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08-29-10, 01:47 PM
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#1 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| Motor tear-down and rebuild... Tear Down.
I will add some photos a little later. I have been talking about this project for a while and now i'm elbow deep in it with no functioning camera and a few questions.
I will also try to keep this thread updated so i can maybe add some tech to this section or help others as they do this.
My question right at this point is:
Do i have to remove the cams to remove the head? I have not even tried to stick a socket down on the head bolts, but the FSM is telling me to remove the cams first, then the head. Can i skip the cam removal and save that for the machine shop?
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95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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08-29-10, 02:10 PM
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#2 | | Addict
Join Date: Jul 2005 Location: Boulder Foothills, CO
Posts: 1,005
| No the cams need to come off first, if you look, you will see the head bolts can not be accessed with out removing the cams.
__________________ 93 FZJ 80, 4.6 l, 6 slee suspenion, Front and rear and side aromor, 44 gal aux tank, 4.88, 35 MTR, daily driver, 36 TSL fun tire, drawer system, dual batteries. Can't wait for a trip.  | |
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08-29-10, 03:30 PM
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#3 | | 10k Club
Join Date: Mar 2003 Location: Boston MA
Posts: 16,388
| FYI, the head bolts are a 12 point 12mm socket. A 6 point socket won't work. | |
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08-29-10, 05:09 PM
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#4 | | Lifer
Join Date: Aug 2003
Posts: 8,615
| No, but you can leave the intake in the engine bay to avoid messing with the wiring that goes between intake tracts. You can also leave the exhaust mans in the engine bay attached to the exhaust pipe.
__________________ Buy Head Gasket DVD for you OR for your mechanic HERE
'93 FZJ since new, 2.2kw starter, Revo 275s (Michelin Alpins in winter), locked, big Hellas, rr fog, rr flood, rr Airlift, synthetics, ARB bullbar. 97 FZJ - exact same stuff but Michelin X-Ice in winter. 2013 Impreza with medium Hellas. 1990 Audi Quattro 20V w/ rear locker. | |
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08-29-10, 05:42 PM
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#5 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| Thanks for your replies! I have already removed the intake and pulled the wiring bundle through the firewall. Might have been a mistake, but i hope not. After i typed my question i went back out and messed a bit and it does appear that you cannot get the head bolts out without removing the cams.
Tank: went and purchased a set of 12 point sockets and a set of ratcheting wrenches for this job. Has made life a lot easier to have the right tools.
Two things i have thought about after the removal of the intake and the wiring harness: 1. The PHH is just that and i would like to eliminate the hard tube all together. THere was a write-up about doing that and i think i will.
2. There has to be a way to re-route the wiring bundle so that the intake can be removed again without pulling it through the firewall?.. anyone looked at that further? I don't plan on removing the intake again anytime soon, but just in case.... I may study on that a little tomorrow.
I'll try to get jfz80 to let me use his camera so i can show my progress and what i'm finding.... think i'm going to find a bent valve.
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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08-29-10, 06:05 PM
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#6 | | Addict
Join Date: Sep 2006 Location: Vidor, TX
Posts: 1,987
| yes you can re-route the phh to eliminate the hard line. http://forum.ih8mud.com/80-series-te...cone-hose.html
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96 LX450: 37x12.5x16 SSR's, MT bumper, 10K winch, 3" suspension lift, 1" body, Surco roof rack, daily driven and in need of 4.88's.
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08-29-10, 06:06 PM
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#7 | | 11400-66041
Join Date: Aug 2004 Location: Istanbul, Turkey
Posts: 10,602
| I routed mine out of the intake runner. I put the injector wire section through the center of the intake clamshell. The other wires--sensors/tranny/xfer/etc I routed underneat the lower portion of the intake manifold.
I did this by taking the wiring harness apart and separating the necessary wires and routing them correctly and then rewrapping them. It took a good day to do this correctly for the long haul.
Good luck Alex.
