Engine Maintenance, Alternator and Starter Rewiring

The Battery terminal leads needed replacing on the diesel engine. We used the terminal leads from the gas engine because they are in better condition. I attached the positive terminal wire to the starter motor. I had to crimp a new eyelet. On the alternator the wiring got hard. The electrical plug the connects to the alternator was different on the diesel engines alternator. I found some wiring diagrams and i problem solved and eventually figured out which wire was which. I labeled the wiring and sodded the wires and put shrink rap in them to protect the wires. There is a picture to the right that shows the finished wiring.

Replace Front brakes and bearing

The front brake are so damage and rust. So

we decide to Replace it. Not thing was hard to me. New rotor and New shoes.

After we done the Brakes, we found the Bearings need to clean too. I take out the bearing on the axis inside the whole space was full with the grease. I take out and wash it. than I put the new and clean grease in it.









Use the Grease packing tool to filed the grease in bearing with out any spce in the bearing in it.  And Remove the old damaged oil seal reinstall a New one and just hammer in carefully bake.

Engine Maintenance Heater Hoses

On the 3.1t diesel engine most of the coolant hoses were cracked and had unwanted stuff in the hoses. Some of the hoses were in positions that were hard to replace them. I replace almost all the heater and coolant hoses

around the engine

. I had to cut and fit the hoses to perfectly fit in their proper positions. One of the hoses had a

one way valve. I cleaned the valve out and put it in place with the new hoses. There are some pictures of some of the hoses i replaced.

work is progressing!

We've been working so hard in the shop that we've fallen behind in our posts!  Each of the 3 guys have been very busy with different tasks related to the conversion or repair project. Time for an update!

Dennis has spent the past week studying wiring diagrams to figure out how to match the electrical components of the diesel engine systems to the electrical wiring of the vehicle.  A conversion process that requires step by step patience and attention to detail.  It's not an easy job to decipher wiring diagrams and match it to the components on the vehicle. Well done Dennis!

Peter completed the conversion of the power steering hoses and reservoir and has been working this week on replacing the front brakes with new components and servicing the wheel bearings and axles.  Meticulous cleaning  and fitting of components and gobs of grease in the right places makes for a job well done!  Good work Peter!

Jonathan took on  the task of engine maintenance, which involved replacing the timing belt, accessory belts, glow plugs, replacing heater hoses and rewiring the alternator and starter cables.  Following the correct procedure to disassemble the components and replace the belts, and then reassemble everything according to procedures, required careful reading and interpretation of the service manual for details on how to do the job right.  And sometimes no information was available, so he had to problem solve on his own.  Excellent work Jonathan!

The engine on the left is the gas engine we removed, the engine on the right is the diesel engine.  We hope to be ready to install the diesel within the next week.  A little more to go on wiring diagrams... :)

Electrical system (Engine)

It's..well, complicated :).

figuring out the porper connections that need to be transfered from the gas engine to the diesel is, as one might think, quite the handful. but a simple method of 'breaking it down' to looking at each component and wire individually at a time, is a very important in working the most effectively

So for the electrical system, the general summery of what to do is to match various wires from the gas to the needed ones for diesels. the diesel connections that are needed are listed below (taken from a trusted forum in which someone had done a conversion or transfer using the same diesel engine).

Glow plug rail:
The Glow plug rail will be inputed imore in depth in another post, since we will make our own cuircuit for it.

Starter
The start system was done by john, usuing similar wiring from the gas engine to be attached to the rebuilt starter.

air conditioning
air condition was the most straight forward. i found the single wire on both the diesel and gas.

12V to Injection pump
The injection pump is a mini 'engine' in itself. its quite complex, but in the late stage of wiring, don found a wiring diagram of which components connect to where. the tach-ometer wire is here as well.

REV counter
tachometer incorpirated in injection pump wiring

Oil-Light and Gauge
Both of these were found attached to the engine

Temp from Plug on Thermo Housing
Temp
Temp
Temp from plug on Thermo Housing
Temp: Note this is teed in on same wire to Ignition pump.

