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Diesel Engine Rebuild. A Quick Documentary.

Discussion in 'Street, Documentary, and Portrait' started by Iconindustries, Apr 13, 2011.

  1. Iconindustries

    Iconindustries Mu-43 Hall of Famer

    Earlier in the week I rebuilt a small Diesel engine from out of a Triton Ute (some of you know them as pick-up trucks) Anyway I thought, why not photograph the interesting parts as I put it together. Engine is a 2.8 Litre Turbo Intercooled Mitsubishi.

    Bare block with parent bores

    <a href="http://www.flickr.com/photos/50527022@N02/5617508978/" title="P1090274 by iconindustries, on Flickr"> View attachment 162127 "640" height="407" alt="P1090274"></a>

    Installing the white metal main crankshaft jounal bearings. aka known as main bearings.

    <a href="http://www.flickr.com/photos/50527022@N02/5616921813/" title="P1090275 by iconindustries, on Flickr"> View attachment 162128 "640" height="407" alt="P1090275"></a>

    Fitting conrod to piston with gudgeon pin.

    <a href="http://www.flickr.com/photos/50527022@N02/5616921367/" title="P1090278 by iconindustries, on Flickr"> View attachment 162129 "640" height="407" alt="P1090278"></a>

    Sliding in piston rings. The 2 top are cast iron compression rings and the lower bottom is an oil ring.

    <a href="http://www.flickr.com/photos/50527022@N02/5616918593/" title="P1090294 by iconindustries, on Flickr"> View attachment 162130 "640" height="407" alt="P1090294"></a>

    In readiness. The block, crankshaft, pistons and cradle all ready for the next stage. The conrod white metal bearings have also been fitted.

    <a href="http://www.flickr.com/photos/50527022@N02/5616921017/" title="P1090279 by iconindustries, on Flickr"> View attachment 162131 "640" height="407" alt="P1090279"></a>

    Crankshaft laid into the main bearings in the block. The cradle is lubricated and oil gallery 'o' rings fitted ready to be placed on top and torqued to correct bolt tension.

    <a href="http://www.flickr.com/photos/50527022@N02/5617507072/" title="P1090285 (1) by iconindustries, on Flickr"> View attachment 162132 "640" height="464" alt="P1090285 (1)"></a>

    With a ring compressor around the piston rings the piston is installed in the top of the block. The conrod goes in first and mates up with the small end crank journal.

    <a href="http://www.flickr.com/photos/50527022@N02/5617497834/" title="P1090305 by iconindustries, on Flickr"> View attachment 162133 "640" height="407" alt="P1090305"></a>

    The conrod end cap is placed down on the conrod bolts. The nuts are torqued turned. This means that the nut is done up to a tension then turned to a set amount of degrees.

    <a href="http://www.flickr.com/photos/50527022@N02/5617499356/" title="P1090418 by iconindustries, on Flickr"> View attachment 162134 "640" height="407" alt="P1090418"></a>

    Here you can clearly see the main bearing caps which are built into the cradle. Main bearing bolts are the large head ones. Smaller nuts are on the conrod end caps. aka known as small ends.

    <a href="http://www.flickr.com/photos/50527022@N02/5617499948/" title="P1090417 by iconindustries, on Flickr"> View attachment 162135 "640" height="407" alt="P1090417"></a>

    Checking piston height protrusion. This is critical as there is no room for error otherwise the piston will hit the head. Believe it or not but the piston protrusion for this particular engine is .5 mm above the block deck. The thickness of the head gasket is the only thing stopping the pistons from smacking the head.

    <a href="http://www.flickr.com/photos/50527022@N02/5616918197/" title="P1090291 by iconindustries, on Flickr"> View attachment 162136 "640" height="407" alt="P1090291"></a>

    The balance weight shafts have been installed (small gears on each edge) The balance weights counteract the weight of the pistons so the engine will not vibrate. Also the oil pump and timing chain has been installed. These gears are all timed with each other and the engine will self destruct if not set properly.

    <a href="http://www.flickr.com/photos/50527022@N02/5617496808/" title="P1090301 by iconindustries, on Flickr"> View attachment 162137 "640" height="407" alt="P1090301"></a>

    Closer view of the same thing. The large hole cutout in the steel backing plate is where the Fuel injector pump is installed.

    <a href="http://www.flickr.com/photos/50527022@N02/5616917687/" title="P1090300 by iconindustries, on Flickr"> View attachment 162138 "640" height="407" alt="P1090300"></a>

    All ready now for the next stage which is putting on the Cylinder Head. if you look closely you can see the head gasket sitting in place.

    <a href="http://www.flickr.com/photos/50527022@N02/5617503096/" title="P1090393 by iconindustries, on Flickr"> View attachment 162139 "640" height="407" alt="P1090393"></a>

    The Cylinder head bolted on and the camshaft installed on the very top of the cylinder head. This is a single overhead camshaft with 2 valves per cylinder.

