OUR VIDEOS GALLERY MEMBER SPONSORSHIP VENDOR SPONSORSHIP

User Tag List

Page 1 of 22 12311 ... LastLast
Results 1 to 10 of 215

Thread: Another TB42 to TD42 Conversion

  1. #1
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)

    Another TB42 to TD42 Conversion

    Hey Fellas.

    Just thought i would post up my diary on my GQ Engine conversion from a TB42 to a TD42t Intercooled.

    TB42e to TD42 conversion – My Experience

    I have 95 GQ Patrol RX TB42e on dual fuel, I love this ole bus but hate the motor, the LPG is temperamental, gutless and now the government duty on LPG has been increased its not even that cheap with LPG prices close to $1/Litre outside of Melbourne, if you can even get it. Because of the LPG the car cannot be set up right on petrol, in order to compensate the ignition timing for the LPG, everything is a compromise & I hate it, having to climb relatively mild hills in second or third gear, while being overtaken by everyone, losing speed as I climb and burning LPG like it’s on fire, oh and only being able to carry 70lts of petrol in the belly tank is a nightmare, every time I go 4wding, I need to know there’s a servo with LPG on route. I had been toying with the idea of ripping out the LPG and running straight petrol on dual tanks, but at the same time I’m thinking I would love to go all out and convert it to a Diesel for range and reliability……………

    After chatting with a few people that have already done this conversion, I concluded that it could be an absolute money pit, but if you discipline yourself, do some research and look out for bargains over a longer period of time, you can do it all about 8k depending on the condition of motor you get, so I kind of started looking out for a TD42 and eventually found one for a price that I could not turn down.

    From here the conversion idea was born, albeit a very slow process due to lack of funds due to building a new house, but a man’s got to have a project I guess, so anyway, here is a diary with some photos of my experiences and thoughts while doing a GQ TB42E to TD42NA -to TD42t conversion.

    Day 1: Picked up my motor!  26th October 2014

    I found a bargain 99, GU TD42 black top motor on eBay for only $1000, it was almost complete with only the power steering pump, water pump and exhaust manifold missing, So I checked the engine number in the local police station to make sure it wasn’t a stolen motor and after it came back all clear I decided to go for it. The downside, and there’s always a downside, was that the motor was located in Woodonga, and I live on the Mornington peninsula, so I hired a ute from thrifty and drove 31/2 hours from my joint to go pick it up then 4 hrs home all in one day on my own, and I was a little tired when I got back. Anyway I got the motor home and put it on an engine stand and begun to assess and figure out what I wanted out of this motor and what the rebuild project involved and what order I should start to do things.

    I knew that I didn’t want massive KW’s but would want to turbo the motor, so I kind of decided that I would settle around 15psi of boost, pretty standard HT18 turbo specs thus not putting too much strain on the motor or my wallet. I also had been advised that the standard 11mm GU diesel injection pump, wound up a little, with no boost compensation should cope ok, it would be as far as it would go, but would be ok up to about 15psi, we’ll just wait n see I guess.

    As Purchased.jpg
    She'll be right mate
    it's a GQ

  2. # ADS
    Circuit advertisement
    Join Date
    Always
    Posts
    Many

     

  3. #2
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    Some Motor Research Info: What are the TD42/TD42t Differences?

    1. Pistons & Gudgeons are different – TD42 28mm / TD42t 30mm
    2. Oil Squirters are different (longer)
    3. Oil Pump is different, Lager rotors that are recessed into the pump body for more flow, a TD42t pump will fit into TD42 for better Lubrication.
    4. Crankshafts are different, the flywheel boss on TD42 is 86mm, TD42t is 96mm, balancer pulley is different but big end journals are exactly the same.
    5. Precomps are bigger in TD42t, Same physical sizes but designed differently, but TD42t precomps will fit TD42 head.
    6. Front and rear main seals are different, due to flywheel boss and crank pulley sizes


