My 2001 TRD Access Cab Repair/Modify Thread

Truck looks great, really admirable job!

Best wishes for a full and quick recovery. My best friend is a kidney stone factory, he literally passes between 30 and 100 per MONTH. Has been this way for 11 years. He has been to every doctor he can think of and nobody can figure out why. The next person that suggests, "you should drink cranberry juice" is going to get throat punched. I've had them twice in my life and I wanted to die.

 

Thanks man. I appreciate it. Ive really enjoyed working on it this year.
I feel for your best friend....
I go to the doctor tomorrow to discuss this PCNL procedure (surgery through my back to remove the stones) so, we'll see what they say.

 

Well, I took a few minutes after work today to peel back the passenger side cam gear cover, just to see the condition of the TB.
I don't think it's ever been changed.
It's got the typical lateral cracks in it and it looks older than Jesus' sandals...

I should have grabbed a photo.

So, although I was hoping to put it off, I think I'm going to tackle it over next weekend. I feel pretty good, and as long as I don't stray too far from a bathroom, I'll be golden!

I did change the PCV valve today and gave it an oil change. The filter was torqued to about 213 Ft. Lbs. Why people do that, I'll never know......

 

Great to hear you are doing well. It sucks having to deal with health issues of any sort.

Looking forward to following your TB change. I need to take a look at my belts condition as well. My plan is to tackle it in the spring.

 

Thanks KT. Doing Well is a relative term. Right now I feel pretty good, so I need to take advantage of the next 5-6 days because after the surgery I’m not going to feel like doing anything! The belt on the UZ series engines really are pretty easy. Everything is accessible and about the toughest part is getting the crank pulley off. I do have the SST which makes it a breeze to remove the crank pulley bolt. I’ll be sure to take a bunch of photos

 

Well, I got home from work early today and hit the garage. Got the radiator out (looks to have been replaced recently) The system was filled with Green coolant so I drained it and was able to flush most of that out. After getting it back in the garage, out came the fan, Fan shroud, hoses, fan hub/bearing unit, T-stat housing, idler pulley, cam covers and by then it was about 2 hours in, and I had enough for today.

So, here are some pics. Again, this about 2 hours worth of tearin it up...



This was shortly after Flushing the cooling system and getting it back in the garage



Radiator. Not sure how old it is, but it's clean. Doesn't look like a Denso, though.



Here's after opening it up. Thankfully, no hardware issues yet. Everything seems to be coming out somewhat easily.


Here's the Timing Belt. When I asked the PO when/if the belt was changed, he seemed to think it was around 135k miles (truck has 172k on it now) but couldn't remember with certainty.

It's Obvious it's never been done.



So, next step is removing the Crank pulley, Alternator, Tensioner and the old belt.. Here's the SST for removing the crank pulley. I'm not a fan of the starter bump method.
This thing works great. I'll probably have to run a tap through the threads on the pulley, where the tool bolts on, but it does work well.


And its always a good idea to have a designated parts area/table.


So, we'll pick it back up tomorrow and see how far we get...


More to come.

 

I didn’t like the starter bump method either. I did tried the 2x4+bolts in it but ended up just destroying the wood. Eventually just bought the SST on Amazon

 

It really is the best way to do it.

 

I spent another 3 hours on the timing belt today. I'm definitely taking my time with this one. I just don't feel like pushing through and working until the sun sets.
I got the crank pulley off, loosened the PS pump to get access to the Alternator, removed the tensioner, pulleys and the timing belt, and decided to call it a day.

That TB would not have lasted much longer. The water pump looked surprisingly good, for being original to the truck. Everything else came off fairly easily for being original..

Pics:

After getting everything opened up and the last bit of old coolant drained out



On the 3UZ, the Power Steering pump is not in the way, but on the 2UZ, there's 2 bolts and a nut that need to come out, so you can slide the pump forward enough to remove the Alternator.




Here's just one of the countless cracks in the belt. I've never had one this bad.



The manufacture date on the water pump..... Yup, that's stamped 11/2000. I'm amazed it lasted this long, but then again..... It's a Toyota!





since the Alternator had to come off, I figure I'll clean it up and paint it before re-installation.




So, at this point, I can start tomorrow with the new water pump install, and continue putting everything back.


More to come...

 

I bought the SST (I'm glad I did!), and then sold it on eBay when I was through with it (I wish I hadn't).

I my case, the two threaded holes in the Harmonic Balancer were so rusted I couldn't thread the bolts. I had to dig up the right tap (I don't remember now what size) to chase the holes first.

