I have been given a 1986 Hiace 2.4 diesel van, a bit rough looking, but if I could get it on the road reasonably cheaply it would be very useful for me. It was always hard to start during the donor's ownership, and there was a lot of fuming from the crankcase when it did run. I have removed the cylinder head and the gasket was blown in several places. I had hoped replacing the gasket might get the van up and running again. However, whilst cleaning things up, I've found that number 2 piston (and to a lesser degree number 4) can be rocked in the bore, perhaps half a millimetre, and in the case of 2 you can hear a slight noise as you rattle it back and forth. One and three have minimal movement. This only happens with the piston near tdc, and is worst at tdc. I'm hoping you guys might be able to tell me how worried I should be about this - I don't have a lot of cash to spend on the van, and in any case the rest of the vehicle wouldn't merit it, but I'd rather know if I'd be throwing money away without attending to this... I was wondering about fitting new piston rings but was put off doing this as the manual I have says the engine needs to come out, or at least the engine crossmenber needs to be removed to get the sump off and this is getting a bit beyond me. If you think I should be removing pistons, I'd be very grateful for confirmation or otherwise on sump removal. I'm tempted to take the bolts out and try to fiddle the sump out just in case it will come, but I'd rather not get stuck! I'm in rural New Zealand incidentally, and quite a way from the nearest engine guy so it's not easy to get someone to take a look for me. One engine reconditioner I phoned said he'd just do the gasket initially, and hope the piston didn't knock. Do you think there's any chance it wouldn't? Thanks in advance for any advice you are able to offer.

- (#14306) Alan Willis, 27 Nov 04 21:21

If the L-series is anything like the C-series in the townace, then a bit of rock in the piston is normal when the engine is stone cold. The pistons are tapered, and sizing is done BELOW the gudgeon pin- in the case of the C engines, cold clearance at this point is a max of .15mm.

What state are the bores in? On my 2C, the original honing pattern was still visible at 100k miles. The rings however can lose their tension somewhat.

And re. the sump, again if it's like the townie the crossmember and antiroll bar need to drop to let it out.

But on balance, I'd concur with your reconditioner. You *might* scuff the cylinder bores lightly to break the glaze, in the hope that the rings will re-bed, but other than that, build'er up...

- (#14306) david miller, 28 Nov 04 02:05

Many thanks for the advice David. Previous owner says he thinks a compression test was done at some time with very poor results, so I might delve a bit deeper after all. Will post again if anything interesting turns up...

- (#14306) Alan Willis, 29 Nov 04 03:20