[dan ahern]

Hi all, decided to start a thread on this as it may be interesting along the way because let's face it who knows what could be in store with a new project. (A lot of pain and heartache most likely ;P ) So to start with it is a very clean Y61 3.0 Patrol (2004) low enough milage 150k. So the story is i had an add up looking for a non runner to break or consider doing up and this lad contacted me from Waterford and the story is he was driving along the road and it started to run out of diesel..it ended up stopping but started and stalled again and that was it. This lad don't sound too mechanicaly minded and he said rather than going to the hassle he just wants to move it on.He said he was advised it was the injection pump. In the meantime he bought a replacment engine for it but never fitted it,that also has a VP44 Pump on it,so i am taking the Patrol and two engines from him (Navara engine and other Patrol engine) and he is just as keen to move on the lot.

So one engine is a ZD30 and the other is a Navara engine but i am not sure which one the Nav is yet as he is sending me pics later but i just want it for the pump as it's the same VP44 on it and that part he knew himself but is it going to be the same pump now is the question! So my plan here is to get it going and sell it on as it's a very desirable crew cab model (Seats in the back) but commercial (cheap tax) these are the sought after models here. I'm sure in Ozz you lads get all the Patrols with rear seats but here in this neck of the woods it's very differnt. If you get the cheaper commercial tax (Goods vehicle) well we are not allowed seats in the back due to insurance reasons for work etc... but however a crewcab is a Patrol that you can tax cheap for the year and use it for work with seats in the back! He said the Patrol is mint and the chassis is the best he has seen. Very rare good ones are getting these days like this!!

So the suspect here is the Injector pump but i myself am a little sceptical because of the low miles, however i will rock on and be divulging in to this soon enough so i am excited to get this project started. My goal is to spend as little as possible funds hopefully on it to get it running. I have plenty of parts as i have been picking up plenty along the way and also have another Patrol i broke for parts (2001 model) so like i mentioned i have also bought this Navara engine and injector pump basically like i say just for the pump because the pump is the same VP44 unit 'Hopefully' and it was just rebuilt before the block so he says on this Navara engine the head is good also and it was pressure tested so when i asked him why he didn't just get the pump fitted he said he didn't want the hassle and is not a mechanic himself.Understandable! I don't need the engines but i am just getting them at a good deal now anyway! I'm not bothered about the condition but he assured me the three engines are running 100percent. The one already in the Patrol never missed a beat he said.

So on a "I'm taking him at his word" basis,i will remove the pump from Navara engine and fit it to this Patrol if needs be. Firstly i am going to give it a good diagnostics check over before drawing any conclusions! My first port of call will be to check for air in the lines and check the fuel situation,then probably the Immobilisor and most likely move on to check the pump in the patrol so see if any diesel is been injected by cracking off one injector line. All simple things like earths and fuses will be checked first before doing anything.
So the deal is done and the Patrol is heading my way. I am looking forward to another project and i will add plenty of pics in due course!

Dan

 

[AndrieK]

So Dan, is it a 5-seat Wagon? Two front seats (obviously) and a second row bench for three?

Funny enough, here in Oz I'm guessing around a third (maybe a liitle less) of Y61 Wagons were DX 5-seaters and two thirds, ST, ST-S, ST-L & Ti 7-seaters. (There might have been a few early ST's also with 5-seats. Not 100% sure.) There's no tax benefit for going either way. DX's didn't have a third row just because it was the poverty pack model. But a very large number of the others lost their third row seats because people fitted drawers etc. in the back. Third row seats are a dime a dozen at wreckers.

