Building my 93 FZJ80.

[wpns4l]

thanks for the photo. Is that exactly how a new head ships? W/valves, springs, etc. it kinda looks like it has buckets and shims, is that right?

I may need one myself

It does not come with valves or spring or anything. I had those installed separately.

 

[wpns4l]

Back from the dead. Haven't touched the cruiser in three months due to life and laziness getting in the way. No pictures to post but my goal today was to get the timing chain and cover back on and the oil pans back on. Turns out my engine is missing the oil sprayer that lubes the chain. No chance I lost it either as I bagged and labeled everything during tear down. Local dealer didn't have it in stock but will have it in tomorrow for me. I also ordered all new sensors that go on the head and the two unions for the head as a brand new one doesn't come with them. The float on my oil gauge sensor crumbled apart but before I order a new $250-300 sensor I am going to try and get a used one from a part out. But I did order the gasket for it.

Once I get these parts in I'll resume the rebuild and take photos. Goal is to have it driving by June just in time for smog.

2582013020	VALVE ASSY, BIMETAL (TVV Sensor)	1
8342016040	GAGE ASSY, OIL TEMPERATURE SENDER (ECT Sender)	1
9043027001	GASKET, ENGINE OIL LEVEL SENSOR	1
8942235010	SENSOR, DIESEL ENGINE WATER TEMPERATURE (ECT Sensor)	1
8879060050	THERMO SWITCH ASSY (ECT Cut Switch)	1
9043012005	BOLT, UNION(FOR NOZZLE LEKAGE PIPE NO.3) (Crush Washer)	1
1351666011	Oil Jet	1
9040608011	UNION(FOR CYLINDER HEAD)	1
9040617007	UNION(FOR CYLINDER HEAD)	1

 

[wpns4l]

So today got the new oil jet installed, new timing chain and new sprockets for the timing chain all installed. Was finishing cleaning up the timing chain cover and noticed it was stamped DNJ. Googled it and apparently they are some aftermarket parts company with parts made in China of course. The part seems well made and fine but if I putting all the time and effort into rebuilding this engine its going to have Toyota/AISIN parts. Im not against using used parts, especially for this, so reached out to my used parts guy to see if he has one. If not, a new one from Toyota is not that expensive if ordered from Partsouq.

Was also cleaning my oil pan bolts in anticipation of getting that back on today and of course my lower pan bolts are all different sizes and makes. So ordered 17 new ones.

9011906600​	Lower oil pan bolts	17
1131066020	Timing cover (will attempt to find used)	1

 

[wpns4l]

So last week I was putting on the upper and lower oil pan and discovered the PO tapped new holes (and in varying sizes) in the upper pan and filled other holes with metal. Who knows why but I ended up buying some used oil pans and got those installed.

Next I got the all new head on and camshafts installed.

Apparently none of my gasket kits came with the oil pump gasket so I'm on hold till that comes in. I also added all new gaskets and parts for the oil cooler which I took off today and was full of coolant crud.

Parts ordered:

90341A0008	Oil plug	1
1513417010	Oil cooler gasket	1
1513164020	Oil cooler valve	1
1513250010	Oil cooler valve spring	1
1513420010	Oil cooler gasket	2
1513320010	Oil cooler plug	2
1578566010	Oil cooler gasket	2
1518866020	Oil pump gasket	1

 

[FMC80]

You are patient! Lots of roadblocks with this one, but for the price you paid for the cruiser, it’s worth it.

Out of curiosity, what kind of timing chain tensioner do you have? Is it the ratcheting type or different?

Btw, without wpns, we’d be just another airline…

 

[wpns4l]

I'm not aware of different tensioners? Mine is spring loaded.

As for the roadblocks, yes plenty of them. They are all small things too where it seems the PO just didn't want to spend the money to do things right so they just did cheap hack fixes that work but are lazy.

 

[FMC80]

Yeah, I knew there were two different types but recently learned there is a third type of tensioner specific to the 1993 series 80.
Here’s the thread where I learned about it if you’re interested.