    Working from some sound advice I was told that a standard rebuilt TD42 motor would handle 15psi boost with no internal modifications comfortably, however I decided that as this was a project motor and I had plenty of time on my hands plus I didn’t want to have a major motor failure in the middle of nowhere, so I decided the internals were going to be replaced to TD42t specs all except crank and Pre-coms, so in order to run 15psi + confidently, I would be making the following internal upgrades:

    • 1x Engine Rebuild kit to Td42t specifications OEM spec Bearings
    • Services of an Engine Block Re-sleeving, head Machining, specialist
    • New Con-rods 30mm Gudgeons
    • Teflon & Ceramic coated Pistons
    • All new bearings (OEM)
    • 6 upgraded Oil Squirters for TD42t
    • New TD42t oil pump
    • High flow water pump
    • Heavy duty clutch kit

    It started to dawn on me that in order to complete this shopping list I may have to sell one of my kidneys or possibly even my Liver to fund the project, and in order to find some of the harder rare spares that I needed, I would have to kidnap the prime ministers daughter or something…

    However after careful consideration I decided that the selling of organs and kidnapping was not strictly legal and besides I may actually need my liver to process the copious amounts of alcohol that I would be drinking during the course of working on this project. So, if I was going to raise enough cash so I would have to save a bit, wait a bit, save a bit more, wait a bit more, get my bonus from work, and then if I don’t have quite enough, bend a credit card a bit…

    After buying the motor and hiring the Ute to go get it + fuel and the rate/Kilometre for the hire, I was already in for $1400, so it was time to start a bit of saving again… In the mean time I would start researching for some hard to find stuff needed for the conversion like Diesel Tacho, Engine Loom, TD42 bell-housing, etc. etc.
    Last edited by Andyh; 6th May 2015 at 11:14 AM.
    She'll be right mate
    it's a GQ

  4. #3
    Legendary happygu's Avatar
    Join Date
    Aug 2012
    Location
    Melbourne
    Posts
    3,019
    Thanks
    122
    Thanked 1,037 Times in 846 Posts
    Mentioned
    2 Post(s)
    Tagged
    0 Thread(s)
    Great stuff so far Andy,

    Wonder if you could pick up a donor vehicle minus engine on the cheap, and then use the required bits from that....

    Mic
    GU PATROL 2011 Ti, with goodies...

  5. #4
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    28th October 2014: G-Dam it, why do bargains always appear when ya wallet is empty, I Just found a TD42 Series II engine loom and standard fuel tank for a really great price… so had to buy them…..

    Melbourne cup weekend 2014
    Had a mates wedding on the Saturday of cup weekend, then I had plans to go away for 3 days over the break after the wedding, however I was very very hung over on Sunday morning and in no condition to drive so had to have a day on the couch to recover.

    The following day (Monday) I decided to go outside and start to strip the head off the TD42 to see what kind of condition it was in, I knew the motor wasn’t seized but needed to satisfy my own curiosity. It didn’t take long to get the head off the main block and I was quite surprised at the internal liners, only 2 were lightly scored but would defiantly need to be replaced, but it was always my intention to replace all 6 anyway.

    Due to the scoring I would say it seems likely the motor may have either heated up a bit too far or blown a piston ring / head gasket, so for the money it cost me for the motor with the intention of rebuilding it to turbo specification anyway, I was still thinking I had landed a bargain.

    As the cylinders showed signs of scoring I thought I would take a close look at the head, the valves and the pre-combustion chambers for signs of heat damage and cracking, but I saw no signs at all. It was always my intention to have the head checked out and reco'd by an engine shop to see if its RS, anyway. It’s just a waiting game now, not much I can do until I get some coin together for the machining and rebuild kit.

