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RicardoJM
12-11-2010, 04:20 PM
I've picked up the assembly lube, rtv, oil, oil filter, coolant, engine paint, plastigauge and engine break in additive. All the nuts bolts and washer have been cleaned up - btw Toyota FIPG is not easy to remove from bolt threads:D.

The machine shop has cleaned the block, crankshaft, camshaft and pistons. The cylinders have been bored to match my pistons. New cam bearings and freeze plugs (OEM) were installed and both shafts polished. The machine shop also picked up new gaskets and piston rings. In addition the the block from the Mule, Randy has given me main and rod cap bearings that match up to the shafts. The necessary parts are in place:thumb:.

I am really excited about this project. The FJ40 will be back in action and I get to keep the balanced rotating assembly. The camera battery is charging, so I should be updating this thread with some Tech stuff; steps, issues and resolutions of the build.

Tomorrow, I'll be putting the F.5 engine together. I'll be working at Randy's and starting about 9:00. If you are interested in seeing an engine be put together (buy a newbee) or just want to stop by and hang out - join us. Last I checked there were only a couple of beers in the fridge, so if there is plenty of room for you to bring some more:hill:. The football game will be on the radio.

farnhamstj
12-12-2010, 08:57 AM
:ranger:

RicardoJM
12-12-2010, 08:28 PM
Upon arrival this morning, we were soon test fitting the main caps and bearings.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild001.jpg

After putting in the block half of the main bearings, we put in place the crank shaft. Assembly lube is good and anything shiny and polished got a good coating of it. Here I am putting lube on the journals where the 3rd main bearing cap goes. Just beofre putting the crankshaft in, the cam bearings are very exposed and easy to get lubed.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild002.jpg

RicardoJM
12-12-2010, 08:29 PM
The one big time sink throughout the day was cleaning parts that I had removed from my block and not cleaned yet:o; timing plate, timing cover, side cover, head, etc..

Even though the block was fresh from the machine shop, each surface that is getting a gasket needs to be cleaned. I am just finishing up the cleaning of the block surface for the timing plate.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild003.jpg

Here is the timing plate and gasket. The oil squirter is installed and pointing down into the cylinder. Before putting the gasket on, I confirmed the oil squirter was installed at the correct depth and staked.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild004.jpg

The timing plate and gasket are held to the block with three flat head screws and a couple of bolts. The flat head screws were staked to hold them in place.

RicardoJM
12-12-2010, 08:32 PM
TheBoomBoom is applying assembly lube to the camshaft prior to instllation.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild005.jpg

Having the engine on a stand, it is easy to rotate it to get access. Here we have it on its side. TheBoomBoom and I worked together to get the camshaft installed and in place. Care needs to be taken when installing the camshaft so that no damage is done to the bearings.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild007.jpg


The gear on the end of the crankshaft and the gear on the end of the camshaft have marks that need to match up. If these marks are not matched up, the timing of the pistions and the valves will not be correct.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild006.jpg

nattybumppo
12-12-2010, 08:33 PM
Boy, I missed out on some fun!

RicardoJM
12-12-2010, 08:35 PM
This was the "mystery" part of the process. I have read and researched, but there is nothing like doing it to bring it all home. Here Randy and I are going over the instructions. Randy walked us through the first one and then left us to it as he took care of some other things.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild008.jpg

The rings are installed into each piston grove. There are four rows of rings and as each is installed the ends of the rings are placed at 6:00, 9:00, 12:00 and 3:00 as you look down on the piston. This is done so that oil does not blow by the rings. After the rings are installed, they are compressed using this thing.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild009.jpg

Each piston is then put into its cylinder. The cylinder wall is lubricated with ATF fluid. The threaded posts of the connecting rod are placed in some rubber sleeves (fuel hose) to protect the cylinder walls. FJBrady and TheBoomBoom and I quickly fell into our roles; I did rings, TheBoomBoom did bearings/assembly lube and FJBrady torqued (two step) the bearing caps to spec.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild011.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild012.jpg

In short order all the pistons were in and we had some fun turing the engine and watching the cylinders do their thing. I also lined up the marks on the shaft gears and confirmed cylinders 1 and 6 were at TDC:thumb:.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild013.jpg

RicardoJM
12-12-2010, 08:38 PM
In this photo, you can see that AirRandy and Nuclearlemon have everything under control. The head gasket is in place. At first I had it on wrong, the tip here is to have the overlap going off the back of the engine.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild014.jpg

The bottom of my head took a bit of work to get cleaned up and smooth. Nothing hard, just some scraping and cleaning. We got the head installed and torqued the bolts to spec. FJBrady put in the lifters, push rods and put the rocker assembly in place. I worked on installing the timing cover; it had to be cleaned, seal replaced. TheBoomBoom started cleaning the side cover. It was getting late, but before knocking off for the evening, we cleaned the block and layed down some engine paint. Here is where it sits now

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild015.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild016.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild017.jpg

I am familiar and experienced with all the other work needing to be finished. It is nice to see everything coming together. TheBoomBoom and I will likely get the rebuild done before the weekend. Perhaps even get the engine and drivetrain back into the truck.

