Project Kilchis!! Update 9/13/09

[Wermz84]

Comming together verynicely!  take all the time you need cheese, these things take time to do it right.     Engine looks good in there wish mine was that clean.


I have one of those double pipes and yes it rattles on my crossmember, going to get it fixed as soon as i can.

keep up the good work.

[Cheesemaker]

Well, I got some stuff from the Toyman!  And I've never been scared of a woman in my life, until I met Christin!    I thought I was talking to a guy from the size of his/her hands, voice, and demeanor, until I noticed he/she had boobs!  While she/he was looking for parts my wife came in and asked me that the kids and her needed to use the bathroom, and I told her I'm not gonna ask!  Then it walked in and my wife's eyes got real big and walked out!  But here's the invoice I got from them!

I like the "JUNK" on there! 

And I didn't get the exhaust downpipe I needed cause they didn't have any!  But I'm glad, cause some of my contacts found three of them.  And they said they didn't have any.  But I got the one I needed for FREE!     And it fits! 

My injectors are on the way back from Witchhunter!  I got to get off my butt and start testing wires, sensors, anything else electrical, and installing my exhaust!  Then after that it's start time!  I'm almost nervous about that!  Since this is my first at attempting anything of this magnitude!


My wife started a piggy bank for the "Toyota Fund!"

[Cheesemaker]

Did some stuff, but not as much as I wanted, but some none the less!

Got the injectors back!  Wow, I'd advice anybody to get there's cleaned!

Before~


After~  Including the cold start injector!


And the report from Witchhunter~

I don't know if you can see, but there was a 12.1% difference before and one injector had poor spray, and after they are all within .8% 

I got the exhaust put on and bolted in!  No pics yet, but it's in, and I got a couple of nuts to get to finish it off!  And I started in on the electrical, tested the AFM and it's all within spec's according to FSM.  Was gonna get more stuff done, but had to go in the house and do something, but the next thing I knew I fell asleep!

[Wermz84]

  that is quite the difference between the before and after.

[86bobbedtoy]

hay I have been watching this build already, looks good.

[Cheesemaker]

I'm starting a mental note on what is needed for the swap.  Especially, if you don't have the funds for a "donor" rig!

So far, I've had to get:

exhaust manifold & down pipe
air intake tube & rubber ends
smaller cc injectors  (22rte runs 295cc/22re runs 205 cc)
upper half of afm/air filter box
ecm
afm
water tube (the one that runs behind the exhaust manifold)
Oh! a 22re motor!


I am reusing:

wire harness (no real difference between them)
turbo flywheel
radiator bypass (the one that goes around alternator)
exhaust from cat back
distributer
tps intake
egr valving (minor differences, but the biggest is the turbo egr shuts down when the turbo kicks in)



Could have reused turbo radiator, but was rotten!  So, I got a larger 4 cyl replacement, I like the larger radiator over the stock one!

I've had to walk through the wall of cooling hoses to find some replacement ones.  The turbo uses one that has a return line to the middle, and I needed one without the return nipple in it!



I will update this later as needed!  For future help for wayward mechanics like me!  I remember looking for help and not much info was out there for this swap!  Most of it was real shady to say the least!

[Cheesemaker]

Got my coil wire spliced in and wrapped, and now it is long enough to go up and around the firewall, brake booster, and master cylinder to the coil plug.  This way it doesn't hang over the exhaust like it was with the old motor!  Installed the injectors, and started testing the wires.  The TPS is a pain to dial it in, and I still don't feel 100% sure it is right on, but according to the fsm it's right about where it needs to be!    

I had plans on spending all day on the truck, I hit a brick wall yesterday morn.  We've been going someplace for the last three weekends, and with all the stress of last week, I slept really good saturday night, and then got up and had breakfast and crashed for another 5 hours!  Hopefully, I'm not coming down with something!  Well, I'm gonna go out and test some more wires!  Later.