__________________
Bend to fit, dent to match."
-CDan
"Nothing is “like” anything else. There are no metaphors, there are no similes. Each thing is the thing it is and nothing else."
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June 1997 FZJ80: Soon to be retired
November 1985 FJ60
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08-29-10, 06:20 PM
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#8 | | Addict
Join Date: Jul 2005 Location: Boulder Foothills, CO
Posts: 1,005
| Wow, it only takes like 10-15 min each side of a head job to pull the wiring harness out of the computer. This allow you to wrap it really well and to check the wires at the computer where they contact some metal( as well as where they are close to the EGR pipe). I really do not under stand why the reluctance to pull the wires. As well as the exhaust manifold and the intake. I have the intakes sent off to the machine shop to soak in a tank to clean them.
The exhaust is just plain in the way, much easier to take them out.
But to each his own.
good luck
__________________ 93 FZJ 80, 4.6 l, 6 slee suspenion, Front and rear and side aromor, 44 gal aux tank, 4.88, 35 MTR, daily driver, 36 TSL fun tire, drawer system, dual batteries. Can't wait for a trip. | |
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08-29-10, 07:21 PM
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#9 | | 10k Club
Join Date: Mar 2003 Location: Boston MA
Posts: 16,388
| I have been tanking the intakes as well as replacing all the vacuum hoses in the truck, That alone takes about 10ft of hose and doing that with the harness still attached and the intake hanging off some support would be a major PITA.
I often find that a little extra time spent on something like removing the harness can pay dividends on time saved elsewhere in the process. | |
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08-30-10, 07:20 AM
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#10 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| I plan on tanking the intake, which is why i wanted to go ahead and get it completely removed. That thing is filthy! I"m also going to replace all the vacuum hoses as Landtank suggests.
Also, i had a bit of trouble removing the lower intake. A lot of bolts, hard to reach hoses... just was like spaghetti to me. That's why i am trying to simplify and to me not having the wiring harness weaved into the intake is simpler.
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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08-30-10, 08:41 AM
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#11 | | 10k Club
Join Date: Mar 2003 Location: Boston MA
Posts: 16,388
| once the harness is out of the way the head and intakes are pulled as a unit, pretty simple. | |
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08-30-10, 10:50 AM
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#12 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| Quote:
Originally Posted by landtank  once the harness is out of the way the head and intakes are pulled as a unit, pretty simple. | You are correct... live and learn! I pulled all the intake, so now i'm sitting with a head and block still in the bay.
I hope to remove the head in the next day or two. 
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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08-30-10, 12:11 PM
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#13 | | 250+ Club
Join Date: Mar 2003 Location: PNW - WA
Posts: 992
| I cut the intake manifold years ago to facilitate no harness fiddling & it still seems like the best idea I've ever had on my 80 - radiused the cut down area, a little extra wrap on the harness to prevent chafing & it's been trouble free for years.
I know some still balk at the idea, but I'm here to tell you all it's worked out great.
If you cut the flat area that is tight to the head just inside the bolt holes & round the edges, it will save ever having to deal with the harness routing ever again. My crazy $.02
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'97 Black/Grey -Slee 4", Retrofit e-lockers, 4.88's, 315 MT-R's, ARB / Warn M12K, Slee step sliders & TC skidplate "Street poser/queen" now
'97 LX450 Green/Tan -J springs & 30 mm spacers fr , ARB locked x2, 5.29's, 38.5" Boggers, ARB / Warn M8K, Hanna sliders & RR bumper, Slee T-case plate, delete flares, cladding, rack, Rhino'ed lower 1/3rd & hood ctr, lotsa extra welds all over. "The fun one"
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08-30-10, 07:23 PM
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#14 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| I was able to find the service bolt to hold the cam gears together at lowes. Think it was around $1.48
IIRC it was a 8x1.0x12mm
I will check the manual again tomorrow to make sure that was correct.