    <a href="http://www.flickr.com/photos/50527022@N02/5616919951/" title="P1090397 by iconindustries, on Flickr"> View attachment 162140 "640" height="407" alt="P1090397"></a>

    Showing the chain driven camshaft.

    <a href="http://www.flickr.com/photos/50527022@N02/5616914055/" title="P1090402 by iconindustries, on Flickr"> View attachment 162141 "640" height="409" alt="P1090402"></a>

    Top view looking down on the cylinder head. See the head bolts (all stretch bolts so therefore torque turned. Because they are designed to stretch they can only be used once. Also note the 4 injectors with the fuel lines attached.

    <a href="http://www.flickr.com/photos/50527022@N02/5617501760/" title="P1090421 by iconindustries, on Flickr"> View attachment 162142 "640" height="408" alt="P1090421"></a>

    Close-up of the camshaft lobes.

    <a href="http://www.flickr.com/photos/50527022@N02/5616915971/" title="P1090398 by iconindustries, on Flickr"> View attachment 162143 "640" height="407" alt="P1090398"></a>

    Bolting on the Turbo.

    <a href="http://www.flickr.com/photos/50527022@N02/5617501156/" title="P1090405 by iconindustries, on Flickr"> View attachment 162144 "640" height="407" alt="P1090405"></a>

    Completed engine. The Fuel injector pump you can see in the fore.
    There are many other bits and pieces I haven't shown, but these are the most interesting. I hope it has been interesting and hasn't bored you to tears!

    <a href="http://www.flickr.com/photos/50527022@N02/5616910749/" title="P1090422 by iconindustries, on Flickr"> View attachment 162145 "640" height="407" alt="P1090422"></a>

    Thanks for looking.:smile:

    • Like Like x 13
  2. Hikari

    Hikari Mu-43 All-Pro

    Nov 26, 2010
    I feel as if I could do that all by myself now...

    or not.
    • Like Like x 1
  3. DownUnderDog

    DownUnderDog Mu-43 Regular

    Well done Icon, you never cease to fail at entertaining us, but still love the pix of you covered in oil that you posted previously. By the way we hear the cotton price is real high, perhaps some new camera gear, or a newer Beemeer is a possibility.
    Cheers DUD
    • Like Like x 1
  4. squeegee

    squeegee Mu-43 Veteran

    Jan 26, 2010
    I must protest! :rolleyes: 

    for those around the rest of the planet... a Ute is a 4 door family sedan where the back seats and trunks are missing and a flat bed is put in it's place. It's also known as the worlds second ugliest vehicle style (The first going to anything citroen produces.)

    A pickup truck is a proper 4x4 style truck with a flat bed. Although not necessarily 4x4, they're not ground hugging family sedans. Now that I write this I feel like running out to get pictures to show... but I should be working... oh well.
    • Like Like x 1
  5. mauve

    mauve Mu-43 All-Pro

    Mar 9, 2010
    Paris, France
    So must I protest too (Citroën Traction 15-Six) :

    <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/OdoCWpEs2b1qfLt13p91hQ?feat=embedwebsite"> traction_15-6. "800" width="800" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">De <a href="https://picasaweb.google.com/manuel.viet0/OLYMPUSEP1?feat=embedwebsite">OLYMPUS E-P1</a></td></tr></table>

    <table style="width:auto;"><tr><td><a href="https://picasaweb.google.com/lh/photo/4XJ0HHFK2eWGTmY9Vd6T7g?feat=embedwebsite"> traction_15-6_calandre. "800" width="607" /></a></td></tr><tr><td style="font-family:arial,sans-serif; font-size:11px; text-align:right">De <a href="https://picasaweb.google.com/manuel.viet0/OLYMPUSEP1?feat=embedwebsite">OLYMPUS E-P1</a></td></tr></table>

    I had the dubious honor of having been driven for some hundred kilometers in one around England. Mind you, this isn't the base model, but the luxury inline-six cylinders, 3.0 liter, 80 HP powered version.

    Top speed : 135 km/h (a solid 90 Mph) real (we went close, at some point the onboard tachymeter was displaying 150 - not bad for a lady over 50 years old, and it showed, if only you had seen the other cars on the highway give us way in a hurry).

    The inside is a palace, outside the sound is a deep grawling.

    But then you realize there's no airbag, no seat belts, no passive security, no disk breaks (drum breaks only). And there are ashtrays...

    Oh well, you only live once !

    • Like Like x 4
  6. Iconindustries

    Iconindustries Mu-43 Hall of Famer

    Cheers for the comments. But to whom it may concern, when I finish work this arvo I'll show you a reall ute. Not those wannabe sedan things.:smile:
  7. bilzmale

    bilzmale Mu-43 All-Pro

    Nice series again icon - did you have to clean your greasy hands before each shot. Oh and I drive a ute (but it thinks it's an SUV). I thought pickups had a compulsory gun rack on the rear window.
  8. Alanroseman

    Alanroseman Super Moderator Emeritus

    Dec 21, 2010
    New England

    You've really found a great spot for yourself. Photographic Documentaries seem to be your thing, and you do them so well.

