Bolero Rebuild - Page 2





Page 2 of 2 FirstFirst 1 2
Results 21 to 33 of 33

Thread: Bolero Rebuild

  1. #21
    Join Date
    Dec 2017
    Location
    Pretoria
    Age
    31
    Posts
    14

    Default Re: Bolero Rebuild

    Quote Originally Posted by jelo View Post
    Well that looks like a decent cast iron lump of a motor.

    Some tips :

    - coolant level sensor and alarm
    - EGR temp sensor and gauge
    - oil pressure sensor and gauge

    Because you still haven't really found out the cause of that broken liner, and liners don't just fall apart in my experience.
    I was also thinking of installing the the EGT and oil pressure gauge, Luckily the coolant fan i now electric and should hopefully keep it cool.
    Current Rides:
    -2004 Ford Ranger 2500D
    -2015 KTM 1290 Superduke
    -2008 Suzuki GSX650F
    EX Rides:
    - 1987 VW Citi Golf - RIP
    - 1988 VW Fox
    - 2009 NO Limit cg 125
    - GoMoto Ballistic naked SI
    - Suzuki DRZ400SM
    - 2007 VW Polo 1.6 Comfortline
    - 1991 MK2 Jetta CLI 20VT
    - 2006 Audi A4 Avant S-Line
    - 2013 Honda CBR1000RR - RIP
    -2007 CBR 1000RR
    -2007 Mazda 6 MPS

  2. #22
    Join Date
    Dec 2017
    Location
    Pretoria
    Age
    31
    Posts
    14

    Default Re: Bolero Rebuild

    Quote Originally Posted by Skylark View Post
    Awesome thread, thanks for posting op!

    With that amount of metal fragments/particles that was floating around the engine in the oil before it completely seized would there not be potential for scoring and issues all over the engine where there are moving parts?

    Wouldn't it have been safer/easier just to source a 2hnd motor?
    The reasoning behind rebuilding is two fold:

    1) it worked out a slight bit less to rebuild actually

    2) we now know we have a new engine that we know the whole history of.

    As jelo stated, the engineering shop was instructed to do a clean, but when we got the block back we also blew as much compressed air in there as we could to remove the most amount of something left over as we could.
    Current Rides:
    -2004 Ford Ranger 2500D
    -2015 KTM 1290 Superduke
    -2008 Suzuki GSX650F
    EX Rides:
    - 1987 VW Citi Golf - RIP
    - 1988 VW Fox
    - 2009 NO Limit cg 125
    - GoMoto Ballistic naked SI
    - Suzuki DRZ400SM
    - 2007 VW Polo 1.6 Comfortline
    - 1991 MK2 Jetta CLI 20VT
    - 2006 Audi A4 Avant S-Line
    - 2013 Honda CBR1000RR - RIP
    -2007 CBR 1000RR
    -2007 Mazda 6 MPS

  3. #23
    Join Date
    Jul 2008
    Location
    Constantia Kloof
    Age
    37
    Posts
    1,970

    Default Re: Bolero Rebuild

    Quote Originally Posted by Echo03 View Post
    I was also thinking of installing the the EGT and oil pressure gauge, Luckily the coolant fan i now electric and should hopefully keep it cool.
    The original factory fitted fan does a great job of cooling the engine, my ex Bolero operated in temperatures ranging from -2 to 40+ degC without issues.

    Get a new oem fan unit and make sure the fan shroud is in place. Unless you have a really high end electric fan and the correct shroud to go with it, I will bet money it won't be as effective as the standard unit, nevermind better.
    2019 Mahindra S6 Pik Up S/C 4x4
    2007 Mercedes Benz ML500 5.5
    1968 VW Beetle 2276

  4. #24
    Join Date
    Mar 2008
    Location
    De Wildt
    Age
    57
    Posts
    35,564

    Default Re: Bolero Rebuild

    Quote Originally Posted by Koebelwagen View Post
    The original factory fitted fan does a great job of cooling the engine, my ex Bolero operated in temperatures ranging from -2 to 40+ degC without issues.

    Get a new oem fan unit and make sure the fan shroud is in place. Unless you have a really high end electric fan and the correct shroud to go with it, I will bet money it won't be as effective as the standard unit, nevermind better.
    I agree

    the OEM viscous was removed because the engine was already shot

    see my previous comment:

    "constant over fuelling causes excessive piston crown temps that eventually melt the piston but initially will cause an undiagnosed over heating issue : hence the locked viscous fan and upgraded radiator.
    they were fixing a problem that they didn't understand"
    2012 Jeep Sahara Unlimited 3.6 V6
    Percivamus

  5. #25
    Join Date
    Sep 2018
    Location
    Cape Town
    Posts
    191

    Talking Re: Bolero Rebuild

    Quote Originally Posted by Skylark View Post
    Awesome thread, thanks for posting op!

    With that amount of metal fragments/particles that was floating around the engine in the oil before it completely seized would there not be potential for scoring and issues all over the engine where there are moving parts?

