Rebuilding Hema Maps’ iconic 76 Series LandCruiser: Part 2

Words Tim van Duyl Pics Capture Factory and Josh Hanger

In this multi-part series we follow the rebuild of Hema Maps’ iconic 76 Series Toyota LandCruiser. In the second episode, the team at the 4WD Workshop strip the 1VD V8 out of the LC76, inspect it and start the process of rebuilding it to OEM spec. Stay tuned for more updates on the rebuild process every two weeks.

Restoring a classic vehicle is no easy task, especially when it’s a workhorse like the 76 LandCruiser. Now, before we get to episode two, if you missed the first episode in this series you can watch it here. 

In this episode we delve into the meticulous process of reconditioning the 1VD turbo diesel engine for the iconic 4WD. Whether you’re looking to revive your vehicle or are simply curious about the mechanical nitty-gritty of an engine rebuild, this guide will walk you through the key stages for the 1VD.

The importance of engine reconditioning

The 70 Series LandCruiser is known for its durability, but like all machines, time and use take their toll. With age, engine performance decreases, components wear out and eventually, the time comes when reconditioning becomes a viable alternative to buying a new vehicle.

The Toyota 1VD-FTV engine, introduced in 2007, is a 4.5-litre V8 turbo diesel primarily used in heavy-duty vehicles like the LandCruiser 70 Series and 200 Series. The engine features common rail direct injection and turbocharging, with a power output of approximately 202kW (271hp) and 650Nm of torque, depending on the application.

As for production numbers and markets, the 1VD-FTV engine was primarily used in Toyota's LandCruiser models. Since its introduction in 2007, around 171,100 units of the 70 Series LandCruiser in Australia alone have been powered by the 1VD V8. 

However, Toyota is phasing out the 1VD engine due to emissions regulations, with the last V8-powered models expected for delivery by 2025.

So, in this case, we decided that reconditioning the engine, gearbox and other critical components would not only extend the life of the car but also turn it into a ‘pre-loved newish’ vehicle that could serve reliably for another 10–20 years. But how do you know when it’s time for a rebuild?

Engine removal 

Signs your 1VD needs reconditioning

Before jumping into a full reconditioning, it’s essential to assess the state of the engine. Here are a few key signs that it may be time to consider a rebuild:

1. Injector knock: A noticeable knock in the engine is often a sign that injectors are worn out and need replacing.
2. Oil leaks: Excessive leaks could make it economical to remove and strip the engine which in turn could justify replacing engine internals.
3. Blow-by: This is when exhaust gases escape past the piston rings into the crankcase, often resulting in a buildup of pressure and oil contamination.
4. Worn bearings: Over time, the bearings that connect the conrods to the crankshaft wear out, leading to serious issues if left unchecked.
5. Piston slap: Worn pistons create a distinctive slapping sound as they move, indicating that the engine is due for reconditioning.

The engine reconditioning process

Once the decision has been made to recondition the engine, the process involves dismantling, inspecting and reassembling each component, often replacing worn or outdated parts with high-quality, genuine replacements. Here’s a breakdown of the steps involved:

1. Oil sampling

Before an engine flush, an oil sample is taken to assess the condition of the internal components. This provides insight into wear patterns and potential issues inside the engine. In forced air-inducted engines, such as the turbocharged diesel in the LandCruiser, blow-by can lead to oil contamination, making regular oil analysis crucial.

Geoff will look for signs of copper and tungsten in the oil which could suggest the bearings are in need of replacement — note that there will always be some copper and tungsten in the oil as it is a perishable part, it’s when it’s low and alloy counts are up that you are heading for trouble. 

Oil leak 

2. Pistons and bearings

One of the most critical components to inspect during reconditioning is the piston and conrod assembly. Wear on the pistons or bearings can cause serious problems, such as piston slap or connecting rod knock. In this case, the primary coating on the conrod bearings had worn off, exposing the copper backing, indicating imminent failure.

With piston slap, bore wear can be accelerated so your engine builder will look at the roundness and scouring of the bore. A hone of the block is often enough for most, but a re-bore is possible on the VD block.

3. Head gasket inspection

The head gasket seals the combustion chambers and coolant passages in the engine. During reconditioning, mechanics closely examine the gasket for signs of leakage or failure. A well-sealed gasket is critical for maintaining engine performance and avoiding catastrophic failure.

