2F Rebuild - First Timer (1 Viewer)

[78fj40mg]

Ok a little update.

So we needed to remove the clutch housing to install the stand clamp onto the block. With not a lot of room on the ground below the block we had to use a high lift jack to tilt it back enough for me to be able to move clutch plate out to be able to reach the flywheel and housing bolts.


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Went to collect the lift from boozewz but the thing was huge and couldn't fit In the RENAULT Kango which is a small van I took along.

So we ended up coming home empty handed.

That when the madness started. We started imaging a million and one ways to lift the engine onto the stand. From stretching tug ropes between two trucks and lifting it up, to using a PowerTank air lifter. All we need was to lift it about 20 inches.

In the end someone suggested a forklift. Luckily there is a construction site next to the house we sent for a fork lift.

Low and behold a forklift arrived and fixed what was a very difficult start to what seemed like a impossible job without a engine lift.

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Positioned the engine and stand next to the gate so he could reach them.

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Done

Im so excited. Now the real work can start.

Nice work!

You will need an engine hoist to get the engine back in the truck:

 

[Arabian Cruiser]

Nice work!

You will need an engine hoist to get the engine back in the truck:

Will start shopping for one near the end of the build. Coz I need to remove the old engine first, then install the one I'm building.

 

[Weber Sarge]

I would love to have one of those 3-wiper windshield frames - in this country people would automatically assume it's custom of some sort , no one would believe Toyota actually built them .
Sarge

 

[Arabian Cruiser]

I would love to have one of those 3-wiper windshield frames - in this country people would automatically assume it's custom of some sort , no one would believe Toyota actually built them .
Sarge

I'm sure I will be getting that from a lot of people here too. It's been a dream for the longest time. And recently when I got my new 40 LX I remembered the three wiper and found one for sale. It was unbelievable. Had to get it. It came a yellow Color and the motor works fine.

Should have been a standard on all trucks. The Fj cruiser has three and that was based on the LX I guess.

Thanks

 

[Arabian Cruiser]

That's what it looked like when I got it.

 

[Weber Sarge]

I would imagine the 3 wiper design would actually clear the windshield pretty well compared to the standard 2-wiper . Visibility isn't so good in winter weather on mine , no matter what wipers I use .
Sarge

 

[micruz60]

Nice work!
I had no idea 3 wiper setup existed.... Iwant, is that Lexy or Pearly with the big eyes?
Fj40jim is the fella with deep wisdom on these engines... Look for the thread 'how not to restore a fj40'
Just for posterity, what is the serial # on the block of your rebuild?
Looking forward to the progress!

 

[78fj40mg]

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That's what it looked like when I got it.

I'd love a three wiper windshield frame, the two wiper system sucks.

 

[Arabian Cruiser]

I would imagine the 3 wiper design would actually clear the windshield pretty well compared to the standard 2-wiper . Visibility isn't so good in winter weather on mine , no matter what wipers I use .
Sarge

Would have to agree with you on these not making a big difference in bad weather. But three hands are better than two ; )

 

[Arabian Cruiser]

Nice work!
I had no idea 3 wiper setup existed.... Iwant, is that Lexy or Pearly with the big eyes?
Fj40jim is the fella with deep wisdom on these engines... Look for the thread 'how not to restore a fj40'
Just for posterity, what is the serial # on the block of your rebuild?
Looking forward to the progress!

Pearly is the one with the big eyes.

This is a picture taken a while ago of all my girls before the 'big eyes'.

in order from the left.

Pearly fj40, Lexy fj40 LX , Sandy FJ 43 and Awax Fzj80

Thanks I'll look for the thread.

Please find the engines serial numbers below.

 

[Arabian Cruiser]

Ok so we started the tear down today.

I'll post the pictures to give you an idea of the state of the engine and the parts we open up so far.

So this was my plan for the oil in the oil pan. Drain it in here after we put some wood on the floor to absorb any lost oil.

This is what happened coz we forgot the wood.

No issues. Got most of it in there.

So after removing the coolant drain plug we noticed that it was blocked. Could the actual plug have broken off in there ?

Will drill that out once I check the plug in another engine to see the length.


Next the water pump and thermo housing came off

This is what it looked like
behind it

It was missing the thermostat.

Then next removed the oil cooler and tubes

After that came the removal of the rocker cover

And the compete rocker assembly and push rods. Plan on buying new push rods so no need to keep them in order.

Then came the spark plugs

Then the cylinder head

Next pictures are of the values
if you look at them long enough you start seeing aliens

And I managed to put together a small working area.

That's it for now.

 

[watrob]

They must be good tiles on that floor as I don't see any cracked ones?

 

[Arabian Cruiser]

They must be good tiles on that floor as I don't see any cracked ones?

Hahaha

I'll start a new thread on cracked tiles. Got plenty. I had chosen this area because of how clean it is and the tile work is solid and would handle the weight of the stand with the engine. I had a section of the garden tiled up where there was a circled grass area. They did a bad job and you could probably crack them by walking on them.

 

[boozewz]

Great start!

Keep up the good work

 

[Arabian Cruiser]

Great start!

Keep up the good work

Thanks Boozewz. We can come over and help you with your build. It's a walk in the park is you know someone. Trust me.

I couldn't have done so much with out the support of these two

Salah the resident chief mechanic and Noel and apprentice
Mechanic

The team is ready : )

 

[Arabian Cruiser]

Ok a little update.

After totally dismantling the engine it was time to get the block cleaned. @boozewz offered on getting it cleaned in a parts washer. Thanks @boozewz for coming through.

This is what was done to the blocks

' We used the Proceco to get the block cleaned. That uses a mixture of water, steam and an alkaline chemical to clean the block. The water galleries were plugged and we cleared them as much as we could, the rest on the inside too as another issue. The cylinder walls might need some machining, you'll notice a lip at the top.

After, we had to sit the block on it's side before starting, we feared it's too light and might get knocked over.

The cylinder head is placed in a chemical which breaks the carbon build up, it's soaked in it and air is bubbled through to activate it and quicken the cleaning. This took about a 5 hour soak. '

This is when I dropped them off to get cleaned.

Before

After

And went to pick it up

Loaded the rest of the parts into the 80 to go to two or three machine shops to tomorrow morning to hear what they have to say and how much they will charge.

Passed by the dealer today to see what size pistons they have in stock and was reassured to find they have all the sizes and all the parts available that I will need to do a complete rebuild. Very happy.

Till the next step.

 

[Arabian Cruiser]

Here is a picture of the 80 loaded up.

 

[boozewz]

@Mcladin glad we could help. Shout out to @BIGWZ as well

 

[Arabian Cruiser]

@Mcladin glad we could help. Shout out to @BIGWZ as well

Thanks @BIGWZ

 

[Arabian Cruiser]

@Mcladin glad we could help. Shout out to @BIGWZ as well

I Just had a great idea .

in support of my local Cat Dealer for that great service they did, i will paint the block a CAT yellow or a close enough shade. considering that color could be trademarked.