Gatorgrl's Grand Gen2 4Runner makeover

OK, heat shield fabrication is complete on the passanger side.



And a view from the bottom, showing how it is now shielding the lines that run right across the top of the header down tube.



So hopefully with the combination of the heat wrap and the new heat shield, we should hopefully keep those lines from roasting.

 

This is the totally wrapped exhaust on the Corvette Race car...patiently waiting for its next adventure.

 

I've heard that flange thickness was an issue on the cheaper headers but those look great. Thanks for all the pictures, it's looking great.

 

Ok, so today we focused on getting that new exhaust in place along with those custom heat shields.

This is the shield he made from an old BMW heat shield. Cut and hammered into shape.



A bit more of the BMW shield now protecting the all important brake lines.



And here is the new exhaust in place. This is not a take out of the box and install type of system. We had to cut down both primaries and intermediate pipe in order to get them to fit nice and tucked away.

It was hotter than hell today so I was rather unproductive. Did manage to go back to my favorite junk yard for 2 replacement studs that I broke yesterday and managed to leave with ZERO relays! Its a record!

 

looking awesome!!!

 

Ok, today we started assembling the top of the engine. Got the timing all set and got stalled with the new headers and fabricating a new tube for the ERG cause the new headers have a different attachment than the original lines. I did what I could and put some of my left over heat shield on the underside of the hood...just because.




He had to come home to get his pipe flaring tool and dropped me off since I have to return to my J.O.B. tomorrow. These headers are great but not for the faint of heart or shy of skills. The tubes had to be cut down and modified, the O2 sensor had to be moved and the ERG tube had to be fabricated since the tubes it came with are not long enough, nor will they bend into position. I had to go get 10' of flexible copper tubing so he could create a new ERG tube.

 

I'm ok with all that, I did the egr delete and I'm a fabricator.

 

Very cool

 

Ok, here's the progress so far:

The fabricated ERG tube in place.


And the rerouted O2 sensor.



He welded and clamped the exhaust in place late last night and will finish up the throttle body today!

 

Well he fired her up yesterday while I was at work and said she is still stuttering when idling. Time to investigate. Wonder if the distributor is wonky?

 

We didn't change the distributor, the alternator or fuel pump. On the plus side...we have A/C now!

 

So here is the finished product. Still fine tuning things, but she is much better than before.

 

Very nice work. Hopefully the fine tuning goes well.

 

Well she was stalling and stumbling on the check out ride, especially with the a/c on. Biggest issue was she wouldn't do it consistently. We changed the fuel filter with a Toyota filter, and she ran good the whole way back home. Will be doing the cap and rotors too. Whoever monkeyed with the fuel filter last, really butchered the fuel lines. Just take the crossmember down damnit!

 

OK, we tested out the mighty Blue Ox on the Runner today, to check for towing fit. It's gonna work!



And here's a look at the connection. We just added a second tow loop to the other side.



And this is where it will sit when it's looked to the bus at the bus's ride height.



No base plate needed when you have a strong chassis to hook to. Gotta love Toyota!

 

And she has an intermitting fuel issue. We drove her to dinner and she was doing great, then something clicked and she started to drag, even with the pedal to the floor and then stalled. I am thinking fuel pump or mungus in the fuel tank along with needing a new cap and rotor on the distributor (will be here tuesday). She is getting fuel starved with no rhyme or reason to it and other times is running fantastic....for a 3.slow.

 

Ok, developing a real love/hate relationship with my 4Runner. On top of her still jumping into limp mode, took her tires to get properly balanced only to find out one of the is broken on the inside and they no longer make those tires. BF Goodrich All Terrain KO's. Then is add insult to injury, we attempt to put the rear wiper back on and now we can't open the rear hatch, can't even unlock it! On and it rained last night and it appears she has a leaking sunroof, that also doesn't function.

What's next?

 

if it was easy, everyone would do it! Hope it works out.

 

At this point, just get a new tank with all new pump and while at it replace the lines. Order a new cab through Toyota, they can get that old plant fired up and running again. As for the wiper issue- take it to the dealer

 

After a bit of research, we will now be looking at the ERG and TPS systems as well as looking for a short somewhere.

 

Fascinating thread OP. This is what passion looks like. Kudos to you guys for taking the time to work through it, frustrating at times, and joyous at times.

 

Thanks! I do love working on my rides. This is my 5th ride project build. 1994 Harley Sportster, 1980 Camaro RS, 1983 Bluebird Wanderlodge, and 1982 Bluebird Wanderlodge as well as a host of other interesting machinery rehabs and project builds. What can i say? I'm a tinkerer.

 

And the mystery continues! Replaced the cap and rotor with a Toyota cap and rotor and now the damned thing doesn't start! WTF?
He has checked all the vacuum lines and all are good, we have good fuel pressure. We drove it into the shop and now it is dead in the water. It turns over but won't crank.
He called the dealership and chewed them a new one. This is mystifying bullshit!

 

Ugh...found out one of the issues.....a broken new spark plug wire at the cap. Replaced it and he said it runs 50% better, but still not perfect. Said he needs to take the TPS out and go over it on the bench.

 

In the end you will know so much about this 4runner and it's issues that you will be a lot of help for future owners!!!

 

No doubt. Today I am flying solo and working on removing the headliner to investigate the leaking sunroof. Stuck so far on how to remove the front light assembly where the rear view mirror is attached. got all the other crap removed already. Also ordered vol. 2 of the factory Toyota book for the 1991 4Runner, that covers the body, chassis etc. Already have all the other books. My runner will have it's own library.

On the tire story. Found a place in Wi that still has a NOS BFG KO in 31x10.5 15R that they sold me, but they called today and said it would cost them $200 to ship it to me in SWFL and they wouldn't do that. They already charged me $285 for the one tire and now can't ship it. WTF? So my only other option now is to buy 4 new goddamned tires!
I refuse to ride around on mismatched tires. Really didn't want to continue hemorrhaging $$ into this build, especially for something we weren't planning on replacing because they still appear to be new. Also need to put a radio in it. The only advantage to buying 4 new tires, would be if we lost one on the road, hopefully replacing it would be possible because it is still a relevant tire that's still being produced, unlike our current KO's. The struggle is real.

 

Always check Craigslist or Offer Up for tires, I found a near mint set that a guy just put on his truck before the motor blew and I was able to get all four tires with rims for $250. I used the tires and sold the rims for $50.

 

Check discount tire direct as well. They’ve been great to deal with in my past dealings

 

Well at least I was successful in removing that pesky headliner all by my lonesome...without those handy plastic trim removal tools, which I left at home.



Would appear we have had a leak on the passenger side for some time. Just great. Will drop the sunroof tomorrow when I have my helper, due to it's size and it being glass and all. Time to hit the homestead and shop for friggin tires!

 

Well we got the sunroof out today and made the decision to turn it into a non-functioning moon roof. One of the moving mechanisms was broken and Toyota wanted $200 to replace the one little piece. Honestly I have a sunroof in my Rav and I rarely, if ever, open it so it's not a deal breaker for me. We had to Jerry rig it into proper position so now it sits right in the roof and doesn't leak. Also had to blow out all the drain lines. 2 were plugged pretty badly. She is coming along...slowly.

Just need to figure out how to get the ECM to think the ERG is functioning, which it is not.