Art Volmer
12-12-2010, 08:38 PM
Looking good Ricardo, it will be running before you know it.

rover67
12-12-2010, 09:18 PM
Looking good!

Can't wait to hear it crank up!

RLMS
12-12-2010, 09:41 PM
Congrats on getting her back together Ricardo!!


Justin

subzali
12-13-2010, 07:50 AM
Looks like Randy and Ige have everything under control! :D

Great job Ricardo! The writeup and pictures are really great!

Air Randy
12-13-2010, 07:23 PM
Looks like Randy and Ige have everything under control! :D

Great job Ricardo! The writeup and pictures are really great!

You have no idea how stressful it is for us to supervise the unskilled! :D It took numerous :beer: to ease the suffering :thumb:

nuclearlemon
12-13-2010, 08:40 PM
lol...some more pics

nuclearlemon
12-13-2010, 08:40 PM
more pics

nakman
12-13-2010, 09:57 PM
that's awesome, Ricardo, can't wait to hear that engine run. Like we were saying at the party you own that thing, nothing can stump you now!!

RicardoJM
12-17-2010, 08:41 AM
TheBoomBoom and I worked on the engine Wednesday evening. TheBoomBoom double checked the torque on rocker assembly, connecting rod caps and mains. We also confirmed that rod caps were aligned the way they should be, i.e. stamped numbers on the same side. TheBoomBoom set the valve lash. We inspected the oil pump gear clearance, it is like new. We Installed the oil pump and dizzy - dizzy stabs smooth.

We dropped more paint on the block. We also touched up the valve cover, side cover. I also scrubbed the battery holder and pulley and dropped paint on them. All the covers were cleaned an prepped for installation.

Thursday evening I went back and AirRandy gave me a hand with a few things, removing the dipstick tube, replacing the pilot bearing, intalling the oil pan and covers. When I left last night the engine rebuild is "complete". On Saturday, we'll put the engine and drivetrain back in the truck.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild025.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild026.jpg

RicardoJM
12-17-2010, 08:41 AM
When the block was dropped off at the maching shop, the rest of the rotating assembly, pistons, connecting rods, connecting rod caps, camshaft, crank shaft, main caps and bolts were also dropped off.

The machine shop measures all these components to determine what machine work is needed and what size bearings are required when the engine is put back together. The machine shop I used has been around a long time and is experienced with the F/2F engine and do very good work.

In my situation, the cylinders in the block needed to bored out to match size of the pistons I wanted to use. My connecting rods/caps only needed cleaning. My camshaft and crankshaft only needed cleaning. All the metal surfaces where bearings go wer polished.

For my piece of mind, I plastigauged the #2 and #4 main caps. They were both solidly in specification. The platigaue is a thin plastic wire. A small piece is cut and placed on the journal then the cap (w/ bearing) is put in place and torqued to spec, this flattens the plastic wire. The next step is to remove the cap and measure at the widest point. Here is what the plastic wire looked like on the #4 main.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild027.jpg

This is the measuring gauge.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild018.jpg

As my stuff was fresh from the machine shop, the measuring was an optional step. If I were looking at rebuilding an engine, I would measure all the mains and connecting rods during the dissassembly. If everything measures within spec, there will be less machine work needed.

RicardoJM
12-17-2010, 08:43 AM
I didn't remove the pilot bearing from the cranshaft before taking it in to the machine shop. We removed the old one using the hydraulic method. AirRandy pumped the grease gun while I held the hose in place and filled the cavity with grease. Next we put in my cluth alignment SST (the input shaft from my old trashed 3 speed tranny) in place an smacked it with the BFH. We had to use some vice grips and hammer to tap everything out, but it worked very well and did not make any mess.

I had not picked up a new pilot bearing and fortunately AirRany had new one in spare and ready to go. In short order it was installed.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild021.jpg

The oil pan gasket, side cover gasket and timing cover gaskets were installed/re-installed. I had done the timing cover on Sunday, but over torqued and split it.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild022.jpg

I've installed the covers and gaskets while they are in the truck and have done them when they are on the stand. It is much nicer to do them on the stand as you can rotate everything for better access.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild023.jpg

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_rebuild024.jpg

FJBRADY
12-17-2010, 08:52 AM
Very very nice.....way to go Ricardo. :thumb:

RedCreeper
12-17-2010, 08:53 AM
that thing is to purty to put in the 40. you will need to get the outside to look as good. oh wait that oil pan does even it up a bit. lol


nice job Ricardo.