 

[dan ahern]

Yes it's the second row we are allowed to have! Most Patrols here have full seats fitted including for the army but they have to be taxed privatly (1200euros per year approx) where as the crew cab is 333euros per year! That's some differnce just for road tax!!
So this Patrol is coming tomorrow evening and i am looking forward to the project but to be honest it's a lot of a gamble and i am only taking him at his word,he said 8 months before it packed it in it had a new clutch and flywheel and to be honest that i believe because they normally go at that milage anyway.
So a quick recap, the Patrol is coming with it's own engine and two other engines, one he got that he says is perfect because he knew nothing at the time and thought it was an engine issue until he was informed it was the pump later on, the other engine he had laying there for a while and is a Navara unit as i say i still do not know which version that engine is yet but the pump is all i want as it's a recently rebuilt unit around two years ago it had been refurbed. On the second engine i am taking off him is a ZD30 motor with pump also but he says he has no idea the condition of that IP.

So god knows what lays ahead with this one, if his word is to be true it is already a stunning deal but if this turns out not to be the case it could be a minefield of problems... in the very worst case i will just break it.

Dan

 

[dan ahern]

Ok so the Patrol arrived today and i am very happy with it. Going to go over my first observations on it.It is the SVE model which is fully loaded. Sunroof,elec windows,A/C, rear seats,rear flip down tv. Milage 150K. Wheels are mint but tires are gone. Body is Very good with not one dent i can see. Paint is faded on the rear panels a little the black over grey the top part is a little faded a few patches but nothing that won't T cut out. It comes with a decent roof rack, CD player and all the usual extras. So far i am happy about the spec and it has a decent front bull bar with rear bumper bars too and a very nice tow bar.
So i had a little struggle to open the bonnet, the cable is broke inside away from the latch. It needed someone inside keeping a pull on the cable while i gave it a coaxing with a nail bar and it popped up. I reckon it's just a little seized from been idle.This Patrol actually has been sitting sinse 2016! The inside is filthy and in need of a real good valet. It is very obvious once you sit in how long it has been idle,once i opened the sunroof cover back all the pine needles were just hanging from it and dropping on my head. The Navara engine is sitting in the back as promised. The sunroof took a little coaxing too to get going and i almost got my fingers jammed trying to unstick it!! lol... All elec windows work apart from passenger side that seems to be dead. The drivers seat is in terrible condition as it has a good few tears but has a cover on it which is ok. Headlights have no bulbs, bonnet strut is missing at one side and i need a support beam to hold it up. Tail lights all work as they should and interior lights surprisingly all work. Chassis is VERY good but covered in typical surface rust from just sitting for so long but is very solid,i went in under it and gave a good look around,it is really solid with absoloutely no major rust or anything to worry about and once you can clean down to solid metal it's good & nothing that a good clean down and repaint won't sort out!

So under the bonnet it seems he was true to his word and the pump is intact but they had a play with it and pulled it apart in the vehicle, the rear plate is missing, pump was unplugged and it looks like they really tried. I plugged every harness back in before cranking it over (It has no battery so i just used jumper cables for now) and engine turns great but the Radiator looks to have a shady looking repair done to the top tank, it was half empty too so i topped it up and for what i don't know cause i'll be probably stripping it all apart anyway. LOL.. It seemed to take around 4 liters to top up. It looks fairly clean in around the core at least from the top.
One big plus is the Immobilisor light is staying on the whole time but it's early days yet and this could somewhat be linked to the pump. Right now it's a shame they went messing with the pump because it's missing parts and deffo needs to come out now!!

It's missing the complete diesel filter assy and housing so i have them anyway in my spares back up. The airbag light is flashing but this most likely can be reset with the key,right now that don't bother me.
A relay is buzzing like mad when the key is turned and the RPM Tacho shoots up and seems to stay at 2600rpm's which is very strange. Everything else around the engine bay looks as it should and under the Patrol has no visable leaks with only a very small oil wet spot under the vaccum pump.
Front hubs look fine and dry but again as it's sitting for so long condition of everything really isn't known yet,this is all just visual for now.

