www.supracharged.com

Posted: Mon Jun 13, 2005 11:41 pm Post subject:

Well I talked to the wrecking yard today about the #6 cylinder. They basically said that I voided the warranty when I starting tearing things apart.... but after they reviewed a few pictures I sent them of the head gasket, they agreed to pay for a new gasket. The where shocked to see the pictures becasue the engine registered 190-200 psi on the compression test. But I had already purchased a new gasket when I bought my other gaskets for the reseal. So either they buy new a gasket (forcing me to return the one I special ordered) or I get store credit for the value of a head gasket based on there return policy... So since I wanted a 3-core, 2" thick V6 radiator for this swap I got one from them and they just called it even. (o I got a $115 credit) So basically I got a free new radiator from discovering the bad head gasket. The new radiator should be in on Wednesday.

I also took the flywheel and exhaust manifold down to the machine shop to be resurfaced. I should get that back tomorrow since they forgot about it today.....Maybe I can get them to drop the price since they forgot about it. (Can't hurt to ask)

I also dug out my 210 York that I removed from the 2wd project. But unfortionately it has a V-belt pulley. I just bought one from my local wrecking yard for $35 for a Buddy so I added that to the list as a cost even though I already had it since its still worth that. But the 7M's need a serpentine belt... So I'm also getting a 6 groove serpentine belt pulley for the York.

YORK/TECUMSEH 6 GR. 5-7/8 " DIA. PULLEY
Part Number: 1687780C92 KA1480 for $83 + $10 core
From the local Kenworth dealer....

The rest of the stuff I ordered from knechts (tune up and gaskets) is now in, so I have to pick that stuff up tomorrow also.
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Mon Jun 13, 2005 11:48 pm Post subject:

I also forgot to mention that the wrecking yard is still working on getting me a 7M Supra Oil Pan, Pickup Tube, Dip Stick, Dipstick Tube since that is a center sump oil pan and the 7M Cressida one I have now is a front sump.... Toyota never made a rear sump! And since my 4runner has very little lift and crossover, I know I will have problems with a front sump.
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Tue Jun 14, 2005 7:47 am Post subject:

Well I decided to work on it some this morning before I go to work so I started cleaning the top of the block and the carbon off the pistons. Ignore the oil in the cylinders, that was another oops on my part....... Wasn't too bad but it takes a long time to try to keep the crap out of the rings. I was using a razor blade and a vaccuum. I would srtap a little, then I would vacuum, scrap, vacuum, etc.....

I got half of it done!

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Wed Jun 15, 2005 12:59 am Post subject:

Well I got a little done tonight, I got the rest of the top of the block cleaned and the carbon knocked off the pistons. The top of the block is also flat. I also quickly checked the head and that too looks within spec. But I will know more when I get it cleaned.

I also got the flywheel and exhaust back from the machine shop today and up a bunch of Fel-Pro gaskets that I ordered through Knecht's.

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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Wed Jun 15, 2005 4:28 pm Post subject:

Found some good info here that I needed for re-assembly the 7MGE / 7M-GE, so I thought I you post some of the info from that site here.

Some cylinder head tech:

Some cylinder/engine block tech:

Some timing belt tech:

Some timing cover tech:

Some oil pump and pan tech:

Some flatness deck tech:

Some flywheel tech:

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Thu Jun 16, 2005 12:53 am Post subject:

Heres the link for the online FSM that I got those pages from since I forgot to add it above:
http://www.cygnusx1.net/supra/library/TSRM/index.html

I got the deck surface of the head cleaned and check it for flatness. Worst spot was at .003" and the toyota max is .004". Also the Block was .002" and the max spec is .002". And both of those spots were not where the oringal head gasket was damaged on #6. So it will be just fine especially since I'm torquing everything to 72 ft-lbs. (Which is 20% more than Toyota recommends because 58 ft-lbs just isn't enough for these engines.) Remember guys that this is just suppose to be a reseal and gasket - NOT a full blown rebuild. And since everything is within spec there is no reason for me to go any further into it. Plus I don't have the cash to do that.

I also got the valleys between the valve covers thouroughly cleaned. On this engine thats where the spark plugs go. When I got the motor it had a good inch thick of "chocolate pudding" crap in each valley from where they pressure washed the engine and thats where all the water and oil crap ended up. What a mess that was..... I don't have a before picture - sorry.

