Hi Richard
I'm reading this very keenly, I am also UK based. Just under two weeks ago I bought a 96 3rd gen with the 3RZ and a manual gearbox, very happy to have finally found such a rare truck, but it's not perfect.
I don't have a CEL on, but the car hesitates at around 1500 - 2000 rpm and has an unsteady idle, though above 2000 rpm it is nice and smooth, and the fuel consumption does not seem too bad. I feel like the engine has more to give however.
I'm going to do an engine rebuild on it for peace of mind, and am starting to worry about all these damn sensors that petrol engines seem to have (I'm a big diesel fan and have never touched a petrol engine before). I'll be putting in new plugs, HT leads, distributor cap and rotor, and will clean the throttle body and MAF. I'd also like to test the O2, throttle-position and knock sensors, and the engine coolant and air intake temperature sensors.
US market vehicles seem to have two O2 sensors, but the JDM has only one, in the engine bay somewhere, which is easy to swap out and relatively cheap. The one at the back of the cat is an exhaust gas temperature sensor (exclusive to JDM vehicles of the 1990s) which I cannot find for sale anywhere and has a list price of over $500, so I hope it works! It looks damn rusty down there too, and I'd be a bit scared to try to get it out. Have you touched either of these? The consunsus is that al these EGT probes do is warn you via a dashboard light that the cat is over temperature. I need new centre and rear exhausts too, which is going to cost...
The car may have an overheating problem, though the leaking radiator cap which is now replaced may have been the cause. In case the worst comes to the worst, would you be able to share where you got the cylinder head from? Was it a genuine Toyota part? I'm hoping mine will be OK with a skim and some new valves, possible guides and seats. What was the problem with yours?
Can I ask why you are taking the starter out?? With engine hot, my starter barely turns it over, whereas it cranks quite happily when cold. It might be a crappy battery, but somehow this goes against common sense, so I suspect that something else must be happening. I'll pull my starter while the engine is stripped down to replace the brushes and make sure the copper contacts on the switch are not pitted.
Another job will be to take out the LPG system that the car came with,
I just had a search for a knock-sensor and turned these up in the US:
Claims to be OEM but not sure:
*NEW* Toyota Lexus Engine Detonation Knock Sensor 89615-50010 *FREE SHIP* | eBay
Definitely OEM and a popular purchase:
OE DENSO TOYOTA LEXUS KNOCK SENSOR OE 89615-50010 A GENUINE DENSO PART | eBay
I'd be really grateful if you could share or point me in the direction of any good resources for the JDM 3RZ-FE Hilux Surf; FSM, fault codes etc etc as this is all new to me!
The ultimate aim for this truck is to build an extreme-cold weather overlander (hence not getting a diesel, I also don't like the 1KZs reputation for cracking heads and the 1KD has common rail electronic injection which is a no-go for countries with questionable fuel), so I need it to be bullet-proof reliable. I got the car very cheap so I'm happy to throw some money at it to get it really good.
Good luck fixing your Surf, you're almost there it seems!
Daniel