Jzilla's FJ60 to BJ60 conversion (2 Viewers)

[jzilla]

Finally an update! Lots has happened!
So I got the big bolt off by welding up a tool (the compressor I borrowed would not budge the crank bolt either). The tool is similar to the SST in the FSM, I used that and a breaker bar…it was on there!

Since I wanted to look at the cam bearings the timing cover had to come off, as well as the side cover and valve cover and then this happened...
Side cover, valve cover, oil cooler housing, oil filter bracket, timing cover and oil pump housing have all been sand blasted primed, painted and clearcoated with plastikote engine paint. They will all be reinstalled with new gaskets, hopefully in the next few days.

Then this happened...why not clean and paint the block?
First I primed and painted the block with the injector pump and alternator still on as well as the oil pump housing (water pump staying). I was going to call it a day, but no, deep down I knew I would not be happy! So the alternator came off with its mounting bracket which I cleaned and painted black. I also ran a drill bit through the hole that the alternator mounts to as the old bolt was stuck in there pretty good. Also ordered a new bolt from Toyota as my old one was quite mangled.

Yesterday the injector pump came off. Removing the lines from the injector pump had me a bit worried! One of the delivery valves got loose in the process. I ended up checking them all with the torque wrench (torqued them to factory spec), they were all a bit loose for some reason. Once this was done I had to clean the block where the injector pump was (this was the cleanest part!).

For block cleaning I found that my drill with a little braided wire brush attachment from Canadian Tire was perfect for getting into all the little crevices, also used a screwdriver and hammer to knock off some stubborn rust flakes, then used brake clean after to wash it down.
Engine mounts and bolts were painted black as well.

Bellhousing is now red as are cast parts of tranny. Would love to do transfer, but I am not taking it off to sandblast (when it needs a rebuild I will, should be a while though as it was done about 8 years ago).

In case anyone was wondering. My painting scheme is this. All cast red, all aluminum gets grey, brackets and pulleys are black. The sidecover was lumped in with the aluminum because it is an oddball.

 

[jzilla]

Now for the cam bearing story…
Once I loosened the bolt holding on the harmonic balancer I had to figure out how to get the pulley off. Well I lucked out as I was able to use my steering wheel puller!
Next was the camshaft. First I had to remove the valve cover and rocker assembly (loosen bolts in a sequence as in FSM). Then out came the pushrods (keep in order). Next the sidecover was removed so that I could remove the lifters (keep in order).
Now I could remove the camshaft once the two bolts holding it on the block were removed. Removed it nice and slow and turned it a bit to help get it out.
Flywheel also had to be removed to access the rear bearing.
Now is there damage to the bearings as both amaurer and kynot62 experienced?? I was really hoping to see some damage! The first bearing only had a little piece out of it, hmm I was hoping for more damage!
Looked inside at the middle and rear bearing with a flashlight, there looked to be some large chunks missing, perfect! Must be why my oil pressure was low.
So now how do I replace the bearings!!?? I mentioned the one engine shop earlier that said they could come up to my place and do it. Well when I went back again to say things were ready they ummed and ahhed and said they would rather have it down at their shop. They offered to pick it up though for a small fee. In the meantime I talk to a friends’ dad who has a shop, he said he was not crazy about this engine shop that I was talking to. So he suggests another one! Amongst all of this I called a really good guy that I knew (but did not know that well… he knows cruisers in and out, he has been working on them for years.) Anyways to make a long story short he offers to come up and replace the bearings with me!

So our SST’s consisted of a 36mm ½ inch socket, some ½ inch extensions, a breaker bar (because I did not have enough extensions) a ½ inch thick piece of steel plate and a big hammer.

We started by seeing if we could knock out the front bearing. Placed the socket on it so that the back of the socket was on the bearing, wham, wham, wham and out it came. Next was the middle one, out it came. To get the third one out we first knocked out the expansion plug with the extensions going through the block. So with all the 3 removed we dropped the oil pan to check them out. The rear one was the worst! So much for theories on the front one wearing more…

Below is the front bearing. Not bad... oh and this engine has 510,000kms on it, I should mention I found chunks in my pan at 380,000kms! (not many though)

 

[jzilla]

Left to right is rear of engine to front...