Mechanic Fixed Head Gasket, At Completion Tells Me I May Require Engine Rebuild

I went over to the shop at lunch today to check in on the Cruiser. Mechanic showed me how the sprocket on my camshaft had failed, and that he ordered a new sprocket arriving tomorrow. At that point he will slap it back together and we will cross our fingers the tick is gone. Did the previous...

forum.ih8mud.com

 

[BILT4ME]

Yeah, I knew there were two different types but recently learned there is a third type of tensioner specific to the 1993 series 80.
Here’s the thread where I learned about it if you’re interested.

You forgot to include the link!

 

[FMC80]

You forgot to include the link!

It’s like I’m back at work sending emails without attachments. Post edited.

Thanks for the catch!

 

[wpns4l]

Ah, I see. That's the one they show in the fsm but it's not what was in my truck or what I replaced with.

 

[wpns4l]

Today got all new parts in the oil cooler and got that installed. Got the oil pump cover installed. Put all new exhaust studs on the head and put new sensors on the head. Its not pictured but I also got the lower plenum on and I replaced those rusted studs by the water pump. Currently I am in the process of replacing all the vacuum hoses on the upper plenum. Hopefully get all that back on next week.

 

[wpns4l]

Sick wife and busy with kids so did not get anything done this week. I did get curious though if all this work fixed my timing issue. So I set everything to TDC and put the diz in and finally.... it lines up like it should.

It points right to the edge of the electrical connector

Before it pointed more towards the screw hole.

Hopefully this is the fix of my original timing issue.

 

[wpns4l]

Also ordered a bunch of parts.

44348-60170	Power Steering Reservoir Hose	1
90980-11153	Fuel Injector electrical housing	6
16351-66010	Water by-pass outlet	1
16268-66010	water by-pass pipe	1
90301-29006	water by-pass o-ring	2
90105-06221	valve cover bolts	13
90923-01396	Fuel hose	1
Advics BMT068	Master Cylinder	1
Rein PSH0328	Power Steering High Pressure Hose	1

 

[ceylonfj40nut]

Any chance you can share $ for parts this? You can DM me if you wish to. Curious.

 

[wpns4l]

For all the parts or certain ones? About 90% of the parts I ordered from partsouq since they are usually 30-50% cheaper than local dealerships. Off the top of my head I think I'm about 3500-4000 in parts right now. 1400 of that being the new head plus I bought used oil pans and timing cover that you hopefully won't need.

 

[FMC80]

Sick wife and busy with kids so did not get anything done this week. I did get curious though if all this work fixed my timing issue. So I set everything to TDC and put the diz in and finally.... it lines up like it should.

It points right to the edge of the electrical connector
View attachment 3274373

Before it pointed more towards the screw hole.
View attachment 3274374

Hopefully this is the fix of my original timing issue.

If this doesn’t completely fix your timing issue, it will certainly make your timing 1000% better.

 

[wpns4l]

Spent today getting the wire harness all patched up and rewrapped. Replaced about 80% of the connectors with new but I'm still waiting on three connectors before completely done.

 

[wpns4l]

Engine is pretty much ready to go in. Getting ready to go away for two weeks so hopefully late May I got this thing going.

Rebuilt the power steering pump and put a new gear on it.

When taking my engine out I couldn't get the fuel line off and ended up bending my hard fuel line. I cut the soft line to get the engine out and today replaced the hard line. Not that hard of a job. There is a heat shield for the muffler held on by three 10mm. If you remove that you can get to the connections at the fuel tank side. Then it's just a bunch of brackets with single 10mm nuts to get off. To make it easier I recommend disconnecting the rear drive shaft, the ebrake cable and one hard brake line going straight down from the MC. With all those out of the way the hardlines come out easy. Hardest part of getting them back in is the new lines aren't bent exactly and it can be a pain to line the brackets back up.

 

[wpns4l]

Other than that I finished up the wiring harness. I'm waiting on a couple miscellaneous bolts and pulley from partsouq. Once I get those engine is ready to go back in.

 

[wpns4l]

Abs and lspv delete while I'm still waiting on parts. I have a new MC and all new extended brake lines to put on too.