If that block is trashed, ask if it can be overbored. <img src="/forums/images/graemlins/notooth.gif" alt="" /> If not, then to the recycler it goes. Plan for that possibility.
Keep the beer on ice until the end of the day, and keep everything CLEAN and in order. Keeps you from tearing your hair out.
Digi documentation is your friend.
Crockpot, pizza, and premade sandwiches in a ziploc to keep your bread clean is also helpful.
PB Blaster or Aerokroil for disassembly; spray around some of the tough stuff first; the fuel filter brackets/lines, exhaust manifold and downpipe bolts, you get the idea.
Antiseize compound and torque wrench for reassembly. A couple sheets of emory cloth and wire brush are also handy for cleaning things up.
Blue towels and Simple Green wipes, two each.
So is a local machinist; shop around. Make sure you ask about warranty.
Get your fuel and CS injectors rebuilt, and get rid of the butt connectors in the fuel harness and solder 'em properly.
www.rceng.com or
www.witchhunter.comConsider 02 sensors;
www.sparkplugs.com for Densos.
REMOVE THE CRANKSHAFT BOLT BEFORE YOU PULL THE ENGINE. You'll hate yourself if you don't. That way you can use the tranny to keep the engine from turning while you remove it.
Leave the radiator out of the truck until you drop the engine back in and retorque the bolt.
The harnesses come off with a small screwdriver to gently pop the clips loose. <img src="/forums/images/graemlins/shame.gif" alt="" /> <img src="/forums/images/graemlins/shame.gif" alt="" />
In addition to the digi pix, a sharpie and the cardboard from the beverage box of choice is helpful; punch in the bolts. I also use cut off oil bottles for oddball stuff, and mark what they are. This is EXTREMELY helpful if you are working on this in your spare time for reassembly.
The timing chain cover is a good example of this, as you've got 3 different length bolts. MAKE SURE you inspect the cover for timing chain holes. EB has them the cheapest by far.
Machinists don't work on nor can control what you bolt back onto the long block. <img src="/forums/images/graemlins/shame.gif" alt="" /> <img src="/forums/images/graemlins/shame.gif" alt="" /> Clean and/or recondition your stuff. Clean the EGR plate, valve, junk out of the intake, etc. If you find any butt connectors or those ungodly crimp on blue things, GET THEM off the harness, and resolder and shrink wrap that area. ALSO, make a note of what you've repaired.
I usually keep a sheet of paper and a pencil on the wipers. One is a shopping list if anything is broken; the other is for stuff that I've fixed for my own reference. It goes into the truck's folder.
It's almost too bad it's a dead engine, cuz also what I like to do for cleaning is to flush the coolant out and run some descaler thru it to clean all the pipes, so everything is in good shape going back together, to include gunk in the heater core being flushed.
New belts/hoses/filters; if in decent shape, toss in a milk crate for trail spares, at least for your trip enyhoo.
Inspect the alternator and starters for contact and brush wear; the articles for this are in our Toyota section above. <img src="/forums/images/graemlins/kewl.gif" alt="" /> Local parts store can bench check 'em for ya.
I'm sure others will chime in. Review the FSM and take some notes for parts and consumeables. Having a list in front of you helps pull things together. <img src="/forums/images/graemlins/cheers.gif" alt="" />
