Hilux Surf 1 kzte heating problems......
Posted: Mon Nov 18, 2019 3:04 pm
Hi There from a new member to this forum. I wish I found you guys six months back!
Long story: My dad bought a Lemon from a guy in Richards bay, This is his first diesel van, an imported hilux surf 3.0 1 KZTE. ( He has always been a mad Toyota fan but could never afford one new) He drove up from Richards Bay to Howick, and it was fine. then him and mom Hooked his caravan up, and did not reach Bergville before it overheated. We collected a disgruntled old man and even more grumpy ouma. Dad having worked on Petrol motors his whole life, with many many successful conversions under his belt, decided to pull the motor. We downloaded manuals, re conned the whole motor. New pistons, new Toyota head (old one assumed cracked, but not tested, so we just tossed it anyway) New water pump, new viscous fan, new bearings, re conned injectors, new belts, new thermostat, everything done and torqued to specs from the Toyota manuals and dads 50 years experience.. We knew we got it right when she Started first swing, no splutter no hassle nothing. Perfect, as it should be. Then,..........we take it on the maiden voyage with much glee......... no hassles. Dad drives the van around Nottingham road / Mooiriver / Howick area no problems 500km and we drop oil and put new. Then hooks caravan with grumpy old lady in tow, and off they go. First hill outside Howick she 3/4 boils. We bring the van back to my engineering shop in Howick......spend hours on hours going through our workmanship, no oil leaks, no water leaks. No bubbles in water tell - tail sign of blown head gasket, no water in oil. Compression test 100%. Assume faulty Radiator. (Copper unit) Silvertons does pressure test, nothing wrong, does flow test, nothing wrong. We replace radiator cap with new. Off we go. Same hill, same results. Under load this motor heats up. Not in traffic not in town, only under load. The we spend even more hours on the net. We end up replacing the turbo with a new unit as the waste gate seat had hairline cracks in. Our thinking was gasses were by passing. Same hill, same results............. Back in to workshop. More hours on the net and re reading our manuals again for the 1023th time. Stumped. We then work backwards. In our manuals we find mention of the EGR valve that might cause these symptoms, this seems to have been removed already. DPF seems clean. We then install an aftermarket Davies Craig EWP115 pump with Electronic feedback and two new 12' fans. Seems marginally better, but still heats under load. Remove electric fans, install fixed blade fan with cowling, run electric pump with no controller attached and there is another small improvement. Still not enough to have 100% faith. Please guy, there must be someone here that knows more than our manual and these pimple faced mechanics on the net that cant even focus a camera. Help.
Long story: My dad bought a Lemon from a guy in Richards bay, This is his first diesel van, an imported hilux surf 3.0 1 KZTE. ( He has always been a mad Toyota fan but could never afford one new) He drove up from Richards Bay to Howick, and it was fine. then him and mom Hooked his caravan up, and did not reach Bergville before it overheated. We collected a disgruntled old man and even more grumpy ouma. Dad having worked on Petrol motors his whole life, with many many successful conversions under his belt, decided to pull the motor. We downloaded manuals, re conned the whole motor. New pistons, new Toyota head (old one assumed cracked, but not tested, so we just tossed it anyway) New water pump, new viscous fan, new bearings, re conned injectors, new belts, new thermostat, everything done and torqued to specs from the Toyota manuals and dads 50 years experience.. We knew we got it right when she Started first swing, no splutter no hassle nothing. Perfect, as it should be. Then,..........we take it on the maiden voyage with much glee......... no hassles. Dad drives the van around Nottingham road / Mooiriver / Howick area no problems 500km and we drop oil and put new. Then hooks caravan with grumpy old lady in tow, and off they go. First hill outside Howick she 3/4 boils. We bring the van back to my engineering shop in Howick......spend hours on hours going through our workmanship, no oil leaks, no water leaks. No bubbles in water tell - tail sign of blown head gasket, no water in oil. Compression test 100%. Assume faulty Radiator. (Copper unit) Silvertons does pressure test, nothing wrong, does flow test, nothing wrong. We replace radiator cap with new. Off we go. Same hill, same results. Under load this motor heats up. Not in traffic not in town, only under load. The we spend even more hours on the net. We end up replacing the turbo with a new unit as the waste gate seat had hairline cracks in. Our thinking was gasses were by passing. Same hill, same results............. Back in to workshop. More hours on the net and re reading our manuals again for the 1023th time. Stumped. We then work backwards. In our manuals we find mention of the EGR valve that might cause these symptoms, this seems to have been removed already. DPF seems clean. We then install an aftermarket Davies Craig EWP115 pump with Electronic feedback and two new 12' fans. Seems marginally better, but still heats under load. Remove electric fans, install fixed blade fan with cowling, run electric pump with no controller attached and there is another small improvement. Still not enough to have 100% faith. Please guy, there must be someone here that knows more than our manual and these pimple faced mechanics on the net that cant even focus a camera. Help.