maybe get lucky on that place. Wrecking Yards are another place to find affordable items too.


Welcome to the Forum :)