Project daily driver 1991 4Runner

We have been busy with junior rodeo season so its been a couple weeks since I have even touched the 4Runner. went out last night mounted my circuit breaker for the new alternator and tried my hand at building battery cables out of welding ground cable. I got both my positive cables made, from the alt to the breaker and breaker to battery. By the time I was done with those it was dark and bed time, hopefully tonight I can get out there and make a couple ground cables and get the alternator put in.
 
Went out last night and routed my positive cables, mounted the alternator and the power steering pump, went to put the power steering belt tensioner on and the bearing is seized. Pulley would move but not free spin, tear it apart and the bearing was spinning on the bolt spacer. pressed the bearing out and am picking a new one up in town today. Looking online the tensioners are about $200, I can get the bearing in town for $15 or order it online for $6
 
Still chipping away at it, went home last night and pushed the new bearing into the pulley, easy as butter and got it mounted, got the water pump pulley bolted on and the belts put on but not tightened yet. Then the family went to dinner down town.
 
new V6 aluminum 3 core radiator with shroud and electric fan showed up the other day, should be able to get it mounted up tonight since i am waiting on parts for the jeep.
 
test fitted the new radiator, had to drill new mounting holes but fitment looks good

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not too keen on how the upper hose fitting points to the passenger side though but I was still able to get the hose on it.

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my de-vacuumed engine

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I was originally going to run the air cleaner in the stock location but after dealing with fitment issues of the intake pipe and now the location of the upper radiator hose I am just going to swap the battery and air filter sides, this should give me plenty of air flow to the filter

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and no I am not going to leave it like that.
 
Saturday while waiting for the wife i was able to go out and look at the AFM harness. I didn't have to cut and extend the wiring like i first thought to move the AFM to the passenger side, I was able to separate the harness from the loom and reroute it. picked up some 3/8" split loom and spiral taped the wires up, came out pretty good and there is definitely enough harness to reroute.

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just a simple elbow and a cone filter with an adapter is needed

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I need to build a battery tray but test fitting the battery in the driver side

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ya I know my distributor is hangin out lol

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Friday took the family to the fair so we could check on my sons photo exhibits, he got 3 1st place ribbons and 1 2nd place.

Saturday was the last rodeo of the season

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Sunday we had to go back to fair to pickup his photos exhibits. Then it was getting the door latch replaced on the TJ, changing the oil in the TJ and the oil and fuel filter in the Cummins. Then i was finally able to get some work done on the 4Runner.

finished building the battery cables, mounted the circuit breaker, mounted a power junction on the passenger side. It is tempting to yank the engine just to be able to clean the engine bay lol.

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Yesterday I got the coolant hoses put on, filled it with antifreeze and the thermostat housing started leaking. I knew it was a possibility with how my broken bolt repair went. I am going to try a quick fix for now but a friend of mine has a spare manifold for me once I can pick it up from him. Set the engine to TDC and installed the distributor, wired in the fan controller for the electric fan, put the battery in, tried to fire it up but no luck. the starter seems to be sluggish and almost hanging up. I need to follow RAD4Runners starter relay fix and see if it fixes it, I also need to check my fuses and fuel delivery because there was not even a spit or sputter but it was late and getting dark so I just closed up last night.



Today was honey-do lists and homework, tomorrow morning is our local States day parade and festivities so maybe in the afternoon I can put a little time in the 4Runner again.
 
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Took a vacation day yesterday, worked around the house and put some time into the 4Runner. Got it running for the first time in a year, had to set and reset the timing but finally got it to fire up. I still need to actually set the timing but my thermostat housing fix didnt work and i had a geyser of antifreeze shooting out, I ordered a lower intake manifold off Ebay for it, still need to finish my electric fan install and replace steering components and it should be drive-able once again.

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Figured since I will be in there I may as well add some Bosch 4-hole injectors, found a refurbished set on Ebay with good reviews for $40. all the parts should be here by the 11th, were going camping that weekend so it will be after that before i can get it put back together and timed.
 
My new(ish) lower intake will be here this week so Saturday I went out and started tearing that side apart, when I was removing the injectors I made sure to twist them so they were free moving and there was no resistance in them. I pulled the rail and they all came out of the intake easily, but number 2 came out like this. surprisingly it wasn't leaking.

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My new 4 hole injectors showed up yesterday, glad I had already planned on replacing them. My pink injectors lol

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One issue i have ran into is the wiring harness runs right through the middle of the lower intake, how did they expect it to be removed?

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I would like to kick a Toyota engineer in the nuts that thought this up. lets run a 13 wire harness through the middle of the intake manifold so it cant be removed with stripping 8 feet of harness out. well i am gonna cut the manifold between these 2 bolt holes.

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The "easy" way to change the fuel filter, I am moving it to the wheel well like i did in the Frankenstein 1st gen

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I figured since i had the intake off it was a good time to install a block heater and change and move the fuel filter to the inner fender. Its almost all back together, just need to put a couple hoses on and fill it with coolant and it will be running again. I removed the front bumper so i can install the winch mount.



first time in a year the grill has been back on

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ITS ALIVE!!!!!!!!!



Yesterday I was able to get the new-new injectors put it, the pink ones I ordered would not fit even though the ad said they would. So I ordered a different set, 4 hole, and these ones went right in. got the rest of the intake put back together, block heater installed, filled with coolant, pitman arm installed, oil changed. It fires right up, drove it around the driveway, BUT the idle is drastically jumping from 1500-2000 RPM, while sitting I give it throttle and it just bogs down and will not build rpm's, unplug the TPS and the rpm's shoot up to redline. the other week when I had it running (and leaking coolant) the rpm's were fine and had throttle response but I realized I had not hooked the coolant lines up to the IACV, I am going to bypass the IAC again and see if it fixes the problem.



but it runs and fires right up each time I start it.
 
Bypassed the IAC last night, same issue. I need to test the TPS but that's not gonna happen until Wednesday at the earliest. Still fired right up though on the first crank.
 
I put about 15 minutes into this yesterday before it got dark at 2 lol. Makes a big difference when the TPS is installed right (i think i had the TPS tangs on the wrong side of the throttle lever tangs) and then get it adjusted correctly. Fired right up, smooth idle, throttle response is back, just a couple small things and it will be drivable. Then its will be done with the repair stage and move on to the accessories stage.
 
Yesterdays project was spark plugs, cap, rotor, wires, and timing.



No issue with changing parts but there is something off about the timing, it runs just fine but the timing mark on the damper is about the 8 o'clock range with the timing light on it. I noticed this when setting the TDC, I couldn't go off the timing mark and had to go off of the piston itself. Not sure if this damper is off a different year or if the pulley has moved on the damper or what.
 
warrpath4x4 said:
I put about 15 minutes into this yesterday before it got dark at 2 lol. Makes a big difference when the TPS is installed right (i think i had the TPS tangs on the wrong side of the throttle lever tangs) and then get it adjusted correctly. Fired right up, smooth idle, throttle response is back, just a couple small things and it will be drivable. Then its will be done with the repair stage and move on to the accessories stage.
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Newbie here having similar idle issues with my truck. Planning on replacing the fuel injectors but was curious what a TPS is?
 
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