So the plan next is to get a fresh battery in it, change out relay that is causing a problem and shoot on from there. To be honest it's looking like some major stripping is going to have to be done with that pump straight away!!
Most of the stuff inc pump is showing surface rust from just sitting for so long but that don't matter and is easily cleaned back up later on.
The last pump i fitted to a Patrol was idle since 2013 and looked far worst with pitting etc but it fired right up!!

So it looks like i have my work cut out here but i will try to crack on with this ASAP! I just love a good project!

-Dan

 

[dan ahern]

More pics! As you can see the surface rust on the chassis but i'm really surprised at how good the chassis actually is on this! A win...

 

[dan ahern]

More...

 

[dan ahern]

And more....

 

[dan ahern]

Few more for now!

 

[dan ahern]

So this is where my project is at and it just started. I have my work cut out and that is the challenge of it! The chassis needs a good clean down and repaint/underseal. The interior needs a lot of cleaning and of course to get it running is the biggest thing.
The 4x4 and drivetrains condition can't really be known until the engine is running but he said all those were spot on and i believe it cause the Patrols drivetrain are just bulletproof.

 

[dan ahern]

Ok made super progress this evenng for a few hours. Got VP44 out of navara engine,i sped that process up by just cutting the timing chain off with my cordless grinder because that engine is scrap anyway bar the head which was pressure tested and is good! So then i stripped my way down and got the pump out of the Patrol aswell which was good progress, the both pumps are Zexel units.
Some negative things about todays work on the Patrol, the first is someone has had this stripped down before and for what reason i don't know. The scissor gear was never locked in place and it was easy to find this out because i couldn't push the drill bit through the holes as they were out of alignment regarless of having the CCC bottom end all timed in the right spot. And when i did rock on and finally remove the large IP sprocket i wasn't surprised about the lack of tension & when the gear didn't spring back,it just done nothing,so this confirmed it for me.
Anyway,this is not too much of an issue and i can just rewind the tension back once timing it back up. Yes unfortunately the timing is not to be trusted now so i have to redo all that aswell!! More work for me...
Another negative was the engine is in the early stages of 'black death' which means the oil looks like it was never changed and the engine parts inside timing case and rocker cover have a black coating of tar like substance (Oil) it ls not a good sign and can sometimes mean the engine was overheated too at some point but not always the case,it can like i say be from just poor servicing...at this stage it's not too much of a worry either and it may be harmless and a good engine flush is what it's going to get when it's all done and a fresh oil change.At least the engine turns over good and there is plenty oil in the sump which is something.The lack of maintainence from some people with their vehicles really astonishes me.

Another annoying one is the guy had the Navara engine sitting in a shed for a long time, so long that the rubber glove ends he used to keep diesel pipes clean had rotted away and two were missing!! So all i can do is give this diesel pump a good wash and compressed air without getting any more dust in there or crap. Short of going to a diesel specialist to inspect the pump this is all i am willing to do for now and take a chance with it!

The chassis as the pics show cleans up really good to solid metal and should be easy to get it right for painting.

Few more pics but for now i am held up with the Hubs on the pumps, i need to swap the Patrol hub over on to the other pump cause the navara has a larger hub. Now time to try to figure out how they come off...i have been at them a while and can't figure it.

A few more pics, first up taking IP out of Navara engine!

 

[dan ahern]

And moving along...and a look at a small section of chassis after a quick clean just to show how solid it is. A good cleaning & painting and it will be like new.It needs a pressure wash first as there is a lot of crud stuck there.

 

[dan ahern]

And stripping the Patrol nicely...Someone had a good play around here before... All injector lines were cracked open and left that way. The pump was partially dismantled to the rear of itself while still in the Patrol and like i said above earlier the timing case had been off before as tension was lost on the scissor gear.

Another job i done this evening was refitted the rear lip spoiler above the back doors as it was just laying in the back of the Patrol.

 

[dan ahern]

Final few pics for now. Next job put IP in Patrol and reassemble everything. Replace CAS with a spare i have and all relays.
Ohh and i forgot to mention the 4 glow plugs were stone dead! I hope that wasn't the issue here before they went stripping pump LOL ....