 

[jzilla]

The install was made easier by turning the engine over. Started by knocking in the first bearing the same way it was knocked out, except we used the steel plate for this. Once the bearing was in deep enough the socket was used. To get the middle bearing in I slid my arm inside the block with the bearing in hand and held it in place so that my friend could get it started. Make sure those oil holes are lined up!

Picture #1 is the rear bearing going in, picture #2 is the front bearing installed.

 

[jzilla]

Finally after everything was installed we checked a connecting rod bearing and a main. They were mint!
The cam lobes looked a bit worn as did the bottoms of the lifters (most of them had some pitting at the bottom). Took everything over to Shadboldt cams in Vancouver, amazingly good service and great guys!! They measured each lobe in front of me, most lobes were down a bit. A few lobes were quite pitted which they welded up. I highly recommend them, they were reasonable as well.
I look forward to starting my truck once everything is all done to see how the oil pressure changes. Shadboldt said that the cams looking like this are common on the 3B because the oil pressure is so low at idle.
Some pics of con-rod and main bearings after 510,000 kms.

 

[jzilla]

Quick update here. Went to put the camshaft in last week and it would not go in the rear bearing! Ended up having to knock out the bearing, measured it and it was smaller than factory spec. It was the correct bearing in the correct place. Anyways to make a long story short I got another one from Toyota. I brought the camshaft with me and showed them the problem, tried the new bearing and it went on fine.
Camshaft is now installed with the new bearings! Still have a few gears to put on.
Will try to update with more pics soon.

On another note, started installing quiet crap from cruisercrap.com Have done most of the front of the truck and also did the hood the other day.

 

[vwluv10338]

sweet. Keep up the good work. Its strange I think this is the second 3b on here with roasted cam bearings. My neglected 2H killed its rings but all the bearings looked great when I tore it down.

 

[jzilla]

It is the 3rd actually, and there may be more as someone else found chunks in the pan recently, can't remember the post though.
Amaurer and Kynot62 both had bad cam bearings. Just because there is chunks though does not mean it can't be driven (not saying it is good by any means!), I found some cam bearing chunks (not many) 130,000kms ago when I dropped my oil pan to install the return fitting for the turbo oil return. I was oblivious to all this at the time and thought oh well it is running good!

 

[jzilla]

Rear main seal retainer gasket has been replaced along with a new rear main seal. Front bearing retainer oil seal and gasket were replaced on the tranny since it is easy to access now.
Still have to install a few parts on the engine, waiting for a new idle shaft for idler gear.

Hoping to finally put the engine in the FJ60 within a week?

Clutch slave has been painted black.

Took the rear passenger grab handles that are on the B pillar from the BJ and installed them on the FJ60 (the FJ did not have any, but the factory threaded holes were there, I just used a piece of wire to locate them through the headliner).

 

[jzilla]

Here are a few pictures to go along with the updates.

 

[jzilla]

some more...eventually I said the heck with it and removed the injection pump to paint behind it

 

[jzilla]

more...

 

[jzilla]

Pics of painted parts and a comparison of the new front main and the old one (the old got some paint on it)

 

[jzilla]

Oil cooler all painted and then filter bracket installed, decided to paint the bolts!

 

[jzilla]

Resurfaced lifters with moly grease on the bottom.

 

[jzilla]

Before oil pan install...

 

[jzilla]

Almost ready to install engine believe it or not!
Couple last details.
Yesterday I decided to paint the rear end plate before mating the tranny with the engine.
Also installed flywheel with clutch, throwout bearing, release fork, greased everything up really good.

 

[jzilla]

And then it happened! I was able to install the engine and tranny yesterday because of the help of a great friend! I am very thankful for his help!

 

[jzilla]

Few more of everything installed!

 

[jzilla]

Few more... Still lots to do but I am happy to have this big step done