Bongo Fury

Hi again to all, would any helpful soul have the torque settings for a complete engine rebuild on a 1995 2.5 turbo diesel please, I've come across the settings for the head but as its a high miler I,m going to put new piston rings and big end bearings in, I've already honed the bores and ordered the parts required just need some technical info regarding torque settings and injection pump settings, any help at all would be gratefully received, thanks , taff.

What O/S pistons are you using.?

The settings for the WLTD 2.5 are ...


Con Rod (big end)


27.0—31.8 {2.75—3.25, 19.9—23.5}
+ (82.5° —97.5° )

Mains

42.66—45.60 {4.35—4.65, 31.5—33.6} +
90° —105° )



N·m {kgf·m, ft·lbf}


Good luck.

I would highly recommend buying the engine manual as it has all the torque settings for every nut and bolt. Available from the club shop: http://www.igmaynard.co.uk/bongo/workshop.htm

Taff, you can get all this information on the internet, search for "Ranger drifter overhaul manual".

It will give you the whole kit and caboodle.


http://www.manualesdemecanica.com/image ... 6cf9ca.pdf

Thanks all for your help, the bores have honed up ok so standard 93 mm pistons going back in , the big ends are standard to so just new big end shells and piston rings, I,'ve stripped and cleaned the oil pump as the head has cracked and it has passed a little water down passed the rings and through the pump, full gasket kit arrived today along with new piston rings , waiting on the big ends now and some time to polish everything up, I'm still in need of the injector break-off in atmospheres , I,'ve heard a rumour that they should be around 125 , 3 of mine are close to 100 and the other is about 110, according to my pop tester, I need to make some shims up for the injectors to get them up a bit but as I said the figure of 125 atmospheres is " an educated guess" by on old diesel engineer, any way thanks again folks for your help, it's very much appreciated, taff.

Sounds interesting
Do keep us informed how it all goes please

taff jones wrote:Thanks all for your help, the bores have honed up ok so standard 93 mm pistons going back in , the big ends are standard to so just new big end shells and piston rings, I,'ve stripped and cleaned the oil pump as the head has cracked and it has passed a little water down passed the rings and through the pump, full gasket kit arrived today along with new piston rings , waiting on the big ends now and some time to polish everything up, I'm still in need of the injector break-off in atmospheres , I,'ve heard a rumour that they should be around 125 , 3 of mine are close to 100 and the other is about 110, according to my pop tester, I need to make some shims up for the injectors to get them up a bit but as I said the figure of 125 atmospheres is " an educated guess" by on old diesel engineer, any way thanks again folks for your help, it's very much appreciated, taff.

Really interesting to read a post by someone who seems to really know his diesels

Hi Taff,I was just wondering if you were going to use PEP pistons, this might help re the nozzles.

Injection starting pressure
11.4—12.1 MPa
{116—124 kgf/cm2, 1650—1760 psi} (New)
More than 10.0 MPa
{102 kgf/cm2, 1450 psi} (Inspection)
4. If the injection starting pressure is not within the
specification, adjust it by installing the correct shim.
Note
Adding/subtracting 0.02 mm {0.0008 in}
thickness shim increases/decreases the
starting pressure approx. 470 kPa {4.8
kgf/cm2, 68 psi}.


Good Luck

Thanks again to all who have shown an interest and taken time out to furnish me with some more technical data, thanks to Rita for the injector break-offs, the upper and lower limits equate to 123.385 and 116.247 atmospheres technical respectively, so the "educated guess" of 125 wasn't a million miles away, according to these figures the injectors need shimming up 0.082 mm which I will do closer to completion of the rebuild. I'm looking forward to completing the rebuild as soon as possible but work tends to get in the way (occupational hazard or what lol) . Anyway time for me bed now , again thanks to everyone for their time, you've all been fab, cheers, taff.

Ditto

Wrong place sorry.