Marlin's 3RZ Conversion

[reklund5]

Ok Mike...it's the 15th.  Does it run yet? 

Ryan

[BigMike]

Well, on my 2nd post I said I wanted to see it running on the 22nd, and with all of the changes that have been done since then and now, there is no way in hell it will be ready any time near the 22nd.

I bet I could get the engine running in a couple of weeks, but I am sure that it will not be drive-able until Round-Up's eve.

I have been hammered with work now, on Monday when I got back, I nearly had no idea where to even begin. So I've spent the first couple days of my return week just figuring out simple things and getting things back to where I was.

Obviously I've been very busy on Marlin's truck and Bevin's truck, so hence I've not even been online here for the past 12 days.

I'll just post up a couple quick pics as I still need to continue working on Marlin's harness right now (yes, at my house and at 11:40pm)..

I left my camera at home on Tuesday, so I've only got a couple pics from Monday and Today..

The 2nd pic show's help from co-worker Alex.
The 3rd pic is where I got it aligned, with 4" of fan clearance, 1/4" more than my setup. I got the engine seated right up on the firewall.

Engine mount plates were made by Andy and I put then inplace and partially welded them into place. Then I pulled the engine and Andy finished welded them and braced the bottoms. I left the shop while he was still working, so I will get the final pictures tomorrow..

[BigMike]

Today I was basically told to just get the wiring done and the guys will do the rest. It's good for me because I am starting school in 5 days, so it's gonna be up to the rest to get the truck running.

I started work on the clutch slave cylinder and the GM (Welder) alternator, and that was it. Since then I've been doing nothing but wiring. I dont know how long I can stay awake tonight, but I am going to press on right now and get some more wiring finished. By tomorrow I will have the wires sorted on the T100 harness and begin integrating it with the Hilux wires..

When the frame conversion was done, the gas tank support was cut out, brake lines removed, on board air lines removed, ARB air locker lines cut, body mounts and bolts missing, yadda yadda yadda.

In addition, many parts are missing from this engine, as it has been sitting in the shop for about 20 months, so I've been looking up part numbers on the micro phische and sourcing used parts from wrecking yards. I hope to get some needed parts in tomorrow....

There is alot of work that must be finished for the round up. This truck must be there and I have no doubt that it will.

Here's a pic of Marlin's Welder installed using the FACTORY 3RZ ALT Mounts! Yes, no modifications required!
And lastly, here's a pic of what happens when your pinky finger wacks a body panel at a very high velocity

I will *try* to get some pics posted tomorrow. Cya!
BigMike

[RHG]

YOU CAN DO IT! Keep it coming Mike. 

[UNBREAKABLE]

ouch

[TacoRunner]

    Mike this is awsome, I wish I were there to help.  Please keep up the posts if possible.

[BigMike]

I've been very productive on the wiring. I will have updates tonight

Off to work I go!
BigMike

[reklund5]

Atta boy, Mike!!  Keep them coming...I'm actually thinking evil thoughts about putting a 3RZ in my truck sometime...

[raybie]

any progress over the weekend? 

[BigMike]

I did not work over this past weekend, but I do have some updates from Tonight, just some more wiring...

Tomorrow night I believe 3 or 4 guys are going to work late and get the gas tank and fuel lines in, and also the engine is ready to go back in, so that should be going in soon also.

BigMike

[Ferg]

To quote Billy Idol,  "...Mo MO MO"

[reklund5]

Ok...so where are the pics?  You're not like, busy with school again, are you BigMike?   

Ryan

[FIREBALL]

Uhh,             Mike,                             hello,                                   the round up is coming soon,                                             we can't have a roundup without Marlin and his red truck!










are you out there?






Stop calling Japan,                    get to work

[RHG]

  This is about the most uneventful conversion yet. C'mon whats going on with the truck right now. Youy still playing sparky on the wiring?

[BigMike]

Hello Guys,

There have been progress but since I am not there daily, I do not have any pictures. I have the wiring about 80% finished and it will be able to run come this Sunday or Monday. I say "able to run", which means that the wiring will be completed, but I believe we still need (1) fuel lines and (2) exhaust built..

A new W56HD has already been built by Marlin and we've got the engine installed with a W59 Bellhousing, the W56HD, and a New Tripple MC08 Drivetrain still needs to be built, and I expect that to be built soon.

Also, Marlin has been working on a bracket for his York Air Compressor which he will mount just outboard and above the power steering pump on the drivers side of the engine bay.

Also, I took complete notes on the wiring work that I did, and I need to post those reports here, including complete wire locations, looming, colors, corresponding page numbers in the wiring book, and more. I have not removed the interior fuse box, but I plan to do so after the round up on both my truck and Marlin's, as we both have the same EFI system onboard.


I will be working at the shop this entire Labor Day Weekend, so expect some updates and photos to come!

Regards,
BigMike

[kneedownnate]

Yea, I like the idea of posting up all the wiring how tos.  Maybe you could compile all you learn from yours, this and all the other swaps you have lined up and make a sticky on it for all us hopefulls.

