92 TOY

scraped the old gasket material off.

found that in following the FSM for installing the EGR to the block, it omitted the step of a new gasket...i had used BLACK RTV...so we will see if that bites me someday. i trimmed the lower intake gasket to subtract for that area.



new gasket



a few PITA parts here are again, those crazy metal pipes and getting the to line up where you need them.....some BLACK RTV again where a rubber gasket is and was able to get the lower intake in place on it.......had trouble getting both bolts to thread and no matter what positioning i tried, i could not get it....so i used the vice grips again, and again, it worked like a charm.





i used my template (pizza box) to re-install the bolts....and don't forget the allen bolt (mine was new from LC Engineering since i had stripped-out the head of the old one)

right under the thermostat






and i was done with the lower intake manifold install

92 TOY

so i got hasty and installed my old (un-serviced injectors).....so it was at this point, that i sent them and my cold start injector to witch-hunter...creating a self-induced delay.

but when they come back tested / refreshed and serviced, it's worth the wait



OLD and disgusting



tasty fresh



a test chart...



and the old dry-rotted stuff back to prove what a mess they were



re-installed cold start injector



and done(mostly)...some tweaking of the wires have to be done...some go over the rail, some under, it's kinda a PITA time here...but i got it right..

92 TOY

remember, use new crush washers at the fuel rail....(big 19mm bolt...2 washers)...forgot to do that, had to order them from the dealer...like $3 or so

92 TOY

i spent far more time arguing with this than i should have had to... for the life of me i could not get this to line up. i finally disconnected the REED valve from where it was mounted to the lower intake and was able to hook it to the pipe this way. i wish i had not given up on this, but no matter what i tried or pryed, i could not get it to line up (about 3 hours worth).

also, i could not find, maybe never had it, the gasket for this area. luckily in my box of bags from disassembly , i found the old one. some copper RTV and i was good to go.

pics...



this gasket



goes here







and i rationalized with myself that the REED valve itself, weighs very little and that it was held securely in the back by the pipe and securely in the front by it's hose and the container that was bolted, so it's not going anywhere.

pointing at the hose (hehehehehe) and with that, this miserable part of the episode was done.

92 TOY

feeling like i was really getting close to done, it was time to put on the upper intake....

prepped and ready....scraped and wiped with acetone





had a bitch of a time getting the small, solid fuel line to bolt to the cold start injector. after dropping a few of the little crush washers, i figured it was time to use a net



MY ADVICE.....unbolt the cold start injector....thread on the fuel line mostly and the re-install the cold start injector.....after several failed attempts at bending the fuel line so it would thread on, i figured this was a better and safer way



and with that, this part was complete

92 TOY

keep reading

92 TOY

having never done any of this before, i was pretty unsure of what to do.....so i took it apart.



i read, and i researched and looked at pics and figured about where the rotor(??) should be pointed and that , on my distributor, the was a little nub....sticking up, apparently denoting where it should lay in relation to the cam gear(??)...should end up right in front of it.......i remember the "holy sh-t, i got it right on the 1st stab" comment..

nub..





the correct position



and it sits like this



and just that fast, i was done....

92 TOY

fini....

92 TOY

Moving right along......was time to put the painted fan back in



Radiator



charge the battery



Time to replace the PCV valve (from the dealer)



standing on the valve cover while prying with vice grips worked....and peel off the remnants of the gasket



here's why it should be replaced



and new valve and gasket in place



put all this back on.....



meanwhile, XXXTREME22R was setting the valves....



while keeping the YOTATECH folks updated



and also using some stored pics and other resources for getting the vacuum hoses right



and we were ready to go....



and the, of course, added oil, filled up the radiator with WATER (for now, and actually, still have water in it now trying to rinse contaminants out).....and the we pushed it out of the garage.

at this point...with nothing left to do but turn the key, i was soooooooooo certain something was messed up and this was going to be a BIG FAT FAIL....because this was a 1st for me, I was a nervous wreck.

Cranked the engine (which surprised me that even happened) with the coil wire off to build up oil pressure until the oil light went off, put the coil wire back on and with a turn of the key.....IT STARTED!!!!!!!!!

one little poof of smoke with the 1st start up (i assume as the assembly lube burned from the cylinder walls) and it was running PERCECTLY.

XXXTREME22R...checked the timing....was off ever so little, and we were done.

although the engine itself smoked ALOT from the paint baking...and the lower radiator hose leaked (because i forgot to tighten it) and the same with a heater hose........but besides that....NO PROBLEMS.


After just shy of 300 miles since starting it up on May 20th, only leak i have is from the very back of te oil pan, presumably because i either made the FIPG too thin there, or smeared it terribly on installation. should fix that...but it leaks sooooooo very little, that it's almost not worth it......I will fix it, but for now, i will bask in it's glory.

92 TOY

and...of course, a start-up video or 2 (never mind the 1st videos tag, it's from my son's YOUTUBE account)

http://www.youtube.com/watch?v=l9boU...layer_embedded

http://www.youtube.com/watch?v=YsbU1...layer_embedded

92 TOY

Again...as i wrote in the original thread.....even though i did this alone (except the last day with a little physical help from XXXTREME22R, and the continual support and encouragement from LUMPY from start to finish)...i didn't really do this alone.

from that terrible day last August, until the day I started it up May 20th.....you guys helped me.....whether it be with technical advice, support, encouragement or a swft kick in the pants....you guys were there.

so for any newbies out there thinking that there is no way you can do this.......yes you can.

i started with no skills and did this job....so you can definitely do it.

i've condensed 8 months and over 100 pages of a thread to 70 posts and 3 pages....so i've likely missed a few details.....feel free to post up questions now.

kiyobrown

Nice work, way to take the time to turn everything into an easy to follow guide for the next guy that wants to tackle this themselves.



Sticky worthy? Maybe.

Lumpy

Got my vote for Sticky!!!

iamsuperbleeder

Very nice!

Again, job well done sir

Magnusian

Another vote for sticky so long as I get credit for my heckling!

Actually, I bookmarked this thread so I have something to reference when it's my motor's turn to get new parts.

92 TOY

personally, i don't think i added enough technical stuff...IE: torque stuff, etc...

kiyobrown

Geez dude, you aren't doing it FOR them. But you have awesome organizational tricks and ideas that are useful, and lots of pics for visual reference. They can wipe their own behind and download the FSM like the rest of us have to find some torque specs.

92 TOY

Ok ok.

kiyobrown

just saying

iamsuperbleeder

your going to make a 3rd thread about it?