2510 diesel Mule engine repair...........

This 2510's Diahatsu DM950D motor was hydro-locked. Broke a rod and aired-out the block..... There's no short or long-blocks available, only 38 to $4200.00 complete engine. After searching the world for a replacement at a decent cost (New bare block costs 648.00 ) we found a complete motor in the corner of the local Kawi dealers shop for 200.00.

At first the shop-owner said it had a rod out the oil-pan, we discovered it did not, then he said "Oh yeah this one was the one that had some kind of noise". So far I cannot find any reason this motor was replaced. Said shop, sadly, is known for some shady-stuff. This motor very well may not have even needed replacing.
I'm waiting for a shop manul to get here so's I can check bottom-end specs on the replacement then back together she goes.

Dead-motor-





Replacement-

Fine looking piece of equipment right there.

Damn that is one big ass hole........ ouch!!!!

Too kewl........Jimbo's building a "SMOKER"....I love it

Foxfire wrote:

Too kewl........Jimbo's building a "SMOKER"....I love it

It kinda scares me tho............I've found out through studies the head-bolts are one-time use only, so bolts are in order. The whole Injection-pump timing thing is a scare too, I've read about "Runaways"...... The pump that came with the motor is likely good, but dunno really if it is. The blown motors pump is good. So I'm at a point, should I try the pump that came with the motor?? Or swap it out. If the pumps no good, you have to pull the motor to swap it............

Well....one thing you know for sure is they did not remove the pump from the engine you bought....so when you get your book, you will be able to see just where all of your timing marks are to line up....at that point you could decide which pump to use and know just where it needs to be installed at....piece of cake

In cylinder #2....what caused the line @ 12:00 (in the pic) ? Do not worry about the "Run Away" deal......no air, on run....regardless of timing. If you get a chance, snap me a pic of the "Accessory Drive" section......the very front of the engine. I can find some of the timing marks but not all and if I can find what I'm looking for I can tell you how to time it from right here.

That's just a carbon-streak in #2, not scored. I see all the timing marks and now understand them....sorta.

No intimidation here. Simple as ABC..............Line-up A with A, B with B, C with C.......DUH.........A 6-year old could do it. Got the pump changed, Timing cover back on...





The pump can also be rotated some, I guess to retard or advance the fuel input. Put it back in the center-stock.



Cover back-on




I tore-down the junk motor just to see how it ticked, the carnage.........

Yes on the pump can be advanced or retarded......stock is safe.....retarded is a little more power. Piece of cake! By the way....nice lookin black box @ bottom right of engine

Foxfire wrote:

Yes on the pump can be advanced or retarded......stock is safe.....retarded is a little more power. Piece of cake! By the way....nice lookin black box @ bottom right of engine

Just for shits and giggles Bryan. Which direction would be retarded??? Opposite of rotation???

Damn is that piston rod twisted and bent? Thats some serious torque.

ridepate wrote:

Foxfire wrote:

Yes on the pump can be advanced or retarded......stock is safe.....retarded is a little more power. Piece of cake! By the way....nice lookin black box @ bottom right of engine

Just for shits and giggles Bryan. Which direction would be retarded??? Opposite of rotation???

Which way is rotation, Jim

Foxfire wrote:

By the way....nice lookin black box @ bottom right of engine

And damn nice sticker!!!!

Big-R wrote:

Foxfire wrote:

By the way....nice lookin black box @ bottom right of engine

And damn nice sticker!!!!

A old Rhino-Box. Still serving and doing duty.

nocerisdave wrote:

Damn is that piston rod twisted and bent? Thats some serious torque.

It is. Looks like pulled taffy............
The compression on this little motor specs @ 493psi!!!!
No wonder the head-gasket is $63.00 and it has 14 head-bolts.

How is the Smoker coming along Jimbo?

Foxfire wrote:

How is the Smoker coming along Jimbo?

I'm sorry forgot to take more pics. It's back-together and at Mikes house. I'll get some pics of us re-installing it. I went ahead and installed new rod and main bearings. I figured why not?? The old stuff looked ok, the crank mic'd fine. Fingers crossed!!!!!

Ready to go back home................



Shes in and moved under her own power this afternoon. We had water in the fuel because the tank went underwater. After fooling with that an hour or so. All's good!!!



Lesson learned. Mules should stay on hard-pack........