Project daily driver 1991 4Runner
 

This weekend the wife and i went and picked up this 91 4Runner. Currently I drive a 06 Jetta TDI but it has had electrical issues and cost us way to much in repairs, I wanted to get something I could work on myself and was 4wd. We had a 93 XJ and while I could work on it, it needed a lot and just didn't feel right, so i sold it and promptly bought this 4Runner.

specs:
1991 4Runner
22RE
5-speed
3" (or 4) lift
33" tires
4.88 gears
ARB locker in rear but needs a compressor (have not verified locker yet)
sun roof

I had planned on putting a header in it and a new radiator but it already has a Doug Thorley header and a new radiator in it. So i will catch it up on maintenance with a full tune up, replace all the hoses, change all fluids, verify the locker and if so add a compressor, add dual batteries (more than likely in a custom box where the spare is currently located), tire carrier rear bumper, winch/bumper front, big 3 upgrade, higher output alternator.

https://i.imgur.com/wu1OzKy.jpg

https://i.imgur.com/jDfJgLe.jpg

planning on repairing this and getting some seat covers
https://i.imgur.com/I6q2JPB.jpg

back seats in good shape
https://i.imgur.com/puqumFW.jpg

onto the rust spots, while its not horrible, they do need addressed
https://i.imgur.com/g9WhmX3.jpg

https://i.imgur.com/htRdWxt.jpg

https://i.imgur.com/PVVbWOa.jpg

https://i.imgur.com/xowkzuD.jpg

https://i.imgur.com/EZDtznW.jpg

https://i.imgur.com/Zs7zChi.jpg

https://i.imgur.com/NnMaOlY.jpg

somebody has already been into the AFM, and there are 3 different types of fasteners loosely holding it together and the piping is cobbled together, i am going to get a cold air intake and build a heat shield for it.
https://i.imgur.com/1dm3xbH.jpg

https://i.imgur.com/1dm3xbH.jpg

new radiator
https://i.imgur.com/rHoqsT9.jpg

i am not surprised it has a power steering leak, even though it is not directly coming from right here
https://i.imgur.com/rRfFjlK.jpg

and i thought this was mud caked on until i took my knife to it and yup, more rust. so far it looks like the frame rust is isolated to the front, i need to look at the frame again but the rest looked ok. so i am going to hit it with a wire wheel, cut as needed and weld in some new steel.
https://i.imgur.com/4AwcrxW.jpg

Awesome looking project; looking forward to following the progress...

I'm in 'paralysis by analysis' on my '94. Can't decide whether to pull the engine and do a full rebuild or just patch things up to get it going... so I've just been driving it as-is for now.

I like the brown interiour :)

Looking forward to your tire carrier bumper mount. I want to do the same :)

my UPS and Fedex drivers are not going to like me next week, they will be at my house every day according to tracking numbers.

tune up stuff
140 amp alternator
cold air intake
winch
new dipstick from LCE
wiring harness for the alternator
latch from McMaster-Carr for the swing out

still need to order a power steering cooler but i need to look at available space with the auxiliary fan in front of the A/C condenser first

thats kind of how the Xj was, not enough to fix it how i wanted it so i just kept driving it.

thanks,

if it wasn't for the tear in the driver side it would be in really good shape, i have been looking for seat covers but they're either generic ones that dont fit well, or $200 a seat.

took it in today to get the one busted wheel stud replaced and a front end alignment (pulled hard to the left), they said they helped the alignment but he couldnt complete it due to the idler needing replaced. so i brought it home (now it veers to the right pretty good) and ordered more parts for it today, idler, pitman, tie rods, and found my steering leak, its the box itself so i ordered a reman box for it.

verified it does have an ARB in it, the bulk head is still in the housing but someone must have cut the hose when they pulled the compressor, now i need to look into how to clean the locker or what needs done since who knows if there is mud or dirt in there. i ordered a Viair compressor and an air tank for it, along with some other little things like USB ports and flush mount LED's for the rear bumper.

digging around in the cubby's in the back i found this
https://i.imgur.com/gnbURvy.jpg

https://i.imgur.com/bHxK27c.jpg

parts are starting to roll in, not really much of an update but the old dipstick wasn't sealing and was just flopping around, while it may have been fine it was only about $20 for a new Toyota OEM dipstick from LCE.

https://i.imgur.com/2pOJVJN.jpg

my cold air intake also showed up and i got it mocked up but the elbow coming off the intake is not long enough so the cross pipe hits the sling hook. i am either going to look for a longer elbow or just get a piece of pipe to extend it out towards the core support. by the time i got that far into it, it was dark.

im currently on the same journey, trying to get my 84 road worthy. good luck to you!

by tomorrow all the big items should be here (the 4runner is full of boxes), i will still need to get the small stuff (belts, wire, fluids). As luck would have it though i fly out sunday for a week in Dallas for work, i wonder if my parts will be thinking of me while im thinking of them lol.

I am back from Dallas and got a total of about 10 minutes to work on the 4runner this weekend.

here is the routing of the CAI hitting the engine hook
https://i.imgur.com/Jc799ZU.jpg

https://i.imgur.com/jd2qntX.jpg

putting it in a bind against the overflow tank
https://i.imgur.com/h0WKXO3.jpg

i ordered up an extension and a new elbow and adapter
https://i.imgur.com/C0iSPFv.jpg

but i think it may be a little too long, i may need to shorten it up a little to align things better
https://i.imgur.com/uAmNhxA.jpg

and i still need to build a heat shield.

last weekend i got the fan, alt, water pump, and associated bracketry removed, tried to test fit the new CS144 alternator but it doesn't look like it will work (without more mods than i want to do right now) so i found a stock size 130 amp unit to put back in that is supposed to be here Monday. I will put the CS144 in my 72 K5 next spring when i revamp the electrical system in it. I have yet to put anything back together between the cold weather and the cold my son gave me i have not done much of anything.

Try a Harbor Freight Needle Scaler on that rusty frame stuff. I was amazed at how much work it did before hitting it with a wire brush or sandblaster.
My son and daughter-in-law are in Moses Lake and have a TDI as well.

any excuse for more tools right? i will have to pick one up and try it.

Finally got some time to work on the 4Runner yesterday with our weird weather were having.

i was wrong when saying the power steering cooler needed replaced, it was the A/C condenser, and since the A/C doesn't work i don't see the point in keeping extra parts on the rig.
https://i.imgur.com/ONjulai.jpg

much more space now
https://i.imgur.com/NjxtF8D.jpg

and without the condenser and everything else in the way, the radiator will get more air flow
https://i.imgur.com/UWhQBC7.jpg

i had planned on keeping the A/C fan but its a little rusty
https://i.imgur.com/0y1aTly.jpg

this is what its suppose to look like
https://i.imgur.com/lGzKYJ0.jpg

with the rust in the front of the frame i was fearing what i was going to find when i pulled their little skid off that was bolted under the radiator... but i was pleasantly surprised.
https://i.imgur.com/bTWRuUF.jpg