cracked piston

[k_san]

K_san, any idea on how much of that 11K was a labour component?

I've decided to pull the motor out myself and get a family friend (ex toyo mech) to check it out and fix it if possible.

If theres bigger issues inside, a fully recon'd motor over here is around 4-5K. A day of my time to swap them over and some $$$ to get the computer re-mapped by Toyota.

Hopefully not going tot cost me anywhere near 10K...

Anyone done this themselves???

Mate i will find out those details as soon as i can for you!

Iv done plenty of petrol motors being a mechanical fitter, but diesel is something that is a little more foreign to me..

Surely labour alone cant cost anywhere that much, i mean really, its still basically a 4 cylinder motor with a heap of accessories...but then again, mechanics do charge like a wounded bull for labour per hour these days hey

Keep in mind, that 11k is a total refresh too tho, all new seals and bearings, head re-done, all new fuel components so im guessing that would be pushing the price up a bit too...

Makes me feel a little uneasy as well as mine too is an 06 D4D..

[cairnzy_j]

Thanks mate. Will be interested to know.

We have pulled the engine out and will strip it this week. We will rebuild what is necessary, once we work out how bad it is inside.

Can get new and improved injectors over here in NZ now which apparently are cheaper, and better (heavy duty) than factory ones. Can you guys get them over there???

[be80hilux]

That's not good alot of coin. After seeing the thread on cleaning out the soot from the intake I am sure the build up in his motor would not only have been excessive but also a contributing factor

[cairnzy_j]

Another question for you other Hilux drivers...

Late last year ToyotaNZ announce that as part of the servicing schedule, D4D motors need their injector seals and seats replaced every 45000kms to prevent carbon build up which essentially leads to blacking the oil screen and then starvation of oil to the top end. I believe this is what caused my piston to crack...I was told this after the engine crapped out

Is this a standard service procedure in Aussie???

Maybe you should look at getting it done if you havn't already

[Hellbound]

Mate never heard of that over here in OZ, do you have any more details about it?

[k_san]

Well i spoke to my mate today about his mates hilux...

He said that injectors were $1200 each brand new, the fuel pump (genuine toyota) is $3800 - so theres more than half the cost of the repairs so far in some of the parts!

All together the final price is $12,388...thats excluding the removal and flushing of the fuel tank and lines as he is doing that himself.

Another question for you other Hilux drivers...

Late last year ToyotaNZ announce that as part of the servicing schedule, D4D motors need their injector seals and seats replaced every 45000kms to prevent carbon build up which essentially leads to blacking the oil screen and then starvation of oil to the top end. I believe this is what caused my piston to crack...I was told this after the engine crapped out

Is this a standard service procedure in Aussie???

Maybe you should look at getting it done if you havn't already

Iv never heard of this, although with all this talk about high priced repairs to blown pistons, injectors and everything else it probably doesnt sound a bad idea - at least worth asking about? Might do that in the next few coming days! I still have to ask about the tailshaft bracket mod (the recall from last year), also want them to check my throttle response as i think its a little bit slackish and might also get them to fit a tonneau cover

[cairnzy_j]

Cheers k_san. I'll let you all know the verdict when I find out myself...

Might be worth asking your Toyota techs over there if the seats/seals service is recommended. Pretty new 'idea' here and lots of Hilux owners that still have no idea it needs doing

In the meantime if anyone has any advice re: rebuilding the motor, feel free to let me know!

[lip]

Denso (what toyota use as genuine) injectors are $595 each plus GST. They only take an hour and a half to fit all 4 including new pipes so i cant see that having the seels and seat done cold be too expensive (few hundred at max).

[k_san]

Few hundred would be worth it too id think?

Might have pictures of the cracked pistons / injectors this week with a bit of luck too!

[edwrf426]

Same thing occured with my 07 TD hilux single cab, according to toyota the injector jamed open and put a hole and cracked the no. 2 piston, it was lucky the block has no damage, 104 000kms, 4 years, just out of warranty however toyota is going to cover everything except half the labour cost which works out to about $ 500. However toyota has fully serviced it and so they can't complain about a sub servicing schedule which has occured to another person i know they reckon he wasn't checking/ replacing fuel filter often enough or something ( toyota BS). I believe it all depends on your service manager and his recomendations to toyota australia.

