Manifold & EGR Ultrasonic Cleaning

Today’s turbo diesel technology is evolving faster than ever before, increased power output, lower fuel consumption and lower emission values are expected with every new model that manufacturers release.

To help accomplish this, most models utilize whats called an EGR system.  This is a series of ports and valves designed to divert a small percentage of the expelled exhaust gases from the exhaust system, and redirect it back into the inlet manifold and back through the engine.  This process aids in reducing an engine’s harmful emissions.

The down side, as you can see in these pictures, is the re-circulation is contributing to an excessive build up of sludgy deposits through the intake system, EGR system, EGR valves, and the inlet manifold and ports.  This buildup restricts the airflow into the combustion chamber, leaving your engine struggling to breathe.  This can have serious consequences including increased engine temperature, an increase in fuel consumption and noticeable decrease in engine power.  Left unchecked, premature engine failure is possible.

Southside Cylinder Heads has invested in state of the art ultrasonic cleaning,  perfect for cleaning the clogged inlet manifolds and EGR valves.  Fast cleaning times means your customer is off the road as least as possible, and the results are immediate and satisfying,  Almost every customer we do this service for calls us back to say what a difference it has made.

Call us today for prices and recommended service intervals.  

Brisbane’s Best Cylinder Heads, 33435899

 

Bulletin – Suzuki Grand Vitara cracking issues

Models Affected – Grand Vitara JB 2008 – 2009 (2.4l J24B Engine)

Fault – Crack in top of cylinder head, water mixing with engine oil

Symptoms – Milky colour oil, loss of coolant with no external leaks present, water contamination in engine oil.

The first run of J24B engines suffer from cracking in the top of the cylinder head.  The crack occurs from one of the three casting bungs that screw into the top of the head (under the rocker cover, between the camshafts), and the crack will normally run to the nearest head bolt hole.

The symptoms mentioned above may be present along with engine overheating or possible internal engine noise. The crack allows coolant into the top of the cylinder head and mixes with the engine oil, it will look like a caramel milkshake!  A tell-tale sign will be if the engine oil is overfull and the radiator is down on water, most likely that water has made its way into the sump.

– See the technical bulletin here Suzuki USA Technical Release –

Suzuki USA has acknowledged the fault and are repairing vehicles under an extended warranty scheme, however to date as far as we are aware, Suzuki Australia hasn’t acknowledged the issue and are not covering any repairs.

To add to the issue, the engine blocks are also known to crack without warning and without overheating.  Steer clear of the early version of these engines. If you are considering buying one, make sure the build date is 2010 or later.

 

Toyota 1KD-FTV Piston Failure

Toyota Hilux 1KD-FTV EURO 4 Spec

 

Models – KUN26, KDJ120, KDJ125, KDJ150, KDJ155

Fault – Crack in piston, can lead to localised rupture

Symptoms – Sudden loss of power, engine runs rough (on 3 cylinders), loud knock at idle, black smoke from exhaust, excessive crankcase pressures

When disassembling the engine, there are cracks detected in one or more pistons (various sizes, up to a local ruptures). The look is radically different from the cases of usual piston melting, and only small local flowing can be observed in the areas of ruptures.

Summary Piston Cut out 1kd

The 1KD engine has been sold in Australia for over 10 years, and has had a bumpy ride in terms of engine reliability.  The first production of the engine is not affected by this issue as it featured a piston design which included a metal fibrous structure fused into the piston crown (as pictured).  This structure added extra strength to the piston thus avoiding failure.

The engine underwent Euro 4 emissions modification which coincided with an overall modernization – reduced compression ratio, increased torque and power. The shape of the combustion chamber in the piston was changed, and any mention about the reinforced zone disappeared.  Considering the circumstances of occurrence, the cause of the problem should be called “inadequate strength margin on pistons”, essentially it comes down to design and construction mistakes on the Euro 4 version of the engine.

1KD-FTV Pistonkd-crack

Three years later the obviously substandard pistons were replaced by a new revision, however whilst this was an improvement, failures were still occurring, but at a lesser rate than previous.  Contributing factors are also associated with the fuel system, but are secondary.

The failures are most commonly occurring around the 100,000 – 150,000 km.  The problem is recognised by Toyota in several service bulletins released between 2011 and 2014.

See – technical-service-bulletin-toyota-1kd

Euro 5 revisions brought yet another design change, and whilst it’s still early days, it looks like the problem may have been resolved.  Time will tell.

