Project PAJ (Kermit)

fullthrottle
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Project PAJ (Kermit)

Postby fullthrottle » Sun Jul 17, 2022 8:30 am

Well!!!

Found my next project and collected it Saturday from Napier.
Nothing like a 4 hour drive back to Welly to find out what's wrong with it.

The bones are all there for a good little truck:
Lifted, 33's and engine swap for a 4D56T (all certified) WoF and Reg.
New Chromoly rear axles and bearings
New front CVs and bearings

It's had a few hands on it with some interesting ideas, but just cosmetic and nothing a bit of time won't fix.

So on the way back home, with about 60k's to go, lost the clutch. No fluid left in the reservoir.
And left rear axle seal might be gone as it's spewed some shit out across the tyre.

Will see what else needs tidying up. Then she'll be ship shape.
received_744487113339749.jpeg
Last edited by fullthrottle on Mon Jul 25, 2022 12:10 pm, edited 1 time in total.

johnny262
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Re: Project PAJ (Kermit)

Postby johnny262 » Tue Jul 19, 2022 7:06 pm

Very cool, fits right in parked on the main street of DVK lol

Will be watching with interest :D

MihiT
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Re: Project PAJ (Kermit)

Postby MihiT » Sun Jul 24, 2022 6:58 am

Looks pretty tidy. Those engines benefit from deleting harmonic balance shaft, EGR, and adding turbo!
- 1990 LWB Safari flatdeck, TD42 -
- 1988 LWB 7-seat Safari, TD42 -
1989 LWB 5-Seat parts hack. TD42

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Mon Jul 25, 2022 12:17 pm

Ah, correction to my initial post. It is the turbo engine.

Was reading about the harmonic balance delete. What is the real benefit?

From what I have read, just removing the balance belt, would:
a) possibly increase engine vibration
but
b) reduce resistance for the motor

MihiT
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Re: Project PAJ (Kermit)

Postby MihiT » Mon Jul 25, 2022 1:31 pm

fullthrottle wrote:Ah, correction to my initial post. It is the turbo engine.

Was reading about the harmonic balance delete. What is the real benefit?

From what I have read, just removing the balance belt, would:
a) possibly increase engine vibration
but
b) reduce resistance for the motor


That's pretty much the gist of it. Spins up quicker, uses less fuel. How much of each depends on more than that, but I reckon it's worth doing.

Everyone I've heard from had no problem with it gone, have heard a couple of stories of increased vibration (always a mate of a mate)
- 1990 LWB Safari flatdeck, TD42 -
- 1988 LWB 7-seat Safari, TD42 -
1989 LWB 5-Seat parts hack. TD42

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Wed Aug 03, 2022 7:43 am

Well have a bit of time now to come up with a shopping list to keep me out of trouble (aka: in the garage away from the annoying kids LoL)

(In no particular order)

1) Harmonic balancer delete
https://youtu.be/aDg91Vb_ods

2) Tuning old smokey. This seems a good place to start: https://delicaforum.com/index.php?threa ... power.707/

3) Build up some barwork

4) Fix leaking rear axle seal

5) Fix clutch ....tick...Just needed bleeding.

6) Clean up the wiring. It's had some interesting ideas.

7) Reconnect the gauges. EGT, Water temp. Wouldn't mind seeing if you can get the standard V6 Rev counter working with the 4D56. Must be some mod out there??

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Sep 11, 2022 7:16 am

Well, it's been a bit of a slow start.

Daughter's car had to come off the road for a bit and I had to rebuild the A pillar. (Bloody 90's Hondas)

Anyway, reinstall the last CV. Wheel bearings could do with some love. The grease has certainly seem some water. Have heard that those AVM manual hubs can let a bit of water in, so will explore the pros and cons of going back to fixed. The transfer system is a bit different to the 80, where I get a 2WD option. But the whole front drive train would still be spinning with hubs fixed.

Thought I would start off with a bit of a more detailed inspection.
20220807_122220.jpg
Engine bay


Front diff oil looked like grey slime, transfer case had about a quarter left in it. Home-made air box seemed more like an oil transfer system with the amount of shit being recycled from the rocker cover. Will either put in a catch can or just extend the breather into the chassis (self anti rusting technique )
20220910_150521.jpg
Airbox oil


Radiator is being pressurised and so slowly blowing water out the overflow. I reckon stuffed headgasket at the least, maybe head. Will plan on whipping this off when convenient.