Air Randy
12-17-2010, 09:51 AM
I think we should take a group poll to try one last time to convince Ricardo to change the paint scheme on this engine before he installs it.

It is currently painted silver & black which are Oakland Raiders colors (boo, hiss)

I think he should paint it blue to match the outside of his truck with orange highlights (Bronco colors). He professes to be a huge Broncos fan, well here is his chance to prove it :)

subzali
12-17-2010, 09:58 AM
I think we should take a group poll to try one last time to convince Ricardo to change the paint scheme on this engine before he installs it.

It is currently painted silver & black which are Oakland Raiders colors (boo, hiss)

I think he should paint it blue to match the outside of his truck with orange highlights (Bronco colors). He professes to be a huge Broncos fan, well here is his chance to prove it :)

x2 paint is cheap Ricardo, and blue looks good on an engine block :thumb:

Uncle Ben
12-17-2010, 10:05 AM
I think we should take a group poll to try one last time to convince Ricardo to change the paint scheme on this engine before he installs it.

It is currently painted silver & black which are Oakland Raiders colors (boo, hiss)

I think he should paint it blue to match the outside of his truck with orange highlights (Bronco colors). He professes to be a huge Broncos fan, well here is his chance to prove it :)

Blue is also a Ford engine color so thats just asking for problems!

wesintl
12-17-2010, 10:09 AM
my vote..

http://img.villagephotos.com/p/2003-11/485145/IMG_2780x.jpg

Air Randy
12-17-2010, 10:17 AM
Blue is also a Ford engine color so thats just asking for problems!

Yes but the outside of the truck is already blue so were just color coordinating.

Air Randy
12-17-2010, 10:18 AM
my vote..

http://img.villagephotos.com/p/2003-11/485145/IMG_2780x.jpg

Ah yes, the "Gay" 2F build. I'll take that as a yes vote for changing it to something more colorful.

Uncle Ben
12-17-2010, 10:29 AM
Yes but the outside of the truck is already blue so were just color coordinating.

Maybe thats where the problem originated!

RicardoJM
12-17-2010, 10:36 AM
I think we should take a group poll to try one last time to convince Ricardo to change the paint scheme on this engine before he installs it.

It is currently painted silver & black which are Oakland Raiders colors (boo, hiss)

I think he should paint it blue to match the outside of his truck with orange highlights (Bronco colors). He professes to be a huge Broncos fan, well here is his chance to prove it :)
I like the color scheme.

x2 paint is cheap Ricardo, and blue looks good on an engine block :thumb:
I like the color scheme.

my vote..

http://img.villagephotos.com/p/2003-11/485145/IMG_2780x.jpg
my vote..

http://img.villagephotos.com/p/2003-11/485145/IMG_2780x.jpg

The firewall does not let me see the image. Perhaps the BoomBoom (or another member) can move the photo to our site, then I can see. EDIT - never mind; I've seen Marshall's color scheme and that is not for me.

RicardoJM
12-17-2010, 10:39 AM
Yes but the outside of the truck is already blue so were just color coordinating.

Maybe thats where the problem originated!

The FJ40 is HutHut's daily driver and that is the color he choose. I like the way it looks, but am not certain it will remain Sail Blue forever.

RicardoJM
12-17-2010, 10:41 AM
Blue is also a Ford engine color so thats just asking for problems!

If there are any problems with this engine, the color will have nothing to do with it, rather it will likely be traced back to something I did (or didn't) do:D.

Air Randy
12-17-2010, 10:42 AM
Maybe thats where the problem originated!

Yes, but this is the special silicon micron impregnated blue paint that makes it slice through the air effortlessly, adds 5 mph to the top speed :D

Uncle Ben
12-17-2010, 10:47 AM
Yes, but this is the special silicon micron impregnated blue paint that makes it slice through the air effortlessly, adds 5 mph to the top speed :D

But its still a Ford color! The quality goes in until the color draws it out!

nuclearlemon
12-17-2010, 07:38 PM
my vote..

http://img.villagephotos.com/p/2003-11/485145/IMG_2780x.jpg

that was my vote too, but he wasnt going for it sunday

RicardoJM
12-19-2010, 09:26 PM
Ok - let's get this thread back on track. I'm not on the youtube, here is a link to a movie of the truck during the break in run.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/breakin.MOV

Edit: It is a bit choppy on my computer. Perhaps one of the members can get it to a better place/format.

RicardoJM
12-19-2010, 09:35 PM
No photos from today. Everything was installed as a single unit. Here it is getting ready to be put into the truck.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_install01.jpg

This is where it is was destined to go.

http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_install02.jpg

Here it is sitting as it was this morning when I started the process of connecting everything back together.
http://www.risingsun4x4club.org/uploads/ricardojm/enginerebuild/w_install03.jpg

RicardoJM
12-20-2010, 08:21 AM
The following is a recap of issues that were encountered during the rebuild and installation process.

