Diesel GOAT: The one I wish Toyota would have built

[cavey]

here's more useless  information , yanmar have a marinised   1HZ with a 80 amp alternator called 6LPA-STP2

[helipilot77]

here's more useless  information , yanmar have a marinised   1HZ with a 80 amp alternator called 6LPA-STP2

Cool info.

It just so happens that nanni diesel has a distributor in Seattle. Thanks for the tip.

[RB]

Great. hopefully those guys will help you locate the parts. I know my boat shop I contacted was having trouble finding gasket sets to rebuild the engine. A new nannidiesel t4 (1kd lump) was $26k!! A replacement long block was $13k, ouch, but if you have boat money.....

[helipilot77]

Front end alternator bearing came today, so I assembled the alternator and installed it on the engine.

[RB]

I bet the 1KD alternator and your 1KZ are the same housings with different pulleys and different plug ends. If you ever want to explore that option, let me know and I can take some detailed measurements of the housing, might be an option to upgrade the alternator amperage at a later date.

[helipilot77]

Last weekend we had some nice weather so I spent a little time on the oil pan. Getting it cleaned up and installing the sump. I am going to need to put some grinder time into the pan to fix my chunky welds. I think once I get the welds cleaned up I might have it powder coated for a durable finish.

[RB]

Did your engine come as a rear sump? If so what vehicle did your engine come out of? I struggling with either modifying the existing sump from front to rear or just buy a new sump and strainer.

[helipilot77]

Did your engine come as a rear sump? If so what vehicle did your engine come out of? I struggling with either modifying the existing sump from front to rear or just buy a new sump and strainer.

yeah it was factory rear sump out of a 94' KZN-130

[Gnarly4X]

... These things are notorious for running dry.

Thank you helipilot! 

This type of information and sharing are the gold nuggets of DIY-Tech!! 

If the failure of a typical fan clutch, after xx,000 miles is that the viscous fluid dries up, then I want to disassemble  the fan clutch I just replaced with a new Aisin and inspect it.  To try the repair, I need to source and price the bottle of viscous fluid.  I'm also curious about how the two halves of the clutch actually seal once its disassembled and bolted back together.

Gnarls. 

[helipilot77]

There is a very fine O'ring that seals the two haves together. Be careful not to stretch it out so that it can be reused. It must be very carefully laid back into the grove.

[helipilot77]

Now that Ol' Blue is back up and running I can get back on task. To help, Zippo came over yesterday and helped move the engine from my back yard over to his house so it can go into the goat. which will happen in two weeks. before he came over I did some last minute buttoning up of items. torqued the cylinder head bolts, torqued the cam caps and re-checked the valve shim clearances which were all spot-on thanks to the shims I ordered through TRUCKWORX UK. then the timing belt and cover went on followed by the valve cover. I didn't really want to put anything else on it for fear of making it too heavy for the move through my lawn and down the stairs which is 13 feet of elevation on a narrow switchback path down to the street .

[FRANKENYOTA91]

Just read the whole thread. Very nice work. Glad to find some more Toyota guys somewhat in the area. Maybe someday I'll be able to see your runner in person.

[redneckcustoms13]

It's a mythical creature. We will call it nessy. Most shall never been granted the privilege to see it in person. 

[Prismo]

It's a mythical creature. We will call it nessy. Most shall never been granted the privilege to see it in person. 

It has actually been to my house. Glad to see you are making progress on this project.

[helipilot77]

As promised major progress was made yesterday. I cant thank Zippo enough for his help. We  started the day by towing the goat from her parking spot under the fir tree to the concrete pad in front of the garage. RockcrawlinJK showed up about that time. We started by plasma cutting the existing motor mounts off the frame and cleaning the pads up with a grinder.

[helipilot77]

There were still a few possible pinholes in the oilpan caused by porosity in the steel maybe because its an oilpan? so Zippo put a good coat of JB weld over the welds. We then made a motor mount negative Jig for mocking up the locations of the mounts in their new locations on the frame rails. once all the measurements were taken we clamped the negative jig in place and made some templates for the side plates out of cardboard. I quickly cut them out with the plasma, which was so handy to have close by any trimming we needed to do was done with the plasma.