Found some rust in the back right cover of the boot. Easy fix and will plate it back up. Removed the remaining carpet and all looks good.

Wiring for the motor is as tidy as my teenagers bedroom. Plus seem to be missing a number of controls in the cabin.
Check out that earth srap bro...
20220809_120240.jpg
Wiring

20220809_120245.jpg
Earth strap


Winch isn't running, Well not even wired in. WTF

Seems like someone was hungry and had a chew on the drivers seat.

So for a start I've flushed and replaced all the oils for diffs, transfer, Gbox, Engine. Actually runs a bit quieter now.
Whipped out the airbox and will replace that useless pod filter with one of those Ryco O2 Rush filters. (Better filtration and cleanable)
Screenshot_20220911_071403.jpg
Filter

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NJV6
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Re: Project PAJ (Kermit)

Postby NJV6 » Fri Sep 16, 2022 9:08 pm

I vote go back to fixed flanges. less abilty to get water in that way, I had genuine AISIN ones and until I went back to solid flanges was doing wheel bearings every WOF, haven't done one now for about 5 years. I do carry one hub with me incase I break a CV on the track and can swap it for the flange. If you ever put an auto locker in the front you will need the free wheeling hubs though. Yes and No with the whole front drivetrain spinning, the front diff disconnect does mean the CV's are spinning but the crown wheel and pinion isn't, just the side gears do. There is no noticeable difference in fuel consumption with or without FWH.
SWB V6 Paj with one or two mods ;)

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Re: Project PAJ (Kermit)

Postby Big » Mon Sep 26, 2022 10:45 am

interesting read, jkust out of curosity, how much boost are you running ? I have a very original std V44 which is a great runner and cheap on gas but it just lacks.. powa..lol its got all the fruity bits as std, intercooler etc so looking at pumping it up a bit :) cool truck btw

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Mon Sep 26, 2022 11:15 am

According to the gauge, it's currently running 8psi. In the Delica forums they say the standard turbo and engine will handle 17psi. That is a massive step up for standard.

With the EGT, Boost and fuel I will just tweak it enough so it's running well with good temps.
It doesn't need to be a dragster LoL.
Plus I am sure the head gasket is stuffed, possibly head. So too much boost this side of looking at it closer, may result in something nasty :-)

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Oct 02, 2022 2:36 pm

Right, decided to tackle the wiring!! What a bloody birds nest! So annoying when people just twist the wires together and slap a bit of masking tape over it :shock:

2022-10-02 10.33.21.jpg
Wiring


I've pulled almost all of the dash out to trace all the wiring. Since it had a 4D56T transplant, I needed to find some of the dodgy wiring and correct it. Looks like I need a new water temp gauge as the sensor wire goes no where.
There are two senders / sensors and from what I can work out, the one in the upper radiator hose housing is the gauge temp sensor (single pin) and the larger one (2 pins) in the head is for the glow plug temp sensor. (circled in RED)

senders.jpg
Senders


LoL, that earth strap connection is a crack-up.

Anyway, I'll replace the sender unit to match the new VDO gauge.

Have pulled out all the redundant wiring and ordered some new power distribution/fuse boxes to clean everything up.
Navra.JPG


I've also been through and labelled all wiring that was added with the transplant.
Still more to do, getting there slowly.

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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Oct 16, 2022 4:37 pm

On this week's episode of putting lipstick on a pig.....

Finally got my VDO water temp gauge and matching sender. Had to tap out the old hole as it was gummed up with thread tape.
Have flushed out the radiator and engine.

More wiring... Have redone all the dash wiring and labelled everything. Honestly some people and their bloody wiring skills.
20221016_124121.jpg
Dash wiring


Stripped out the back end also to see if there are any more treats.
20221016_124114.jpg
Rear clean out


Also soaked the seats in soap and water blasted them. They will do for a while and will just put the sheepskin covers on.
20221016_124132_copy_1280x960.jpg
Seats

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Mon Oct 24, 2022 3:49 pm

Temperature!! What Temperature problems you say??

Thought I would take it for a small adventure into Rallywoods this weekend. I'm sure the rest of the lads (with their cruisers and safs) were thinking WTF is this green monster that has crept up on us in the bush...LoL.

