Builds 94 FZJ80 - Let the Adventure Ensue (1 Viewer)

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Greeneville, TN
It’s like looking into my future about a month from now. Kinda looking forward to it, or at least the thought of how awesome the truck will run afterwards.

Just a thought if you missed it; no better time to replace those motor mounts if you‘re pulling the whole thing.
 

FMC80

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Sep 30, 2017
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2,546
Location
Jonesborough, TN
The following is a working list of the shiz I have for my rebuild. I have already replaced many of these components during my baseline in 2020, so I won't be replacing everything, but if I hadn't baseline it less than 3 years ago, I would. Let me know if you see something I missed!

HG & Engine Removal Parts List
Injectors out for cleaning/service
Steering Box/Frame support kit from DVS
FIPG00295-00103
Silicon spray
Red coolant
Rebuild head
Assembly Lube
Valve shims
plugs
Rotor19101-66010
Wires90919-21557
Distributor O-ring90099-14118
Distributor rotor o-ring19127-66020
Rotor Assy19102-61240
Head Bolts90910-02111
Head Bolts Washers90201-12222
Head Gasket Kit (Kit comes with a lot-not sure what it all comes wth)04111-66061
Oil cooler cover gasket15725-66010
Oil cooler gaskets (x2)15785-66010
Oil cooler o-rings (x2)15134-20010
Small hose material90999-92003
Cyl Head bolts (x14)90910-02111
Cyl Head washers x1490201-12222
Exhaust manifold studs x1390116-10169
Exhaust nuts x1390179-10128
Exhaust mani to pipe stud x490080-12007
Exhaust mani to pipe nut x490080-17187
Water PumpWPT-023
Fuel Filter23300-69045
Thermostat90916-03117
x2 Oil Cooler Gasket15785-66010
ECT sensor gasket (in head gasket kit? Other sensor gaskets?)90430-12005
Fuel pressure regulator23280-75010
Chain Assembly13506-66010
Tensioner assembly13540-66011
Chain Damper13561-66010
Chain Tensioner gasket13552-66010
Camshaft Sub Gear13529-62901
Camshaft Gear13523-66020
Crankshaft Gear13521-66020
Wire sensor for knock sensor x282219-35010
Knock Sensor x289615-30050
Thermistor assembly88790-60050
Alternator Brush27370-75060
#1 AC tube88716-6A421
A/C Dryer Assembly88471-50020
PCV Kit:
Vent hose 112261-66021
x2 Clamps for hose # 190467-14001
Vent hose 212262-66021
x2 Clamps for hose #290467-20002
PCV valve12204-35040
PCV grommet90480-18001
Hoses:
Water bypass #499555-10200
Water bypass #316267-66020
Water bypass #116261-66040
Water bypass #216264-66021
Rad Hose #116571-66030
Rad Hose #216572-66021
Rad Hose #316573-66010
Power Steering Rebuild04446-60080
O-ring90301-73004
High-pressure gasket44327-30030
Hose Sub Assembly Water87209-60441
Hose Sub Assembly Water87209-60301
Engine Insulators/mounts
Stabilizer brackets x2 (optional)12381-66010
Engine Insulators x212361-17011
Transmision/Engine Insulator12371-66030
Nuts w/washer x290179-12115
Washers x290201-12208
Nuts x 290179-12090
 
Last edited:
Joined
Aug 22, 2019
Messages
1,091
Location
Greeneville, TN
The following is a working list of the shiz I have for my rebuild. I have already replaced many of these components during my baseline in 2020, so I won't be replacing everything, but if I hadn't baseline it less than 3 years ago, I would. Let me know if you see something I missed!