[helipilot77]

Once the plates were all cut out they were all friction fit one at a time and tacked in place.

[helipilot77]

With the motor mounts tacked in place we test fit the engine to see how clearances were. Suspension up travel appears to have as much room as it did in the previous location.

[helipilot77]

The motor came back out so that the mounts could get fully welded with the addition of some top plates to box them in. With the mounts now fully welded we installed the engine again to check hood clearances which was the whole reason for lowering the mounts. Using some crumpled aluminum foil on top of the high spots of the engine we placed the hood back on and latched it. Clearance looks much improved. With that success we pulled the motor back out and called it a day.

[THK Matt]

[helipilot77]

This weekend I went over to Zippo's place again and we installed the engine and transmission for the final time. It all went in fairly easily. I was relieved that all of our measurements worked out. The car dolly wasn't available to bring the goat home this weekend but it should be available this week sometime, then I'll be able to tinker with it where all the parts are close at hand. She'll be running again soon. I bolted up the rear driveshaft while Zippo installed the radiator. When I tried to install the front driveshaft I couldn't get it to expand. The splines are seized for some reason. We tried using a come-along to pull it apart but with no luck. I'm going to have to make a puller tool for it. 

[helipilot77]

Last night I rebuilt the power steering pump. Sorry I didn't take any pictures. I was flying blind since the Factory Service Manual for the 1KZ doesn't cover the power steering pump and it is like none of the other pumps that Toyota uses. I had to use the press while carefulling gingerly so that I didn't press too hard on something that still had a keeper on it. Fortunately everything went well.

[helipilot77]

I rode my motorcycle over to zippo's yesterday in an attempt to load the goat onto the car dolly to bring home. It was one failure after another. We got it on the dolly but the tire straps weren't long enough to go over my 35's so we tried letting all the air out of the drivers side tire, but it didn't gain us enough. Then we strapped over a shock hoop temporarily to move it to level ground and the truck shifted forward driving over the dolly and off it then the dolly unhitched from the truck. It was a real mess that I'm glad I didn't take of picture of to share. We had to disassemble the dolly and use the high lift jack to raise my truck and slide the dolly out from under the truck. Fortunately nothing broke in the calamity. At that point we parked everything and ordered some longer dolly straps. Then I rode home in a thunder storm. 

[:)bestgen4runner]

I know a guy with a sweet trailer and a really nice truck.
Next time phone a friend.
He's available for Mountain Dew and gas money.

[helipilot77]

I know a guy with a sweet trailer and a really nice truck.
Next time phone a friend.
He's available for Mountain Dew and gas money.

Thanks Chris. I would have but it was one of those things where you don't know it won't work until it doesn't. For $30 the longer straps will allow Zippo to haul his truck to whoever he ends up selling it to.   

[helipilot77]

This is for "sivaru" and anyone else who might need it. He asked what the input shaft length was for the R-151f. The input is 6" or 152mm which is longer than that of the R-150f. This is a critical distinction when doing a 1KZ-te swap, since the bellhousing is deeper to accommodate the dual-mass flywheel. Therefore the input shaft is also longer. The input shaft on the much more common R150f will not engage the pilot bearing in the crankshaft. I have heard that the input shafts can be interchanged between to two but have not confirmed this for myself.

[sivaru]

Thank you very much! , I'll measure my transmission next week to find out, starting to think about finding an engine with transmission already.

[helipilot77]

Big thanks to :)bestgen4runner for picking up my truck and hauling the goat over to my house. I'm cleaning up the turbo then I think everything can go back on.

[helipilot77]

over the holiday I got the turbo all cleaned up and painted with VHT. I have been gradually getting them all rotated through the oven curing process.

[helipilot77]

Turbo kit arrived yesterday, so I stayed up too late getting it all put back together.

I also drilled and tapped the hole for the Pyrometer/EGT sensor.