***JAN 25TH UPDATE***
Since the plan for repairing my engine has greatly changed since this thread was started, I won't be logging my work here; I'll start a fresh thread for that.
To summarize, this thread has effectively become "QA/setup" for the plan, which is swapping in DOHC cylinder heads from the 1992-1995 engine instead of replacing numerous valvetrain components which are known to be trouble-prone. Read on if you want to find out how this plan came to be; otherwise, stay tuned for my work log which should be starting within a few weeks.
***END JAN 25th UPDATE***
***FEB 15TH UPDATE***
Major revision to the plan. This entire time, a feeling has been building in the back of my mind. A general uneasiness about the fact that I'm putting so much money and time into the engine's top end but am leaving the bottom end alone (without having a clue as to the condition/remaining life of the bearings, oil pan, journals, and various other components). So I made the decision last week to rebuild the bottom end as well. Will hopefully be starting a month from now. Again, read on to learn the ins-and-outs.
Also, for anybody impatient for progress: Nasty610 is much further along with his identical project. See his thread here: http://forum.planetisuzoo.com/viewtopic.php?f=22&t=81719
***END FEB 15TH UPDATE***
This will be a pictorial log detailing work on my 1997 Trooper (192000 miles) 6VD1 SOHC to remedy:
-A CEL (P0304, cylinder #4 misfire)
-Oil leaking out of my engine from somewhere
-A possible vacuum problem (high idle; when shifting, RPM hangs for a moment before nosediving then bouncing back up)
-High oil usage
-Lifter ticking
-Failed valve cover gaskets and/or spark plug tube seals
This thread is effectively a sequel to one (link: viewtopic.php?f=4&p=752719#p752719) detailing my initial attempts to figure out what was causing the CEL. In that thread, gwana66, geoffinbc, and jeff97r all contributed to my decision to tackle the problem properly: full gasket replacement, intake cleaning, and hopefully hunting down the exact lifters ticking.
I have not yet begun the work, as I am first going to come up with a full parts list based on my understanding from these threads...
viewtopic.php?f=17&t=81334
viewtopic.php?f=17&t=6640&start=25
...and any suggestions/corrections you lovely people provide.
Parts list so far:
1) GASKETS/SEALS/O-RINGS (1a thru 1n I believe are included [along with head gaskets and a few other bits] in Fel-Pro's gasket set "HS 9174 PT-2")
1a) 3pc upper & lower intake gasket set
1b) 3pc EGR valve gasket set
1c) 2pc valve cover gasket set
1d) 6X spark plug tube seal
1e) thermostat gasket
1f) throttle body gasket
1g) water pump gasket
1h) 2pc camshaft rear seal set (each piece is for each camshaft)
1i) 2pc camshaft front seal set (each piece is for each camshaft)
1j) 24pc valve stem seal set (1 for each intake valve, 1 for each exhaust valve)
1k) 12pc fuel injector o-ring set (2 pieces for each injector)
1l) 2X water manifold gasket
1m) coolant housing gasket
1n) 2pc o-ring pair for the crossover pipes underneath the intake
2) WHILE WE'RE HERE, WE MAY AS WELL DIVE HEADFIRST INTO THE RABBIT HOLE
2a) timing belt
2b) timing belt tensioner
2c) timing belt idler
2d) PCV valve (cleaned it already but it's cheap, so why not)
2e) 2pc thermostat set (temp. switch and temp. sensor)
2f) water pump
2g) EGR (if for some reason I can't clean it)
2h) IAC valve (if for some reason I can't clean it)
2i) 6X ignition coil power supply connectors (1 for each coil)
3) HOPEFULLY NOT NECESSARY, BUT MAY BE NEEDED TO RESOLVE THE TICKER AND UNDO ANY ASSOCIATED DAMAGE
3a) unknown number of intake valves (total of 2 on each cylinder)
3b) unknown number of exhaust valves (total of 2 on each cylinder)
3c) unknown number of lifters (total of 4 on each cylinder)
3d) unknown number of intake rocker arms (total of 2 on each cylinder)
3e) unknown number of exhaust rocker arms (total of 2 on each cylinder)
3f) unknown number of intake valve guides (1 for every intake valve)
3g) unknown number of exhaust valve guides (1 for every exhaust valve)
3h) unknown number of valve springs (1 for each intake valve; 1 for each exhaust valve; both springs are identical)
3i) unknown number of intake valve seats (1 for each intake valve)
3j) unknown number of exhaust valve seats (1 for each exhaust valve)
3k) unknown number of intake rocker shafts (total of 2)
3l) unknown number of exhaust rocker shafts (total of 2)
4) HOSES/TUBING/PIPING
4a) PCV valve hose (upstream of TB butterfly valve)
4b) PCV valve hose (downstream of TB butterfly valve)
4c) coolant hoses (should be 4 of them, according to the first thread link I posted)
4d) any heater hoses (should be 2 of them, according to the first link I posted)
I heavily suspect there are some hoses and/or vacuum tubes (and maybe a gasket or o-ring) not on this list because I don't know about them or forgot. If this is the case, could anybody clue me in? Please don't be afraid to tell me if there are some parts that I shouldn't bother replacing. Spark plugs were all replaced during the prequel thread.
Note that for gaskets, I'm leaning towards Fel-Pro. For the water pump and timing built, I've seen some kits on Amazon produced by Evergreen; anybody have any experience with their products?
Obviously, after we finalize the parts list, I'll have to wait a few days for them to arrive before work can progress beyond the teardown.
A big ol' thanks to anybody who can contribute!
