1) Preparation and diagnosis
- Do: Record symptoms (low compression, oil consumption, knocking, coolant in oil, overheating), run compression and leak-down tests, oil pressure check.
- Theory: Pinpoints which systems failed (rings/bores, valves/head gasket, bearings, cooling passages). You only overhaul the parts that cause the measured faults.

2) Remove engine from vehicle (if required) and drain fluids
- Do: Disconnect battery, drain coolant and oil, remove intake/exhaust, accessories, wiring and fuel lines, lift engine out with proper rig.
- Theory: Full access is needed to remove head, crank and pistons and to measure/block-machine accurately. Draining prevents contamination and hazards.

3) Strip external components and remove cylinder head
- Do: Remove turbo (12H‑T), manifolds, pump, sensors, rocker assembly, then unbolt and remove head. Keep fasteners in order.
- Theory: Access to cylinders, valves and deck. Head removal lets you inspect gasket failure, warped deck or cracked head — common causes of coolant/oil mixing or low compression.

4) Inspect head and valves
- Do: Visually check for warped surface, cracks, burned valves. Pressure-test or dye-penetrant if needed.
- Theory: A warped or cracked head will leak combustion/coolant. Repair (machine or replace) restores sealing surface and fixes leakage or loss of compression.

5) Remove oil pan, timing gear/covers and front/rear seals, then remove pistons and connecting rods
- Do: Remove oil pump and pickup, caps and rods, push pistons out from top, tag rods/pistons to cylinders.
- Theory: Allows inspection of bores, ring condition, and rod/journal condition. Worn rings or scored bores cause oil consumption and low compression; rod/crank damage causes knocking.

6) Inspect crankshaft, bearings and journals
- Do: Measure journal diameters and bearing clearances; inspect for scoring, overheating or discoloration.
- Theory: Excess clearance or worn bearings cause low oil pressure and knock. If journals are scored beyond tolerance, crank must be reground/undersize and matching bearings used.

7) Measure cylinder bores for diameter, taper and out‑of‑round
- Do: Use bore gauge at several depths and orientations. Record wear pattern and size.
- Theory: Out‑of‑round or taper prevents piston rings sealing; causes low compression and blow‑by. Bores determine if honing, sleeving or rebore to standard/oversize is needed.

8) Decide machining scope: deck, bore, align/hone, line‑bore, crack repair
- Do: If deck warped > service limit, have block surfaced. If bores within tolerances, fine hone; if worn, rebore to oversize or install cylinder liners/sleeves. Check main bore alignment — line hone/align bore if distorted.
- Theory: Deck surfacing restores head sealing plane (fixes head gasket leaks). Boring/honing restores roundness for ring seal. Line boring restores main alignments to prevent crank bind and bearing failure.

9) Check for cracks and pressure-test the block
- Do: Dye-penetrant, magnaflux or pressure test coolant passages. Repair small cracks by welding or freeze‑plug replacement; replace block if major.
- Theory: Cracks cause coolant-oil cross contamination and compression loss. Proper repair or replacement restores structural integrity and sealing.

10) Clean oil and coolant passages
- Do: Thoroughly remove sludge, carbon, and machining debris; flush oil galleries and coolant jackets.
- Theory: Blocked galleries starve bearings and pump; cleaning prevents immediate failure after reassembly.

11) Machine work (if needed)
- Do: Have a shop perform boring/honing to correct diameter and finish; surface the deck; line bore mains; grind crank journals and polish; press in new cam/main bearings and freeze plugs.
- Theory: Machining restores geometry to spec so bearings and rings can seal properly. Crank grinding and bearing selection restore oil clearance to eliminate knock and low oil pressure.

12) Prepare parts: pistons, rings, bearings, seals
- Do: Check piston rings for correct end-gap in new bores, install new rod and main bearings, replace camshaft and lifters if worn, new timing components, seals and gaskets.
- Theory: New rings restore compression and reduce oil consumption. Bearings sized to ground journals restore oil pressure and remove play/knock. New seals prevent external leaks.

13) Reassembly of rotating assembly
- Do: Fit mains and torque to spec with correct clearances; fit crank, measure end‑play; fit pistons/rods with correct orientation and torque rod caps; install oil pump and pick-up; prime oil system prior to first start.
- Theory: Proper bearing clearances and endplay maintain oil film thickness and alignment, preventing bearing seizure and knock. Primed oil system avoids dry-start damage.

14) Reinstall head and timing components
- Do: Clean mating surfaces, use correct head gasket, torque head bolts in specified sequence and stages; set cam/crank timing and valve lash.
- Theory: Correct head bolt torque and sequence compress the gasket evenly for combustion seal. Correct timing restores valve/piston synchronization preventing valve damage and restoring compression/power.

15) Assemble external components, cooling and fuel systems
- Do: Refit manifolds, turbo (if applicable), water pump, thermostat, radiator hoses, fuel lines, injectors, sensors and intercooler plumbing.
- Theory: Restores flow paths for air, fuel and coolant. Replacing worn components avoids exceeding engine limits that caused previous failure.

16) Fill fluids, prime systems, and perform break‑in
- Do: Fill with correct oil and coolant, crank to build oil pressure (priming), run engine at idle monitoring oil pressure, coolant temp, and leaks. Follow piston ring break‑in procedure: moderate load and controlled revs for first hours.
- Theory: Break-in seats rings to the cylinder using proper pressure and heat cycling so rings conform to bores and seal. Priming prevents bearing damage on first start.

17) Post‑repair checks and measurements
- Do: Re-check oil pressure, compression across cylinders, and look for smoke, overheating, or knocking. Re-torque head bolts after recommended miles if specified.
- Theory: Verifies the overhaul restored correct clearances, sealing and timing. Early detection prevents catastrophic failure.

How each major repair action fixes common faults
- Boring/honing or new rings: fixes low compression and oil burning by restoring ring-to-bore sealing and correct ring end gaps.
- Head surfacing and new head gasket: fixes blown head gasket, coolant-in-combustion or combustion-in-coolant and restores compression across cylinders.
- Crank grinding and new bearings: fixes rod/main knock and low oil pressure by restoring journal roundness and oil clearance.
- Line boring/align honing: fixes uneven bearing wear and crank misalignment that cause premature bearing failure and vibration.
- Cleaning oil galleries and installing new oil pump: fixes low oil pressure and bearing starvation.
- Replacing cam/lifters/valves: fixes misfire, low power and valve-related compression loss.
- Repairing cracks or sleeving bores: fixes coolant/oil mixing and persistent leakage; sleeving restores bore integrity without replacing entire block.

Quick safety note: Follow the Toyota service manual for exact tolerances and torque specs; machine shop services are required for line bore, crank grinding and deck surfacing.
rteeqp73

Mr Landcruiser Special - HJ47 12HT Mega Build In this special long episode the Mr Landcruiser team start with a backyard build and finish with a 12HT equipped mega touring rig.

12HT Clutch & Gearbox Install - HJ75 Troopy Build (EP3) On this episode we get the new Clutch Industries Mantic built 4Terrain ultimate heavy duty clutch kit installed The Toyota H55F ...

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