    As Purchased Tops off.jpg
    As Purchased Head off 1.jpg
    As Purcahsed Head off.jpg
    She'll be right mate
    it's a GQ

  6. #5
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    Tuesday 4th November
    I had started to price some up rebuild kits and was a little dubious about the eBay ones that I saw for about 1400 bucks, so after doing some research got onto a mob called SMS Diesels, they are specialist dealers of OEM & copy kits. Requested a quote from them for a TD42t and it came back at $1195+gst for a copy kit, or $1495+gst for a OEM Japanese kit, I asked the question what make are the bearings in the Japanese kit, and they came back to me right away with the information, NDC or Daido which are the suppliers to genuine manufacture and are Japanese spec Bearings. Well it’s a no brainer in my book. The store is reasonably local and SMS Diesels have a great reputation with stores here and in Europe over an unknown eBay kit…..

    A couple of mates know engine machine shop owners and have given me contact details to get prices, I may do that this week to get an idea on costs.

    Today I also found a bargain of a clutch on eBay, it’s a used but in near new condition heavy duty gold tough clutch that go for around $750 new, I just sold a boat that I no longer own (house deposit) so will chuck a bid on it and see how it goes.. 2 days to go…. Winning so far.
    She'll be right mate
    it's a GQ

  7. #6
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    6Th November
    Dam…. I missed out on the clutch, someone else wanted it really badly by the looks of it and was prepared to buy at any cost.. lol…. EBay, it’s only a bargain if you don’t get outbid! Anyway I still have lots of time to look … early days.

    My Mate picked up my 95ltr diesel tank from Bayswater today, it’s also got its original bash plate, and it’s in good condition no dents cracks or anything, just a little dirty.
    I am stoked, for $50, you can’t go wrong, and now as the tank is sitting in my garage, it smells like diesel in there, so that’s even more motivation…
    Anyway that’s another item crossed off the shopping list & Spoke with 2 engine machine shops waiting on estimated prices.

    Standard Diesel tank 90lts.JPG
    She'll be right mate
    it's a GQ

  8. #7
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    14th November
    No progress, still waiting on quotes from engine builders (I know I said no stress no rush, but sheesh) to top it all off, even my engine loom hasn’t turned up from NSW, & I’m beginning to wonder if it will… The guy I purchased it from through Gumtree is ignoring my sms’s and email message requesting postage details. A-Hole! If nothing turns up after I come home from work Monday 17th I will be reporting it to PayPal…

    17th November
    Well I eventually heard from the guy who sold me the loom, he was going to check with the courier as he said it had been sent last week, however when checking with the courier they said there were delays of up to 7 days due to the G20 summit or something. Anyway it’s defiantly been sent and I should get it any day.
    In the mean time I started to pull off the Harmonic Balancer, the nut was as tight as a nun’s nasty and swinging off a breaker bar with ľ drive and extension bar was just flexing the engine stand! It wasn’t moving at all, so I had a re-think & managed to scrounge a 240v rattle gun off a mate and with a little applied heat had it undone in like 3 seconds.  Just got to use the right tools I guess…

    Anyway the harmonic balancer was on the crankshaft so dam tight that even when using a dedicated puller, the lip on one of the belt drive slots on the balancer cracked and broke off …
    So in the end to get it off I just heated up the balancer taper lock collar again with a butane torch and tapped the end of the nut to loosen it then applied more force using the puller and it eventually popped off but it was really on there. In the in between time a mate with a TD42 just upgraded his radiator for a aluminium one, and I had asked him if I could buy his standard one … But, now had to text him and say since my balancer just cracked wouldn’t have the spare cash for the radiator.. Anyway he called me a #$@# for breaking it and told me he could maybe pick me one up off a dead engine for nothing if I wanted it. Sweet, if so I can now buy the radiator and replace the cracked balancer  winning.