Then I got the rest of the block cleaned up and painted. I just used some semi gloss black engine paint to make it all one color and with it being black I didn't have to get every nook and cranny perfectly clean. Turned out pretty good.

Then I installed the timing belt case, the water pump, crank timing sprocket and oil pump sprocket.

Here is a close up picture of the Fel-Pro gasket that I installed.

And this is what it looks like now. I was real careful on getting the head on there right. I cleaned and lubed all the head bolts and washers with a light coat of engine oil as per my service manual recommened. Then I really took my time on the torqueing process. First I ran them all down hand tight, then hand tight with a small rachet, Then 30 ft lbs on the torque wrench, Then 40, 50, 60, & finally 72 ft-lbs. Then I ran around them all one more time at 72 to make sure none of them would move.

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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Fri Jun 17, 2005 12:21 am Post subject:

Got a present from MarlinCrawler today..... Its a 1200 lb pressure plate, ceramic clutch, throwout bearing and pilot bearing. Thanks guys...... I'm not sure if the ceramic clutch is the right application for my driving style but we will see. Hopefully its just sticky enough to hook up and yet with the 1200 lb pressure plate weak enough to let me slip it when I need to.

I didn't get much done tonight since life got in the way.... (Selling the 2wd first gen xtra cab, balancing the check book, moving money around in the banks, doing the bills, going shopping, etc...) but what I did work on was getting the intake side of the head thoroughly cleaned.... Check out the top surface of the intake ports.

Now the bottom surface of the intake ports. that crap was hard to get off. but I did it.

And now the intake side is nice and pretty...incuding around the injectors!

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Sat Jun 18, 2005 12:59 am Post subject:

Well I took today off from work to work on the motor and to do parts runs.... Well it didn't quite work out as planned since I spent 4 hours running around!!!!

But I did get the front of the engine cleaned up.

Installed the timing belt.

Picked up my new 1988 V6 radiator which is 3 core and 2" thick.

And returned the motor mounts that the wrecking yard gave me for some 'REAL' 5M-GE mounts. I (and they) had no idea what they gave me before but they where wrong for this conversion. I still find it odd that they bolted up to the block. Anyways this is what the 5M-GE mounts are suppose to look like to make it possible to bolt this motor directly into the truck/4runner 4 cylinder frames.

Then I basically finished assembling the rest of it. The only main parts that are missing is the plenum, throttle body and the exhaust. I'm getting closer to the point where I will actually start working on the 4runner!

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Sun Jun 19, 2005 12:29 am Post subject:

I got the exhaust side of the head all cleaned and ready for the manifold. But I can't put the exhuast on until I get the Supra oil pan, pickup tube, dip stick tube and dip stick installed which the wrecking yard is still having a hard time getting a hold of.

I also got the intake plenum installed.

I also got all the rest of the other little stuff taken care of so now its time to start on the runner.

But before I started tearinginto the 4runner I decided to get some base line test for its performance.

Test #1
0-40 MPH on flat ground
10.5 second average (2 runs)

Test #2
0-60 MPH on flat ground
23 second average (3 runs)

Test #3
Hillside Drive - mild hill close to the house
Top speed at crest was 48 MPH in 3rd gear

Test #4
Sunset Drive - really steep hill close to the house
Top speed at crest was 31 MPH in 2nd gear

So those should give me some good performance numbers to compare to after I get the new motor installed. I also weighed it at the truck stop and with me in the 4runner it weighed 4500 lbs +/- 10 lbs with an empty gas tank. and just for reference thats with my built 22RE, W56, Dual cases, 1/4" thick drivelines, 5.29 gears, 36" Bias ply IROKS at 15 psi.

I also then did a very thorough compresion test since this motor is up for sale!

#1 Cylinder, 122 PSI dry, 148 PSI wet (26 psi increase)
#2 Cylinder, 133 PSI dry, 174 PSI wet (41 psi increase)
#3 Cylinder, 158 PSI dry, 184 PSI wet (26 psi increase)
#4 Cylinder, 156 PSI dry, 175 PSI wet (19 psi increase)
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Sun Jun 19, 2005 12:29 am Post subject:

Then Chris and Pete came over to help me pull the motor out of the 4runner. (They just got done pulling Chris' motor at Petes house since he spun 2 rod bearings and was now looking for a good long block.) Thanks Guys for all the help!

