My 80 Evolved v2.0 - 1997 40th Anniv Edition

FloridaFJ80

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I never thought I would be starting a new Build thread for another 80. When I purchased my 96 LX450, I said this is the last 80 I will buy since I never planned on selling it. Well as you can see in my build thread, I tried to do everything right the first time.

https://forum.ih8mud.com/80-series-tech/647305-my-80-evolved.html

Well 3 years of ownership about, I was getting to the point where the truck was running in excellent condition, didnt have any more project time on it, and I was happy and content with my LX until I found a salvaged locked 40th anniv in Sage in Miami's craigslist. I was like hummm price seems about right, its the perfect color (always loved the sage) and it had lockers. My LX was unlocked and only found myself in the mild wheeling that I have done needing lockers a time or two. I was like lets flip that 40th. Lets bring it back to life and help it find a great MUD home. The 40th 80 had a front end collision, where the frame endcap split at the welds and the body mount before the crossmember, so it was totaled by the INS. Miles were high @ 269k, rust free, needed the normal TLC. Truck ran when I went to buy it, but didnt drive it because it had a leaking front DS caliper. Lockers engaged. Needed some TLC, definitely not a quick flip. Settled on the price and took it home.

Got home and started looking it over more in depth. Found it needed a little more TLC then anticipated. Here is the short list:

  • New Radiator
  • New AC lines from drier to radiator and drier to DS inner fender
  • New AC compressor
  • New front DS Caliper
  • Needs a complete baseline
During my continued drive way inspection, the engine developed a knock under acceleration, It seemed the timing was off and started adjusting timing via the Distro. During my inspection in-cab I noticed there wasnt any oil pressure showing on the gauge. I went to Harbor Freight and bought an Oil pressure gauge and an engine compression gauge. Did the compression test and all cylinders were over 170lbs. Did the Oil pressure gauge test and I had no oil pressure. Engine was knocking. Lets just say that I wasnt to happy at this point.

To make a long story short, a family member moved back to the states and was needing an SUV. She lived in NJ so I told her, hey I have an 80 for sale do you want to buy it, sent her pics and she said yes. Now I needed to get working on the 40th anniv. Christmas came around and just like that my LX was substituted for the 40th anniv, and I ended up selling my LX in stock form to my family membr. I had a month to deliver the LX.

So this puts up until now. I have been dismantling my LX bringing it back to stock form, whille at the same time working on the 40th anniv.

Here are some pictures of when I picked up the 40th anniv.

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FloridaFJ80

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Here are some more initial pictures of when I picked up the 40th Anniv.

Interior Shots:









Damage Shots: Other than this damage, rig was in excellent condition outside, no rust, no peeling clear coat nothing. Just a wax and call it a day!





 
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FloridaFJ80

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So I knew I needed to rebuild this rig, and I wanted to do it the right way from the start. I had some funds from the LX sale so I needed to budget my build right. I started by sourcing a used 100k mile motor out of Tampa for the project. I decided to go this route, because I wanted to get the rig back on the road quickly and I wanted to baseline the motor on an engine stand. I live in gated community, and I dont want to piss off the HOA by doing it on the rig.

Here is a poser shot of my LX before the dismantle.

 
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FloridaFJ80

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Engine showed up, in good condition for being a 100k motor. Can tell it had some maintenance done to it, Oil pump cover gasket, front main seal, valve cover.





I decided that by not having any history on the motor besides the mileage and that it came from a roll over, I decided to baseline the engine and due the head gasket and all seals. Gave Sam Stewart a call, and started placing my order. Man base lining this rig is going to cost me!!! Here is what I ended up ordering:

QTY PART # DESC
1 04111-66036 Gasket kit
1 11310-66020 Timing Cover
1 23300-69045 Fuel filter
1 23217-16490 Fuel filter (in tank)
1 23219-03010 Fuel filter clip
1 Hose-Kit Coolant hoses
3 90999-92003 Vacuum hose
1 87240-60170 Heater valve
1 90910-12043 VSV
1 90910-12079 VSV
1 25870-66011 EGR Modulator
1 25620-66011 EGR Valve
1 25627-66010 EGR gasket
1 25628-66010 EGR gasket
1 16100-69325 Water pump
1 90916-03117 Thermostat
1 16346-66020 Thermo gasket
1 90916-02353-83 Belt set
1 99332-10910-83 Belt
1 16603-66010 Idler pulley
1 88440-26090 AC Idler pulley
1 16400-66040 93-94 radiator
1 04446-60080 Power Steering Rebuild kit
1 90301-73004 PS pump O-ring
1 Auto Trans Filter
1 16210-66020 Blue Fan Clutch
1 27370-75060 Alt Brush Kit
1 RC engineering Injector cleaning
1 47750-60060-84 LF Caliper (Reman)
1 47730-60060-84 RF Caliper (Reman)
1 47750-60070-84 LR Caliper (Reman)
1 47730-60070-84 RR Caliper (Reman)
1 Head Rebuild Head Rebuild
1 Axle-Kit Rebuild kit
1 58510-6A190-E0 80 Series Carpet

Total came out to just shy of $3800 bucks. I didnt want to risk working on this engine while on the truck, I had to do most of these on my LX and I know how big of a pain in the ass it is, so I closed my eyes and went for it.

Also called up Shane (MetricTLC) for the 80 series leather kit, picked that up during black friday!!
 

FloridaFJ80

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Before I could get started with this huge project, I needed some tools. Took a trip over to Harbor Freight and picked up a 2 ton engine crane, a 1/2 ton engine stand, went to sears and picked up a 26 gallon air compressor, a craftsman mig welder and a plasma cutter.

 

FloridaFJ80

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Started taking the engine apart. First thoughts on previous maintenance, had Autolite wires, plugs and a NAPA filter. Didnt say much about the PO. Glad I decided to move forward on the rebuild. Let me know your thoughts on the engine..

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FloridaFJ80

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While I am waiting for parts, I started removing all the accessories from the LX and stock piling them in my small one car garage. Where I also have an old Bantam I am rebuilding into an off road trailer, hence the need for the welder and plasma cutter.

Transferred over the 4" Heavy duty Dobinson Springs to the 40th. (sorry for the crappy cell phone pics)



Here is how UGLY my LX is looking after I removed the suspension and the 35"s.



Next to do is the removal of the Sean rear bumper and the welding of the rear crossmember to fit the stock LX bumper.
 

FloridaFJ80

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New timing belt cover, all 4 calipers, water pump and a whole bunch of seals and gaskets came in, as well as the 3 core OEM brass radiator for 93-94 FZJ.

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Tried removing the 7 screws to replace with some upgraded torq screws from 1FZPHH.com and this things are on there. gonna have to go get a nice #3 phillips head from HF.

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FloridaFJ80

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Got the head back from the Machine shop.. man she is looking hot!!!

They did a complete valve job on it. Changed out all the valve intake and exhaust seals from the OEM gasket kit. Everything on the head was in spec so didnt need anything else. They put new shims in as well.

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FloridaFJ80

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Progress on the engine rebuild.

I ordered the complete Gasket kit from TOYOTA 04111-66036, and I have been slowly changing all O-rings, gaskets, torquing every nut and bolt to Factory Specs. Got the new head gasket on and put the head on just like the FSM states. It was a great experience for me learning to do this. i wouldnt have done it without the help of MUD.

Installed the New Timing cover, new Water pump, new thermostat, New front main seal. Some of the connectors of the main harness had broken off so I went ahead and ordered all new connectors. This included all the injector connectors as well. Didnt want to put in the main harness with broken plugs.

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