Here is a copy of the article from 4wd Toyota Owners Magazine.
http://www.4wdtoyotaowner.com/

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I'm in Bend half time and Eugene the other half, I'll be sure and meet up with you guys. The 35's go on in a week or so but I need to stuff some 4.88's and a locker in there before I'll even try to follow you and Pete. Do you know anyone trying to unload some 35's, I hate paying retail. later, nice intake

hood vent welded



welds ground down



bondo



sanded



painted



Eventually I will get around to sanding the whole hood down and repainting the whole thing but for now this will work. Just wanted to make sure I could use the rig during turkey weekend....

Heres what I noticed so far from the hood vents:

I can still overheat the motor with high RPM's and low speeds - I'm not surprised....

Might be a touch more throttle response and power at higher speeds. I suspect that its just from more airflow under the hood and cooler fresh air getting into the motor - or it could be just in my head.

Temperature of my intake and plenum are lower after extended freeway driving. Before it was HOT to the touch and now its just warm.

With the engine warm and at a idle you can feel the heat escaping out the vents. which I believe in turn also lets the engine cool down faster when it gets overheated. Which I have experienced - its defintely cools down faster went its overheated even with it parked and at an idle.




I also finally got around to testing my thermal fan switch and its dead - so I have to get another one.... Luckily that was covered under its warranty because its only 5 month old.




Also with this little adventure a couple trips ago:

http://img.photobucket.com/albums/v75/bioxide02/June25thShotgun/113_1303.jpg
http://img.photobucket.com/albums/v75/bioxide02/June25thShotgun/113_1307.jpg

With me winching myself up and out of the ditch where my nose was buried into the ground, I ended up litteral shoving tons of mud, sticks and rocks thru my fairlead, under the winch and right into my electric fan..... I tried hosing out that area with the garden hose but that didn't work. I ended up removing the winch and hosed on the fan for like 30 minutes trying to get all the crap out. I even needle nosed some leafs and sticks out of the fan. I got most of it, but not all of it. You could still hear rocks bouncing around inside the fan.

So I'm now in the process of taking some sheetmetal and making a fan shroud spaced slightly away from the radiator to hopefully allow any crap that gets in there to be flushed down and away from the radiator. also it should help the cooling issues since now the fan will be blowing air over the whole radiator surface instead of just the cross-section of the fan. I'm also planning on make some type of dirt guard on the lower part of teh fan so this won't happen again.

Unfortunately those rocks and sticks messed up the front of the radiator pretty good. basically it just bent over all the fins on the outer 1" diameter or so from the fan. so after about an hour with a small screwdriver I got those straightened back out now. But since everything is so tight aroudn teh hood latch and the bumper - its going to be a challange to make everything fit.

So here is the start of the fan shroud. Its a piece of 18 GA sheet.



Unfortionately with adding the fan shroud, that is going to move the fan out another 3/4". Which is good for air flow but not good for my winch clearance. doing this is forcing me to totally rework my winch plate.......



See the fan use-to-be mounted flush against the front surface of the radiator.



Which also means I had to nibble some material off the cross tube on my all-pro winch bumper to make clearance for the fan..... Then I capped it off with some sheetmetal. Its not pretty but atleast its sealed....



This is pretty much the finished fan shroud. I also formed the edges to give it some more rigidity... for attaching the fan to the shroud, I just weled some nuts on the back side of the shroud. The only think I got left to do is to cut a small hole in it so I can connect the wiring harness back to the electric fan thermal switch.

Well last night I got the New Shroud & Fan installed, along with everything else. I ended up reworking the hood latch to make everything fit properly. Boy is that a tight fit now!!!! But now it fits. Now I'm in the process of reworking the winch mount so I can move the winch out ~ 1 1/4" because as it sits now, I can't bolt the winch back in since I moved the fan out ~3/4" and I only had 3/8" of clearence before. What a PITA!

Heres how I modified the AllPro Winch Bumper. Basically I cut the front of the winch plate off and moved the winch out 1 3/8".



Heres how the final product turned out....



And here you can see the hole that I left right after the fairlead so if I bury the front of the 4runner into the ground or enbankment, the dirt and rocks will get forced out the bottom instead of being carried under the winch and into the fan like it did before.



And now I have 1" of clearance between the end of the fan and the back of the winch!!!



We will see how it works out this weekend!

The fan shroud is working great.... I went on a snow run and the only time it would start to overheat is when the front bumper was 100% packed with snow. In the picture below it was still running at normal temperature and I would consider it 95% packed. you can see the hole in the snow on the driver side where the fan was still getting air flow. there was also another small air flow hole on the passenger side. and if you looked in those holes you could see a large cavity behind the winch that was also snow free. As long as those passages stayed clear, the motor would keep cool. before the fan shroud it would only take a couple inches of snow on the top surface of the bumper before the motor would start overheating. I also ran it pretty hard going up the mountain to get to the deep snow and it stayed nice and cool. So I'm extremely happy with the results.



Now the only other issues I'm fighting is my OBA belt. My brackets are slightly off and these flat multi-rib belts are not as forgiving as the v-belts are for how much misalignment they can take. So far I've trashed 3 OBA belts and one alternator belt..... That should be fairly easy to fix, just have to rework the main bracket some.

That and I'm not real happy with the gas mileage. this last snow run I got 6.4 mpg. I usually get around 10 mpg on the typical trail run. And on the freeway driving at 70 mph for 300 miles, I averaged around 13.5 mpg. I was told that I should be getting around 16 mpg on the highway....

So given the mileage and performance, would you do the swap again?

Yes, I would do the swap again. the additional power and torque make the vehicle way funner to drive - But it would probably be to a Taco 3.4...... easier to find a good motor, better fit, easier to cool but it would have probably cost just a touch more.

i noticed your occupation is listed as a mechanical engineer. you are my motivation to get finish my college education and get my mechanical engineering degree. i know the education had to help out in the engine swap and the fab stuff you do. its my first time viewing this thread and i just spent an hour and a half reading it(its currently 3:23AM haha). it is by far one of the best writeups i have ever seen. thanks for taking the time and doing it.