Project daily driver 1991 4Runner
 

This weekend the wife and i went and picked up this 91 4Runner. Currently I drive a 06 Jetta TDI but it has had electrical issues and cost us way to much in repairs, I wanted to get something I could work on myself and was 4wd. We had a 93 XJ and while I could work on it, it needed a lot and just didn't feel right, so i sold it and promptly bought this 4Runner.

specs:

1991 4Runner
22RE
5-speed
3" (or 4) lift
33" tires
4.88 gears
ARB locker in rear but needs a compressor (have not verified locker yet)
sun roof


I had planned on putting a header in it and a new radiator but it already has a Doug Thorley header and a new radiator in it. So i will catch it up on maintenance with a full tune up, replace all the hoses, change all fluids, verify the locker and if so add a compressor, add dual batteries (more than likely in a custom box where the spare is currently located), tire carrier rear bumper, winch/bumper front, big 3 upgrade, higher output alternator.

Attachment 208438

Attachment 208439

planning on repairing this and getting some seat covers
Attachment 208440

back seats in good shape
Attachment 208441

onto the rust spots, while its not horrible, they do need addressed
Attachment 208442

Attachment 208443

Attachment 208444

Attachment 208445

Attachment 208446

Attachment 208447

Attachment 208448

somebody has already been into the AFM, and there are 3 different types of fasteners loosely holding it together and the piping is cobbled together, i am going to get a cold air intake and build a heat shield for it.
Attachment 208449

Attachment 208449

new radiator
Attachment 208451

i am not surprised it has a power steering leak, even though it is not directly coming from right here
Attachment 208452

and i thought this was mud caked on until i took my knife to it and yup, more rust. so far it looks like the frame rust is isolated to the front, i need to look at the frame again but the rest looked ok. so i am going to hit it with a wire wheel, cut as needed and weld in some new steel.
Attachment 208453

my UPS and Fedex drivers are not going to like me next week, they will be at my house every day according to tracking numbers.

tune up stuff
140 amp alternator
cold air intake
winch
new dipstick from LCE
wiring harness for the alternator
latch from McMaster-Carr for the swing out

still need to order a power steering cooler but i need to look at available space with the auxiliary fan in front of the A/C condenser first

Looks like a good base to start with!

took it in today to get the one busted wheel stud replaced and a front end alignment (pulled hard to the left), they said they helped the alignment but he couldnt complete it due to the idler needing replaced. so i brought it home (now it veers to the right pretty good) and ordered more parts for it today, idler, pitman, tie rods, and found my steering leak, its the box itself so i ordered a reman box for it.

verified it does have an ARB in it, the bulk head is still in the housing but someone must have cut the hose when they pulled the compressor, now i need to look into how to clean the locker or what needs done since who knows if there is mud or dirt in there. i ordered a Viair compressor and an air tank for it, along with some other little things like USB ports and flush mount LED's for the rear bumper.

digging around in the cubby's in the back i found this
Attachment 208436

Attachment 208437

Looks like it's going to be interesting to watch, see what happens to the old 2nd gen 4banger. Good start with the correct number of pedals. :D

only reason i brought it home was because its a 4 cylinder and a manual, according to the seller the engine was rebuilt about 70,000 ago but the body has 324,000+ on it.

parts are starting to roll in, not really much of an update but the old dipstick wasn't sealing and was just flopping around, while it may have been fine it was only about $20 for a new Toyota OEM dipstick from LCE.

Attachment 208435

my cold air intake also showed up and i got it mocked up but the elbow coming off the intake is not long enough so the cross pipe hits the sling hook. i am either going to look for a longer elbow or just get a piece of pipe to extend it out towards the core support. by the time i got that far into it, it was dark.

by tomorrow all the big items should be here (the 4runner is full of boxes), i will still need to get the small stuff (belts, wire, fluids). As luck would have it though i fly out sunday for a week in Dallas for work, i wonder if my parts will be thinking of me while im thinking of them lol.

mine was a storage unit for a long time too!
getting all the stuff in makes it nice to all the stuff at once

I am back from Dallas and got a total of about 10 minutes to work on the 4runner this weekend.

here is the routing of the CAI hitting the engine hook
Attachment 208387

Attachment 208388

putting it in a bind against the overflow tank
Attachment 208389

i ordered up an extension and a new elbow and adapter
Attachment 208390

but i think it may be a little too long, i may need to shorten it up a little to align things better
Attachment 208391

and i still need to build a heat shield.

last weekend i got the fan, alt, water pump, and associated bracketry removed, tried to test fit the new CS144 alternator but it doesn't look like it will work (without more mods than i want to do right now) so i found a stock size 130 amp unit to put back in that is supposed to be here Monday. I will put the CS144 in my 72 K5 next spring when i revamp the electrical system in it. I have yet to put anything back together between the cold weather and the cold my son gave me i have not done much of anything.

only one on my phone and this is from 3 years ago but it still looks the same, even the ugly front bumper i swore i was going to take off when i bought it 4 years ago, its a 72 that the PO put a 70 grill on.

Attachment 208351

finally getting over this cold, wasted some time Saturday installing the water pump..... only to realize after installation that its the wrong pump. apparently someone swapped the block out with a pre-85 block, all the mounting holes match up but the top of the water pump wont seal. pre 85 is a straighter design than the later swooping design.

i bought it for my son who is 7(he was 3 at the time), when he gets a little older and i get a couple other projects done we are going to rebuild it. its a good candidate for it since it was a frame off restoration about 20 years ago and has been driven very little since then (72,000 original miles). right now its having charging/starting issues, in spring i am going to rewire the engine bay and get it back up and running.

it is a fun rig to drive, i daily drove it for 2 years in wyoming, gets a lot of looks. Our oil rep kept trying to buy it from me, offered me $8K for it which was tempting since i only paid $1200 for it and put about $500 into getting it back up and running.

You need a different car... :D


https://cimg8.ibsrv.net/gimg/www.yot...3fa31214ce.png



https://cimg2.ibsrv.net/gimg/www.yot...40130cce29.gif

:safari:

ya, i would take any of my parents high school cars. mom had a 64 impala convertible with the 327, then after my uncle wrecked it she got a 65 GTO. dad had a 74? nova with a 262 V8 that would pull the nose off the ground, he had that till i was about 5.

Finally got some time to work on the 4Runner yesterday with our weird weather were having.

i was wrong when saying the power steering cooler needed replaced, it was the A/C condenser, and since the A/C doesn't work i don't see the point in keeping extra parts on the rig.
Attachment 208304

much more space now
Attachment 208305

and without the condenser and everything else in the way, the radiator will get more air flow
Attachment 208306

i had planned on keeping the A/C fan but its a little rusty
Attachment 208307

this is what its suppose to look like
Attachment 208308

with the rust in the front of the frame i was fearing what i was going to find when i pulled their little skid off that was bolted under the radiator... but i was pleasantly surprised.Attachment 208309