[Cheesemaker]

Got the upper intake mounted and started putting things back together until I broke the EGR valve!  Had to loosen the one big nut to get it turned to bolt to the back of the intake.  And then I realized I had the wrong gasket in, and went to loosen it, it just broke.  CRAP!!    I hate breaking parts!  I'm getting excited, I'm getting closer!  Now, I just have to find a EGR.  Had to extend the wire for the O2 sensor!  It's close! 

[Cheesemaker]

Well, I've got it all together and have been testing all the wiring at the ECM.  What a pain in the butt testing all the wires and making sure they all read in the right range!     This is got to be the worst part making sure all the wiring is not shorted or corroded and bad!  I've still got a few to check, but I have to put some things on hold!  Got too many things going on right now!  But in two weeks I should have it running !    I'm gonna take it over to a buddy's that generally does my mechanic stuff and have him double check some things and help me start the truck for the first time!  He knows alot more about first time start ups than me! 

I rewired the tail lights, and while I was at it, I also piggybacked the trailer lights in at the same time!  I'm running out of $$ so, I'm gonna have to put the bed back on for now.  It may look ugly but it will work until I can raise the $$ for a flatbed! 

Besides that I got only a few small things that can be dealt with later when the rainy season comes!


PS ~ This should be my 1,000th post!!   

[89toy]

Would you happen to have the contact info for the guy who built your motor?  Lookin' good...can't wait to see it movin'.

[Cheesemaker]

DP Automotive
3611 E. Third St.
Tillamook, OR  97141

1-503-842-7946

He's generally in on Monday thru Wednesday for sure! 
He sells some stuff on E-bay!

He's an old German.

[89toy]

Thanks!  I'll see what he might be able to pull with my poopie little LC motor.

[Cheesemaker]

Well, I finally got to the point that I think I got everything all installed right!  Between life and various other things taking up alot of my free time, I finally pulled the truck out of the shop!



I wish I really had enough experience to confidently try to start up my truck and break it in!  But I was gonna have a family friend that is/was a mechanic help me with this, but he decided to wrench in his spare time and work full time servicing our local boweling alley mechanical workings.  So, I had to find another qualified mechanic.  Most guys didn't want to help me since I did the work myself.  Sometimes, I wish Dean was still here to help me!  This motor swap was my first real major mechanical thing vehicle wise, so I just wanted a mechanic to go over it and make sure everything is right and working before it gets started for the first time!  So, I gave the mechanic a very detailed list of what I wanted done and checked before startup, and hopefully I get a call in the next couple of days to come and drive it home! 

Here's the tip tied tail lights and my crappy bumper I put on!  I wanted the fuel pump checked and figured I leave the bed off until I knew the pump was good! 


So, hopefully the next time I post in this post, it'll be it's running! 

Later and keep your  for me and Kilchis!

 

[rebelKrawler83]

nice motor and build

[Cheesemaker]

  IT'S ALIVE!!!!!!!!!!! 


Well, it fired on the first turn, so I did everything right!!  The only thing that isn't working right now is the temp gauge, and we aren't sure if it's the sending unit, or something between the ecm and the instr. panel!  But that is a minor thing to worry about for right now!  I'll get a cheap gauge for the time being, just so I can keep an eye on the temp!  I should be driving it around in the next couple days!  YAHOO!!  I'm ready to tear up the hills now! 

I'd like to thank those who helped me with my questions!  And Snoshoebrue, TOYO487, and 86bobbedtoy for the parts I couldn't get locally from my buddy Rick that was very cool on all the free parts!  If our paths cross on the trail I owe you guys some cold beverages!

I think I just gave an acceptance speech!   




Now,I got to put that 89 bed on it for now and save up for the next project:  Flatbed!!

[Duffil]

NICE!!! It's about time that thing rolled under it's own power!

[topar]

  Cool have fun with it now!