Owners and potential buyers of the “EURO 4” affected models of the Hilux, Prado and Hi-ace should be wary.  The advice is simple, avoid chip tuning, avoid long driving at high speeds (especially under load) and service the fuel injectors every 100k.  This will reduce the likelihood of failure, but the only to overcome the inherent design fault is to change the pistons.  Speak to Southside Cylinder Heads today about repair and failure prevention options.  Engines & cylinder heads since 1977.

 

 

The Importance Of Maintaining Your Engine

 Toyota_Kluger_rear_deepVehicle maintenance is of vital importance both for safety, longevity and performance, and today we want to talk about the importance of maintaining your engine and the surrounding components that make it possible for your engine to operate.

The engine is the heart of your car, and its fluids are its blood. In your own body, your blood has kidneys and a liver to keep the blood clean — aside from the oil filter, a car engine can’t clean its own fluids. That’s why it’s important to change an engine’s oil regularly, and to make sure that change happens before the oil gets too dirty. Dirty oil may suffice in the short term and things may go fine for a while, but eventually it will lead to disaster. Even small amounts of dirty buildup over time can lesson an engine’s lifespan.

Toyota Kluger 2GR-FE Engine

Your coolant is just as important.  Having a clean and correct mix of coolant increases the cooling efficiency and capability of your engine, and prevents rust and corrosion forming.  Your radiator and water pump also play an important part in this, the pump’s job is pretty self-explanatory, it pumps coolant through the engine, then through the radiator to be cooled and then back into the engine in a continues cycle.  If maintenance is lacking and part of your cooling system fails in its duty, major engine damage can happen in a matter of minutes.

For example, the engine block pictured is out of a 2010 Toyota Kluger with 79,000kms clocked.  Basic oil changes have been maintained but a lack of cooling system maintenance has resulted in a major engine overheat, so bad that the alloy in the block has separated from the cylinder walls. 

The repairs required to get this car back on the road came in at a little under $10,000.  Don’t let this happen to you, practice a good maintenance schedule with your trusted mechanic, and pay attention to what your engine is telling you. If your car’s gauges say the engine is getting too hot, the oil pressure is low, your check engine light is on, or it’s making a noise that it never used to make, don’t wait. Take it to a mechanic you trust.

 

 

Engine Block 2GR-FE

Holden Cruze 1.8 Petrol Camshaft & VVT Problems

Our home grown Holden Cruze has had several different engine options since its inception in 2002.  The most popular has been the 1.8 petrol (Z18XER/F18D4), which first came out in the JG Cruze in 2009. There are two common problems we would like to discuss to help make your diagnosis and repairs easier.

Oil Flow Tubes

Firstly, a few of our customers have had problems with oil feed to the variable valve timing units after having head work or timing belt repairs carried out.  There is a small plastic tube that is being left out during re-assembly that is crucial for oil direction and flow to the variable units.  Without the tube in place, oil is not being fed to the variable unit, which triggers an engine light as well as loss of power through the rev range.  Theses tubes are located inside the camshafts at the front, right behind where your camshaft gears bolt on.  There is one for each camshaft.  Make sure these are in place before refitting the cam gears because the engine will not operate correctly without them.

Oil Coolers

Second issue is a high number of vehicles ending up with oil in the cooling system. These engines (Z18XER and F18D4) run oil coolers which are renowned for failing.  If you have oil mixing with water, check your oil cooler before racing to remove the cylinder head as this is most likely your problem.  Southside Cylinder Heads can pressure test your oil cooler for you.   The coolers are located next to the oil filter and forms part of the oil filter housing assembly.  Currently replacement coolers are only available OEM.  Southside Cylinder Heads, Brisbane’s best choice!

 

 

 

 

 

 

 

 

 

 

Congratulations to our winners!

winners_banner

Congratulations to Mike of Strathpine Auto Care and Matt at Midas Car Care Beenleigh, both will enjoy a two night getaway at Ramada Golden Beach on the Sunshine Coast for two people, with ocean views and a bottle of wine on arrival.  We hope you enjoy your stay 🙂

Southside Cylinder Heads would like to thank Mike, Matt and all our loyal customers who missed out on the major prizes for their ongoing support.  Watch this space for more helpful tech articles and promotions.

 

New Rugo 100 guide honing machine!!

