Joelzy's 96 5SPD(daily) & 5VZ block-up rebuild

[Joelzy]

Exact same thing happened to me too. WTF. My nut still rattles around in there.

now that would drive me crazy, maybe that's why he did this

Update: Got the upper balljoints and new AC compressor, dryer, and condenser. Going to swap in the Comp then get the radiator in and button everything up to run.

 

[96RedRunner]

new AC compressor, dryer, and condenser..

Rollin right along Joelzy!
Don't know your experience with A/C systems, Got PAG oil?

 

[Joelzy]

Rollin right along Joelzy!
Don't know your experience with A/C systems, Got PAG oil?

My experience is zero haha, luckily the friend & tech who let me use shop space to rebuild the motor is going to charge it up for me as i have never messed with it. He is also the one who made me buy all new components for it.

 

[Joelzy]

Got the new slave cylinder in and clutch re-bled

New reverse switch

AC compressor

And finally radiator

Planning on running it more tomorrow and burping the coolant system and potentially getting rid if at least one exhaust leak before the gibson catback comes in.



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[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Update: burped, topped off the PS res and took her out for the first tank of gas.

Had a couple times that it tried to die and then after running and driving for a good 30-45 minutes i couldnt get a crank. Thought it was weird until i charged the battery a bit, started it and tested the voltage at the battery while running.

Womp womp, luckily i have the alternator from the other motor so hopefully it’ll still work


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[Joelzy]

Well i’ve been driving the 4R as much as i can to work out the kinks.
Seems pretty good and im only getting one code for lean bank 1.
Figuring its a vacuum leak and getting the fuel trims confirms it as far as i can tell.

ST looks good but LT is still way off and im struggling to find the leak. Going to try smoking it if nothing else.


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[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Triple check your important bolts people, srsly

Had a minor heart attack when the motor started making this noise yesterday out of the blue

https://youtu.be/h60OX3wjHtA

As you can see in the video, i had already ruled out all accessories so at that point i was borderline losing it thinking it was something in the bottom-end.

Bought a stethoscope at harbor freight for 4 bucks and narrowed it down to the driverside head.
Then, in hopes of an easy fix i pulled off the timing cover and voila! The cam gear wasn’t completely torqued from when i had to go back and loosen it to reroute the knock sensor harness.

Now i have been as careful as possible to make sure stuff like this doesnt happen by triple checking everything but alas, it happened and i got lucky it was the cam gear.

Whew

Also realized my front CV boots shat themselves pretty good, womp

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[phattyduck]

Now i have been as careful as possible to make sure stuff like this doesnt happen by triple checking everything but alas, it happened and i got lucky it was the cam gear.

Whew

Had a similar thing happen with a crank pulley bolt on another vehicle. Thought I had a bottom-end bearing issue! Good job tracking it down.

-Charlie

 

[128keaton]

Had a similar thing happen with a crank pulley bolt on another vehicle. Thought I had a bottom-end bearing issue! Good job tracking it down.

-Charlie

I can semi-one up you. My friend did his timing belt and _forgot_ the crank bolt.

:dance:

 

[Joelzy]

Ouch! Just glad its resolved. We’re moving a couple states away and i have no time for another rebuild


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[JJ300K]

Great Job

Wow. Outstanding job. Another great thread on a forum with many great threads. Was on the fence on whether to buy a reman long block at https://spprecision.com but your work inspired me to follow suit and completely rebuild. Appreciate all the pictures and lessons learned!

 

[Joelzy]

Wow. Outstanding job. Another great thread on a forum with many great threads. Was on the fence on whether to buy a reman long block at https://spprecision.com but your work inspired me to follow suit and completely rebuild. Appreciate all the pictures and lessons learned!

Well thank ya and Happy to help! Figured people seeing me fumble through the process might help them to avoid some of my mistakes


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[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Wooommmppp

Did a couple smoke tests knowing i have a vacuum leak of some sort.
Hard to see but i got my phone in enough to be able to tell on video that the smoke was coming from under the intake either between the plenum and manifold or from an injector.

I dont notice any issues while driving(aside from the lean bank 1 code) but it seems that if it wasnt running lean it would definitely run even better and it’ll also pass inspection.
Soooooo i took it back apart to the manifold.

The smoke test my friend used is supposed to leave a UV trace you can see but i cant really see any specific spots that leaked with it.

Going to replace the injector seals and redo the manifold gasket in hopes of sealing this mother up.


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[r_wett]

fantastic rebuild thread!

If im not mistaken, you owned a beautiful grey mk4 vw at one point. I think i remember you from the old vwvortex days.

 

[Joelzy]

fantastic rebuild thread!

If im not mistaken, you owned a beautiful grey mk4 vw at one point. I think i remember you from the old vwvortex days.

haha yup! that was me alright. :rapture:
Been a while but nice to see Im not the only one who made it over to this side. My daily is an e39 but couldn't get into the bimmer culture so this is my new outlet.

 

[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Welp, i dug back in and got it torn down but not put back together just yet.
Cant tell for sure but im thinking its an injector as the rest seemed pretty solid.

Another 100 bucks in seals

Fuel rail out and ready for new seals

Got called away this afternoon but hoping to reassemble tomorrow and see what happens

Update: got it back together. Havent had a chance to get it out of closed loop to see if i fixed my issue but im hopeful.
Alt pulley is squealing and i think my fan bracket is squeaking as well. Oy will this thing ever be quiet?

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[Joelzy]

Success!
Trim numbers are looking good after the new intake gaskets and injector seals!

Also figured out that the old fan bracket was squeaking and the alternator was squealing so though i didnt want to, i replaced both with OEs from IMC.

Also figured out that my fan bracket was from the JDM sludge motor that mustve come from another vehicle as it is offset a little further out for a 6PK alternator pulley. That was a whole other thread but i got it all sorted now.

So now everything lines up perfectly and no more squeals or vac leaks! Woohoo
Decided to drive it to Thanksgiving at the in-laws house about an hour away where my brother-in-law brought this bad boy.

Hard to compete with that minus the graphics


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[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Well, getting close but she’s still nickel and diming me.
On the way to get it inspected, after over 100 miles, O2 sensor code popped [emoji849]

Got a new sensor, swapped it on and back to cycling for readiness. Last night we had someone coming to see our house so i loaded the dogs in the 4R and left for a bit. Soon after i realized something in the clutch hydraulic system let go because it was not holding clutch pressure. Tested a little later and tried a couple of methods of bleeding but no luck. Slave is brand new and i see no active leaks so Master it is!

If you push the clutch in and hold it, you can watch the new slave cylinder release slowly. So hoping to get an OE master cyl today and replace that. Then maybe we can inspect tomorrow. Oy


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[weekendclimber]

Chasing these little gremlins has got to be frustrating. I've been watching this thread from the start and I would have thrown so many tools at this point. Kudo's to you for sticking to it!

 

[Joelzy]

Joelzy's 3rd gen & 5VZ block-up rebuild

Chasing these little gremlins has got to be frustrating. I've been watching this thread from the start and I would have thrown so many tools at this point. Kudo's to you for sticking to it!

hahahahaha tools have been thrown, i've cussed more than usual and my wife is questioning the 4runner all together but I'm so close to everything being new now that i might as well keep going. Whats another 60 bucks on a blown budget right? :dizzy:



Once we move and i don't have my OE part connection it will be much more pricey so its good to get it out of the way now i guess.

Update: FIXED! Fingers crossed that readiness will be set tomorrow on my way to work and i’ll drop it off for inspection