FJ40Z's '97 FZJ80

This site may earn a commission from merchant affiliate
links, including eBay, Amazon, Skimlinks, and others.

Picked up back on it Saturday, got started wrenching around 3 pm. Nothing like an early start right? This whole process has really went very smoothly with nothing causing any major problems. Jason and I both would be working on different things and if one of us got stumped on something the other would take a look to help or we would move on temporarily then revisit later so steady progress was always being made.

IMG_3725.webp


IMG_3726.webp


IMG_3727.webp
 
Will continue with the updates momentarily. Work is getting in the way LOL
 
Ok back on track, the bulk of our time on Saturday was spent on freeing up the harness so we could fish it through the intake. Once that was out of the way the we could get to the good stuff. I know this picture is in the wrenching thread but we were both so proud to finally get it out of the way I have to post it again here.

IMG_3730.webp
 
Next was removal of the camshafts. This was really a neat process, the sequence of removal of the bolts and bearing caps utilizes the pressure of the lifters to raise the camshafts if done properly. If it doesn't work you have to reinstall, retorque and start all over. Thankfully we got it right the first time on both.

IMG_3739.webp
 
The head bolts are pretty straight forward, just sequencing until all are removed. I have yet to measure them but the threads on all look great, if they are within spec I plan to reuse if not I'll order new OEM. So finally it's OFF WITH HIS HEAD!!

IMG_3752.webp
 
That harness work sucks, guess a whole loom connector there made too much sense.


psssst..... you forgot late friday fuel rail fun and to include a warning about excessive torque on banjo fittings :D
 
Man it felt good to get that point. I think by then it was going on 1 AM and we were both pretty beat. So besides removing the lower intake and a few more sensors most of the hard disassembly was done. Here are a few pics of the valves and pistons, the valves show the mileage and the burning of the coolant. As far as the head gasket we never found one place we could pinpoint a leak but the entire section around #6 was really saturated and looks like it had been saturated for quite some time.

IMG_3741.webp


IMG_3751.webp


IMG_3753.webp
 
One thing I really don't understand is how misshapen some of the rings on the old head gasket are?

IMG_3756.webp


IMG_3758.webp


IMG_3761.webp
 
So that's where we're at right now. I have to go back up to the shop this evening to get a few more things to drop off at the machine shop and if I have time I will clean up the block. The head is at the machine shop as well as the upper and lower intake. I'm hoping to tackle the oil pump seal and oil cooler this week while I'm waiting on the head.

If anyone wants to come up to hangout or watch or to jump in with us feel free but don't feel obligated. It's about 30 minutes northeast from my house in Madison. PM me for directions.
 
jfz80 said:
That harness work sucks, guess a whole loom connector there made too much sense.


psssst..... you forgot late friday fuel rail fun and to include a warning about excessive torque on banjo fittings :D
Click to expand...

YEEESSS!! I did forget! A few of the clips on the injector harness took quite a bit of time. Of course when your working with 20 year old plastic neither one of us were going to force the issue.

Then there was this whole banjo bolts on the fuel filter fiasco. Someone had replaced the fuel filter at sometime which is good, but they must have tightened the banjo bolts back down with a 3' breaker bar which is bad.

Oh and there was one harness clip that almost had me to the point of a nervous breakdown/meltdown but other than that, a piece of cake.........:bang:
 
Impact screwdriver wouldn't get it?

I'm familiar with the hammer-in method of creating torx bits :lol: Nice work.
 
We didnt have room for a manual impact driver, even with rad out the ac condensor was still prohibiting hammer swing (that and we didnt have one on hand that night)

20V electric impact broke 3 bits and finally the head of screw shattered and stripped..... hence the drill and torx efforts.
 
So bit of a delayed update. Another big thanks to @jfz80 and a big thanks to @Rice for spending last Friday evening helping with the 80. We fell short of getting the head back on because the machine shop didn't get finished with it in time despite their best efforts. So we dug in on the last few things on my while you're in their list. A big thanks to @stevezero for giving me his new aisin water pump so I could go ahead and get it on. We managed to get the oil cooler disassembled inspected and reassembled, new thermostat, new water pump, new front main seal and new oil pump seal as well as getting the deck of the block cleaned up before the new gasket and head goes on. Had a problem with 2 of the oil pump cover screws but we got it figured out:hillbilly:

IMG_3780.webp


IMG_3782.webp
 
Later that night after I had gotten home I got really sick, terrible sore throat, fever and have been out of commission since. Had to go yesterday and have my tonsils lanced which really sucked. I'm supposed to call them back soon and schedule having them removed. Been out of work all week sick and the head has been ready for pickup since Monday morning. Talk about terrible timing :bang:. Starting to feel a little better today but still pretty rough. Just ready to get this thing buttoned up and back on the road:steer:
 
Feel better bro!
 
You must log in or register to reply here.

Share this page

Back
Top Bottom