Thread: 4BD1 Rebuild, Sanity Check Needed Please

Hello all. As some of you may have read in the thead on excessive smoke, I decided to rebuild the engine in the 110 County and in so doing the engine is now torn down, parts inspected, parts identified for replacement, calibration, etc. and sourced (though I have not yet ordered the parts, it seems I can get it all to me within about 4 days of order - the hardest part was measuring to determine the liner grades which were not stamped on the block as indicated in the manual for some reason).

Anyway, I've not rebuilt a diesel engine before and this is my first go at anything like this. I am hoping this one goes well and if so I may be doing another next year for one of the Perenties, so I wanted to get some experienced mentoring here from this group.

The items I've identified for the rebuild are as follows (at a high level, planning for things to go well as the only things out of sorts seem to be the two cylinder liners that were gouged, the fuel pump needing to be calibrated and the crank case oil seals needing to be replaced. That said, I am redoing all four cylinders and pistons/rings since I have things broken down anyway and yes, this is how these things get more expensive than planned, I know, as I'm also now taking the time to rebuild the LT85 to solve the 5th gear rattle I noted last year and now that's got me to thinking perhaps some suspension tweaks as I have an aluminum off road trailer I fabricated, so maybe time to address that too now that everything's apart.....when does it end? ).

Tear down engine
Check all 4 rods
Clean (vat) and Check Block
Replace 4 liners and CAM bearings
Check and polish cam shaft
check and polish crankshaft
Rebuild head (guides, valve stem seals, keepers)
Rebuild water pump
Dress the rocker assembly
Check and surface flywheel
Check and surface exhaust manifold
Check fuel pump and calibrate
Check all misc housings, covers, oil pan, etc.
Rebuild Engine and re-assemble
Run Engine on Dyno to test (machine matching adapter to do so)
Check 4 injectors
Hone all (4) cylinders for liner replacement

I estimate, if everything continues to go smoothly from here (when does it ever, but please indulge me) - the work will take around 60 hours total - again, if it goes as planned without further incident. Does that sound reasonable to those who have done this?

Also, the parts I have determined with the help of an Isuzu supplier here in the States, and while the engine was originally naturally aspirated, now that it runs with a Garrett G22 turbo, I think I should be choosing the turbo options where applicable. The parts list is as follows (there is redundancy in a few parts, such as the bolts, as I am not yet sure which ones I will need):

5-87810-567-4 GSKT.SET;ENGINE EACH 1 FOR NON TURBO MOTOR (ONLY ONE AVAILABLE HERE)
5-87814-567-1 LINER KIT EACH 2 GRADE 3 TURBO LINER KIT (kit includes pistons, rings, etc.)
5-87814-568-1 LINER KIT EACH 2 GRADE 4 TURBO LINER KIT (kit includes pistons, rings, etc.)
8-94132-813-2 METAL KIT;CRNK EACH 1 TURBO CRANK BEARINGS
8-94117-032-1 METAL SET; MAIN EACH 1 NON TURBO CRANK BEARINGS
8-94114-565-2 THRUST;BRG EACH 2
9-12271-608-0 METAL SET; CONN EACH 4
9-11691-048-1 METAL KIT; CAMS EACH 1
9-11693-035-1 METAL;CMSHF,INT EACH 2
1-09070-100-1 BOLT;CYL HD TO EACH 4 NON TURBO - M12X102
8-94367-436-0 BOLT;HEAD TO BL EACH 2 TURBO 10X25 M12X119
5-09009-060-1 BOLT; CYL HEAD EACH 1 NON TURBO 12X115
1-09070-101-1 BOLT;CYLINDER H EACH 13 NON TURBO 12X115
1-09070-100-1 BOLT;CYL HD TO EACH 4 TURBO 12X106
1-09070-101-1 BOLT;CYLINDER H EACH 12 TURBO 12X119
1-11721-013-0 GUIDE; VALVE,IN EACH 8
5-12565-006-0 COLLAR; SPLIT EACH 20
8-97120-167-0 SEAL; VLV GUIDE EACH 8

Other than sanity (which I clearly no longer have, if ever did), what am I missing parts and time estimate wise on this rebuild? What should I consider or plan for now so it doesn't bite me later? BTW, the parts list above comes to about AUD$3,500 here in the States. How does that measure up with there)?

Thank you again for sharing your knowledge and experience.

It's a lot, granted and I appreciate your willingness to slog through it. Having never done this before I'm trying to be as thorough as possible, wanting this engine to last (and last well) for at least 500kms. This has been an extreme learning experience and it sounds like the added few days will likely have me learning more! Thank you for everything. Will keep posted (perhaps in less detail).