Background...

In 2000, I had to rebuild the engine, and it did not go well. Carr Parts (Santa Cruz, Ca) misassembled the engine, resulting in the oil control ring cutting a notch into the #2 cylinder. To repair it, it was sleeved. Later, I was informed that they had an accident, and dropped the block, but no damage was done (more on this later). 

In 2001, I developed an oil leak. It was the front main gasket. A known problem, to repair takes an front main sleeve repair kit. Apparently the engine rebuilder did not know about this.

In 2002, The head gasket was apparently blown. Once the head was off, a crack was found and I needed a new cylinder Head, so it was replaced with a LCE Pro Cylinder Head. 

See the link below for the gory details of my first engine rebuild: http://members.cruzio.com/~bhawk/22RET_rebuild.htm

It is four years later, and I finally have gotten around to write about the latest engine rebuild, my latest saga of my Toyota Turbo Truck...

In 2005 I noticed that the coolant tank was full, but the radiator was low on coolant (I noticed because it was running a little hot). I found the hose inside the recovery tank, was not a tight fit, and was missing the factory spring clip (hose clamp), and as such coolant was not sucked back into the radiator. Not sure if this was the cause of, or the beginning of my problems...

Eventually, My engine was burping coolant in to the recovery tank, but was not sufficiently sucking it back in to the radiator. I took it to my regular mechanic. A chemical test was done, to look for engine combustions by-products. It was fond to have, a likely blown head gasket. Once the head was removed, it was found to also have a worn out cam and rockers, and the exhaust valves were bad to. The worn cam, was do to the, LC Engineering, high performance springs (part of a packaged HP street head, for the 22RTE at that time (I cant find it on there page?) The machinist told me this could only be from HP springs, putting too much pressure on the cam. So, I had to over haul the head, too. It got new every thing. I only reused the the LCE head casting. All the new parts, came from DOA. http://www.doaracingengines.com/

When I got the truck back, it had the same problem, but worse! The head was pulled back off, and with a very bright light, a crack was found in side the number three cylinder, on the front edge (facing the number two), this crack was between the water jacket to cylinder (See below, also there was a crack back to the sleeved cylinder) it was is almost imposable to see unless you knew it there. It was likely there from when my engine was originally rebuilt (from the sleeving, or when it was dropped). We decided to replace the block with a salvaged block. Luckily we found one, since 22RTE's are very uncommon. The block was magnafluxed (checked for cracks) and was found good. It was already bored 20 (thousands) over (it was likely rebuilt before). So it was bored to, 30 over. I could not find forged pistons, that were not way over the original approximate 8.0:1 (actually Toyota reports it's: 7.95:1) compression. I had the pistons custom made, from LCE. I wanted to get them from DOA, but he had delivery problems? I had to pay LCE for an expedite fee, almost costing the amount of the pistons (you dont wanna now how much I paid). It seems like, I waited 3 months or more. LCE takes the pistons, and adds valve reliefs into them, but leaves very sharp edges. I had to smooth out (Drimmel) the milling, done by them. The block was line bored. All the typical HP rebuilding things were done. Including balancing all the rotating assemblies. The knock sensor was moved to the new recommended location (one boss to the left, I think). I used ARP head studs, and had the head and block was finished (RA#) to except MLS type head gasket, if later I decided I need better sealing. Gaskets came from ROL: http://www.rolmfg.com/gasket.htm I got them from: http://www.awep.com/  

In the end, I went 100% over budget. I was expecting to spend about 3K.

2009. Currently have less than 10K on the new engine, and it runs grate. Passes SMOG fine. No more weird misses. No more ECU loosening its mind and random misfiring...

Only one thing, I'm not so happy about, fuel economy. I get about 12-15 MPG in town, and 16-20 MPG Highway (take 55 MPH to get 19-20MPG (I cant drive 55 in a 75+ MPH world), and it takes Premium Gas! I dont drive it, all that much, any more, since I have a 2001 Honda Accord Ex. It gets 21-24 MPG in town, and 25-30 MPG highway (up to 70-75 MPH); With Winter fuel (California gas has up to 10% alcohol) and the AC on, can yield the worst case highway FE (25-27 MPG, other wise I get 27-30 MPG).

Pictures below. The first two are with the camera up side down. This was the only angle the camera would get the crack really good? See the last pic, to see what I mean...

The Cracked block (I was holding the camera upside down?):

Crack goes through to the sleeved #2 cylinder (the camera is up side down?)...

Normal View, can you see the cracks?

ROL Graphite Head Gasket kit:

Neal Henry
Arizona Wholesale Engine Parts
555 W. 2nd Avenue # A18
Mesa Arizona 85210
602/447-0833
http://www.awep.com/

Author: Bruce Hawkins
Copyright © 2009 Bruce Hawkins. All rights reserved.
All referenced trademarked names belong to there owners...

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