HG & Engine Removal Parts List
Injectors out for cleaning/service
Steering Box/Frame support kit from DVS
FIPG00295-00103
Silicon spray
Red coolant
Rebuild head
Assembly Lube
Valve shims
plugs
Rotor19101-66010
Wires90919-21557
Distributor O-ring90099-14118
Distributor rotor o-ring19127-66020
Rotor Assy19102-61240
Head Bolts90910-02111
Head Bolts Washers90201-12222
Head Gasket Kit (Kit comes with a lot-not sure what it all comes with)04111-66061
Oil cooler cover gasket15725-66010
Oil cooler gaskets (x2)15785-66010
Oil cooler orings (x2)15134-20010
Small hose material90999-92003
Cyl Head bolts (x14)90910-02111
Cyl Head washers x1490201-12222
Exhaust manifold studs x1390116-10169
Exhaust nuts x1390179-10128
Exhaust mani to pipe stud x490080-12007
Exhaust mani to pipe nut x490080-17187
Water PumpWPT-023
Fuel Filter23300-69045
Thermostat90916-03117
x2 Oil Cooler Gasket15785-66010
ECT sensor gasket (in head gasket kit? Other sensor gaskets?)90430-12005
Fuel pressure regulator23280-75010
PCV Kit:
Vent hose 112261-66021
x2 Clamps for hose # 190467-14001
Vent hose 212262-66021
x2 Clamps for hose #290467-20002
PCV valve12204-35040
PCV grommet90480-18001
Hoses:
Water bypass #499555-10200
Water bypass #316267-66020
Water bypass #116261-66040
Water bypass #216264-66021
Rad Hose #116571-66030
Rad Hose #216572-66021
Rad Hose #316573-66010
Power Steering Rebuild04446-60080
O-ring90301-73004
High-pressure gasket44327-30030
Hose Sub Assembly Water87209-60441
Hose Sub Assembly Water87209-60301
Engine Insulators/mounts
Stabilizer brackets x2 (optional)12381-66010
Engine Insulators x212361-17011
Transmision/Engine Insulator12371-66030
Nuts w/washer x290179-12115
Washers x290201-12208
Nuts x 290179-12090
Looks pretty good. I would just add exhaust gaskets for the manifolds to the y-pipe (assuming it’s the same design as my ‘95).
 

FMC80

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Messages
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Location
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These come in the HG kit from Toyota. No need to get these separately.
Have I told you lately that I love you? My HG kit comes with a bunch of unlabeled sh*t. Thanks for the assist, Onur.
 

OGBeno

11400-17120
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Don't waste time weeding through BS posts on MUD from people who have no clue what they are talking about.

Start here first.

 

FMC80

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Sep 30, 2017
Messages
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Location
Jonesborough, TN
Don't waste time weeding through BS posts on MUD from people who have no clue what they are talking about.

Start here first.

I appreciate this Onur. I didn’t buy 04112-66036, I instead bought 04111-66061. I assume it’s close to the same kit?
 

OGBeno

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I appreciate this Onur. I didn’t buy 04112-66036, I instead bought 04111-66061. I assume it’s close to the same kit?

I would not know. I have never touched a -66061 nor ever looked into it. What you have is an engine gasket kit (04111 vs. 04112) for a 1FZ from a non-US market. You'd need to discuss with your parts professional.
 

FMC80

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I would not know. I have never touched a -66061 nor ever looked into it. What you have is an engine gasket kit (04111 vs. 04112) for a 1FZ from a non-US market. You'd need to discuss with your parts professional.
I am 69% confident I read on here from @SNLC that the 04111 and 04112 kits are the same but the 04111 kit is designated for the FZJ-105 w/ 1FZ-FE variant.

Nothing catastrophic either way.
 
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FMC80

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Updated the parts listing from post #806. I'll continue to update that post as I move along.

I am almost to the point of pulling this thing...I think. I follow the FSM step by step, bagging and tagging, and safety wiring the hardware to each component as I remove it. I've been soaking the exhaust manifold bolts & nuts for about 7 days with PB blaster. Hitting each one every other day with a dousing of PB blaster.

IMG_8510.jpeg
IMG_8511.jpeg
IMG_8521.jpeg
IMG_8513.jpeg

Tomorrow, I will do a once-over, pull the transmission support, and lay a jack under her with some wood, as called out in the FSM. A special shout out to @BILT4ME for his patient guidance as I fumble around and try not to f*** things up too badly.
 

PNWTreeOctopus

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Salish Sea
Updated the parts listing from post #806. I'll continue to update that post as I move along.

I am almost to the point of pulling this thing...I think. I follow the FSM step by step, bagging and tagging, and safety wiring the hardware to each component as I remove it. I've been soaking the exhaust manifold bolts & nuts for about 7 days with PB blaster. Hitting each one every other day with a dousing of PB blaster.