The above 5 'temp' listings are all connected to the 'thermo housing'. we will identify the function of each when connected to the trooper so we can test and check to see which work with the corresponding function of each wire.



What we've done is, after identifying the wires, is snipped them with a decent amount of length from the gas, and we will solder the wires from the diesel to the cut wires with plug fittings from the gas engine. we want it to be easy to plug and unplug the wires still, instead of permanently soldering directly from the engine to the car.



stay posted for more on 'Electrical system (transmission)'

Engine Maintenance Timing Belt

Earlier in a post i said i was going to change the timing belt. I change it and I'm going to share with you the steps on changing the timing belt on the 3.1t Diesel engine.

Step 1

Remove the crankshaft pulley and the timing belt shield

Step 2

Turn the crankshaft so the key lines up with the TDC timing mark

Step 3

Aline the camshaft pulley and the Injection pulley but putting a bolt through the alinement hole on both of the pulleys to mark sure that they stay at their TDC position.

Step 4

Mark the timing belt on the injection pump and camshaft pulley.

Step 5

You are now ready to remove the old timing belt loosen the tension pulley and remove the old timing belt

Step 6

Transfer the marking to the new timing belt. MAKE SURE YOU LINE UP THE MARKS PERFECTLY!!

Step 7

Place the new timing belt into position and line up the marking.

Step 8

using a scale put a 9kg load on the timing belts using the tensioning arm to transfer the load

.

torque the tension pulley to 76Nm. Remove the alinement bolts from the injection and cam

pulley. Rotate the engine 45 dgrees anti clockwise and ensure all the slack is on the tensioner

side.

Step 9

Return the engine to TDC the ensure that the bolts go into the alinement holes

Engine Maintenance Starter Motor

The Starter Motor is a the motor that turns over the engine so you want it to work. I removed the starter motor and my teacher "Don" sent the starter motor to be rebuilt. One of the connections was different because we are using the battery positive cable from the gas engine. The rebuilt starter came in and i put grease on the starter motor gear and placed the motor in the right position. There is a picture showing the rebuilt starter motor in place.

air conditioning

In order to re-assemble the air conditioning, the hoses from the compressor had to be re-fitted and relocated, because the compressor is on the opposite side of the diesel engine.  The compressor connector ends were taken to a local a/c shop where they were welded and crimped with new hose (see picture).  Extra hose was used so they are long enough to later be reconnected to the a/c condenser and a/c evaporator.  The original condenser and evaporator can be reused by re-fitting the lines. The receiver/dryer will be replaced before the system is recharged after installation is complete.

Relocation the Power steering pomp contianer

Today, I removed the Power steering pomp contianer ,and put it on a New location .

First I take off the contianer from the braket ,Than I removed the Base braket .

And Find a now place to set in the right front of the car , I drill 3 holes on the Front and make a new braket for the 3 holes adjust the position,

Engine Maintenance - Glow Plugs

The 3.1 turbo diesel has about 100,000 km so we decided to check the glow plugs, better to check well the engine is not in the trooper, much easier. The glow plugs are under the inter-cooler so I removed the inter-cooler. the inter-cool was attached by four bolts and two air hoses. There is a picture showing the inter-cooler being removed. I checked the glow plugs for their resistance with a volt meter. The resistance should be around 1.3 to 1.5 ohms. All of the glow plugs were in that area. To be safe we ordered new glow plugs from the United Kingdom. When they come I well replace them.

Jonathan

Engine Maintenance Belts

Early this week we decided to do so engine maintenance on the the engine. I removed the engine fan so that I could check the condition of the belts. There are two belts that are the same length. After talking with my teacher we decided to remove and replace them. I released the tension on the two belts. The Alternator moves to titan or release the belts. The belts were removed. We are ordering new belts soon.




I removed the timing belt inspection cover to take a look at the condition of the timing belt.  We decided to change the timing belt. So I remove the crankshaft pulley and removed the plastic shield that protects the time belt and pulleys. The service manual would have the information on replacing the time belt but we don't have the manual. Via internet search we found a write on a form how to do replace it. Below there are some picture of the process.