New 4.2 Ute 'Hexie'

[NomadTech]

Step 8 - Hoses, thermostat, Coolant flush, cut-off solenoid, injectors, injector lines.

This started when I pulled up at a mate's place and my fuel cut-off solenoid embarrassingly decided to stick on. Ran for several seconds rattling like an unbalanced washing machine after I pulled the key out.
Within a couple weeks it went from intermittent to almost guaranteed. Oh joy: Time to dig down into the depths...

Had fun finding the right replacement. Every supplier said their solenoid was incompatible with my TD42ti (even Patrolapart). Yet no one listed a solenoid that WAS compatible. Eventually got down to the details and it was purely due to the TD42ti having NATS. Mine is a DX - No NATS, so I worked out that yes, it's just the standard solenoid even though I get the "This part does not fit your vehicle" message ... Usual parts fun.

I had a gander at the engine bay and realised this was going to very difficult to get a Spanner down in there with the injection lines still on the pump. I have a new assembly for the lines, so guessed this was about as good a time as any to do that swap. Then figured: "I don't know the history of these injectors, who knows when they were last rebuilt. Be mad to have this all apart and just leave them unchecked."

Ok, so at this point the intake manifold is gonna be coming off. That will give easy access to the EGR cooler hose aswell. I have new hoses and fresh coolant.
Job to replace fuel cut-off solenoid now includes: New injector lines, refurbish Injectors, new hoses, new thermostat, Coolant flush.

Block plug was a mongrel to get out, required multiple 3/8" extensions to bring it out the wheel arch, then a breaker bar to crack it. I don't think she's been flushed in a while ...
Habit from work is marking parts to be replaced with red electrical tape. Really helps keep track of things when you've got to remove 100+ parts from a machine.

Ran a dose of descaler through the whole system before flushing it completely.

Gave the heater core a good flush with the garden hose from both directions. Some pretty nasty sludge came out (Heater now works).

Rest was pretty straight forward, injectors were rebuilt by First Diesel in Penrith. They charged a bit more than many online services, but I've also read some horror stories about cheap internet injector exchanges. Considering I now own TD42 Patrol, thought it might be good to build a relationship with the local diesel shop.

They told me I needed a special injector socket to get the torque wrench onto injector #1 with the sensor on it. Get out the angle grinder... Gotchya.

On reassembly, sleep deprived: I left a Nitrile glove over the intake when I first started it. True to form for this vehicle she took the middle finger clean off. Think it got stuck on a valve for bit but seems to have been thoroughly incinerated now.

Only thing that brought me to tears on this job was getting new hoses to seal. The old hoses had moulded themselves to the worn out/cavitated fittings. New hoses bled about a litre of Coolant over a 20 minute test drive.
Had to order some new fittings and go back to good old screw type hose clamps.

This was a 10 day job, fitting in around work and waiting for some parts I hadn't planned for.

... I've since spent several weeks trying to chase all the leaks. It seems the Aftermarket hose kit from Patrolapart had two hoses that were a little too large in diameter. (Workmate tells me hose tolerances seem to be getting worse with time rather than better). Replaced one with a genuine Nissan hose and finally got it to seal. The other I only just found and will have to see what I can do about it... So not quite there yet
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