Topic: Diesel GOAT: The one I wish Toyota would have built

[helipilot77]

I have been pretty busy, maybe after we get a little snow we can hit some forest roads!

I have been using the 4runner for a fair amount of family camping though. The sleeping platform and the fridge make life easy. And I am getting a lot of use out of the back seat now which has a semi permanently fixed car seat in it. It still carries myself, my wife, my daughter and my dog with all our gear, the kayak on the roof and the sailboat in tow.
The bumper is coming together. I didn’t like the mounts that came with it so I designed my own and had them laser cut by Oshcut, out of 5/8” plate. They showed up the other day. So if I get some time I can finish it up.

[blackdiamond]

https://shop.saferide4kids.com/collections/stage-2-forward-facing/products/ridesafer-travel-vest

This is what use for my kids in the 4Runner plus the tether to give them shoulder restraints. These are pretty slick.

[helipilot77 [OP]]

Now that we have been camping in the back frequently I was thinking about getting a diesel heater for the cab one of the other members bought this one for his chinook build and liked it. Can’t beat the price and it has a form factor much smaller than a Webasto. Would make those cold nights so much more comfortable.

[Rockcrawlintoy]

Now that we have been camping in the back frequently I was thinking about getting a diesel heater for the cab one of the other members bought this one for his chinook build and liked it. Can’t beat the price and it has a form factor much smaller than a Webasto. Would make those cold nights so much more comfortable.

What heater is it. I hear a lot of good things on the overland forums

[helipilot77 [OP]]

What heater is it. I hear a lot of good things on the overland forums

It’s just a cheap chineese “happybuy” 5 Kw diesel heater with a 12v fan and digital thermostat. 

It's a happybuy from Amazon. 5kW . With the remote start. It was somewhere around $135 - $150 I believe . I flipp'n love it so far..  it comes with a 10L plastic fuel tank. Totally fine. But opted for a green jerry can I have permanent all mounted on the back bumper. The heater kit. Comes with a little ¼" bulk head  so you can tap into any tank . Whether it be the plastic tank they supply , or in my case.  The jerry.

Sent from my SM-G960U using Tapatalk

[emsvitil]

How do you avoid the fumes and CO ?

[helipilot77 [OP]]

How do you avoid the fumes and CO ?

Excellent question. They use a heat exchanger so the combustion gas is completely separated from the heated air. A combustion air supply and exhaust must be routed to the unit to outside air. They are essentially an miniaturized  oil furnace like what you might have in your home. I think I will mount mine on the drivers side opposite the fuel tank under the rear seat so it is outside, below the fuel tank and in a good location for the air supply to be piped into the cab.

[helipilot77 [OP]]

I took all of the Thanksgiving week off and have had some time to find the fuel leaks. Last week I had some time and replaced the #1 injector pipe. So that puddle of fuel was no longer showing up pooling in a void on top of the intake manifold. I was however still getting fuel dripping in the driveway. So yesterday I really opened her up. I new I needed to remove the pump to replace the oil cooler with stripped threads at the oil pressure sender port. Once I pulled the pump I noticed there was a fuel stain on the side of the block in a location that didn't seem to be caused be the injector leak because I had degreased and power washed the motor after the injector pipe replacement and the block was wet with fuel in this location. I figured I must have a pump leak, which is a known problem with these ZEXEL ME202 pumps, or really any Bosch VE pump clone including the Denso that would have come on these 1KZ-t engines. Fortunately I had a re-seal kit for the Electronic version of the pump which included the shaped rubber O-ring for the cover, however, because it was a seal kit for the electronic version it didn't include the O-ring for throttle shaft. I called up Seattle Injector Co., and they hooked me up with an new O-ring for free.    

[helipilot77 [OP]]

I got a little further today. I installed the new seal and O-ring in the pump. I found a great write up from South Africa, and it mentioned using a string or hooked wire to pull the governor forward while installing the top. There were also pictures of the clocking of the splines for the throttle lever, which was helpful because I had neglected to mark mine when removing the lever.
Back on the motor I drained the coolant, and removed the oil filter, then dropped the starter to get to the bolts for the oil cooler. It came loose nicely then I mopped up the mess on the side of the motor. That's where I left off for the day.

[helipilot77 [OP]]

I was able to dedicate another good chunk of time to the 4runner yesterday. I was able to get it mostly back together.
I used the die grinder to open up the timing slots on the Zexel ME202 so that I could rotate the pump a bit more toward the engine block for more timing. Everything is back together with the exception of the water temp sensor that fed the ECU and the electrical connector that attaches to the water temp sensor that feeds the gauges. The water temp sensor connector wire broke while removing it from the sensor. It was so old and brittle that it was hanging on by a thread of copper. I was trying to fix it in the shop when the connector completely crumbled on me. Years of heat and oil exposure finally got the best of it. I have a new connector coming in the mail soon. The water temp sensor that fed the ECU was not being used since I removed the ECU and I have been wanting to install a second sensor for the VDO gauge I have. I tried hooking up the VDO gauge to the Toyota sensor but I guess Germans don't speak Japanese(different resistance?) . I had a VDO sensor that I had ordered in preparation, but the research I did on the thread size was wrong so the correct M12x1.5 VDO sensor is also on the way. Pictured below is a brass T-fitting I installed that will also give me redundant oil pressure readings. I started it up and ran it. It wouldn't idle at first because I had installed the throttle shaft off by one spline so a quick 5 minute fix and it started right up and idled. So far there are no leaks. I didn't want to run it for too long until I install the sensor and fill it back up with coolant. For now it looks like the leak on the top of the pump was the biggest source of the problem. I should have put new seals in it before even installing the first time. I was just nervous to mess something up on it initially though. Live and learn. I'll be riding the motorcycle in to work until that sending unit shows up, fortunately the weather looks good for the near future.