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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08-31-10, 04:01 PM
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#15 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| So far the only strange thing i have found is the number 1 bearing cap on the intake cam, the rear of the cap had a slight indication of wear. All the other caps looked great. Wonder why just the rear of this one had a little wear?
Was about to pull the head but it's getting dark and i need another set of hands so i don't blow my back out.
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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09-02-10, 08:12 AM
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#16 | | Lifer
Join Date: Oct 2003 Location: North Cadillac
Posts: 8,155
| i'm hoping that jfz80 will post up some pics when he gets a chance. I don't have a camera so i snapped a few pics yesterday of the head gasket and head.
I was absolutely surprised how good the head gasket looked. In fact, i am wondering if it had been replaced at some point. The #6 cylinder did not show any signs of moisture.
I'm still wondering what that loud ticking was when it was running? More to come soon.....
__________________
95' FZJ80 OME med./J lift, ARB rack, ARB Bull Bar w/tmax 12,500, 35" truxus, Aussie locker-rear, Center Diff Lock, Sliders, IPOR Skid, IPOR rear bumper, upgraded slee sticker, custom dents, supercharged. . .
Remember it's a gateway drug, so it will actually lead to "crystal meh".
Go 80, or go unsatisfied
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09-02-10, 02:04 PM
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#17 | | Lifer
Join Date: Jun 2005 Location: NC
Posts: 4,927
| Quote:
Originally Posted by concretejungle i
I'm still wondering what that loud ticking was when it was running? More to come soon..... | dunno yet but im afraid its contagious 
My junk now has a case of the tickitytickitytickities
Here are some pics of the head and internals, anything look out of the ordinary? I thought it looked pretty dang clean for quarter million miles 
Valve cover off, rockers out, timing chain retained w/ screwdriver 
oblique above view 
pizza box bolt retention system 
valve train bearing caps 
head off, view of top of block, HG in place (from front) 
HG detail from front 
ole number sixer  
bottom of head from front 
bottom of head from back 
and top of cylinder bottom of head/valves 
whats up with the carbon flaking off #1 (or did you do that CJ)
and the intake valves on #5 look like they have gotten a lil steam cleaning maybe ?
__________________
Jason
__________________________________________________ _________
95 FZJ80 -- 4''/35's 250k w/ Kazuma EMS SLEEsliders 4x4LABS ARB w/ warn12k fun time campermobile
77 FJ 45 -- SOA/37's tbi350 sm420 4wheeldisc rust 8274 on a homeade bar dd company worktruck :P
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09-02-10, 02:23 PM
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#18 | | 10k Club
Join Date: Mar 2003 Location: Boston MA
Posts: 16,388
| ah, that screw driver trick was a mistake unless you are planning on pulling the timing cover. | |
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09-02-10, 03:44 PM
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#19 | | 10k Club
Join Date: Jul 2004 Location: Chandler, AZ
Posts: 15,973
| Wasn't this the motor that reportedly had a hole burned in a piston? I'm not seeing evidence of that in the pix? 
__________________ Kevin Patterson '96 LX450 '84 4x4 Mini '73 FJ40 Copper State Cruisers #007
"We have come to the conclusion that we can run our car over any road that a man can take a team of horses and a wagon, providing we can get traction." Dr. Horatio Nelson Jackson, 1903 | |
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09-02-10, 03:51 PM
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#20 | | Addict
Join Date: Jul 2003 Location: Finger Lakes, New York
Posts: 2,216
| Quote:
Originally Posted by Tools R Us Wasn't this the motor that reportedly had a hole burned in a piston? I'm not seeing evidence of that in the pix? | now that's not even funny...
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Mike R.
04/1995 FZJ-80
A man may be a fool and not know it, but not if he is married.
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concretejungle
1988 BMW M3
1997 Toyota Landcruiser
Chuck the Truck
Pork Chop
the Girken
1995 Toyota FZJ-80 Land Cruiser