Anyway, just wanted to see how it handled offroad. A very different experience from the 80, driving this thing that weighs bugger all, is manual and has plenty of traction.
Didn't take it down anything too hard since I haven't connected the winch and it doesn't have any recovery hooks....yet.

With the new gauge and sender I did notice that the temp was creeping up a bit and wouldn't maintain a normal running temp. Was sitting around 60 degrees cruising down the road.

So this weekend....

Popped in a new thermostat, and to my surprise I found the temp regulation problem.
The existing thermostat had been put in the wrong way and had been jammed open with some wire. WTF

20221024_095847.jpg
Jammed1


20221024_095855.jpg
Jammed2


New thermostat (correct thermostat) looks much better. A bit tricky to get in as you need to put a dab of high temp silicone to glue it in place.
20221024_095914.jpg
New thermostat


Runs perfectly now. Maintaining around 80 degrees and gets only to 95 on a long uphill with my foot in it all the way.

Looks a lot cleaner layout now. And those sheepskin covers, you would think you were driving a rolls.
20221024_162632.jpg
Interior


Also made a new gearbox floor moulding out of a rubber car mat. Just glued and screwed.
20221024_151612.jpg
GBox


That's all for now folks....

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Oct 30, 2022 3:04 pm

Just a little bit of work this weekend.... Well took a lot of mucking around, but that's always the way with small jobs.

Wanted to tap in the EGT probe so I could start playing around with the tuning.
There seems to be a few 4d56T variants out there, taking about inserting the probe through the EGR blanking plate, but mine doesn't have that.
Only place I could find suitable was in the turbo dump pipe. Will give me an indication of Temps.

20221030_093704.jpg
Engine bay1

20221030_093657.jpg
Engine bay2


Anyway, as you can imagine it's a right shit to get at. The nuts were seized more than my back. Applied plenty of penetration lube and soaked for a while and bingo.
Removed the dump pump and tapped the probe in.

20221030_132922.jpg
Tapped

20221030_144712.jpg
Assembled


Took it for a fang around the neighborhood with just the dump pipe.
Neighbors love that sort of thing on a quiet Sunday afternoon. Reading reasonable EGTs now, so can tickle it up a bit.
Last edited by fullthrottle on Sun Nov 27, 2022 12:43 pm, edited 1 time in total.

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1kz_surf
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Re: Project PAJ (Kermit)

Postby 1kz_surf » Mon Oct 31, 2022 7:28 pm

How deep into tuning it are you planning to go ?


I have new injector nozzles copper washers shims and a tester if ya want to get that into it mate


What sort of egts are you seeing post turbo ?
poor little suzuki :lol: :lol:

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Nov 27, 2022 12:50 pm

1kz_surf wrote:How deep into tuning it are you planning to go ?


I have new injector nozzles copper washers shims and a tester if ya want to get that into it mate


What sort of egts are you seeing post turbo ?


Was thinking of giving this a shot....

https://delicaforum.com/index.php?threa ... power.707/

I have been told from the previous owner that the injectors need rebuilding. Not really sure how you can tell though. And how reliable that info is, is questionable.

Getting about 400-500 post turbo. With a max hitting 600. Like everything in this truck though, it's been molested so not sure how accurate the chicity China gauge is. Might just get another VDO gauge since I can get them super cheap.

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Nov 27, 2022 12:57 pm

Slow going ....but a little bit of work.

Started thinking about some barwork designs and so ripped off the front bar and extracted the winch.

Thought I would rebuild it and oh my what a treat! Gearbox was as sloppy as the village girl and solenoid has been swimming for a while. Motor seems all good though. Fairly clean and plenty of life in the brushes. This will save me some dollars.

Turns out to be a Novawinch as well, so not too cheap and nasty.

20221126_130736.jpg
Winch


Stripped down, new grease, clean motor, new seals and a fresh coat of paint. Will test at a later stage to see if the solenoid is stuffed.

Will look at getting some new rope also.

fullthrottle
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Re: Project PAJ (Kermit)

Postby fullthrottle » Sun Nov 27, 2022 2:57 pm

Yep, FUBARed......

20221127_145219_copy_1024x768.jpg
Solenoid

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