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I started reading the FSM last night... then I drank... a lot.
 
For whatever it's worth, a plan I've been kicking around works something like this for major engine work on my 94:

  • Have a functioning second vehicle in good shape with insurance / tags that can handle the winters around here. Check.
  • Buy a "it-works" 1FZ engine to drop in.
  • With "my" existing engine out and the vehicle running again on its donor-transplant engine, take the time to rebuild / remachine everything you want.
  • Swap the engines.

I like the idea of getting the 80 back on the road as quickly as possible, but I also like that I can take the time to make the engine capable of handling many more hundreds of thousands of miles. And if I'm going to really be an 80 guy for a while, having a spare (the transplant) 80 engine laying around that I can also make beautiful isn't bad at all. I'm always buying up random parts that I'm worried I'll one day need and will have a tough time acquiring.
 
^^ I contemplated this idea, as there is one here local with over 200k on it, but two things that I don't have... the $2400 for that engine to have a second, and more importantly... the space to store a full engine.

Just to catch everyone up... I am checking local shops too and have been pm'ing @tominboise (thanks again Tom!) regarding what I've found so far. The truck drove from Bremerton, WA (West of Seattle) to Boise, ID on Saturday, at an average of 70MPH (a total of over 550 miles).

This tells me (through Tom) that really there should not be anything major wrong with the engine, so to me this makes for a very viable platform for a rebuild. This confirms some of my thoughts and takes a load off of my mind regarding whether I would be throwing money away moving towards a rebuild option or not. I am feeling better about the whole idea of tearing this thing apart and really getting a GREAT truck after putting some money and effort into it.
 
I was wondering about the real damage - I'm over here ~80 mi N of Bremerton / Navy base & so you did drive it a decent distance.

If it's not a pressing issue & you have a secure housing situation & garage where you can work, you might just drive it & monitor.

How long was there a growl going on with your son?

It may be a case where you drive it as is until you find a ~$1500 1FZ.
As many guys as go glowplug or V8, a used 1FZ shouldn't be a hard find - I know I saw 2 late 1FZ's in the last 6 months, one I really should have bought all of, but just took what I needed.
 
Drive it as is and source 1HDT is exactly what I would do but then again, its what I've been wanting all along. My 1FZ just won't stop running like silk! It really is a fine motor but I find myself being intrigued with both diesel and FI. I can't see you parting with that 80 even with the possible major engine problem. I'd be interested in seeing what's in the oil pan.
 
I was wondering about the real damage - I'm over here ~80 mi N of Bremerton / Navy base & so you did drive it a decent distance.

If it's not a pressing issue & you have a secure housing situation & garage where you can work, you might just drive it & monitor.
My wife and daughter did the drive to Bose. I would never have left my son's place hearing that. I am tentative to even drive it around town because I don't want to cause additional damage.

How long was there a growl going on with your son?
I was texting my son this morning to find out exactly when it started making this racket. (He is the sole Army guy on that Navy base, BTW.) It was about a month ago, he says. Also, it is a knock in the bottom end, along with valve clatter, just for clarity.

It may be a case where you drive it as is until you find a ~$1500 1FZ.
As many guys as go glowplug or V8, a used 1FZ shouldn't be a hard find - I know I saw 2 late 1FZ's in the last 6 months, one I really should have bought all of, but just took what I needed.
I am debating whether to pull this one and have somone rebuild, or maybe try and do it myself. The 1st option seems the most likely, as I have never gone that deep into an engine... trial by fire, right?

Locally, there is one 1FZ that has over 200k miles, not rebuilt, no warranty, and is $2400. No thanks. IMHO, I should pull mine out and have it rebuilt rather than buying a second one that will need to be rebuilt in ~70K miles. I did call 1 guy here local who quoted a range of $2800 - $3800 depending upon what all is found wrong with it. I can at least deal with that sort of logic. It's an option.

Drive it as is and source 1HDT is exactly what I would do but then again, its what I've been wanting all along. My 1FZ just won't stop running like silk! It really is a fine motor but I find myself being intrigued with both diesel and FI. I can't see you parting with that 80 even with the possible major engine problem. I'd be interested in seeing what's in the oil pan.

How much of the electronics would get swapped out too? I am thinking that you would be into swapping wiring harnesses and ECUs at the very least... and maybe exhaust.

I like this engine too... Yeah, diesel LC sounds like a cool thing to brag about, but for me, that would all I get out of it. I already have a 100 series with the 4.7L and a 200, with the 5.7L, so I don't need more power in my 80. For me, the 1FZ-FE is plenty of engine... when it is running, that is.

Long term, my wife and I were discussing taking this thing completly back to stock... Ok, well mostly stock... but really nice with a few small changes... front bumper... sliders, small lift, 33" tires (it has 285 75/16s now), weather techs, etc. You know... "stock".

Thanks guys!
 
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