Another FZJ80 Engine Rebuild Thread (Renamed Thread)

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cme4lyt

cme4lyt

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I decided to rename my thread so that if others are contemplating doing what I'm doing, then they have a better chance of finding my posting.

So, the disassembly saga continues...

My major issue today involved the removal of the torque converter. The FSM states you pull the TC by unbolting it via access thru' a 'hole' below the flywheel. The issue is that you have to rotate the engine to get to all 6 bolts. I cannot rotate anything since it's all siezed up !

My plan right now is to unbolt both the small and large oil pans and then tip the engine upside down. This will then allow me to access some of the TC bolts. I might have to loosen/remove the crank so that I can rotate everything and get to the remaining TC bolts.

The lower oil pan was disgusting and filled with a gooey, brown, syrup type liquid. It smells foul and I can see a great deal of time is going to be spent on cleaning everything: hours and hours will be spent just cleaning and trying to get back to virgin material !

Only one pic from today showing the lower oil pan removed. More to follow. My original thread is below.

Rgds...

https://forum.ih8mud.com/80-series-tech/380788-look-what-just-arrived-my-place-oldie-but-goodie.html
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Another late night wrenching session...

Once again, found myself all alone with a case full of Tecate and some more 80's music. What else you gonna do on a quiet Friday night when you have a sad looking engine block just begging for attention ?

Finally seperated the large oil pan from the block. The usual disgusting muck and filth was everywhere and the smell, kinda like a bad burnt, fleshy smell: kinda kreepy ? I also managed to get at three of the TC bolts but the others are buried behind the block so that going to be tomorrows improvise session.

Since the pistons are going to be well and truly stuck in the cylinders, I filled all the holes with a great deal of PB Blast hoping that it will seep down the cylinder walls overnite and 'unstuck' them a litttle. Wishful thinking but we'll see what tomorrow brings.

Some pics attached for your viewing pleasure !

Rgds...jonathan
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3 more from tonite's session...
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And the final 3...
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gotmud said:
Sounds like a party to me! What are your plans going forward?
Click to expand...

The big plan is to turn this into a 'new' engine that will get me another 350K miles. What I actually end up doing will depend on what I find as I disassemble and inspect.

I should get to the crank, pistons, rods today so then I'll know what drama I have on my hands....if any !

Rgds...
 
subscribing .... good luck.
 
I missed the first part; what happened? Did you buy it like that, or was it yours and it seized? Did you keep after maintenance? Sorry for the stupid questions, Ned
 
Can we fast forward to the point where you've got shiny block and head with all shiny components. That is ofcourse after you give it a HOT Bath. You're gonna do that right?
 
Riad said:
Can we fast forward to the point where you've got shiny block and head with all shiny components. That is ofcourse after you give it a HOT Bath. You're gonna do that right?
Click to expand...

He'd better not or he is going to blow the un-obtanium bushing and then be really SOL (unless he has a good machinist)....

C'mon bro....you knew that already!

;)
 
retrofive said:
See post #1 (hint: there is link in it) ;)
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See # 1 post and follow that link to my original thread.

I'd be happy to explain more if you still have questions.

BTW, will post again shortly since I have two weeks of the project to cover with you all.

Progress is being made but it's slow.... and it involves a lot of cleaning ! I've cleaned for probably two weeks solid, grabbing a bunch of stuff every evening and trying to bring it back to it's former glory: trying to get everything ready for being bolted back in place.

Rgds...
 
Yeah bro. I forgot bout that :o. But I meant good cleaning though. Giving hot bath will blow the un-obtanium bushing indeed. So what else can he do if can't give it a good bath?

Is it gonna look like this? :D

attachment.php
 
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Riad said:
Yeah bro. I forgot bout that :o. But I meant good cleaning though. Giving hot bath will blow the un-obtanium bushing indeed. So what else can he do if can't give it a good bath?

Is it gonna look like this? :D

attachment.php
Click to expand...

I'm not sure I'm ever going to get it THAT clean but I think I'll have some pretty cool pics to share after this weekend.

I've gotten most of what I've tried so far very clean: I'm only about a third of the way thru' all of the parts and pieces but so far it's coming together very well.

My magic solution seems to be huge amounts of Simple Green and time. I have about six different tuppawares filled with a solution of about 80% Simple Green and I simply let stuff soak: up to 48 hours in some cases. It actually works better than any solvent I've tried and is far nicer to work with.

The gunk, whatever it is, simply peels away. You might need a slight dab with an old paint brush but it really just rinses away. I'll show you before and after pics of the inside of my valve cover and you'll be amazed.

I did use the old oven cleaner trick on my large oil pan simply because I couldn't find a tuppaware big enough to support it. The oven cleaner works like a dream but the stuff is nasty and you better be sure to get it all off otherwise it keeps on 'eating' the metal.

I'll post some pics of all the cleaning stuff and results this weekend: it isn't fun but I think it's necessary !

Rgds...
 
How much are you gonna have in pulling, machine work, rebuild kit and re-install? Just curious. I had a guy to pull mine and put back in for 300!!!!! The kit was 500 and the machine work was 700. Was wondering if anyone else comes out that good????
 
whatatrout said:
How much are you gonna have in pulling, machine work, rebuild kit and re-install? Just curious. I had a guy to pull mine and put back in for 300!!!!! The kit was 500 and the machine work was 700. Was wondering if anyone else comes out that good????
Click to expand...

I don't have all the numbers back yet: still getting quotes on various parts and pieces.

Right now I have the complete head rebuild at $700, set of pistons @ $450, all bearings $150 and set of rings $270.

Still waiting on the block rebore quote and then there's all the millions of gaskets, o-rings, clamps, seals, timing chain and slipper and the HG kit that I haven't even started to price up yet.

I'm guessing I could get to $3500 pretty quick ?

Rgds...
 
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