 

New RUGO 100 Honing Machine

 

We are pleased to welcome our newest upgrade to our ever expanding workshop, the spanish built Rugo 100 valve guide hone.  Capable of honing a wide range of valve guides from motorbikes to small trucks,  as well as small end bushes, this machine gives a uniform, friction-less finish far superior to what can be achieved with old style hand reamers.

With the ever increasing use of bronze and brass in valve guides, valve guide clearance is more critical than ever before, and incorrect clearance can result in valve seizure in the cylinder head as well as premature wear in the guides.  Southside Cylinder heads strives to stay at the forefront of technological advances in the industry, so we can better serve our customers now and into the future.

 

 

 

Volkswagen Turbo Diesel Camshaft Issues!!

Models Affected:

 – Volkswagen Transporter T5 2004 – 2010 2.5 TD
 – Volkswagen Transporter T5 TDI 2004 – 2010 2.5 TD

Volkswagen Transporter 5 cylinder turbo diesels are having issues with the valve train.  Hydraulic lifters, camshafts and camshaft bearings are wearing out prematurely resulting in excessive noise from the engine.  The exact cause of he failure is still yet to be pinpointed but poor lubrication to the top end is likely to be playing a major part.

 

 

 

 

 

 

 

As shown in these pictures the damage can be quite severe and left unchecked will continue to damage surrounding components and engine failure will be inevitable.

 

 

 

 

 

 

 

 

If caught early you can rectify the issue by simply replacing the camshaft, all hydraulic lifters and camshaft bearings.  However if the damage has extended to the valves then the cylinder head will need to be removed for repairs also.  Southside Cylinder Heads have SST timing kit required carry out these kind of repairs on your Volkswagen.  Give us a call anytime and we can look after you 🙂

See our online store for replacement camshaft kits

 

 

 

BMW Head Bolt Thread Problems

2003_bmw_3-series_sedan_330i_fq_oem_1_300There is a run of 6 cylinder BMW engines causing mechanics and owners all sorts of grief when it comes to repairing cylinder heads and replacing head gaskets.

The 6 cylinder BMW engines affected include the M50, M52 and M54 that come out in various models from the early 1990’s through to about 2007.  3,5 and 7 series vehicles as well as the  Z3, Z4, X3 and X5 are all at risk.

Now the problem is simple….the aluminium blocks are stripping the head bolt threads when you try to torque down the cylinder head after gasket replacement, even if the engine hasn’t been overheated.  bmw-engineYour options are to source a second hand motor of unknown condition and take your chances with it, or have the threads repaired.

Southside Cylinder Heads and Engine Reconditioning Australia have a thread repair kit available to do the job.  This kit is suitable for both flush threads and recessed threads.  Its available as a rental with security deposit and you can fit them yourself, or we can come to you and supply and fit the thread inserts on site and in car.   $POA

                                     Please contact us for pricing phone 07 3343 5899

Thread Repair Kit BMW

Thread Repair Kit BMW

 

Nissan YD25 EGR Cooler Issues

Problem:

EGR Cooler corroded or split and leaking Coolant

Vehicles Effected:

Nissan Navara D22 & D40 with YD25DDTI 2.5 Turbo Diesel Engine

Nissan Pathfinder R51 with YD25DDTI 2.5 Turbo Diesel Engine

EGR Cooler

EGR Cooler setup Nissan YD25

We are seeing more & more problems with the EGR coolers in the YD25 Nissan engine.  The coolers tend to corrode or split resulting in loss of coolant and due to the high temperature of the exhaust/EGR system the coolant loss often goes undetected as the coolant evaporates and doesn’t leave a puddle on the ground.  If the problem goes unchecked the cooling system will run dry and the engine may overheat and require major repairs.

To fix the issue some people elect to bypass the EGR system completely using blanking plates on both the exhaust and inlet manifold & disconnecting the coolant flow to the EGR cooler.  From all reports this has been an effective fix but Southside Cyl Heads doesn’t recommend this because removing the EGR will alter the vehicle’s emissions levels & render the vehicle unroadworthy

EGR Cooler Faults

Faults in the EGR cooler YD25

We recommend simply checking your coolant levels regularly and if you notice a drop in the level, get the cooling system checked and check for stains around the EGR pipe ancooler area.

Catching the problem early and rectifying the issue could save you thousands in cylinder head repairs in the event of the engine overheating.  If you suspect your EGR cooler could be leaking, give us a call and we check over the system and put your mind at ease.