    Wouldn't it have been safer/easier just to source a 2hnd motor?
    Safer/easier yes, as much fun-no!

  6. #26
    Join Date
    Dec 2017
    Location
    Pretoria
    Age
    31
    Posts
    14

    Default Re: Bolero Rebuild

    Monday night update:

    Went past Mahindra on the way home to pick up a new slave cylinder, got home and took the old one off and drained the whole system to make sure it is clean, this is what the reservoir looked like:



    after that was clean installed new slave and bled the system, was unusually quick as it only took one bleed and all the air was out. Thought to myself, "This was way to easy"

    I pressed the clutch pedal again to see if it was fine and POP it went, so I took it out again and this is what I found:



    Managed to install the old piston in the new housing as the old one was pitted and managed to get the clutch working.

    Then we installed the thermostat and after sorting some water leaks, this finally happened:



    We did about 50 km last night just around the neighborhood and managed to find a small pinhole in the metal water pipe from behind the head to the oil cooler, will have to see what we can do to repair it. There is also some oil leaks that we are hoping is just the sump gasket but will confirm one the engine has had a nice wash.

    all and all she is running good, will have the diesel pump adjustment checked very soon to confirm that all is well there, but after the initial smoke from the startup and all the oil in the exhaust cleared it seems to be running very healthy with just a little smoke when getting into boost.

    On the cooling side, all seems to be looking good, temp switch we have in is a 86C to 78C and fan switches on for about a minute when standing still so I think it works very well, can clearly feel it sucking in air from in-front of the grill. Temp gauge does not go over halfway mark.

    Will keep updating as we go but progress will start to slow now as the bakkie will start to work, on light duty first, from tomorrow.
    Current Rides:
    -2004 Ford Ranger 2500D
    -2015 KTM 1290 Superduke
    -2008 Suzuki GSX650F
    EX Rides:
    - 1987 VW Citi Golf - RIP
    - 1988 VW Fox
    - 2009 NO Limit cg 125
    - GoMoto Ballistic naked SI
    - Suzuki DRZ400SM
    - 2007 VW Polo 1.6 Comfortline
    - 1991 MK2 Jetta CLI 20VT
    - 2006 Audi A4 Avant S-Line
    - 2013 Honda CBR1000RR - RIP
    -2007 CBR 1000RR
    -2007 Mazda 6 MPS

  7. #27
    Join Date
    Jun 2014
    Location
    George
    Posts
    2,799

    Default Re: Bolero Rebuild

    Nice, always an awesome feeling successfully firing up an engine after a rebuild or major work.

  8. #28
    Join Date
    Jun 2013
    Location
    Alberton
    Age
    58
    Posts
    6,055

    Default Re: Bolero Rebuild

    Utmost respect. Bloody well done.
    Lusted for a Landy but the Pajero was sexier and bigger in the right departments, just like my Missus.

    2004 Gen 3. 3.8i petrol V6 (PAJTU)
    X Factor Bundutop trailer (designed by me)
    1998 Blister Fender Pajero 3500 24V (PAJ) (Sold)
    BMW R1200R

  9. #29
    Join Date
    Feb 2010
    Location
    Bellville
    Age
    47
    Posts
    145

    Default Re: Bolero Rebuild

    Triton 3.2 DiD

  10. #30
    Join Date
    Dec 2009
    Location
    Kathu
    Posts
    1,051

    Default Re: Bolero Rebuild

    Awsome thread! Well done! I had a Scorpio for 10 years with the 2.6 tdi engine. Served me well!
    Toyota RAV4
    Chevrolet Utility

  11. #31
    Join Date
    Sep 2006
    Location
    Durban
    Age
    55
    Posts
    709

    Default Re: Bolero Rebuild

    Echo03 what happened here, bakkie running all good?
    2006 Isuzu DMax 300Tdi DC 4x4

  12. #32
    Join Date
    Mar 2013
    Location
    Centurion
    Age
    31
    Posts
    373

    Default Re: Bolero Rebuild

    I see you also chipped the engine...

    Jokes aside, how difficult was it to source parts for this rebuild? I have been told that it is quite a mission, but would like some first hand experience.

    Don't ask me why, but I really like these Boleros.
    Attached Images Attached Images  
    2008 KB300 D-TEQ 4x2

  13. #33
    Join Date
    Aug 2015
    Location
    Kraaifontein
    Age
    38
    Posts
    58

    Default Re: Bolero Rebuild

    Hi Echo, how is the bakkie running after the rebuild?
    Brynmor

    2014 Ford Ranger 3.2 Extracab 4x2
    2012 Ford Ranger 3.2 Extracab 4x2 (Sold)

    2009 Mazda BT50 3.0 Extracab 4x2 (Sold)

Page 2 of 2 FirstFirst 1 2

Bookmarks

Posting Permissions

  • You may not post new threads
  • You may not post replies
  • You may not post attachments
  • You may not edit your posts
  •