[cairnzy_j]

Hey guys.

Bit of an update on my Hilux...

Over 3 months later I'm finally about to put my fresh motor back in the Hilux. What a long 3 months its been! Thankfully I've had the V8 100 series to use for work...

In the end I went for a full rebuild on my motor as at least I knew what I was getting. Finding a new (or going 2nd hand) Hilux motor over here was a bit hard at short notice, and bloody pricey.

After being rough "quoted" anywhere "from $7K to $16K" by our local Toyota dealership I decided to do the as much of the work myself as I could. This mainly involved pulling the motor out and dropping it off at a independent diesel engine specialist in town! One bonus with the hilux...the engine is bloody easy to get out, and we had it on the trailer in under 2 hours.

After stripping the motor down we discovered that #1 piston had seized and #2 had been cracked. This was my initial assumption. The cylinders both had some good scratches but were machinable. We fully stripped the motor to find that generally it was in good nick (for 160,000 odd kms), however I decided it was best to spend some coin on it while we had it out and went for a full rebuild.

Next we got the injectors checked as I didn't want to have to replace them at $3500 if I didn't have to! Interestingly, the injector tests came back fine, but the seats and seals on 1 and 2 were buggered, leading us to believe this was the initial cause of my engine failure. This matches well with Toyota NZ's theory on servicing the seats and seals every 45,000 - 50,000kms....

Anyway over the last couple of months, in went new bearings, oversized pistons, polished crank etc, and today we have picked up the shiny rebuilt engine.

While I had the engine out I got my hands on a heavy duty clutch to go back in with the motor, and all things going well by this time tomorrow afternoon the old girl should be back on the road! For anyone interested, the rebuild cost me $6080 incl 15% GST, and the clutch $197 mates rates from BNT. Should be up and running for $6500 including oils/coolants etc, which I'm comfortable with.

Going to Toyota for a goodwill claim, so hopefully things are looking a bit brighter in that department too!

I'll let you all know how it goes over the next couple of days!

Cheers
Josh

[dermy]

that sucks having to go thru that.. but 6500 for full rebuild and a new clutch is pretty bearable

[KTM525EXC]

16k How can they expect ppl to hand over that kind of cash I wonder how much a exchange rebuild would be?
Hope the lux serves you well now with it's new heart transplant.

[cairnzy_j]

16k How can they expect ppl to hand over that kind of cash I wonder how much a exchange rebuild would be?
Hope the lux serves you well now with it's new heart transplant.

Yeah man I know...a figure plucked from their rear ends. And you'd think they'd have a better idea considering they've been doing a couple a month! Thats why they didnt get my business.

Exchange rebuild through a couple of different places over here ranged from $5200 to $6900 + GST. I went with my original motor, mainly because I knew its history and its condition, but also because it was going to cost less to overhaul.

I hope it goes well too, I've missed it...

[cairnzy_j]

Engine back in guys. It took my brother and I about 6-7 hours to get it in and running. Fairly simple for a modern vehicle.

Had issues with a air lock in the cooling system and the engine ran hot for a while, however once we got that all sorted she ran like usual. Broke the motor in, now got to clock up a couple of thousand kms before my next oil change.

So far I've done a couple of hundred kms with no noticable issues, so hoping for a decent run out of the new motor.

Have got it booked in at Toyota for a computer check, and general going over on Monday.

[amitch888]

Hope it treats you well mate, good luck with it

[OFFTRAK]

Great work, cairnzy! Hope you get some success with Toyota and the goodwill claim.

[KTM525EXC]

Good to hear it's all up and running well done

[Hilux Max]

After being rough "quoted" anywhere "from $7K to $16K" by our local Toyota dealership I decided to do the as much of the work myself as I could. This mainly involved pulling the motor out and dropping it off at a independent diesel engine specialist in town! One bonus with the hilux...the engine is bloody easy to get out, and we had it on the trailer in under 2 hours.

If I ever encounter this, a Lexus V8 will be going straight in, much more affordable conversion than a new diesel engine costs....

well done with fixing the issues.

[brusa]

I'd strongly consider a LS 1 chev V8 heart transplant if my D4D ever had a terminal illness like this......