Dmech

So long story short. I bought a 1991 4Runner 3.0 5 spd 4x4 with no motor. I had a motor ready to go in it, completely rebuilt. Got the whole thing in, go to put on the distributor and find that it will not go in all the way. It stops about 1/2 in out.

I do some searching and inspection and wouldn't you know, the heads were swapped!!

The pilot hole in the head that accepts the dizzy's shaft was never machined. it needs to be 10mm and is about 8-9mm.

This means that the cams are also not at home so there is bound to be some clicking that will never go away.

I could machine a drill guide that'd fit in the dizzy port and drill it out and clean out all the shavings and run with it.

Or I could spend 10 -15 hours swapping the heads back. I know the good and bad of both options but just need some opinions.

As far as I know that pilot hole size is the only difference between the heads.
correct me if I am wrong.

Green93

It sucks when you think you're almost done and some other obsticals pop up. Did you build this motor or did you have it done?

You said the truck is a 91. Is it possible that the motor is from a 92+? I know there were small differences in the heads when I was looking for a replacement for my truck. Could it be as simple as having to find the newer style distributor,cap and wires? Not sure where to look to find out if there are size differences in the distributors but someone here should know. I'd do some research before pulling anything apart.

Dmech

I didn't think of that of year to year shaft sizes, I'll check.

Dmech

I did build the engine, this is completely my fault. But not so fast! The engine is from a 95. the 95 distributor has a shorter shaft that doesn't reach down far enough to sit in the pilot hole. This leads me to believe that the other head's pilot hole is most likely not drilled out either.

This means, theoretically, that the heads have a chance of not being swapped.

so now its just a matter of making a wiring harness to got from my 91 harness to the 95 distributor.

Dmech

Problem solved. I whacked off the end of the 91 distributor shaft. Hope my theories are right! No harness needed. Its easier to give it a shot than to rip that motor apart.!

Green93

That was quick. A man of action i see. I'm not sure if the wiring harness would be different but the cap and wires are. Are the distributor gears the same size?

Dmech

everything is exactly the same as far as gear placement and body are concerned. the internals are different. I guess in 95 they decided that that end of the shaft didn't need support.

Its already installed, I'm gonna fire it up tomorrow. Fingers crossed.

Thanks!!

Green93

No problem. Good luck and let us know how it goes.

Dmech

Well I got her running again after a few set back. Timing belt mis-aligned. oops! The distributor operates flawlessly. the there is no ticking from the engine! When I first started her I got codes 24 and 31. This was fixed with a spare MAF I had lying around. The next big hurdle is P52. When I saw this come up, I just took a deep breath.

I rang out the wire to the ECU, 1.2 ohms, I rang out the shielding, 52 ohms, Yikes! I then hooked up my meter to the KS and battery ground and got voltage from the KS (new KS wire installed). so I am a little stumped. I thought the KS only produced voltage when it pang? but mine just seems to constantly produce voltage. So I am down to the shielding.

Any thoughts?