[RHG]

Holy crap, the benefits of being Marlin. New motor, new tranny and new triples!?!?! How bout that, is he keeping that disconnect transfercase thingy? Ya know for the front wheel drive burnouts! Sorry bout the un-technological terms, I forgot what it was called. Anyways, I am going to have to make it to the round up just so I can see King Marlin and his truck in action.

[BigMike]

Here is a pic of the interior wiring loom..

First the pic of the T100 loom all torn apart,

Then the pic of what is needed and reloomed and ready to be installed. Removed 6 pounds of wires!!

Also, I've included a pic of one of my four pages of wiring notes that I need to go through and convert into text here so I can post what needs to be done for a first gen 3RZ swap! (1995-1996 years)

[BigMike]

Here's a pic of Andy's KICK ASS Engine Mount before we put the engine back in

[h0nke]

wiring is scary....cant wait to see updates this weekend Mike

[reklund5]

Good work, BigMike!  Keep it up!

Ryan

[BigMike]

Ok guys, wow, UPDATES!!!!!!!! YEAH!!!!!

I worked over this past weekend on Marlin's truck and got 99% of the wiring installed and wired in, and got 99% of the dash back together. All that's left is to change out the oil sender to the 22R unit, and wire in the A/C switch (not a real priority right now).

The ECU still needs to be mounted, and the fuse box in the engine bay is just resting on the fender wall right now. I plan on finishing everything up Saturday evening if my other plans go through ok.

On to some pics!

[BigMike]

So as you can see, I've been pretty busy It's almost finished now so that's good news for me

While I was buttoning up the wiring, Marlin was busy mounting his York on-board air compressor, and I must say, he is one excellent fabricator! He built on sick mount! You'll have to see it in person to really understand the engineering and thought that went into this bracket, a true work of art!

After I got the GM Welder/Alternator Installed, Marlin went the distance and adapted a V-Groove pulley onto the Alt, so now it's got a Serpentine Belt groove for the 3RZ and a V-Belt groove for the York.

He even impressed me! Marlin

[TrackVino]

Looks sweet, cant wait to see it in person.

[RHG]

Oh its gunna be a close call isnt it? How many days left, one, two,...10 days left! Well I am very disapointed becuase I am not going to be able to make it to the Roundup and meet the Toyota Master I hope ti see a bajillion pictures though so that will make it somewhat alright. I am absolutly amazed at how well Marlins truck is turning out. This thing is a born again crawler.

[BigMike]

So I headed back to the shop tonight (Tuesday) and what else did you expect me to do?

MARLIN'S 3RZ IS ALIVE!!!


Strating Up the 3RZ Powered Crawler Truck! (960 Kb)

[BigMike]

IS THAT SWEET OR WHAT????

Of course there is still a ton of work left to do, but man this was a huge milestone that feel great to have now passed!

Things off the top of my head that needs to get done before the round-up:

• Get an Intake plumbing built and get an air filter
• Modify and Mount the Downey Header
• Hook up the onboard air lines
• Wire in the Welder Back in
• Mount the Battery
• Mount misc items in the engine bay like air box, igniter, charcal canister, yadda yadda yadda
• Install the Radiator and hoses and get some coolant in this beast
• Mount the IFS Steering Box and finish the HySteer
• Rebuild the rear diff to fix a bad ARB line
• Hook up the brakes
• Hook up the throttle cable
• Hook the winch up
• Build and install a new front bumper and rock sliders
• yadda yadda yadda

What? You thought this was gonna be easy? ha!

Here are a couple more pics from tonight. A fuel leak that we had when I was testing the fuel pump circuit minuets before the first start-up, and a pic of the Jerry-rigged duct-taped Intake so that we could start it up :gap: Hey, it's the first item on the above list all-right!

[BigMike]

And since this is the third 3RZ I have resurrected in the past week (seriously), I have more screen shots of the OBD-II program to validate it

[RHG]

  Where the hell was that fire coming from? Is that why you need to modify the header? It sure sounds like a beast! You are the godfather of 3RZ conversions Mike!

[BigMike]

Just like on Dean's and Bevin's systems, since these guys all have automatic setups, I was of course expecting to run into computer codes for various Autotranny related issues.

Marlin's system however, being a bit more naive than Dean's and Bevin's, only reported two trouble codes compared to Dean's 4 and Bevin's 6 codes. But we don't even have both O2 sensors hooked up nor the VSV purge tank valves either, so obviously many more codes would be thrown right now if we were to drive it around in a Closed Loop state, that's for sure.

So as for me, I've still got a bit of work to do with the wiring and to finalize this job for myself, and even though I am determined to tricking the computer about the Automatic tranny issues and bypassing all of the trouble codes, Marlin still thinks he should get a Manual computer for his truck. So we looked on Car-parts tonight and he can get these computers for about $50-$100 bucks, and I checked in the wiring book, and the plugs are all the same, so I think this might be the quickest and most reliable approach to take in fighting the Automatic issues.

More to come later, Can't wait to get this thing out on the road and see what she'll do! MCR4 HERE WE COME!

Regards,
BigMike