Resurrection of a 1991 FJ80 (1 Viewer)

[BreezyF]

Thought some may like to follow along. I have started the resurrection of a 1991 FJ80 3FE. First step was to replace the fuel pump to get her in the garage. Got the radiator out last night. Obviously there is plenty of leaking. Would love some advice on what I should replace now that I have the radiator out. Going back with a CSF radiator once I have replaced some items now that I have room. Inside has had water sitting in it for about 8 years. I believe its coming from the windshield and pooling in the foot wells. I would appreciate any recommendations on getting a baseline and idea where it could be leaking (Im guessing Power steering pump and I know Valve gasket). Below is what I have purchased and is on hand. Thanks and I will continue to post my progress!

AUTOBEST	F239S	Fuel Pump Strainer
AUTOLITE	XP64	Spark Plug
BOSCH	68200	Fuel Pump Gasket / Seal
CARTER	P90012	Fuel Pump
DENSO	1432097 (143-2097)	Air Filter
MOBIL	M1301A (M1-301A)	Oil Filter
STANDARD MOTOR PRODUCTS	55935	Spark Plug Wire
WIX	33500	Fuel Filter
WVE	5D1304	Distributor Cap
WVE	4R1142	Distributor Rotor Private Label Package

Relay	Novita Technologies Novita Technologies 13.5 Amp 3 Terminal Turn Signal Flasher	Flasher
Relay	Import Direct Ignition Import Direct Ignition 10 Amp 5 Terminal Multi-Purpose	Multi-Purpose Relay
Relay	MasterPro Ignition MasterPro Ignition 22 Amp 4 Terminal Multi-Purpose Relay	Multi-Purpose Relay
Relay	Blister Pack Littelfuse Blister Pack 60	Amp Fuse
Fuse	Blister Pack Littelfuse Blister Pack 10	Amp Fuse
Fuse	Blister Pack Littelfuse Blister Pack 7.5	Amp Fuse
Fuse	Blister Pack Littelfuse Blister Pack 15	Amp Fuse
Fuse	Blister Pack Littelfuse Blister Pack 20	Amp Fuse
Felpro	Felpro Valve Cover Gasket Set	Gasket

Battery

EverStart Maxx Size 24

Battery

DORMAN	42058	Positive Crankcase Ventilation (PCV) Grommet
MAHLE	SS20218	Valve Stem Seal
STANDARD MOTOR PRODUCTS	V281	Positive Crankcase Ventilation (PCV) Valve
VICTOR REINZ	711652400 (71-16524-00)	Throttle Body Gasket

Toyota

90210-13001

Valve Cover Washer Seal

AISIN	WPT029 (WPT-029)	Water Pump
APEX	AWP3095	Water Pump Gasket
CONTINENTAL	49032	Tensioner Pulley
CSF	2709	Radiator
DAYCO	89039	Idler Pulley
FEL-PRO	35307	Thermostat / Thermostat Housing / Water Outlet Seal
MOTORAD	245180 (245-180)	Thermostat
US MOTOR WORKS	22076	Radiator Fan Clutch

 

[BreezyF]

Photos x2

 

[BreezyF]

Photos x3

 

[jonheld]

General Tech - 3FE Tune Up Info

3FE Tune Up Info

forum.ih8mud.com

General Tech - 3FE EFI Diagnostics

3FE EFI Diagnostics updated for 2020

forum.ih8mud.com

General Tech - 3FE Belt Routing

3FE Belt Routing with part numbers. Original shamelessly stolen and modified.

forum.ih8mud.com

 

[Michael Hanson]

Hi, All water hoses for sure and while radiator is out soft lines on power steering.Also battery should be a 27.

 

[BreezyF]

Hi, All water hoses for sure and while radiator is out soft lines on power steering.Also battery should be a 27.

Thank you for your input. I wonder if those hose kits you see actually work for the 91. Also I didn’t know that I just replaced it with what was in it. Maybe next go around or if I find something else that needs a battery I’ll swap.

 

[BreezyF]

Looking for some more help here. These wires look like they run under the fuse box and are connected to the back side of the alternator. Any idea what they are for? Also how should I go about the repair. One looks like it lost its connector or corroded off. Both look sketchy other than the plug. Thanks

 

[BreezyF]

Alternator out, broke one bolt on the mounting bracket. To the ultrasonic cleaner she goes.

 

[UsedLuxury]

This is the diagram I have for the charging system. It should help give you an idea of what you're looking at.

 

[BreezyF]

Thank you for the input I’ll hav

View attachment 3251278View attachment 3251281

This is the diagram I have for the charging system. It should help give you an idea of what you're looking at.

Thank you for your input I’ll have to dive in a little more because she actually ran fine before my discovery of this.

 

[BreezyF]

I am going to double nut the studs so I can take the pump out without having to remove the ac pulley (I think that’s what it’s called). Do I need to put any rtv or lock tight on the studs?

 

[BreezyF]

And she’s out. Probably will go ahead and do thermostat while I’m waiting on my hoses from Wits End

 

[BreezyF]

Pulleys replaced

 

[BreezyF]

New thermostat and gasket installed

 

[BreezyF]

After speaking with UsedLuxury, I believe I am going to open up my existing fan clutch and replace the fluid. I have read a lot here:

Blue fan clutch mod...Thread has gone to hell, read at your own risk

History: On my first drive this summer after replacing my transmission I was having an overheat condition with the truck. On the following weekend while towing a camper it was real severe in the 230* range. After returning I was able to confirm that my Blue hubbed fan clutch was to blame...

forum.ih8mud.com

Was wondering what people would recommend with the viscosity of the CST fluid for my 91 (green hub i guess) fan clutch. I live in north carolina so I was thinking somewhere around 10K.

 

[BreezyF]

Anyone have any idea what pitch and length this bolt may be? Id try to get the other one to check but I dont want to end up in the same boat. I found it in the FSM but no part number (I highlighted it anyway).

 

[BreezyF]

Anyone have any idea what pitch and length this bolt may be? Id try to get the other one to check but I dont want to end up in the same boat. I found it in the FSM but no part number (I highlighted it anyway).

View attachment 3254481

View attachment 3254483

FYI I believe it is part number : 9161160820

I ordered it from the local dealership today and should be available tomorrow. Probably will pick it up and let y’all know for future reference. Still have to extract the broken bolt.

 

[BreezyF]

Little update started vacuuming the horrendous inside (respirator included). Nice piece came in today I found to replace the missing fuel door.

 

[BreezyF]

Little update, water pump and studs with new gasket back in. Got new 5/8” green stripe gates hoses for the bottom right section. Went to the dealership for a 40 min drive to get all the lower and upper radiator hoses. Now just gotta tighten everything down and work my way back out!

 

[BILT4ME]

I'm going to suggest you do a serious cooling system flush with distilled water, run it, the drain. do this 5 or 6 times.