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ilea 02-21-2018 09:30 PM

99 sw2 engine rebuild thread
 
Heading up a really steep bridge (Huey P Long for those in NOLa) my sw2 coughed up a puff of smoke and started shaking violently. Check engine light flashing (misfire cyl 4) and all. Limped her home and compression tested her. 0 on cyl 4.
Borrowed rack space in a friends garage.
Behold my fallen soldier.
[IMG]https://i.imgur.com/WcyM8Z6_d.jpg[/IMG]
So I'm looking at a rebuild at 188k.

colonelhogan44 02-21-2018 09:41 PM

Re: 99 sw2 engine rebuild thread
 
Were you at or close to WOT when it happened? I bet your fuel filter is original?

ilea 02-21-2018 09:57 PM

Re: 99 sw2 engine rebuild thread
 
I was close to WOT. I changed the fuel filter when I got her 4 years ago. Already got a new fuel filter and pump on my workbench waiting to go in after the rebuild. Thank goodness for napa employee discounts.

OldNuc 02-21-2018 10:49 PM

Re: 99 sw2 engine rebuild thread
 
Check the fuel pressure and only use a WIX 33731 filter regulator or you will be burning more valves.

Fuel pressure must be 45-51 PSI at all times or you will burn valves. If there is an exhaust leak ofr a restricted preCAT you can run lean at high RPM WOT and mor burned valves. As you noticed this happens very fast.

The actual filter element rarely plugs up unless you are stealing AG gas at night.

ilea 02-21-2018 11:18 PM

Re: 99 sw2 engine rebuild thread
 
I got the wix filter and a delphi pump. New oxygen sensor too. Got a rebuild kit and waiting on a reman'd head to show up. Gonna do the control arms and struts while I'm at it. Cv axle too cause when I got in there I saw the outer boot was cracked and had just about run dry.

Should I replace the injectors?

OldNuc 02-21-2018 11:49 PM

Re: 99 sw2 engine rebuild thread
 
Check your fuel pressure and hope the head you bought is not just cleaned up junk. Once you know the preCAT has been gutted and the exhaust is bubble tight at 3-4psi then injectors would be a lovely idea. Which injectors can be an interesting discussion. Rebuilt and tested Bosch injectors can be purchased relatively cheaply. A higher flow injector will usually keep the >75% throttle fuel mixture on the power side of the curve. Changing the timing chain is a good idea while it is all apart, that is pump gears - complete timing set.

Exhaust leak test.
--Locate a low pressure high volume air source, reversible vacuum cleaner, large fan, leaf blower or what ever you can find.
--Loosely couple to cold exhaust at the tail pipe, or direct fan at tail pipe.
--Spray every inch of the exhaust between the head and CAT outlet flange with a mixture of 2 or 3 drops of dish soap and water in a spray bottle.
--Pay close attention to the lower flange, lower support clamp, and flex connector.
--The flex connector is under the protective braid so it requires quite a bit of solution to show any leaks.

ilea 02-22-2018 12:56 AM

Re: 99 sw2 engine rebuild thread
 
I'm probably going to replace the exhaust from the manifold flange back. She needs a new cat and the muffler is oem so it's about time. I'm getting my head from clearwater cylinder heads. My friend who is letting me borrow a bay has used them before and so far so good.

I intend to keep my wagon for awhile. ☺️

OldNuc 02-22-2018 09:09 AM

Re: 99 sw2 engine rebuild thread
 
At one time they were OK then ther was a bout of out of spec Chineese castings and poor machining. Inspect carefully.


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