Main Bearing Caps - The main bearing caps from my old block were used on the new block - big mistake. Fortunately, the main bearing caps from the new block were still in the shop. The #4 main bearing was destroyed but the crankshaft journal was in reasonable shape. To address this issue, new bearings were rolled in and the correct caps installed. Fortunately all of this was easy to do - just drop the oil pan and there is clear access to everything.

Dipstick Tube - The dipstick tube on the block was bent and damaged. Fortunately we removed the tube from my old block. It was a good call on Randy's part to grab it; it was the last thing we removed from the block before it went to the scrap yard. Getting the broken tube out was a bit of a challenge. Initially, I tried splitting it with a punch. Ultimately, we determined that a size 10 tap was the appropriate size to thread in. With some vice grips on the tap, we were able to pound it out with a brass punch and BFH.

Broken bolt - There was one broken bolt; the bolt that holds the oil pump mounting bracket snapped during install. Fortunately, we had both bolts from the other block.

Timing Cover gasket - I managed to over torque the timing cover gasket and split it. There were no spares but it was in stock so I just picked up a new one.

Oil pump - After checking the clearances of the oil pump gears, the bottom cover was installed backwards. It is very obvious when you go to install the pump in the block. This was easily corrected.

Parts bagging and labels - The engine mounts were not labled correctly. This cost Randy and I a huge amount of time (hours) on Saturday. The first mount we put in place was not the correct one and subsequently we could not get any of the other mounts to line up. Once we figured this out, the engine was in place in less than an hour.

Fluid Heat Riser - I had picked up a fluid heat riser a couple of months ago. I bolted it in place (no gasket) on the bottom of the intake manifold. During the reassembly, I removed it to put in place a gasket and some rtv. Upon reassembly one of the bolts would not tighten. The aluminum had given way, that is to say when I removed that bolt there was manifold aluminum in the bolt threads. I have another intake manifold, hopefully the bolt holes on the bottom of it are in beter shape.

Initial distributor off a gear - As Steve was starting it up for the first time, we had to advance the timing as far as the bracket (Big Cap dizzy) would go to get the timing to where it will start. It will be straight forward to re-postion the dizzy.

Starter ground strap - As I went through all my work yesterday, I realize that I did not connect the ground strap from the frame to the starter. I am pretty certain that mistake is going to cost me a starter.

Exhaust leak - Upon determining that my fluid heat riser needed some work, I opted to re-install my used remflex gasket. It was damaged during the teardown and leaks.

I still have a punch list (feels long) of wrap up activities/improvements.

Finish bib install :thumb: 12-22
Starter ground connection :thumb: 12-22
Sort out starter :thumb: 12-22
Tune timing, idle :thumb: 12-22
Install front drive shaft :thumb: 12-22
Install tranny to t-case bypass hose :thumb: 12-22
Install clutch cover :thumb: 12-22
Install skid plate :thumb: 12-22
Adjust parking brake:thumb:
Sort out fluid heat riser:thumb:
Sort out exhaust leak:thumb:
Adjust valves :thumb:
Hook install spring, clutch fork to bracket
Install heater valve - inline

subzali
12-20-2010, 09:47 AM
Wow, that's a lot of work Ricardo! I imagine you'll be glad to have this behind you! Just keep plugging away at one thing at a time and you'll get there! Sorry about all the miscellaneous issues, but this experience and your sharing of the experience will bring great value to any of the rest of us who might be interested in performing a project of this nature at some point!

On the fluid heat riser, you might look into helicoiling the intake manifold if the other one ends up not working out for you.

Jacket
12-21-2010, 08:26 AM
Looks like you've built your own birthday present. Great progress!

I'm sure you've got plenty of sources, but I've had good luck finding gear reduction starters at the salvage yards for $20-30 if you want to save some pennies. Last time I was at Blakes they had several out of FJ60's.

RicardoJM
12-23-2010, 08:10 AM
Alright, I'm declaring this project done:D.

Yesterday evening, we took installed a new Toyota re-manufactured starter and took care of most of the items on the punch list above and changed the fluids in the tranny and t-case. The FJ40 is now back at the house and arrived there under its own power. Aside from the exhaust leak (and quite likely accompanying vacuum leak) the truck runs very nice. It has the same power and smoothness that were there before getting the new block.

Randy, Sascha, Steve, Ige and Rick - thanks a bunch for all your assistance on this project. I learned quite a bit more about my truck and am looking forward to driving it for many years to come knowing the engine was built by me and my friends.
:risingsun

subzali
12-24-2010, 10:01 AM
Great job Ricardo! Glad you got through it and hopefully you won't have any problems for a long time!