[helipilot77 [OP]]

Today the new connectors came for the brittle ones that broke. I bought a few other that I suspect have the same problem. If you are doing a motor swap or any kind of electrical work Ballenger Motorsports has all kinds of connectors for Toyota and other manufacturers.

[Gnarly4X]

... Ballenger Motorsports has all kinds of connectors for Toyota and other manufacturers.

Hey h...

THAT is awesome information!!

Thank you for sharing!

Gnarls.

[helipilot77 [OP]]

Over the weekend the water temp sensor arrived, so Sunday evening I installed it, filled it with coolant and took it for a test drive. It seems that I have fixed that leak. However it is making another leak more clear. I have oil coming from around the bellhousing. I must have a rear main leak. That aftermarket gasket and seal kit I bought from RoughTrax seems to be disappointing me. The gasket that I had on the oil cooler was a paper gasket from the kit, however the Toyota gasket I just replaced it with was formed metal. 

[RB]

Damn that stinks, hope iit isn’t a bad leak, but with a clutch it needs addressing sooner than later.

[LittleSteve]

Is it done yet?

[helipilot77 [OP]]

Is it done yet?

NEVER!

[LittleSteve]

NEVER!

Excellent.
Make sure it stays that way so that I can continue to give you about it.

[helipilot77 [OP]]

Well, It's been awhile since my last post. There are a couple projects I have been working on in the back ground. Just kinda collecting parts. I finished my fridge slide and made some tie down straps for it. I have also been collecting 18650 lithium cells to build a camping battery. I'm not sure Lithium-Ion is the chemistry I will go with though. I have some of the Headway 38120 cells and really like them. I replaced my motorcycle starter battery with 4 cells and it has always fired right up. Even in the dead of winter. The Headway cells are Lithium-Iron-Polymer and don't need any kind of fancy charge controller to run and have really high amp output. They are also much safer as far as fire goes, but I would have to buy them, whereas I already have the 18650's for free. I have been wanting to power my daughters Radio Flyer wagon... I might use the 18650's for that project and go with Headway cells for the fridge backup.
What do you guys think I should do?

[helipilot77 [OP]]

In case anyone is wanting to know where to get Headway cells.
https://jag35.com/collections/lithium-batteries/products/authentic-headway-38120hp-8ah-25c-200amp-lifepo4-super-high-power-cells

[Tyler9537]

just read the whole thread, nice build.

[LittleSteve]

But is it done yet?

[helipilot77 [OP]]

Project update:
This month we welcomed our new baby boy, Cyrus Oliver to the family and bought a new house and moved, so that we can begin the process of tearing down our old house to prepare for the house we have been planning that I will be building for my family.
The new house has a garage and a workshop which will help with projects on the 4runner. Not having a garage for the last 5 years has been a real challenge for me. I have been having to do all repairs and projects H8PVMNT style out in the rain and cold. Before I get too involved with projects I still have to finish getting everything organized and get the garage wired for the welding gear.

[OVRAROK]

Project update:
This month we welcomed our new baby boy, Cyrus Oliver to the family and bought a new house and moved, so that we can begin the process of tearing down our old house to prepare for the house we have been planning that I will be building for my family.
The new house has a garage and a workshop which will help with projects on the 4runner. Not having a garage for the last 5 years has been a real challenge for me. I have been having to do all repairs and projects H8PVMNT style out in the rain and cold. Before I get too involved with projects I still have to finish getting everything organized and get the garage wired for the welding gear.

Congrats Nate...

[RB]

Yes, congratulations!

[helipilot77 [OP]]

Thank you both!

[helipilot77 [OP]]

I am finally getting around to fixing the rear main seal leak. In order to get the flywheel bolts out I made a second flywheel lock cause I can't find the original one that I made. I cut a 1-1/4" slice off a 2" x 2" aluminum square bar that I have then cut out the shape on the bandsaw. The flywheel is now off and ready to give way to the rear main seal. It doesn't look as messy as I would have expected. I will be replacing the transmission input shaft seal as well since I am in there. Fortunately the flywheel and clutch were bone dry, so no need to replace anything.

[Gnarly4X]

Pilot bearing? 

Gnarls.

[helipilot77 [OP]]

Pilot and throwout bearing are relatively new. So no need to replace them unless I suspect there is an issue with either, and they have been smooth and quiet.

[Gnarly4X]

Congratulations on your new little boy, house, garage, and a WORKSHOP!!!! 

Gnarls.

[helipilot77 [OP]]

I was finally able to get ahold of the genuine Toyota injection pump timing tool from an ebay seller in Japan, so now I can start to do some timing adjustments. Also all of the seals have arrived, so I can start putting things back together.