Just a silly comparision shot ...

We stripped it down to the block and Chris decided he wanted the block so we stuck it in a rubber maid container.

So we could put it in the back seat of my car to get it over to Petes house. Looks like the car is a little pisse off with it in the back seat....... Pete also had his eyes on my thorley head, so he bought that from me.

And now this is what the 4runner looks like!

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Mon Jun 20, 2005 3:43 pm Post subject:

Well I took Fathers Day off from the project to go compete at a RC Rock Crawling Comp..... I had a great time plus I got 1st place in the Unlimited Class with my Clod and 2nd place in the 2.2 Class with "The Wife's" RC which really locks in my position for 1st place in the big truck for the championship points....

Heres some pictures (so far) and info about the event if you guys are interested. http://www.rccrawler.com/forum/showthread.php?t=9725
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Mon Jun 20, 2005 5:13 pm Post subject:

Looks really good, can't wait for more updates/pics!

-I

Posted: Tue Jun 21, 2005 12:23 am Post subject:

Heres some pictures of the two bell housings side by side. This W58 bell housing is from a 87 Supra non turbo 5 speed. The W56 is from my 85 22RE 5 speed 4Runner.

For the clutch line I just cut the line and re-double flared it.

Then I re-used the factory steel and rubber line combo that the W56 used. The feet on the clutch slaves are different so you need to make sure you get the one for your new bell housing.

For the throttle cable I removed the one for the 22RE since its like 2 feet too long and installed the one from the donor cressida. This is basically a bolt -in part..... just need to find some longer bolts and some large washers. The only kicker here is that I heard you need to install it from the inside of the cab to make it work. So thats what I did.

I also cleaned up the engine bay a bit. Just a quick wipe down is fine for me......

_________________
Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Tue Jun 21, 2005 11:12 am Post subject:

Okay just talked to the Salesman on the wrecking yard about the 7M Supra oil pan, pickup, dip stick and dip stick tube that they still owe me......

I guess they got the oil pan in that I need but it doesn't have anything else with it. So they shipped it back and ordered another one from another wrecking yard. Well that wrecking yard finally shipped it and the same thing happened AGAIN!!! He thinks they are just pulling the pan off the shelf and shipping it and not reading the rest of the PO.....

So he has now found one off a motor out of Washington and its getting
overnighted to him with everything included. So hopefully I will have that tomorrow. I can't go any farther in my swap until I get the correct oil pan, so I can drop the motor into the 4runner and start working on fitment issues. If I don't get the oil pan soon, there is no way I can make my dealine for making to the 'Con over 4th of July weekend. Heck tonight I think I'm going to have to work on the wiring without the motor even being in the rig!
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)

Posted: Wed Jun 22, 2005 8:53 am Post subject:

Well I didn't get much done last night....

The easy thing I did was I got the fuel line extended using some fuel line hose and hose clamps. I know its not pretty but it should work. Hopefully later on I will be able to find a company that can make me a nice line for it.

Then I started trying to tackle the wiring!! What a nightmare. I'm no wiz when it comes to wiring but I do feel comfortable doing it. The main problems I'm having is that all the info I've found on the web doing this swap refers to a donor Supra vehicle where I'm using a Cressida as the donor. So with the great knowledge of toyota, ALL the main connectors that everyone refers to are totally different!!! Different color, Different shape, different number of conductors, etc.... Plus my donor vehicle is a 1989 and the FSM's I'm borrwing is for a 1991 cressida and the CD I got off ebay is for a 1989 Supra. And the chiltons I have just SUCKS!!! I think, I've figured out the main differences but I still feel LOST!!!!!

So basically all I did was just start tracing and labeling all the plugs on the harness to figure out what goes where. Plus that will also hopefully help me out on figureing out what I can cut out of the harness. Then I found what I believe are the main plugs to splice everything into my 4runner harness and now I'm trying to identify what each wire does.....

Hopefully my oil pan comes in today so when I go to pick that up and can stop off at Sky's shop to see exactly what they did on their project 4Runner.
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Project Quasimodo
'85 Xtra Cab (2wd, 22RTE, Auto => 4wd, 3RZ, w56, 2.28x4.70)