    This is two in a row, both wonderful, like reading a good magazine with great narrative and perfect images.

    What a great post Brady...

    Thanks! Alan
  9. Brady, makes sure it has a bullbar and some bad-ass spotties on it so that you can show these foreign folks what a Ute really is!
  10. Alanroseman

    Alanroseman Super Moderator Emeritus

    Dec 21, 2010
    New England
    It's going to be hard to be intimidated by "spotties", like fluffies, or sweeties...
    or puffies, Oooooooh scary... sounds wicked awesome...

    Oh yeah Brady, be sure to put the old "spotties" on there so we foreign types can be awestruck..

    Oh baby..... :rofl:
  11. Hmm, not sure if we're on the same page with "spotties", but here's a nice Bullbar.

    Bullbar: 1, Bull: 0
  12. Iconindustries

    Iconindustries Mu-43 Hall of Famer

    Thanks penguin for your support. These foreigners don't know what a real ute is!! Jimny Crickets.

    Also the exhaust works much better coming up behind the cab. The aerials ensure good radio reception and also help the police scanner work better.

    This is your typical ute. A Toyota Landcruiser decked out to catch the girls.
    This one is a bit shiny,usually the chrome isn't as shiny as that, but this is real business.

    <a href="http://www.flickr.com/photos/50527022@N02/5617688285/" title="A real ute by iconindustries, on Flickr"> View attachment 162182 "640" height="484" alt="A real ute"></a>

    The general idea is to see how long you can last with as much wattage of light before the Cops tell you to take some off.

    <a href="http://www.flickr.com/photos/50527022@N02/5617684625/" title="A real ute by iconindustries, on Flickr"> View attachment 162183 "640" height="484" alt="A real ute"></a>

    This one is from the circle work championships at the Deni Ute Muster.

    <a href="http://www.flickr.com/photos/50527022@N02/5617777747/" title="d4 144 by iconindustries, on Flickr"> View attachment 162184 "400" height="241" alt="d4 144"></a>
    • Like Like x 3
  13. squeegee

    squeegee Mu-43 Veteran

    Jan 26, 2010
    lol, sweet!

    now see I'd call that a pickup truck, and I'd call that blue car behind it in the second picture a ute, or the third picture a ute.

    I'd also call it a roo-bar, not a bull bar.
    After last weekend maybe a womb-bar....

    I think the problem is I'm too close to the city... no one needs a serious flatbed like that around here, most ute's here are for show only.
  14. Iconindustries

    Iconindustries Mu-43 Hall of Famer

    You could be my TA for a bit and learn the ropes!

    DUD you're a top bloke. Thanks for your comment. The cotton is looking super salubrious and my brother will be helping with the picking of our neighbours crop tomorrow. Newer Beemer may be out of the question as I've just spent a bit on mine making it look brand new. Got most of it resprayed and upholstery work done. Camera gear maybe! But what do I need, I'm pretty content with what I've got actually.

    I didn't clean my hands this time. I just grabbed a rag and put it where i held the camera then took the photos. The only problem with the rag is that it stops intimate contact with the camera.

    Cheers man. I'm a very methodical kinda guy so maybe that's what makes it work!
  15. Alanroseman

    Alanroseman Super Moderator Emeritus

    Dec 21, 2010
    New England
    Okay Nic,

    I'm officially impressed... great "spotties" on that thing...
  16. alessandro

    alessandro Mu-43 Regular

    Jan 29, 2010
    Great story! To be a very fine, sure publishable documentary-artistic "essay" as they call them now, we just miss some more human presence... Go self timer or remote - and greased face of course!!! :) 
  17. See, I knew he'd come through! Nice spotties (spotlights).
    • Like Like x 4
  18. grebeman

    grebeman Mu-43 All-Pro

    Mar 13, 2010
    South Brent, south Devon (UK)
    great set of pictures, better than the ones that appear in the manuals. I hope you washed your hands before each photo shot, having seen just how mucky you can get :biggrin:, good work.

    • Like Like x 1
  19. Bermuda

    Bermuda Mu-43 Regular

    Jan 7, 2011
    nice photos m8. I "Uted" (is that even a word?) my old Suzuki Vitara 4 years ago or so. Spent 1 year building it ( LOTS AND LOTS OF MODS inc 35" tyres etc ) then met a girl used it for 3 months and sold it so i could move in Bermuda. Some times i do miss the 4x4ing as i did it for over 9 years but then i just go down to the beach and forget about it :) 

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    • Like Like x 3
  20. Iconindustries

    Iconindustries Mu-43 Hall of Famer

    Bermuda you've looks like you had a fun time back in the hey day with your ute. Those Suzuki's are pretty much a go-kart when it comes to having fun. Shame you only had it for 3 months.
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