So can anyone tell me how to remove these Hubs?? That would be a big help! I have the nut off the Patrol pump but can't get hub off,i thought it may come off with a puller but it looks to be threaded on the shaft. Very tough to get this off and the Navara hub looks worse!!

 

[joet]

Great read do far, alot of info. Thanks for sharing. keep it up.

 

[dan ahern]

Thanks Joet.

Ok,so i hit a little obstacle today with this project. After contacting two diesel specialists just because the second opinion was nice to get, and after giving them the numbers from both pumps it seems that the Navara pump will not work for this project because the ECU and hub are differnt, apparently certain numbers need to match on the pumps or they just will not work. Ford transits and a wide variety of other vehicles here use the VP44 pumps and for sure a lot of them are not interchangable even though they may look exactly the same! The second diesel specialist shop said the same thing.

So the pump part is on hold for the time been until i can find a good used pump if possible, the thought crossed my mind to have the pump rebuilt in the new but i'm not sure yet i want to be putting that sort of money in to this project but i'll see how it goes and in any case i'm in no major hurry with this project.
In the mean time i plan to get the loan of a compression tester and check all cylinders.
Needless to say i have plenty of work to do with this besides the pump is only one part of many jobs to be done so i will rock on.
Ohh and i picked myself up a nice used battery today in the breakers yard for cheap so that's out of the way now!
Must order a set of glow plugs now too in the meantime.

 

[dan ahern]

In my limited spare time I got the rear of chassis all cleaned down and painted. I'm delighted with the results!! Ohh and after giving it a lot of thought I have decided to send Diesel pump away to specialist for a full rebuild. It will only add more value to this Patrol anyway and in any case I would prefer it new selling it on to someone else!

 

[dan ahern]

Not sure why my phone uploaded some of those pics twice 🙈 anyway, delighted with how it's turned out. It got a primer coat and two finish coats of proper anti corrosion chassis paint with anti rust protection.Long ways to go yet on this chassis though,so far around 5 hours spent and I have only the rear end done. It's tough to brush paint this on but it's a far better way to do it.

 

[dan ahern]

Few small updates this evening. I put in the battery and cleaned off all earths so that seemed to fix the jumping rpm needle conundrum 😊 Win😄 I also fixed the airbag light by resetting it with the key. I oiled

up all locks and door hinges with good old wd-40 and used rubber silicone spray on all elec window rubbers to help them a little. This Patrol has been sitting sinse late 2016. Anyway, any progress I will try to update as I go but apologies in advance if it's slow from here on because I'm on a lot of other Patrol forums & sites too and I'm doing this project when I can make time for it😉

 

[dan ahern]

Some goodies arrived from UK today. Four new glow plugs and a new water pump for my own 07 Patrol daly driver. Thc Glow plugs were a steal at 30pounds from a reputable shop in UK. They are called Tramac and made in Turkey actually. I paid 35 euros each for my own Denzo!! Next thing I wonder about is the quality🤔 I spose it's better than no glow plugs in it 🤣 They look exactly like Denzo plugs. Full metal tips! I really love the shop in the UK it's called 4x4 and pick up spares.👌 The waterpump was a good price too @80pounds. Japan parts is the brand and they are as good if not better than the original.

 

[dan ahern]

Some updates on this project! Made some great progress in my limited time. I am building a new shed at the moment too,been a family man and running my own business means time is hard to find but I managed a few hours.So I drove to Waterford and picked up the other ZD30 engine with pump in it. Engine is good he said but pump state ' unknown' So after a long spin I got the engine home and quickly pulled the pump. Next step I decided to take was strip my two pumps down and take a look and possible clean the up.... I learned a lot by doing this 😉 Ok so here is the engine im my trailer and yes it leaked some oil as the rocker cover was loose... 🙈 no big deal though but would have been nice had he told me. So parts off and pump off it was first job.