Since the plan for repairing my engine has greatly changed since this thread was started, I won't be logging my work here; I'll start a fresh thread for that.
To summarize, this thread has effectively become "QA/setup" for the plan, which is swapping in DOHC cylinder heads from the 1992-1995 engine instead of replacing numerous valvetrain components which are known to be trouble-prone. Read on if you want to find out how this plan came to be; otherwise, stay tuned for my work log which should be starting within a few weeks.
***END JAN 25th UPDATE***
***FEB 15TH UPDATE***
Major revision to the plan. This entire time, a feeling has been building in the back of my mind. A general uneasiness about the fact that I'm putting so much money and time into the engine's top end but am leaving the bottom end alone (without having a clue as to the condition/remaining life of the bearings, oil pan, journals, and various other components). So I made the decision last week to rebuild the bottom end as well. Will hopefully be starting a month from now. Again, read on to learn the ins-and-outs.
Also, for anybody impatient for progress: Nasty610 is much further along with his identical project. See his thread here: http://forum.planetisuzoo.com/viewtopic.php?f=22&t=81719
***END FEB 15TH UPDATE***
This will be a pictorial log detailing work on my 1997 Trooper (192000 miles) 6VD1 SOHC to remedy:
-A CEL (P0304, cylinder #4 misfire)
-Oil leaking out of my engine from somewhere
-A possible vacuum problem (high idle; when shifting, RPM hangs for a moment before nosediving then bouncing back up)
-High oil usage
-Lifter ticking
-Failed valve cover gaskets and/or spark plug tube seals
This thread is effectively a sequel to one (link: viewtopic.php?f=4&p=752719#p752719) detailing my initial attempts to figure out what was causing the CEL. In that thread, gwana66, geoffinbc, and jeff97r all contributed to my decision to tackle the problem properly: full gasket replacement, intake cleaning, and hopefully hunting down the exact lifters ticking.
I have not yet begun the work, as I am first going to come up with a full parts list based on my understanding from these threads...
viewtopic.php?f=17&t=81334
viewtopic.php?f=17&t=6640&start=25
...and any suggestions/corrections you lovely people provide.
Parts list so far:
1) GASKETS/SEALS/O-RINGS (1a thru 1n I believe are included [along with head gaskets and a few other bits] in Fel-Pro's gasket set "HS 9174 PT-2")
1a) 3pc upper & lower intake gasket set
1b) 3pc EGR valve gasket set
1c) 2pc valve cover gasket set
1d) 6X spark plug tube seal
1e) thermostat gasket
1f) throttle body gasket
1g) water pump gasket
1h) 2pc camshaft rear seal set (each piece is for each camshaft)
1i) 2pc camshaft front seal set (each piece is for each camshaft)
1j) 24pc valve stem seal set (1 for each intake valve, 1 for each exhaust valve)
1k) 12pc fuel injector o-ring set (2 pieces for each injector)
1l) 2X water manifold gasket
1m) coolant housing gasket
1n) 2pc o-ring pair for the crossover pipes underneath the intake
2) WHILE WE'RE HERE, WE MAY AS WELL DIVE HEADFIRST INTO THE RABBIT HOLE
2a) timing belt
2b) timing belt tensioner
2c) timing belt idler
2d) PCV valve (cleaned it already but it's cheap, so why not)
2e) 2pc thermostat set (temp. switch and temp. sensor)
2f) water pump
2g) EGR (if for some reason I can't clean it)
2h) IAC valve (if for some reason I can't clean it)
2i) 6X ignition coil power supply connectors (1 for each coil)
3) HOPEFULLY NOT NECESSARY, BUT MAY BE NEEDED TO RESOLVE THE TICKER AND UNDO ANY ASSOCIATED DAMAGE
3a) unknown number of intake valves (total of 2 on each cylinder)
3b) unknown number of exhaust valves (total of 2 on each cylinder)
3c) unknown number of lifters (total of 4 on each cylinder)
3d) unknown number of intake rocker arms (total of 2 on each cylinder)
3e) unknown number of exhaust rocker arms (total of 2 on each cylinder)
3f) unknown number of intake valve guides (1 for every intake valve)
3g) unknown number of exhaust valve guides (1 for every exhaust valve)
3h) unknown number of valve springs (1 for each intake valve; 1 for each exhaust valve; both springs are identical)
3i) unknown number of intake valve seats (1 for each intake valve)
3j) unknown number of exhaust valve seats (1 for each exhaust valve)
3k) unknown number of intake rocker shafts (total of 2)
3l) unknown number of exhaust rocker shafts (total of 2)
4) HOSES/TUBING/PIPING
4a) PCV valve hose (upstream of TB butterfly valve)
4b) PCV valve hose (downstream of TB butterfly valve)
4c) coolant hoses (should be 4 of them, according to the first thread link I posted)
4d) any heater hoses (should be 2 of them, according to the first link I posted)
I heavily suspect there are some hoses and/or vacuum tubes (and maybe a gasket or o-ring) not on this list because I don't know about them or forgot. If this is the case, could anybody clue me in? Please don't be afraid to tell me if there are some parts that I shouldn't bother replacing. Spark plugs were all replaced during the prequel thread.
Note that for gaskets, I'm leaning towards Fel-Pro. For the water pump and timing built, I've seen some kits on Amazon produced by Evergreen; anybody have any experience with their products?
Obviously, after we finalize the parts list, I'll have to wait a few days for them to arrive before work can progress beyond the teardown.
A big ol' thanks to anybody who can contribute!