    Busted harmonic balancer.jpg
    She'll be right mate
    it's a GQ

  9. #8
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    20th November
    Well with every up, there must be a down I guess, its official the guy I purchased the TD42 engine harness off is an absolute waste of oxygen, I got a message from him last night after I sent him yet another message (a slightly stronger worded one this time) asking for postage details on the harness as it had still not arrived…his reply was “Hey man, I think I sent it to the wrong address”. So I asked him “what address did you send it to?”, and yep yet again, no reply. What a slack git, honestly how hard can it be to post an item to someone? Bloody redneck. Anyway, as I had paid via PayPal I have now started a claim process to get my cash back.

    I guess it looks like I will be just adapting the TB42 harness after all… So Glad I used PayPal, and if you buy anything on Gumtree, always use PayPal, as I recon these useless hillbillies are all over gumtree ….

    On a positive note I had a call from one engine machinist today, he has quoted me a pretty good price to machine the deck, fit new sleeves, hone, machine the flywheel, grind and balance the crank, test & Recon the head if needed, set valve / piston protrusions, the whole kit and caboodle for around $2900 inc GST. He also put me in touch with Engines Australia as as he thought he could get me a much better deal, he also explained that in his experence Engines Australia had amazingly good quality gear. I contacted Engines Australia, I asked for a quote and they said they can provide me with a complete kit for TD42N/A to TD42t rebuild including all new con rods, Ceramic Teflon coated pistons and all the gaskets and bearings I will need to rebuild the motor to high specifications. Engine kit was quoted at $2240 + GST, this is a bit more expensive than SMS but hey, these are engine internals and I don’t want parts failing on me, so considering its all OEM Japanese equipment the price is not too bad I thought considering what I get in the kit…
    Last edited by Andyh; 24th February 2015 at 02:02 PM.
    She'll be right mate
    it's a GQ

  10. #9
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    December 1st 2014.
    Well on the 1st of December I finally got a PayPal refund on the wiring loom from Mr Redneck, so I spent some of it on a mates TD42 radiator and on Saturday I will go pick up.
    My mate also regretfully informed me that the free harmonic balancer was not possible as the motor had been scrapped.

    Ah well I had some cash from the refund now so purchased a used harmonic balancer I found on eBay for $65 delivered from Tasmania…. Not a bad price for a $250 part I thought.
    Replacement Harmonic Balancer.jpg
    She'll be right mate
    it's a GQ

  11. #10
    Expert Andyh's Avatar
    Join Date
    Oct 2014
    Posts
    134
    Thanks
    54
    Thanked 72 Times in 43 Posts
    Mentioned
    0 Post(s)
    Tagged
    0 Thread(s)
    December 3rd 2014
    Isn’t it funny that as soon as you put a project on hold, all sorts of rare opportunities expose themselves like a dirty ole man in an long rain coat..
    Well since getting the motor, I had been sending out emails and enquires asking about GQ TD42 Series II instrument clusters and power steering pumps with mounting brackets and had nothing back but messages informing me that they would not separate as they wanted to sell with the motor or they are rare as and not available…

    Well today out of the blue and after I had temporarily given up hope for a while, I got a message from local wrecker, saying they had both the Series II cluster and a Power Steering Pump with all mounting brackets, in stock, so bracing myself for anal violation on price, I asked. “How Much?” I was presently surprised to find it was only $350 for both parts with an additional $10 delivery fee to my office in the CBD.

    Out came the credit card again, cos let’s face it when stuff this rare comes up, you just got to take full advantage of it, especially when the power steering pump comes with a mounting bracket and tensioner arm!, because that is rarer than rare.

    They also told me that they may have a TD42 Series II engine loom available for $350, but I’m not really that worried about it now, after being let down last time I think I have convinced myself just to convert the TB loom and put in a manual glow circuit. I know of someone who has done this and said it was fairly easy, he sent me instructions on how to do it as well. If I change my mind I can always contact them later down the line I guess.

    TD42 Cluster.jpg
    PS Pump.jpg
    She'll be right mate
    it's a GQ

Page 1 of 22 12311 ... LastLast

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •