Anybody recognize this diesel engine manufacturer?

[Gcorron]

Wow!! You've done a lot of work, and 'shade tree' machining! I thought I was the last one.

We'll keep our fingers crossed for you, sounds like you're headed for success!

Great Job!

George

 

[Egon]

Commendable job.

If there were any marks on the piston they may burn thru??

 

[Ilikeurtractor]

Thanks for the support but I'm not counting any chickens yet. I figure I've got about a 50/50 chance of it running close to what it did before the belt snapped, if at all. It seems like it had low compression as it turned over very easily with the starter before it failed and I'm not doing anything to help with that. It wouldn't idle without white smoke and missed under about 1500 rpm but above that it actually seemed to be ok with no smoke at all. I'm just hoping to get it running enough so I don't have to keep pushing the loader around until I get the other engine ready. The welds, although ugly, seem to be holding pretty well. I used pre-heat and let them cool in mineral wool insulation which took the better part of a day so hopefully no cracking problems will show up. Reuse of the head gasket is concerning of course.

The replacement engine is a Continental TMD27 which is a little closer to the size the loader actually should have (2.7 liter vs 2.2 on the Toyota.) The pump does not pump at all. I took it to a shop and they stripped it down and determined the plungers were stuck but now they are free. They wanted $850 to put it back together. That was out of my budget range. The good news is the pump is a Stanadyne and the manauls are freely available on the internet and seal/o-ring kits are only $30 off eBay. I will attempt a reassembly and see if I get lucky enough not to have to take it back to the shop. I won't be able to verify the tuning though but we'll see what happens.

Egon - not sure on burn through but there are valve marks on the pistons but they don't seem to be very deep and may only be marks in the carbon deposits. I'm hoping it won't be an issue - lots of hope required on this one

 

[fidowanttobe]

Didn't Toyota put a lot of engines in forklifts? Surprised you can't find any parts for it.

 

[Gcorron]

Sometimes that doesn't make a difference. Neighbor has a Bobcat, not THAT old for a piece of equipment (mid 90's I think), and the fuel pump went bad. Bobcat could not get it, Isuzu no longer provided. Lucky an electric pump from NAPA worked fine. It would truly be a pity to have a piece of equipment sidelined for such a minuscule part.

George

 

[Ilikeurtractor]

I haven't hit any dealers or auto parts stores, just what I could find on the net which was really only the belt. I think I might have seen the timing gear cover which is just a plastic molding but mine is ok. I saw rockers cheap on eBay but I can't confirm they are the correct ones without either buying them or a parts list.

The belt and injector pump seal showed up yesterday so I installed the seal and put the pump back on the engine, installed the cam, rockers, and associated timing pulleys. I set the valve clearance at 0.012" on all valves and later on found out they need to be set at around 0.010" on the intake and 0.018" on the exhaust so I'll need to go back and redo that. Looks like the head bolts should have been torqued to 75 ft*lbs but I'm not going back and loosening them now. Rocker arms should be 18 ft*lbs. but I was pushing 30 and that felt a bit much at the time so backed it to 25.

I had trouble with the belt since the crankshaft and injector pump pulleys were clearly marked on the engine in the 12 o'clock position but I couldn't find a mark for the camshaft pulley on the engine. I made the assumption it should line up with the split line for the valve cover by noting where the cam lobes were relative to the #1 piston, but I ended up picking the wrong side. The cam pulley mark should be in the 3 o'clock position but I initially set it in the 9 o'clock position. The good news with this mistake is there were no interference issues with the pistons so I could successfully test the rocker cycling, at least when rotated by hand. I eventually found a diagram on the net that showed the correct arrangement. Without the diagram, I would have had to check and see when the injector pump was injecting on the #1 cylinder as I didn't know if the pulley timing is set up for #1 cylinder firing on TDC or for it entering the intake stroke.

I was going to try to finish up tonight but it's raining. I should be able to test before the weekend is over and I'll get a video of it trying to start up the first time and post it.

 

[Ilikeurtractor]

Please excuse the host.

Toyota 2 2L first start after failed timing belt - YouTube

 

[Gcorron]

Hope springs eternal brother!! At least no 'clank, clank....thud'!!

Tuxedo t shirt would be appropriate! A little showmanship....'Ladies and gentlemen, announcing the rebirth (abysmal failure?) of, the 2.2 Toyota!! May I have a drumroll please'

We're all curious, keep us in the loop.

George

 

[Ilikeurtractor]

Last one:

Toyota 2 2L bugs worked out - YouTube