View attachment 3176624View attachment 3176625View attachment 3176626View attachment 3176627
Tomorrow, I will do a once-over, pull the transmission support, and lay a jack under her with some wood, as called out in the FSM. A special shout out to @BILT4ME for his patient guidance as I fumble around and try not to f*** things up too badly.
This is a silly way to clean your engine bay.

You got this.
 

FMC80

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So here's the deal. About 9 days ago, I had a minor towing issue which compelled me to buy a new bumper, front valance, hood, DS fender (ought both front fenders $1100 shipped), and driver's side headlight. I bought the hood and valance. The hood was sourced locally through a Toyota dealer. I have three Toyota dealers nearby, and one beat the others on price by $100. The hood cost me $720 after taxes and the valance was $170 shipped. The headlights will be replaced with Freedom Retrofit, Bi-LEDs ($1200 ish). There is a 22-24 week lead time for these. Crazy. This towing mishap cost me a sh*tload of cash.

This morning on my walk around, I realized I never disconnected the high-pressure steering lines. I didn't have a 17MM flare wrench, but I got a standard open-end wrench to work on removing the line that connects to the power-steering gear assembly. I could not find an open-end wrench to fit under the high-pressure line banjo bolt to loosen that, so I removed the line connecting to the steering gear assy.

Removed my extended breather lines and two 17MM nuts from the bottom of the engine insulators. Removed the fuel line that runs to the fuel filter.

My mother-effing jack decided to piss out its fluid while not in use, so I need to replace an O-ring on that b*tch before I can support the transmission and proceed with engine removal.

My engine harness removal through the firewall was uneventful. Still, in removing one of the smaller branches of the wire harness, I found a previous repair and wires pulled out of the connector. I also identified most of my injector connectors would need to be replaced with new ones. They are brittle; they snap, crackle, and pop just by looking at them.

I need to remove the transmission cross-member. I may use a s***tier jack that I have in the garage to do so.

Here's the new hood.

IMG_8522.jpeg

And the front valance still in the box. I may not even need this sucker since I need a new bumper too...ahem! Delta VS...
IMG_8524.jpeg
 
Last edited:

FMC80

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Before removing the engine, @BILT4ME gave me some good tricks of the trade. He informed me to remove the Torque Converter Clutch Mounting bolts while the engine is still installed in the frame because it is difficult to do so when the engine is out since it isn't supported by anything but the hoist. There are 6 bolts, and one of them is painted green. I marked it with a paint pen, so it would find its rightful place upon reassembly.
 
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Messages
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Location
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So here's the deal. About 9 days ago, I had a minor towing issue which compelled me to buy a new bumper, front valance, hood, and driver's side headlight. I bought the hood and valance. The hood was sourced locally through a Toyota dealer. I have three Toyota dealers nearby, and one beat the others on price by $100. The hood cost me $720 after taxes. The headlights will be replaced with Freedom Retrofit, Bi-LEDs ($1200 ish). There is a 22-24 week lead time for these. Crazy.

This morning on my walk around, I realized I never disconnected the high-pressure steering lines. I didn't have a 17MM flare wrench, but I got a standard open-end wrench to work on removing the line that connects to the power-steering gear assembly. I could not find an open-end wrench to fit under the high-pressure line banjo bolt to loosen that, so I removed the line connecting to the steering gear assy.

Removed my extended breather lines and two 17MM nuts from the bottom of the engine insulators. Removed the fuel line that runs to the fuel filter.

My mother-effing jack decided to piss out its fluid while not in use, so I need to replace an O-ring on that b*tch before I can support the transmission and proceed with engine removal.

My engine harness removal through the firewall was uneventful. Still, in removing one of the smaller branches of the wire harness, I found a previous repair and wires pulled out of the connector. I also identified most of my injector connectors would need to be replaced with new ones. They are brittle; they snap, crackle, and pop just by looking at them.

I need to remove the transmission cross-member. I may use a s***tier jack that I have in the garage to do so.

Here's the new hood.

View attachment 3176872
And the front valance still in the box. I may not even need this sucker since I need a new bumper too...ahem! Delta VS...
View attachment 3176873

I mean you're already waiting 24 weeks for headlights they're bumper should arrive just in time.
 

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