So here are some details and issues we faced.
Day one we did Dyno test. The total HP was 148 at wheels and around 300nm of torque.
The engine was making weird noise after some runs. Temps were going up and there was excessive blow-by.
Day 2 the work started with removal of manifold, tappet cover and injectors. The +30 injectors we ordered came with new washer set. But the old injector washers were stuck and after spending half a day we decided to remove the head for removing washer and to also inspect engine heath. Just to add something here i was told by one of the diesel shop to just put teflon tape on new injectors and reinstall. But that will never work because there is extreme heat and pressure here. I told that head guy to leave pls. Because this behavior in the first place resulted in stuck washers.
The head was removed sent to machine shop for removal of washers. The machine shop guy is sitting in azizabad area karachi in a small shop but extremely professional.
Day 3 The washers were removed. We found valve, valve seats and piston etc in prestige condition. Head was reinstalled with genuine head gasket and cam oil seals. Care should be taken here not buy cheap head gasket as that will result in issues..
The 2nd issue came here. Toyota shop in-charged marked everything to put back together the way it was but that weird noise I mentioned earlier came back and this time even on slowly rotating the engine. He found out that timing was not correct. So shop manual was referred and timing was re done. No more weird noise now.
All head bolts were torque to spec and guess what there was torque wrench involved which is a rare site in Pakistan.
Day 4 The engine was started and holes were made to install intercooler. The engine was started after test fitting of everything.
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Back to Dyno and power was around 252 hp torque 600 nm.
But another issue popped up. There was oil coming out from injector boots.
Day 5 off to toyota people again tappet cover was removed one of the boot was torn so new one was installed. Never put silicone here if there is leakage teflon can be used here for snug fitting.
All fittings were removed for final installation. The ac lines were in the way of intercooler so had to sacrifice refrigerant. Ac lines were removed and all fittings were finalized. Just to mention here turbo was bolt on kit so no issues there.
Day 6 the vehicle was off to exhaust shop for removal of muffler and Ac lines were rerouted by a welding shop at tariq road. The ac refrigerant was charged by a guy at tariq road MS autos. Very well done.
The vehicle is back to dyno final tuning was done as the transmission is not upgraded the power was limited to 277 hp and 620nm of torque at wheels. Unfortunately i did not caputre the Hp but here is torque graph.
The vehicle is different beast now although there is around 50 to 60 more hp to be gained but currently transmission slippage is limited factor.
Here is 0 to 100km time and quater mile.