Signs of excessive pressure on the head gasket could suggest the head and block were not mating at the correct pressures or that there is excessive pressure in the cylinders or oil, or water galleries. A good builder will inspect the gasket during strip down as it will help guide what’s needed as the process continues.

4. Injector and fuel system overhaul

Diesel injectors, especially those in high-performance engines like the LandCruiser’s, operate under extremely high pressures — up to 30,000 psi. Over time, the tiny holes in the injector nozzle can wear out, leading to uneven fuel distribution and poor combustion. Replacing injectors and ensuring the fuel system is up to spec is a vital part of the reconditioning process.

The role of genuine parts in reconditioning

When rebuilding a classic engine, the choice of parts can significantly impact performance and longevity. Although there are aftermarket options available, using genuine parts from the original manufacturer is often the best choice. Genuine pistons, timing chains, guide rails and other components are engineered to withstand the high pressures and temperatures specific to diesel engines.

One notable supplier for this rebuild was Cornell Diesel, renowned in Australia for its top-tier injectors and pump-rebuilding services. The precision required to manufacture these components is immense, and using non-genuine parts can compromise the integrity of the engine.

Cost considerations for a 1VD rebuild

A common concern among vehicle owners is the cost of reconditioning. While the price tag can be steep — ranging from $22,000 to $29,000 — it’s important to remember the benefits of investing in a comprehensive rebuild. Here are a few reasons why cutting corners is not advisable:

1. Longevity: Spending extra on high-quality parts ensures the engine will last longer and run more efficiently.
2. Warranty assurance: Using original or certified parts guarantees that the engine will meet manufacturer specifications, reducing the likelihood of costly warranty claims.
3. Performance gains: A properly rebuilt engine will deliver better performance, fuel efficiency and power, especially when paired with modern enhancements like ECU tuning.

Enhancements and upgrades

New brake kit supplied by CBA

Beyond the reconditioning, the rebuild also opens the door to performance upgrades. For this LandCruiser, we made several improvements:

• ECU reprogramming: To optimise fuel delivery, increasing power output and fuel efficiency.
• Clutch upgrade: With increased torque from the remapped ECU, a heavy-duty clutch capable of handling 860 Newtons of clamping force was supplied by the team at Clutch and Brake Australia. 
• Brake upgrade: The extra power and torque necessitated improved braking performance to ensure safe handling under load, especially when towing. CBA again helped out here with a PowerStop Kit including new rotors and pads at each wheel. 

Conclusion: Why reconditioning is worth the investment

Rebuilding an engine is more than just restoring lost power — it’s about ensuring your vehicle continues to perform reliably for years to come. While the upfront costs may seem daunting, a comprehensive reconditioning using genuine parts pays off in the long run by providing peace of mind, enhanced performance and extended vehicle life.

If you’re considering a rebuild for your vehicle, make sure you’re working with trusted professionals who understand the importance of quality components and precise workmanship. With the right approach, your reconditioned engine will run like new and keep your LandCruiser on the road for many more adventures.

By understanding the detailed steps involved in an engine rebuild, you can appreciate the craftsmanship required to turn a well-worn engine into a reconditioned powerhouse. Whether you're doing it for love of the vehicle or simply for practical reasons, reconditioning an engine can be a rewarding investment.

The 4WD Workshop

Geoff Whitehead of The 4WD Workshop

Geoff Whitehead, who runs the 4WD Workshop in Seaford, VIC, is highly regarded for his knowledge and passion for 4x4 vehicles. Known for excellent customer service, he and his team provide high-quality fittings and expert advice on vehicle accessories and modifications. 

The workshop is a Platinum Distributor for Ironman 4x4, ensuring access to premium products. Geoff is noted for treating customer vehicles as if they were his own, delivering outstanding results with great attention to detail.

You can find more details about his workshop here.

Keep up to date

Look out for the remaining three episodes which will be released fortnightly:

• Episode 3: Fitout Part 1 — Power, Lights, Wheels & Tyres 
• Episode 4: Fitout Part 2 — Ironman Suspension, Bar Work & Alu-Cab
• Episode 5: 30,000km Later — What Went Well and What We’d Do Differently

And make sure to subscribe to our YouTube channel so you get all updates on the project.

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