As the title suggests, I along with my friends overhauled engine of my car. A little history, this car is with us since last 10 years and has been overhauled before by a jugaaru mechanic. It had CNG installed in it and was in use by the previous owner. The issues which led to this overhaul were:
1- Excessive oil burning and leakage.
2- Knocking/pinging noise (carbon build up on the pistons)
3- Running on wrong oil grade i.e. 20w50
4- Low compression. Values were 105 95 100 104 psi
The car previously overheated too and blew a head gasket (which was fixed by that jugaaru mechanic).
All of these seem perfect recipe for a disaster. Before taking up the overhaul, we searched junkyards to find a good clean engine which can be swapped in and save the effort and time of overhaul. But all in vain, junkyard engines were, you guessed it right, junk. Not a single clean 2e, 4e, 4efe, 4afe, 5afe, 7afe (even checked 4ages) was available. It didnt seem wise to get such engine and rebuild it all over again.
Hence the decision was made to rebuild the existing 2e engines. After which, list of parts was made and procured (toyota genuine parts were used when available). Machinist was decided, service manual was arranged and gone through, all bolt torque, clearance etc values were gathered.
I had to take leaves from the job to carry this out.
First step was multiple runs of real concentrated solution of citric acid in the cooling system (it ran on water and had rust deposits) and then the disassembly started. I will attach pictures and steps in following posts.
