I will be in foster from 28/12/2012
for to weeks if this helps
or just give me a ring 0402153916

cheers
Rod

 

Rod,
I may ring you if I get stuck on anything mate.

 

Going to start the HPOP removal, repair and reinstall tomorrow. One question I have is, I have been reading up on a few installs and some of them make a point of leaving out the SPRING POPPETS. Is this right?

 

Havnt read that one m8. I would give Clay an email and see what he says. Let us know how you go. Good luk.
Remember - WE LUV PICS

 

Brian,
I got that info off the Adrenalin web page fopr there HPOP. I just went ahead and reinstalled the spring poppets anyway, as I figured they were there for a reason.

Well I started at 10am and retired at 8pm and have only just refitted the HPOP, torqued it to the right spec and RTV silconed the front cover plate back on.

What went wrong! Everything, namingly the previous owner. Pulling eveything out was pretty easy. I hit trouble when I got to the HPOP, and front gear. When I went to undo the 18mm gear bolt, it was barely tight at all. Then I noticed all the silcone between the HPOP and front cover. It has been removed before!!! I went to undo one of the 10mm bolts, Drivers side and it was loose as. Didnt think much of it until I pulled it out, along with all the thread!!! The other one was really tight.

Pulled the HPOP and put the kit through it. Pretty easy, and a couple of the seals had been done before, but I re did them anyway. What to do with the stripped thread??

I put a M10 start tap and then a bottom tap up it. I required a 8.8mm hole in order to tap it, and the hole was 8.5mm so worked out ok. Went to reinstall the HPOP and as soon as I tighted up the passengers side it stripped as well. So I had to remove the pump again and tap that one as well. I had the drill the HPOP out from 9mm to 10mm, gasket as well. Plenty of room to do that. Only issue was that an M10 bolt has a 16mm head on it. Worked ok on the drives side, but not on the passengers side. There was absolutely no room to even get a 16mm socket on it.

What I ended up using was a turbo to pedestol hold down bolt. Had to shorten it 5mm with the grinder though and trim back the flange around the head of it, but it works and I could easly get a 13mm socket on it.

What a stuff around today has been. Hopefully it all go,s back together tomorrow and starts, fingers crossed. I put a new IPR it while I was there just to be shaw that it will not give trouble hopefully.

I can say one thing. The HPOP has not been sealed up properly for quiet some time, but is now, with out the use of silcone. The IPR was also finger tight.

Well see what tomorrow brings as it has thrown everything at me today.

 

bloody hell m8 talkn bout murphy's law. Good bit of back yard mechanics. Im crossing my fingers as well

 

Well, It took a couple of hrs to get it the point where is was ready to be started. Getting the new HPOP lines on was a struggle. Those things have a mind of their own. Primed it 3 times. Turned it over and it fired after 5 seconds, ran rough for about 5 seconds and then sat there and idled prefectly. Unbelivable!!! Took it for a run and checked for leaks when I got back. Nothing. I am stoked.

I noticed it is easier to start now, as if the motor turns over quicker. No delays in the time it takes to start. Gernied the engine and took it for a 60km run just to ensure that all the air was out of the system. Still no leaks.

 

Good job, you must be stoked. I think you scored a "get out of jail for free" card

 

G'day Wallsy,

Excellant mechanical improvisation right there M8 .

Re-working some other dolt's job is a real PITA.

Good result .

Cheers,
Reg

 

Congrats on a great fix Wallsy! Hopefully that's the last of the PO's legacy problems too.

 

I should create my signature now with all the mods hey!!! I hope that is all of the dodgy crap sorted from the previous owner. I ve been at this truck since I purchased it in october 2011, repairing stuff. Now its time to enjoy if for a while and its new reliability.

 

Well, checked the engine valley today and there is a small puddle of oil directly under the HPOP. I did a bit of checking around with a small telescopic mirror and looks to be coming from the IPR? I bumped the mirror on the flimsy nut on the end of the IPR and got a good drop of oil on it. This was a brand new IPR I put in there. Anyone heard of this before.

 

Hi Wallsy, I think I have. From memory the conscencus on the US bro's form was don't touch it if it is not leaking as replacing a non-leaking one with a new one increases the likelyhood of getting a leak.

Got your old one still?