 

Yeah, it's odd. The 3UZ-FE (LS, GS) has M8-1.25 threads in the crank pulley, and the 2UZ has M7-1.0 threads. Why they aren't the same, who knows? Thankfully I had a couple of 7mm bolts that were long enough to thread into the balancer.

 

Quick update for today...

I didn’t spend a whole lot of time on the truck today. Just wasn’t feeling it. I did install the new water pump, after cleaning up the mating surface on the block.

Then, I spent an hour or so cleaning and painting all the ancillaries I removed.

Tomorrow should be more productive. I should be able to finish, baring any problems...

Water pump installed (Torque is 15 ft. Lbs)



And a whole table of fresh, clean parts ready to be installed..


So, we’ll get back at it tomorrow morning!

More to come...

 

Update time...

I didn't do anything yesterday. Just wasn't feeling it. Man I'll be glad when this kidney stone crap is over....

Anyway, I pretty much finished it up today. Got the radiator back in, shroud, hoses, coolant, new plugs installed, and it fired right up. The old spark plugs Were Bosch platinums which were very rusty and a real bear to get out. Those plugs were in there a while.
Before I installed the new NGK plugs , I grabbed my boroscope and took a look inside a few of the cylinders. I have to say, the piston tops and cylinder walls are surprisingly clean.
I could see a couple of the valves as well and they looked clean too. So, the only thing left now, is topping off the coolant, which I'll do tomorrow morning. I bought 2 gallons, which obviously wasn't enough.

So, on to the photos...
I took a bunch today.

Coming together... The repainted Cam Gear covers look good.



These are the 2 Radiator supports. They had some rust on them, so I threw em in the blaster and cleaned em up. Left is done, right is next.


And the finished product. They came out looking good, even though no one will see them...




Bead blasting the engine cover. It too had a bunch of rust.



The old plugs.... they were well worn.



I didn't measure the gap, but I'm guessing they were ready to be replaced





The freshened up fan shroud is back in, and the engine is just about ready to start


Here's the cylinder wall for #1. The cross hatching is visible.



The top of #1 piston



Piston #2 looked just as good



Here's one of the valves in the #4 cylinder. It's blurry, but still looks decent.




So, tomorrow morning I'll top off the coolant system and then I can finally install the skid plate on the truck, and that will just about wrap this project up. For now...

One last thing I need to do is detail the engine cover script. I painted it black, but now I have to highlight the lettering.


After that, Finally, time to enjoy it!

 

Well, I topped off the coolant today and took it for a long drive. The truck runs great. About the only thing left that needs to be done, is bleeding the brakes again. The ABS pump still runs between 3-5 mph when coming to a stop.
I got the skid plate mounted and the splash guards on either side of the skid plate mounted as well.

I ordered LED bulbs for the instrument cluster and the interior lighting and I still need to finish the engine cover paint. I hope to accomplish the rest in early November after the 2 upcoming surgeries.

So, it looks like this XK40 is done... For now.

 

Good work and fingers crossed for successful and easy surgeries

 

Thanks man. Just got home from the hospital. The laser procedure went well. I may have to go for a second procedure on the left kidney, but we'll see. Doc was able to break up about 90% of the stone.

time to rest...

 

Scrolling the forum, I kept thinking this was an Air Con thread. So I skipped, until today. Holy shmokes.... well done brother.

 

Thanks a bunch, man. Now that you mention the AC thing, I guess it could be construed that way.

 

I bet this truck project has been good therapy for you. I know mine has.

 

Absolutely has been great therapy. I learned a bunch, got to brush up on my welding skills, and I ended up with a very well sorted truck. My wife is glad it's done. Spending 9 months in the garage wasn't something she was fond of.

 

Uh Oh.....

 

Doh!

 

isn't this rubberized? A known NO GO..

 

Not sure as I didn’t use that product.

 

Yeah after driving it for part of the last week, I noticed a puddle under the engine. I think I cracked the lower tank when I installed the hardware between the rad and the side bracket. I initially put a bolt in that was too long. I noticed coolant dripping from the area of the lower hose, opened the hood and saw the tell tale marks on the timing cover.

 

touche, why i quoted the poster
on another note, mind shedding some (more) light on the surface rust touch up? Need to do my hood, rear corner where it meets the tailgate..

 

got it. I went over each spot on my hood with touch up paint and then sanded the hood with 2000 grit, compound and then wax. It’s not perfect, but it looks better than it did.

 

Wasn’t sure if it was. After the many recommendations here, I have since decided to go with Fluid Film/Woolwax to spray inside the frame.

 

the eastwoods stuff is more like paint.. no rubber ive noticed.

 

FIIK
https://www.eastwood.com/eastwood-rubberized-undercoating.html
that's why i just ask questions here