[Cheesemaker]

Oh, it will be used for sure, and half of it will be fun! 

I got to put the break in miles on the clutch and the motor, and then I got all this crap that has been piling up around here for the last year!  HELLO, dump runs!!  And then it's off to get a head start on fire wood for the next year!  I'll be almost out of wood in about 3 months so I gotta get on it ASAP! 

And I'll be getting our X-mas tree with it next month!  I will get pictures of the first maiden off roading adventure when I do!  I've been needing mud and gravel under my tires for a very, very long time!

[Cheesemaker]

I've been driving it today!  And this truck is gonna rock!  The boys already want rides in it, and I still gotta put the bed on it!

[Cheesemaker]

Well, I took my annual Turkey day drive up the Kilchis River, but this time I did it with my truck and I took my boys with me for the first run in the mountains!  Was only gone an hour!  But it was a beautiful drive! 

They gave me their approval!


And some pics of Project Kilchis!




And I took a pic of us on the river bank!


Already wishing I had a rear locker in it!  I had some difficulty getting out of a small trail from the river, but that will be later!

[topar]

  Looks like a good father sons adventure 

[Cheesemaker]

Took the boys out to play in the snow yesterday!  Did pretty good, except for the fact that the tires I got aren't that good in snow, and they are down in tread, so I was sliding around pretty good!  But fun!  I was doing things that I had problems attempting with my Nissan, and I had no problems with the Toyota, and I was wishing I had bigger tires with more surface area to really play in the snow!  I really want to get into some better snow, but I had to get ready for work too!







The rock pile had some really nice spots to flex out the suspension, but with IFS that is pretty limited.  But I had fun anyway!

[Cheesemaker]

Well, I've gotten over 800 miles on my new motor, and I have to get some things fixed already!  It's leaking anti-freeze out of some freeze plugs from what I can see.  And one of them may be the one behind the flywheel.  And the front main is leaking oil.   
So, I have to figure everything out before I go see the rebuilder.  Been hearing alot of bad things lately about his rebuilding abilities.  Sounds like he's getting burnt out. 

Besides that, I know that the rear pinion seal needs replaced.  The gear shifter needs the seats replaced to take out the slop in it, and a rubber boot on the top of the tranny. 


And what's up with all the ball joints & steering linkages with no grease fittings?  I'm gonna check the FSM.  Got all the driveling zerks greased.      

[Cheesemaker]

I'm getting the freeze plugs fixed next week!    He said the front main is norm to leak to some small degree.  It's just a small leak, so I'm not gonna get excited too much.  But the freeze plugs is important. 



Got my exhaust finished!  I'm happy now! 

[Duffil]

I'm getting the freeze plugs fixed next week!    He said the front main is norm to leak to some small degree.  It's just a small leak, so I'm not gonna get excited too much.  But the freeze plugs is important. 



Got my exhaust finished!  I'm happy now! 

get a new seal, and sand off the rubber on the back of it...drive it in all the way until it seats against the oil pump.  say goodbye to your leak.  Oh, and don't forget to grease the ID before you install it.

[jimbo74]

my front seal leaked liek crazy when i replaced it after my timing chain job... spent the $10 and got the Toyota gasket from the dealership and it went away

[Cheesemaker]

I think that's what I'm gonna do later.  I'm not really concerned about a little oil leak, but the freeze plugs is a big concern. 

I've got connections with Toyota now!!    LaDawna works for Toyota now!

[Duffil]

I think that's what I'm gonna do later.  I'm not really concerned about a little oil leak, but the freeze plugs is a big concern. 

I've got connections with Toyota now!!    LaDawna works for Toyota now!

uhoh...there went the neighborhood.


Just joshin ya cheesy.

[86turbotruck]

sweet

[Cheesemaker]

Doing some updates!  Getting some things under my build up instead of having them floating around.

Here is the link.
http://board.marlincrawler.com/index.php?topic=46728.0